Page 2 If further information is required, Thermo King Corporation should be consulted. Sale of product shown in the Manual is subject to Thermo King’s terms and conditions including, but not limited to, the Thermo King Limited Express Warranty. Such terms and conditions are available upon request.
Page 3 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.
Page 5: Table Of Contents
Table of Contents Safety Precautions ............... . . i Specifications .
Page 6 Table of Contents (continued) Electronic Controls (continued) Displaying the Software Revision ............34 Operating Service Test Mode .
Page 7 Table of Contents (continued) Engine Maintenance (continued) Adjusting Engine Valve Clearance ............65 Front Pulley Bolt .
Page 8 Table of Contents (continued) Structural Maintenance ..............97 Unit And Engine Mounting Bolts .
Page 9: Safety Precautions
Safety Precautions GENERAL PRACTICES REFRIGERANT ALWAYS WEAR GOGGLES SAFETY Although fluorocarbon refrigerants are classified as safe GLASSES. Refrigerant liquid and battery acid can per- refrigerants, certain precautions must be observed when manently damage the eyes (see First Aid under Refrig- handling them or servicing a unit in which they are used.
Page 11: Specifications
Direct to compressor; belts to fans, alternator and water pump * Thermo King synthetic oil is compatible with petroleum lubricants so there is no danger if accidental mixing occurs or if an emergency requires addition of petroleum oil. Mixing is not recommended, how- ever, since it will dilute the superior performance properties of the synthetic oil.
Page 12 Specifications (Rev 6/98) REFRIGERATION SYSTEM Compressor Model Thermo King X430 Refrigerant Charge—Type 13 lb (5.9 kg)—R-404A Compressor Oil Charge 4.1 quarts (3.9 liters)* Compressor Oil Filter Oil Charge 0.75 quarts (0.71 liters) Compressor Oil Type Polyol Ester type P/N 203-413...
Page 13 Specifications (Rev 6/98) ELECTRICAL COMPONENTS NOTE: Disconnect components from unit circuit to check resistance. Current Draw Resistance—Cold (Amps) (Ohms) at 12.5 Vdc Fuel Solenoid Damper Solenoid: Large Small High Speed (Throttle) Solenoid Glow Plug (One) Pilot Solenoid 17.0 Starter Motor—Gear Reduction Type 250-375* Modulation Valve (Optional) 1.7**...
Page 15: Maintenance Inspection Schedule
Maintenance Inspection Schedule Every/ Annual/ 1,500 4,500 Pretrip Hours Hours Inspect/Service These Items MICROPROCESSOR • Run Pre-trip (See Pre-trip in uP IV+ Microprocessor Operation). ENGINE • Check fuel supply. • Check engine oil level. • • • Inspect belts for condition and proper tension (belt tension tool No.
Page 16 Maintenance Inspection Schedule (Rev 6/98) Every/ Annual/ 1,500 4,500 Pretrip Hours Hours Inspect/Service These Items REFRIGERATION • • • Check refrigerant level. • • • Check for proper suction pressure. • Check compressor oil level and condition. • • Check throttling valve regulating pressure on defrost. •...
Page 17: Unit Description
A CYCLE-SENTRY Start-Stop fuel saving system provides Thermo King X430 Compressor optimum operating economy. Select Continuous or The unit is equipped with a Thermo King X430, four-cylin- CYCLE-SENTRY operation using the selector switch der compressor with 492 cm (30 cu. in.) displacement.
Page 18: Sequence Of Operation
Unit Description (Rev 6/98) Features of the CYCLE-SENTRY system are: microcomputer. The microcomputer is connected to the Data Pac interface on the front of the control box. A brief • Offers either CYCLE-SENTRY or Continuous Run graphical or tabular report can then be printed on the Data operation.
Page 19 Unit Description (Rev 6/98) Modulation Modulation Enabled Modulation is disabled if the setpoint is out of the modula- Units that are equipped with modulation and have modula- tion range, if the unit is in defrost, or if the unit is in tion enabled use the following operating modes: CYCLE-SENTRY.
Page 20: Unit Model Super Ii Sr+ W/Thermoguard Iv
UNIT MODEL SUPER II SR+ W/THERMOGUARD IV+ DESIGN FEATURES se 2.2 Diesel Engine • X430 Compressor w/Synthetic Compressor Oil • Thermo King Radiator • Stainless Steel Grille • Stainless Steel Evaporator Hardware • Tapered Roller Bearing Fanshaft and Idlers •...
Page 21: Protection Devices
Unit Description (Rev 6/98) PROTECTION DEVICES Engine High Coolant Temperature Sensor • Engine Low Oil Pressure Sensor and Switch • Engine Low Level Switch • Evaporator High Temperature Sensor • Refrigerant High Pressure Cutout Switch • High Refrigerant Pressure Relief Valve •...
Page 22 Unit Description (Rev 6/98) AEA1350 Front View...
Page 23 Unit Description (Rev 6/98) AEA1351 Right Side Door Open...
Page 24 Unit Description (Rev 6/98) AEA1352 Left Side Doors Open...
Page 25: Operating Instructions
Operating Instructions UNIT CONTROLS PREHEAT-START Switch. This switch is used to man- ually start the diesel engine. When held in the PRE- Two sets of controls are used to operate a unit that is HEAT position, it energizes only the glow plugs to help equipped with a THERMOGUARD uP IV+ microprocessor start the engine.
Page 26 Operating Instructions (Rev 6/98) AEA1354 Control Box Cover...
Page 27: Microprocessor Control Panel
Operating Instructions (Rev 6/98) CAUTION: With the selector switch in the CYCLE- Hold the Preheat-Start switch in the PREHEAT posi- SENTRY position and the unit On-Off switch in the tion for the required time. ON position, the unit may start at any time without Preheat warning.
Page 28: Unit Instruments
Operating Instructions (Rev 6/98) UNIT INSTRUMENTS If defrost is initiated manually, the unit will start and run on low speed. When the defrost cycle is complete, the unit will AMMETER. The ammeter is built into the micropro- run in the operating mode called for by the microprocessor. cessor.
Page 29: Unit Protection Devices
Operating Instructions (Rev 6/98) UNIT PROTECTION DEVICES inspect the restriction indicator periodically to assure the air filter is not restricted. Service the air filter when FUSIBLE LINK (Current Limiter). The fusible link is the yellow diaphragm indicates 22 in. of water column. located electrically between the 2 wire and the battery.
Page 30: Unit Operation
Operating Instructions (Rev 6/98) valve fails to reseat properly, remove the refrigerant BELTS. The belts must be in good condition and charge and unscrew and replace the valve. adjusted to the proper tensions. The high pressure relief valve is located on a high pres- ELECTRICAL.
Page 31: Starting Cycle-Sentry Equipped Units
Fresh fruits and vegetables, especially asparagus, Equipped Units bananas, broccoli, carrots, citrus, green peas, lettuce, The Thermo King CYCLE-SENTRY system is designed to peaches, spinach, strawberries, sweet corn, etc. save refrigeration fuel costs. The savings vary with the com- •...
Page 32: After Start Inspection
Operating Instructions (Rev 6/98) After the unit starts from microprocessor demand, defrost At the end of the preheat period, the engine will begin initiation, battery voltage dropping below the CYCLE- cranking and should start and run. The glow plugs SENTRY Battery Voltage setting, or engine coolant temper- remain energized during the cranking period.
Page 33: Pre-Load Operation
Operating Instructions (Rev 6/98) Pre-Load operation Post Load Procedure Adjust the microprocessor setpoint to the desired tem- Make sure all the doors are closed and locked. perature. Start the unit if it was shut off to load (see Restarting Allow the unit to run 30 minutes before loading to Unit).
Page 35: Electronic Controls
Electronic Controls SR+ CONTROL PANEL CAUTION: The unit may start and run automati- cally at any time when the On-Off switch is in the The SR+ Control Panel includes the microprocessor display ON position and the CYCLE-SENTRY Continuous switch and keypad; and the unit switch panel. is in the CYCLE-SENTRY position.
Page 36: Manual Defrost Switch
Electronic Controls (Rev 6/98) starting. The glow plugs should be energized for 10 to 90 seconds, depending on ambient temperature. Holding the switch in the START position engages the starter to crank the diesel engine. Manual Defrost Switch The manual defrost switch is used to initiate a manual defrost if required.
Page 37 Electronic Controls (Rev 6/98) AEA1356 Display Mode Description Icons uP IV+ Microprocessor Display...
Page 38: Microprocessor Keypad
Electronic Controls (Rev 6/98) MICROPROCESSOR KEYPAD SELECT—Pressing this key selects other prompt or display screens. See the list on this page. HOURMETER KEY—Pressing this key displays total hours, engine hours, electric hours and the three pro- grammable hourmeters. OIL PRESSURE—Pressing this key displays the diesel engine oil pressure.
Page 39: Select Key Prompts And Displays
Electronic Controls (Rev 6/98) Select Key Prompts and Displays [DIS.A] Discharge air temperature [TPDF]Temperature differential [COIL] Coil Temperature [AMB.T] Ambient temperature [SPR.1] Spare sensor 1 [SPR.2]Spare sensor 2 [BATV] Battery voltage [RPM] Diesel engine rpm [DEFI] Defrost interval when not in-range [DEFN] Defrost interval when in-range [DDUR] Defrost duration AEA1357...
Page 40: Selecting Cycle-Sentry Or Continuous Mode
Electronic Controls (Rev 6/98) Selecting CYCLE-SENTRY or [RPM] Diesel engine rpm CONTINUOUS MODE [DEFI] Defrost interval when not in-range NOTE: The CYCLE-SENTRY icon will appear when [DEFN] Defrost interval when in-range CYCLE-SENTRY mode is selected and the On-Off switch [DDUR] Defrost duration is ON.
Page 41: Initiating A Manual Defrost Cycle
Electronic Controls (Rev 6/98) Initiating A Manual Defrost Cycle NOTE: If the condition that caused the alarm code has not been corrected, the alarm code will continue to appear. NOTE: The defrost icon will appear whenever the unit is NOTE: ALWAYS record ALL alarm codes that are in a defrost cycle.
Page 42: Software Revision 04Xx Alarms
Electronic Controls (Rev 6/98) SOFTWARE REVISION 04XX ALARMS AEA1358...
Page 43 Electronic Controls (Rev 6/98) SOFTWARE REVISION 04XX ALARMS (CONTINUED) AEA1359 *Cleared through guarded access only Note: A dash (-) before an alarm indicates it was generated during a pretrip.
Page 44: Running A Full Pretrip Test
Electronic Controls (Rev 6/98) RUNNING A FULL PRETRIP TEST OPERATING SERVICE TEST MODE NOTE: The unit must be in diesel mode. NOTE: Read and understand the “Service Test Mode Notes,” and the “Service Test Mode Functions,” section in Turn the unit On-Off switch ON. Be sure the unit is in this chapter before operating the unit in the service test CYCLE-SENTRY mode (the CYCLE-SENTRY icon mode.
Page 45: Service Test Mode Notes
Electronic Controls (Rev 6/98) SERVICE TEST MODE NOTES • If a Shut Down Alarm occurs, the unit will record the alarm, shut down and exit service test mode. Service Test Mode should be CAUTION: • If the On-Off switch is OFF the unit will exit service used only by qualified technicians.
Page 46: Service Test Mode Functions
Electronic Controls (Rev 6/98) SERVICE TEST MODE FUNCTIONS The test mode functions listed below can be selected by pressing the ENTER key when the test is shown in the dis- play. A different test mode function can be entered by pressing the up or down arrow keys to select the new function and then pressing the ENTER key.
Page 47: Service Test Mode Function Table
Electronic Controls (Rev 6/98) SERVICE TEST MODE FUNCTION TABLE Action Results Function Definition This display appears The display will show The unit is forced to high speed cool mode upon entering service [tESt] and [HSC] The run relay and high speed relay are energized. test mode.
Page 48 Electronic Controls (Rev 6/98) SERVICE TEST MODE FUNCTION TABLE Press the up arrow key The display will show The unit is forced to modulation cool bypass mode— again to display [tESt] and [MB1.0]. modulation valve 50% closed. [MB1.0]. Press ENTER The run relay is energized.
Page 49: Electrical Maintenance
When testing alternators use accurate equipment such integral regulator is accomplished by installing a as a Thermo King P/N 204-615 (FLUKE 23) digital jumper from terminal F2 to ground. Attempting to full- multimeter and a Thermo King P/N 204-613 amp field the alternator by applying battery voltage to terminal clamp or an equivalent.
Page 50 Electrical Maintenance (Rev 6/98) • Make sure the drive belts and pulleys of the charging The B pin is the excitation circuit and should be at system are in good condition and are adjusted properly 10 volts or higher. If not, check the excitation cir- before testing the alternator.
Page 51 Electrical Maintenance (Rev 6/98) The voltage at the B+ terminal should be 13 to 18 volts Connect a jumper wire between the F2 terminal on the and the amperage in the 2A wire should be at least as alternator and a chassis ground, and note the ammeter high as the rated output of the alternator.
Page 52: Full Field Test
Electrical Maintenance (Rev 6/98) aea694 Check Point for 2A Amperage Position for Full Fielding Jumper Full Field Test...
Page 53: Battery
Electrical Maintenance (Rev 6/98) BATTERY GLOW PLUGS NOTE: The PROCESSOR On-Off switch must be placed Glow plugs heat the combustion chamber to aid in quick in the OFF position before connecting or disconnecting starting. The glow plugs are energized when the Preheat- the battery terminals.
Page 54: Fuse Link
Electrical Maintenance (Rev 6/98) • A 15 amp fuse (F18—High Speed Solenoid) protects Engine Low Oil Pressure Switch the 7D circuit, which supplies power to the high speed Engine oil pressure should rise immediately on starting. The solenoid. switch will trip the reset switch and stop the engine if the oil •...
Page 55: Thermoguard Μp Iv+ Microprocessor Controller
Electrical Maintenance (Rev 6/98) Defrost Components NOTE: If the return air sensor temperature goes out of range during unit operation, defrost cycles again are initi- Manual Defrost Switch ated on the 4-hour interval. Even if the return air sensor temperature returns to in-range in just 2-3 minutes, the The manual defrost switch is located on the control panel.
Page 56 Electrical Maintenance (Rev 6/98) NOTE: The unit will not defrost during normal unit oper- cessor will not initiate a defrost cycle. A faulty evapo- ation unless the defrost cycle is initiated while the evapo- rator coil sensor is reported on the fault indication rator coil temperature is below 7.2°...
Page 57: Air Switch Testing And Adjustment
Electrical Maintenance (Rev 6/98) A code 02 (coil sensor fault) is a faulty evaporator coil sen- sor. If the evaporator coil sensor fails during defrost, the microprocessor defrost timer automatically terminates DEFROST in 30 or 45 minutes. Test the evaporator coil sensor.
Page 58: Oil Level Switch
Electrical Maintenance (Rev 6/98) indicates a completed circuit with the gauge reading The switch should open and there should be no continu- 35.6 mm (1.4 in.) H 0. Release the pressure. ity between the OLS and the 8F circuits with the oil level between the low mark and the full mark on the Repeat the procedure several times to be sure the set- dipstick.
Page 59: Sensor Tests
Electrical Maintenance (Rev 6/98) Diode Test Slide the float up to the upper stop and check the conti- nuity through the switch (between the 8F wire and the The sensor can be tested with a Fluke multimeter set on the OLS wire).
Page 60: Sensor Replacement
Electrical Maintenance (Rev 6/98) Discharge Air Sensor The voltage drop across the sensor should be 2.3-3.4 Vdc. The voltage drop across the sensor is directly proportional Access the discharge air sensor by opening the right side to the sensor temperature. At a sensor temperature of door and removing the upper access cover.
Page 61: Engine Maintenance
Engine Maintenance ENGINE LUBRICATION SYSTEM Rocker Arm Shaft Camshaft Crankshaft Oil Pump Oil Filter sp2008 Lubrication System The se 2.2 diesel engine has a pressure lubrication system. Oil passes from the main bearings, through drilled passages Oil is circulated by a gear-type oil pump driven off a gear on in the crankshaft, to the connecting rod bearings.
Page 62: Engine Oil Change
Engine Maintenance (Rev 6/98) Engine Oil Change All water cooled engines are shipped from the factory with a 50% permanent type antifreeze concentrate and 50% The engine oil should be changed according to the Mainte- water mixture in the engine cooling system. nance Inspection Schedule.
Page 63 Engine Maintenance (Rev 6/98) AEA1361 Radiator Expansion Tank Radiator Cap Thermostat Housing Coolant Level Sensor Accumulator Tank CAUTION: Avoid direct contact with hot cool- Changing the Antifreeze ant. Run the engine until it is up to its normal operating Run clear water into the radiator and allow it to temperature.
Page 64: Bleeding Air From The Cooling System
Engine Maintenance (Rev 6/98) operate the unit in accordance with instructions of CAUTION: IF YOU SUSPECT THAT AIR IS the flushing agent manufacturer. TRAPPED IN THE BLOCK, DO NOT START THE ENGINE WITHOUT BLEEDING THE AIR OUT Open the engine block drain to drain the water and OF THE BLOCK.
Page 65 Engine Maintenance (Rev 6/98) AEA1362 Air Cleaner Starter Throttle Solenoid Flywheel Sensor Alternator Fuse Link Oil Filter Engine Compartment...
Page 66: Engine Thermostat
The banjo fitting also acts as a transfer point for overflow The fuel system used on the Thermo King se 2.2 diesel fuel coming from the nozzles and a point to bleed air from engine is a high pressure distributor (VE type) injection the system.
Page 67 Engine Maintenance (Rev 6/98) Injection Line Injection Pump Injection Nozzle Transfer Pump Return Fuel Line Hand Pump Fuel Filter Bleed Screw Water Separator Engine Fuel System...
Page 68: Bleeding The Fuel System
Engine Maintenance (Rev 6/98) Maintenance Bleeding the Fuel System The fuel system is relatively trouble-free and if properly If the engine runs out of fuel, repairs are made to the fuel maintained will usually not require major service repairs system, or if air gets into the system for any other reason, between engine overhauls.
Page 69: Water Separator/Fuel Filter
Engine Maintenance (Rev 6/98) To prevent reduced fuel flow to the engine: Water Separator/Fuel Filter Trim the 1/4 in. fuel line at a 45° angle. The water separator removes water from the fuel and stores it. When the stored water reaches the level of the bleed port, Do not insert the line more than 19 mm (3/4 in.) into it returns to the fuel tank through the fuel return hose.
Page 70: Water Separator/Fuel Filter Replacement
Engine Maintenance (Rev 6/98) Water Separator/Fuel Filter Replacement Spread the retaining clips. Pull the separator or filter away from the base. Place the new separator or filter on the base, and secure with the retaining clips. AEA1365 Retaining Clips Filter Base Fuel Filter Water Separator Water Separator/Fuel Filter Installation...
Page 71: Engine Speed Adjustments
Engine Maintenance (Rev 6/98) Engine Speed Adjustments Pull the plunger out of the solenoid enough to loosen the jam nut. Turn the plunger eye bolt clockwise to When the diesel engine fails to maintain the correct engine increase the speed and counterclockwise to decrease speed, check the following before adjusting the speed: the speed.
Page 72: Injection Pump Service
Engine Maintenance (Rev 6/98) Low Speed Injection Pump Service Loosen the jam nut on the low speed adjustment screw. NOTE: The procedure outlined will assume the pump is being removed and replaced on the engine. If the pump Run the unit with the throttle solenoid de-energized. has not been removed, only the last portion of the proce- Adjust the screw to the desired speed.
Page 73 Engine Maintenance (Rev 6/98) TC Mark on Flywheel Injection Timing Mark The engine now has the No. 1 cylinder at the fuel injec- NOTE: The injection timing mark is a line scribed in tion mark of its compression stroke. the flywheel approximately 1-3/8 in. (35 mm) from the TC mark.
Page 74 Engine Maintenance (Rev 6/98) Before installing the pump, rotate the gear until the “O” rotate the engine back and forth no more than 13 mm marked on the gear is approximately in the 10 o’clock (0.5 in.). The dial indicator should stay at zero. position as you face the gear end of the pump.
Page 75: Adjusting Engine Valve Clearance
Engine Maintenance (Rev 6/98) ADJUSTING ENGINE VALVE CLEARANCE Remove the rocker arm cover. Torque the cylinder head bolts to 85 N•m (63 ft-lb) before adjusting the valves. The valve clearance should be checked after the first 500 hours of engine operation. It is very important that the valves be adjusted to the correct specifications for satisfactory engine operation.
Page 76: Front Pulley Bolt
Engine Maintenance (Rev 6/98) Turn the crankshaft clockwise from the front, until An alternate method is to remove the camshaft the TC mark on the flywheel aligns with the gear access cover and rotate the engine until the pointer on the flywheel housing. “O”...
Page 77: Crankcase Breather
Engine Maintenance (Rev 6/98) CRANKCASE BREATHER ENGINE AIR CLEANER (Filter) The crankcase breather system ducts gases formed in the Dry Type crankcase directly to the intake elbow. Harmful vapors that A heavy duty, dry air cleaner filters all of the air entering the would otherwise collect in the crankcase and contaminate engine.
Page 78 Engine Maintenance (Rev 6/98) AEA1371 Air Cleaner Intake Manifold Air Restriction Indicator Dry Air Cleaner System...
Page 79: Belts
Engine Maintenance (Rev 6/98) BELTS will engage the belt. Make sure the hook is on the face of the belt, not in a notch. Release the plunger with a quick Belts should be regularly inspected during unit pre-trip for motion and without pulling on the belt. Then read the dial. wear, scuffing or cracking.
Page 80 Engine Maintenance (Rev 6/98) CAUTION: Do not attempt to adjust belts with the unit running. 1.6 mm (1/16 in.) CAUTION: With the On-Off switch in the ON position, the unit may start operation at any time without prior warning. Switch the unit On-Off switch to the OFF position before performing maintenance or 1.6 mm repair procedures.
Page 81 Engine Maintenance (Rev 6/98) AEA1374 Engine Pulley Lower Belt Guard Lower Idler Grille and Orifice Assembly Belt Guide Control Box Fan Belt Replacement...
Page 83: Refrigeration Maintenance
Mode. Testing for an Overcharge Use the microprocessor thermometer to monitor the Use the following procedure to identify a Thermo King unit return air temperature. with an excessive refrigerant charge: Run the unit on high speed cool until the air in the box Install a calibrated gauge manifold on the compressor.
Page 84: Refrigerant Leaks
Refrigeration Maintenance (Rev 6/98) NOTE: If the ball and liquid level in the receiver sight Moisture Indicating Sight Glass glass drops during step 4, the unit is not overcharged The receiver tank is equipped with a moisture indicating and it is not necessary to complete the procedure. sight glass.
Page 85: Checking Compressor Oil
Refrigeration Maintenance (Rev 6/98) CHECKING COMPRESSOR OIL To check compressor oil level with an ambient air temperature below 10° C (50° F): The compressor oil should be checked when there is evi- Run the unit through a complete defrost cycle. After com- dence of oil loss (oil leaks) or when components in the pleting the defrost cycle, run the unit on Cool for ten min- refrigeration system have been removed for service or...
Page 86: Three-Way Valve Condenser Pressure Bypass Check Valve
Refrigeration Maintenance (Rev 6/98) Raise the discharge pressure of the compressor first by blocking the condenser coil air flow by covering the condenser grille with a piece of cardboard. If this does not raise the discharge pressure to the cutout level of the HPCO, increase the engine speed by overriding the throttle solenoid.
Page 87: Modulation Valve
Refrigeration Maintenance (Rev 6/98) the valve is to improve heating/defrosting ability and three- MODULATION VALVE way valve response. The modulation valve is normally open. As a controlled To check the operation of the valve: electrical signal is applied to the coil the armature over- comes spring pressure and the valve moves a precise Remove the condenser pressure bypass check valve cap amount in the closed direction.
Page 88: Modulation Valve Test
Refrigeration Maintenance (Rev 6/98) Outlet Inlet Armature Opening Spring Electric Coil 6. Seats Modulation Valve Test Check the suction pressure while the unit is in modula- tion. The suction pressure should be 0 to 69 kPa Make sure that the unit has a modulation valve and that (0 to 10 psi).
Page 89: Hot Gas Solenoid Valve (Hg)
The unit operates the same as a standard unit. If the low side will not pump down, diagnose the prob- NOTE: The Thermax-V expansion valve does not have a lem using the procedures in Diagnosing Thermo King bleed port in it. Refrigeration Systems TK 5984-7. Do not prematurely...
Page 91: Refrigeration Service Operations
Refrigeration Service Operations NOTE: It is generally good practice to replace the filter drier whenever the high side is opened or when the low side is opened for an extended period of time. Removal Installation Pump down the low side and equalize the pressure to Slide the compressor into the unit.
Page 92: Discharge Vibrasorber
Refrigeration Service Operations (Rev 6/98) Recharge the unit with proper refrigerant and check compressor oil. Install the top screen. DISCHARGE VIBRASORBER Removal Recover the refrigerant charge. Heat the connections on the vibrasorber until the vibra- sorber can be removed. Valve CAUTION: Use a heat sink, P/N 204-584 or Neoprene Seal wrap the vibrasorber with wet rags to prevent...
Page 93: Bypass Check Valve
Refrigeration Service Operations (Rev 6/98) RECEIVER TANK Pressurize the refrigeration system and test for leaks. If no leaks are found, evacuate the system. Removal Recharge the unit with proper refrigerant and check the Recover the refrigerant charge. compressor oil. Unsolder the condenser check valve line from the receiver tank.
Page 94: Filter Drier
Refrigeration Service Operations (Rev 6/98) FILTER DRIER Remove the expansion valve mounting bolt and remove the expansion valve from the unit. Removal Installation Pump down the refrigeration system and equalize the Install and bolt the expansion valve assembly in the pressure to slightly positive.
Page 95: Heat Exchanger
Refrigeration Service Operations (Rev 6/98) HEAT EXCHANGER Remove the rear panel from the evaporator housing. Disconnect and remove the sensors. Removal Remove the feeler bulb from the suction line clamp. Pump down the low side and equalize the pressure to Note the position of the feeler bulb on the suction line.
Page 96: Accumulator
Refrigeration Service Operations (Rev 6/98) ACCUMULATOR SUCTION VIBRASORBER Removal Removal Pump down the low side and equalize the pressure to Pump down the low side and equalize the pressure to slightly positive. slightly positive. Disconnect the coolant lines from the accumulator tank. Unsolder the suction hose from the suction service valve.
Page 97: Three-Way Valve Repair
Refrigeration Service Operations (Rev 6/98) THREE-WAY VALVE REPAIR 10. Remove the screen. If any particles drop from the screen into the discharge line, the discharge line must NOTE: The three-way valve can be repaired in the unit if be removed at the compressor. leakage or damage to the Teflon seals should occur.
Page 98 Refrigeration Service Operations (Rev 6/98) Check Valve Assembly Top Cap Spring Piston O-ring Teflon seal Gasket (2) Clip Seat Stem Screen Bottom Cap Three-Way Valve AEA1375 Three-way Valve...
Page 99: Three-Way Valve Condenser Pressure Bypass Check Valve Repair
Refrigeration Service Operations (Rev 6/98) THREE-WAY VALVE CONDENSER Installation PRESSURE BYPASS CHECK VALVE Coat the O-ring with compressor oil and install it on the REPAIR check valve stem. Insert the spring into the hole in the check valve stem Removal and then install the Teflon check valve on the other end Recover the refrigerant charge.
Page 100: Pilot Solenoid
Refrigeration Service Operations (Rev 6/98) PILOT SOLENOID Install and tighten the high pressure cutout switch and reconnect the wires. Removal Pressurize the refrigeration system and test for leaks. Remove the refrigerant. If no leaks are found, open the refrigeration service Disconnect the wires.
Page 101 Refrigeration Service Operations (Rev 6/98) SCREW - mtg plate 10. GASKET - piston housing FLATWASHER PISTON PLATE - bellows end 12. SPRING - piston GASKET - end plate 13. NUT - adjusting WASHER - adjusting 14. PIN - cotter SPRING - bellows 15.
Page 102 Refrigeration Service Operations (Rev 6/98) Disassembly • Bellows end cap for damage in the pilot hole. Remove the piston end cap (round end). NOTE: The bellows is normally replaced. Remove the cotter pin from the castle nut and remove Clean the parts that will be reused. the nut.
Page 103: Modulation Valve
Refrigeration Service Operations (Rev 6/98) Installation Oil the gasket, install it on the housing, and place the shims in the end cap (use same number as removed). Install the throttling valve using a new O-ring soaked in Tighten the end cap in place with the vent hole closest compressor oil.
Page 104: Hot Gas Solenoid Valve
Refrigeration Service Operations (Rev 6/98) HOT GAS SOLENOID VALVE 10. Unsolder and remove modulation valve from the suc- tion line assembly. Removal CAUTION: Use a heat sink or wrap the valve Recover the refrigerant charge. with wet rags to prevent damaging the valve. Disconnect the wires and remove the coil from the Installation valve.
Page 105: Liquid Line Check Valve Replacement
Refrigeration Service Operations (Rev 6/98) Install the fan module, the fan belt, and both idler pul- leys. Tighten the fan belt to the proper tension, and install the grille. Open the refrigeration valves and run the unit. Check the refrigerant charge and compressor oil. LIQUID LINE CHECK VALVE REPLACEMENT Removal...
Page 106: Thermax-V Expansion Valve
Refrigeration Service Operations (Rev 6/98) THERMAX-V EXPANSION VALVE Removal Pump down the low side and equalize the pressure to slightly positive. Remove the grille, both idler pulleys, the fan belt, and the fan module. Remove the feeler bulb from the clamp. Note the posi- tion of the feeler bulb on the suction line.
Page 107: Structural Maintenance
Structural Maintenance UNIT AND ENGINE MOUNTING BOLTS Check and tighten all unit and engine mounting bolts during scheduled maintenance inspections. Torque the unit mount- ing bolts to 81.3 N•m (60 ft-lb). Torque the engine mount- ing bolts to 203 N•m (150 ft-lb). AEA1378 Thick Washer Plate Standard Washer...
Page 108: Condenser, Evaporator, And Radiator Coils
Structural Maintenance (Rev 6/98) CONDENSER, EVAPORATOR, AND RADIATOR COILS Check the coils during scheduled maintenance inspections. Remove any debris (e.g., leaves or plastic wrap) that reduces the air flow. Clean dirty coils with compressed air or a pressure washer. Be careful not to bend the fins when cleaning a coil.
Page 109: Fan Module
Structural Maintenance (Rev 6/98) FAN MODULE Installation Place the fan module in the frame and loosely install all Removal of the mount bolts. Remove the condenser grille. Tighten the fan module mount bolts. Remove the condenser screen. Install the upper idler. Remove the condenser frame mount bolts and remove Install the lower idler but do not tighten the idler.
Page 110 Structural Maintenance (Rev 6/98) Condenser Grille Condenser Screen Condenser Frame Condenser Orifice Condenser Fan Fanshaft Assembly Bulkhead Evaporator Blower Evap. Inlet Orifice AEA1380 Fan Module Assembly...
Page 111: Fan Shaft Assembly
Structural Maintenance (Rev 6/98) FAN SHAFT ASSEMBLY With the roll pin removed, place a pipe over the shaft and drive one bearing down until the opposite bearing The unit is equipped with a one-piece fan shaft assembly and bearing spacer release from the shaft. that contains tapered roller bearings in a sealed oil reservoir.
Page 112 Structural Maintenance (Rev 6/98) AEA1381 Seal Plug Retainer Cap Seal O-ring Plug Bearing Spacer Shims Roll Pin Splash Guard Bearing Shaft Air Vent Fanshaft Assembly...
Page 113: Condenser Fan Positioning
23 N•m (15-17 ft-lb). bearings. Check the clearance between the taper hub and the fan NOTE: Use ONLY Thermo King special fan shaft oil hub. A minimum clearance of 2.5 mm (0.10 in.) assures P/N 203-278 in this assembly.
Page 114: Evaporator Blower Alignment
Structural Maintenance (Rev 6/98) EVAPORATOR BLOWER ALIGNMENT When mounting the evaporator blower assembly on the fan shaft, the blower and inlet orifice must be properly aligned for proper air flow and to prevent damage to the blower. Slide the blower onto the fan shaft. Shim the inlet orifice to position it 198.1 ±...
Page 115 Structural Maintenance (Rev 6/98) Bulkhead Panel Check Clearance with 2.3 mm (0.09 in.) gauge wire 198.1 ± 1.3 mm (7.8 ± 0.05 in.) Shim as needed Blower to inlet orifice overlap 2.5-3.8 mm (0.10-0.15 in.) Blower Assembly Inlet Orifice Evaporator Blower Alignment AEA1383...
Page 117: Electrical Diagnosis
Electrical Diagnosis CONDITION POSSIBLE CAUSE REMEDY Run relay will not energize K7 relay defective Remove and test K7 relay Fault in RRP circuit Test RRP circuit No power to pin 85 Check for power on 8F circuit Faulty microprocessor Replace microprocessor Faulty relay logic board Replace relay logic board Fuel solenoid will not pull in...
Page 118 Electrical Diagnosis (Rev 6/98) CONDITION POSSIBLE CAUSE REMEDY Faulty high speed solenoid (HSS) Test HSS Faulty 7D circuit Test 7D circuit Poor ground to HSS Test CHS circuit Unit will not heat Fault in 26 circuit Test 26 circuit Faulty pilot solenoid coil Test pilot solenoid coil Poor power to pilot solenoid coil Test power to pilot solenoid coil...
Page 119 Electrical Diagnosis (Rev 6/98) CONDITION POSSIBLE CAUSE REMEDY Fault in MV circuit Test MV circuit Faulty modulation valve coil Test modulation valve coil defective microprocessor Replace microprocessor Microprocessor Dead Fuse open Test fuse 12 Fault in 2P circuit Test 2P circuit Fault in CHP circuit Test CHP circuit Battery dead...
Page 121: Fault Indication Diagnosis
Fault Indication Diagnosis The following fault indicator functions will be held in mem- Alarm Code Legend ory and displayed on the temperature readout display when (ST) = Stored Alarm the Alarm [CODE] key is pressed. There are several alarm types that can be indicated by the controller. (CH) = Check Alarm (SH) = Shutdown Alarm SHUTDOWN ALARMS...
Page 122 Fault Indication Diagnosis (Rev 6/98) 03 (CH) (*) Return Air Sensor 05 (ST) (*) Ambient Air Sensor Possible cause: open sensor lead. Possible cause: open sensor lead. Test procedure: test for continuity. Test procedure: test for continuity. Possible cause: shorted sensor lead. Possible cause: shorted sensor lead.
Page 123 Fault Indication Diagnosis (Rev 6/98) 07 (ST) (*) Engine RPM Sensor 11 (CH) (*) Unit Controlling On Discharge Air Possible cause: faulty rpm sensor. Possible cause: faulty return air sensor. Test procedure: test rpm sensor. Test procedure: check return air sensor. Possible cause: faulty FS1 or F52 wire.
Page 124 Fault Indication Diagnosis (Rev 6/98) 17 (SH) (*) Engine Failed To Crank 21 (CH) (*) Cooling Cycle Check (CYCLE-SENTRY) Possible cause: low on refrigerant. Possible cause: CYCLE-SENTRY system failure. Test procedure: check refrigerant level. Test procedure: test CYCLE-SENTRY system. Possible cause: defective three-way valve. 18 (SH) (*) (**) High Engine Water Temperature Test procedure: check three-way valve operation.
Page 125 Fault Indication Diagnosis (Rev 6/98) 22 (CH) (*) Heating Cycle Check 23 (SH) (*) Cooling Cycle Fault Possible cause: low on refrigerant. Possible cause: low on refrigerant. Test procedure: check refrigerant level. Test procedure: check refrigerant level. Possible cause: defective three-way valve. Possible cause: defective three-way valve.
Page 126 Fault Indication Diagnosis (Rev 6/98) 24 (SH) (*) Heating Cycle Fault 26 (CH) (*) Check Refrigeration Capacity Possible cause: low on refrigerant. Possible cause: low on refrigerant. Test procedure: check refrigerant level. Test procedure: check refrigerant level. Possible cause: defective three-way valve. Possible cause: compressor inefficient.
Page 127 Fault Indication Diagnosis (Rev 6/98) 28 (SH) (*) (**) Pre-trip Abort 32 (CH) (SH) (*) Refrigeration Capacity Low Possible cause: defrost damper stuck closed. Possible cause: low on refrigerant. Test procedure: free defrost damper. Test procedure: check refrigerant level. Possible cause: On-Off switch turned OFF during amps Possible cause: defective three-way valve.
Page 128 Fault Indication Diagnosis (Rev 6/98) 34 (ST) (CH) (*) (**) Check Modulation Circuit 40 (CH) (*) High Speed Circuit Possible cause: modulation valve disconnected. Possible cause: defective K2 relay. Test procedure: reconnect modulation valve. Test procedure: test K2 relay. Possible cause: open circuit to modulation valve coil. Possible cause: open 7DD and 7D circuit.
Page 129 Fault Indication Diagnosis (Rev 6/98) 52 (CH) (*) Heat Circuit 73 (ST) (*) (***) Maintenance Interval Hourmeter #6 Exceeds Set Limit Possible cause: faulty heat relay. Possible cause: hourmeter 6 has exceeded its limit. Test procedure: test relay. 74 (SH) (*) (***) uP Reverted to Default Setting 55 (CH) (*) No Low Speed CAUTION: All calibrations and setups must be Possible cause: speed solenoid stuck.
Page 131: Mechanical Diagnosis
Mechanical Diagnosis CONDITION POSSIBLE CAUSE REMEDY Unit switch ON—LCD blank or Battery discharged Charge or replace battery backlight does not come on Faulty battery cable connections Clean battery cables Fuse blown Check for short circuit in unit wiring Unit switch ON and LCD backlight Batteries discharged Replace or recharge battery ON but engine will not crank...
Page 132 Mechanical Diagnosis (Rev 8/97) CONDITION POSSIBLE CAUSE REMEDY Engine stops after starting Fuse blown Check for short circuit in unit wiring (Continued) Engine does not develop full Air intake system clogged Clean air intake system power Fuel tank vent clogged Unclog vent Clogged fuel tank or fuel lines Clean fuel tank and fuel lines...
Page 133 Mechanical Diagnosis (Rev 8/97) CONDITION POSSIBLE CAUSE REMEDY Engine knocks heavily Air in system Bleed fuel system Injection pump not timed Retime injection pump Wrong fuel Change fuel Compression too low Overhaul engine Injection nozzles fouled or opening Clean, repair or replace injection pressure too low nozzles Valve out of adjustment...
Page 134 Mechanical Diagnosis (Rev 8/97) CONDITION POSSIBLE CAUSE REMEDY High oil consumption Oil leakage Check and eliminate possible causes at cylinder head cover, oil lines, oil filter, front timing cover or crankshaft seals Damaged valve seals Replace seals on valve stem Worn valve stem Replace valves Broken piston rings or cylinder bore...
Page 135: Refrigeration Diagnosis
Refrigeration Diagnosis POSSIBLE CAUSES • • • • Overcharge of refrigerant • • • • • • Shortage of refrigerant • • • • • No refrigerant • Air through condenser too hot (ambient) • Air flow through condenser restricted •...
Page 136 Refrigeration Diagnosis (Rev 6/98) POSSIBLE CAUSES • • Expansion valve open too much • • Expansion valve closed too much • • Expansion valve needle eroded or leaking • • • Expansion valve partially closed by ice, dirt or wax •...
Page 137: Refrigeration Cycle Without Modulation
Refrigeration Diagnosis (Rev 6/98) REFRIGERATION CYCLE WITHOUT MODULATION Compressor Discharge Service Valve Discharge Vibrasorber Discharge Line Three-way Valve Three-way Valve Bypass Check Valve Condenser Coil Condenser Check Valve High Pressure Relief Valve Receiver Tank Sight Glass Receiver Outlet Valve Liquid Line Dehydrator Heat Exchanger Expansion Valve...
Page 138: Refrigeration Cycle With Modulation
Refrigeration Diagnosis (Rev 6/98) REFRIGERATION CYCLE WITH MODULATION Compressor Discharge Service Valve Discharge Vibrasorber Discharge Line Three-way Valve Three-way Valve Bypass Check Valve Condenser Coil Condenser Check Valve High Pressure Relief Valve Receiver Tank Sight Glass Receiver Outlet Valve Liquid Line Dehydrator Heat Exchanger Expansion Valve...
Page 139 Refrigeration Diagnosis (Rev 6/98) DEFROST AND HEATING CYCLE WITHOUT MODULATION Compressor Discharge Service Valve Discharge Vibrasorber Discharge Line Three-way Valve Three-way Valve Bypass Check Valve Condenser Coil Condenser Check Valve High Pressure Relief Valve Receiver Tank Sight Glass Receiver Outlet Valve Liquid Line Dehydrator Heat Exchanger...
Page 140 Refrigeration Diagnosis (Rev 6/98) DEFROST AND HEATING CYCLE WITH MODULATION Compressor Discharge Service Valve Discharge Vibrasorber Discharge Line Three-way Valve Three-way Valve Bypass Check Valve Condenser Coil Condenser Check Valve High Pressure Relief Valve Receiver Tank Sight Glass Receiver Outlet Valve Liquid Line Dehydrator Heat Exchanger...
Page 141 Schematic Diagram SBIII/SII/RMNII 30 SR+ MPIV+...
Page 142 Wiring Diagram SII/SBIII/RMN30 SR+, MPIV+ Page 1 of 4...
Page 143 Wiring Diagram SII/SBIII/RMN30 SR+, MPIV+ Page 2 of 4...
Page 144 Wiring Diagram SII/SBIII/RMN30 SR+, MPIV+ Page 3 of 4...
Page 145 Wiring Diagram SII/SBIII/RMN30 SR+, MPIV+ page 4 of 4...

Thermo King Super II SR+ Manual

Safety Precautions

Specifications

Maintenance Inspection Schedule

Unit Description

Operating Instructions

Electronic Controls

Electronic Controls (Continued)

Electrical Maintenance

Engine Maintenance

Engine Maintenance (Continued)

Refrigeration Maintenance

Refrigeration Service Operations

Structural Maintenance

Electrical Diagnosis

Fault Indication Diagnosis

Mechanical Diagnosis

Refrigeration Diagnosis

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