Thermo King SB-190 30 Manual
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Thermo King SB-190 30 Manual

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SB-190 30
TK 51245-2-MM (Rev. 2, 12/03)
Copyright© 2001 Thermo King Corp., Minneapolis, MN, U.S.A.
Printed in U.S.A.

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  • Page 1 SB-190 30 TK 51245-2-MM (Rev. 2, 12/03) Copyright© 2001 Thermo King Corp., Minneapolis, MN, U.S.A. Printed in U.S.A.
  • Page 2 If further information 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 Express Warranty. Such terms and conditions are available upon request.
  • Page 3 Recover Refrigerant At Thermo King, we recognize the need to preserve the environ- ment 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 Specifications ................1 Maintenance Inspection Schedule .
  • Page 6 Table of Contents (continued) Engine Maintenance............... 37 Engine Lubrication System .
  • Page 7 Table of Contents (continued) Refrigeration Service Operations (continued) Three-Way Valve Repair ..............73 Three-Way Valve Condenser Pressure Bypass Check Valve Repair .
  • Page 9 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 10 Safety Precautions (Rev. 02/03) ELECTRICAL HAZARDS First Aid IMMEDIATE action must be initiated after a person has High Voltage received an electrical shock. Obtain immediate medical assistance if available. When servicing or repairing a refrigeration unit, the possi- bility of serious or even fatal injury from electrical shock The source of shock must be immediately removed by exists.

  • Page 11: Specifications

    Specifications ENGINE Model Thermo King se 2.2 Number of Cylinders Cylinder Arrangement In-line vertical, number 1 on pulley end Firing Order 1-3-4-2 Direction of Rotation Counterclockwise viewed from flywheel end Fuel Type No. 2 diesel fuel under normal conditions No. 1 diesel fuel is acceptable cold weather fuel Oil Capacity: Crankcase 14.2 liters (15 quarts) crankcase...
  • Page 12 Specifications (Rev. 12/03) REFRIGERATION SYSTEM Compressor Thermo King X430L Refrigerant Charge—Type: 13 lb (5.9 kg)—R-404A Compressor Oil Charge 4.3 qt (4.1 liters)* Compressor Oil Type Polyol Ester type P/N 203-413 Throttling Valve Setting 27 to 29 psi (187 to 200 kPa) Standard with non-ETV...
  • Page 13 Specifications (Rev. 12/03) ELECTRICAL COMPONENTS NOTE: Disconnect components from unit circuit to check resistance. Current Draw (Amps) Resistance—Cold at 12.5 Vdc (Ohms) Fuel Solenoid Damper Solenoid Throttle Solenoid Glow Plug Pilot Solenoid 17.0 Starter Motor—Gear Reduction Type 250-375* Modulation Valve (Optional) 1.7** Hot Gas Bypass Valve (Optional) 11.1...

  • Page 15: Maintenance Inspection Schedule

    Maintenance Inspection Schedule Fuel Every Every Annual Inspect/Service These Items Island 1,500 3,000 4,500 Pre-trip Hours Hours* Hours Engine • Check fuel supply and engine oil level. Inspect belts for condition and proper tension • (belt tension tool No. 204-427). •...
  • Page 16 Maintenance Inspection Schedule (Rev. 12/03) Fuel Every Every Annual Inspect/Service These Items Island 1,500 3,000 4,500 Pre-trip Hours Hours* Hours Engine (Continued) • • • Check air cleaner restriction indicator (change when indicator reaches 22 in.). Replace EMI 3000 air cleaner element at 3,000 hours or two years (whichever occurs first) if air cleaner restriction indicator has not reached 22 in.
  • Page 17 Maintenance Inspection Schedule (Rev. 12/03) Fuel Every Every Annual Inspect/Service These Items Island 1,500 3,000 4,500 Pre-trip Hours Hours* Hours Engine (Continued) ENGINE OIL CHANGE INTERVALS (see below) NOTE: Change engine oil and filter (hot). • • • Standard blue (or silver) oil filter. •...
  • Page 18 Maintenance Inspection Schedule (Rev. 12/03) Fuel Every Every Annual Inspect/Service These Items Island 1,500 3,000 4,500 Pre-trip Hours Hours* Hours Structural • • • • Visually inspect unit for fluid leaks. • • • • Visually inspect unit for damaged, loose or broken parts (includes air ducts). •...

  • Page 19: Unit Description

    Unit Description The unit is a one-piece, self-contained, diesel powered CYCLE-SENTRY Start-Stop Controls refrigeration-heating unit. The unit mounts on the front of A CYCLE-SENTRY Start-Stop fuel saving system provides the trailer with the evaporator portion extending into the optimum operating economy. Selecting Continuous or trailer.
  • Page 20 Detailed graph or table trip • Preheat indicator buzzer. reports can then be created. Thermo King X430L Compressor The unit is equipped with a Thermo King X430L, four- cylinder compressor with 30 cu. in. (492 cm ) displacement.

  • Page 21: Sequence Of Operation

    Unit Description (Rev. 12/03) Refrigeration Modulation System • Discharge Pressure Protection. This protection algo- rithm provides an additional measure of protection The ETV system provides precise control of the refrigera- against high discharge pressures and possible compres- tion system and the temperature of the cargo area. As the sor damage.
  • Page 22 Unit Description (Rev. 12/03) Diesel Operation timer can be set for 4, 6, 8 or 12 hours. The standard setting is 6 hours. When the unit is not In-Range, defrost intervals In diesel operation the microprocessor will select the oper- are determined by the Defrost Interval Not In-Range timer ating mode from the list of possible modes below: (DEFN).

  • Page 23: Design Features

    DESIGN FEATURES • SE 2.2 Direct Injection Diesel Engine • X430L Compressor • Top Mount Muffler • Thermo King Radiator • Rust-Free Composite Lower Doors and Panels • Injection Molded Grilles • Fiberglass Top Cap • Stainless Steel Exterior Condenser Hardware •...

  • Page 24: Protection Devices

    Unit Description (Rev. 12/03) Unit Model SB-190 30 (002006) PROTECTION DEVICES • Engine Coolant Temperature Sensor • Engine Low Oil Pressure Switch • Engine Low Oil Level Switch • Evaporator Coil Temperature Sensor • Refrigerant High Pressure Cutout Switch •...

  • Page 25: Serial Number Locations

    Unit Description (Rev. 12/03) SERIAL NUMBER LOCATIONS Unit. Nameplates on the roadside of the 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.
  • Page 26 Unit Description (Rev. 12/03) AJA890 Front View...
  • Page 27 Unit Description (Rev. 12/03) AJA894 Defrost Damper X430L Compressor se 2.2 Engine Back View...
  • Page 28 Unit Description (Rev. 12/03) Condenser Fan X430L Compressor Condenser Coil Fuel Filter/Water Separator Expansion Tank Air Cleaner SE 2.2 Engine Front View with Doors Open (Model 30)
  • Page 29 Unit Description (Rev. 12/03) Discharge Service Valve 10. Receiver Tank Sight Glass Suction Service Valve Battery Tray Throttle Solenoid 12. Hand Primer Pump Air Restriction Indicator 13. Dipstick Fuel Solenoid 14. Oil Filter Fuel Bleed Screw 15. Starter Alternator 16. Compressor Sight Glass Filter Drier 17.
  • Page 30 Unit Description (Rev. 12/03) ARA158 DAS (Optional) Relay Board Microprocessor Control Box Components...

  • Page 31: Operating Instructions

    Operating Instructions CONTROL PANEL On/Off Switch This switch turns the unit on and off. When the switch is in Most of the controls used to operate the unit are located on the “Off” position, the display will be off and the display the control panel.
  • Page 32 Operating Instructions (Rev. 12/03) WARNING: unit start When the switch is in the “On” position, the display back- automatically any time the On/Off switch is in the light will turn on and the Standard Display will appear. “On” position. When the switch is in the “Sleep” position, the unit will enter the Sleep Mode, the display backlight will turn on and On/Off/Sleep Switch (Optional) the display will show [SLEEP] and [MODE].
  • Page 33 Operating Instructions (Rev. 12/03) NOTE: The unit will not control the box temperature Alarm Icon Appears when the microprocessor when the switch is in the “Sleep” position. detects an alarm condition. Modulation 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.
  • Page 34 Operating Instructions (Rev. 12/03) Thermo King Logo Key Allows selection of Pretrip Select Key Pressing this key displays temperature Test, Print and Start of Trip and displays software sensor reading and Sleep Mode Wakeup Time (if pro- revision and clock/calendar settings.

  • Page 35: Unit Indicators

    Operating Instructions (Rev. 12/03) UNIT INDICATORS Fuse F21 (25 amp) protects the circuit that provides power to the On/Off switch. RECEIVER TANK SIGHT GLASS. The receiver A number of 2 and 5 amp fuses protect microprocessor tank sight glass is used to check the amount of refriger- circuits, control relay circuits, remote light circuits and ant in the system, and the moisture content of the various components.

  • Page 36: Unit Operation

    Operating Instructions (Rev. 12/03) SETPOINT/MODE KEY BUZZER. This buzzer ELECTRICAL. The electrical connections should be sounds when the setpoint is changed until the Enter securely fastened. The wires and terminals should be Key is pressed. It also sounds when a Mode Key selec- free of corrosion, cracks or moisture.

  • Page 37: Selection Of Operating Modes

    Selection of Operating Modes PRE TRIP has started. The Thermo King CYCLE-SENTRY system is designed to • The amps check will continue for several min- save refrigeration fuel costs. The savings vary with the com- utes, then the unit will start automatically and modity, ambient temperatures and trailer insulation.

  • Page 38: Restarting Unit-Diesel Operation

    Operating Instructions (Rev. 12/03) Your selection of the operating mode for the proper protec- Restarting Unit—Diesel Operation tion of a particular commodity should use the following This procedure is used when starting units that have been guidelines: shut off for short periods of time. When a unit that has been shut off for a long period of time is first started, it should be Examples of Products Normally Acceptable for started and put through a full pretrip.

  • Page 39: Loading Procedure

    Operating Instructions (Rev. 12/03) imum of 1/2 hour (longer if possible) before loading the Load the product so that there is adequate space for air trailer. circulation completely around the load. DO NOT block the evaporator inlet or outlet. This provides a good test of the refrigeration system while removing residual heat and the moisture from the Products should be pre-cooled before loading.
  • Page 40 Operating Instructions (Rev. 12/03)

  • Page 41: Electrical Maintenance

    Electrical Maintenance AUSTRALIAN BOSCH ALTERNATOR CAUTION: The F15 fuse must be removed from the relay board on units equipped with the Australian NOTE: Units manufactured with CYCLE-SENTRY and Bosch alternator. The voltage regulator will be dam- alternators with integral regulators MUST use replace- aged if the unit is turned ON with the F15 fuse in ment alternators with integral regulators.
  • Page 42 When testing alternators use accurate equipment such The A pin is the battery sense circuit and should be as a Thermo King P/N 204-615 (FLUKE 23) digital at battery voltage. If not, check the sense circuit (2 multimeter and a Thermo King P/N 204-613 amp or equivalent) in the alternator harness and in the clamp or an equivalent.
  • Page 43 Electrical Maintenance (Rev. 12/03) 13. Check the amperage in the 2A wire and record the read- Field Current Test (Checks the field windings, brushes and slip rings) ing. Check the voltage at the B+ terminal and continue to observe this voltage for a few seconds to see if it Perform this test with the On/Off switch in the OFF increases, decreases, or stays the same.
  • Page 44 Electrical Maintenance (Rev. 12/03) Check Point for 2A Amperage Position for Full Fielding Jumper Full Field Test...

  • Page 45: Battery (Dealer Supplied)

    Electrical Maintenance (Rev. 12/03) BATTERY (DEALER SUPPLIED) • A number of 2 and 5 amp fuses protect microprocessor circuits, control relay circuits, remote light circuits, and NOTE: The unit On/Off switch must be placed in the OFF various components. position before connecting or disconnecting the battery terminals.

  • Page 46: Glow Plugs

    Electrical Maintenance (Rev. 12/03) GLOW PLUGS and the reset switch is burned out. Check each glow plug, a shorted glow plug will have very low resistance. Glow plugs heat the combustion chamber to aid in quick starting. The glow plugs are energized when the Preheat- Start switch is held on the PREHEAT or START position (or when the Cycle-Sentry control module initiates a unit start- up with the Cycle-Sentry switch in the CYCLE position).

  • Page 47: Engine Maintenance

    Engine Maintenance ENGINE LUBRICATION SYSTEM oil filter. The oil is forced through the oil filter into the main oil gallery. The main oil gallery supplies oil to the main The se 2.2 diesel engine has a pressure lubrication system. bearings, camshaft, and camshaft idler gear support. Oil is circulated by a gear-type oil pump driven off a gear on Oil passes from the main bearings, through drilled passages the camshaft.

  • Page 48: Engine Oil Change

    Provides lubrication for the water pump seal. The oil filter should be changed along with the engine oil. Antifreeze Maintenance Procedure Use a genuine Thermo King oil filter. As with all equipment containing antifreeze, periodic Remove the filter. inspection on a regular basis is required to verify the condi- Apply oil to the rubber ring of the new filter and install tion of the antifreeze.
  • Page 49 Engine Maintenance (Rev. 12/03) Changing the Antifreeze Checking the Antifreeze Run the engine until it is up to its normal operating Check the solution concentration by using a temperature temperature. Stop the unit. compensated antifreeze hydrometer or a refractometer (P/N 204-754) designed for testing antifreeze.
  • Page 50 Engine Maintenance (Rev. 12/03) Open the engine block drain and completely drain the Bleeding Air from the Cooling System coolant. Observe the coolant color. If the coolant is Jiggle pin thermostats are original equipment on units that dirty, proceed with a, b and c. Otherwise go to 3. have se 2.2 engines.

  • Page 51: 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 52 Engine Maintenance (Rev. 02/03) AJA897 Fuel Filter Bleed Screw Water Separator Injection Pump Transfer Pump Injection Line Prefilter Return Fuel Line Hand Pump Engine Fuel System...

  • Page 53: Bleeding The Fuel System

    Engine Maintenance (Rev. 12/03) Maintenance Fuel transfer pump replacement or repair.* The injection pump and fuel transfer pump are relatively Injection line replacement.* trouble-free and if properly maintained will usually not Injection pump and governor adjustments. require major service repairs between engine overhauls. Injection pump timing.

  • Page 54: Draining Water From Fuel Tank

    Engine Maintenance (Rev. 12/03) Fuel Filter/Water Separator To bleed air from the fuel system: Loosen the bleed screw on top of the injection pump The fuel filter/water separator removes water from the fuel about one turn. and returns it to the fuel tank. Unscrew the priming pump handle and manually prime Fuel Filter/Water Separator Replacement the fuel system until air bubbles are no longer visible in...
  • Page 55 Engine Maintenance (Rev. 12/03) Check the prefilter screen. Check the speed. NOTE: If the correct speed cannot be set close enough with half turns of the eye bolt, use the Allen Bleed the air out of the fuel system. Check the speed. wrench to turn the plunger in smaller increments.

  • Page 56: Injection Pump Service

    Engine Maintenance (Rev. 12/03) Injection Pump Service NOTE: The procedure outlined will assume the pump is being 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 Remove the fuel injection lines.
  • Page 57 Engine Maintenance (Rev. 12/03) ditdc diitm Injection Timing Mark TC Mark on Flywheel NOTE: The injection timing mark is a line scribed in Before installing the pump, rotate the gear until the “O” the flywheel approximately 35 mm (1-3/8 in.) from the marked on the gear is approximately in the 10 o’clock TC mark.
  • Page 58 Engine Maintenance (Rev. 12/03) Install the pump in the engine, lining up the “O” with Rotate the engine backwards, counterclockwise from the timing mark cast into the access hole. the front, to approximately 89 mm (3.5 in.) from the TC mark on the flywheel.

  • Page 59: Adjusting Engine Valve Clearance

    Engine Maintenance (Rev. 12/03) ADJUSTING ENGINE VALVE CLEARANCE Remove the valve cover. Torque the cylinder head bolts to 85 N•m (63 ft-lb) before adjusting the valves. It is very important that the valves be adjusted to the correct specifications for satisfactory engine operation. Insufficient valve clearance will result in compression loss and misfiring resulting in burned valves and seats.
  • Page 60 Engine Maintenance (Rev. 12/03) 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 61: Positive Crankcase Ventilation

    Engine Maintenance (Rev. 12/03) POSITIVE CRANKCASE VENTILATION Checking Crankcase Pressure The Positive Crankcase Ventilation (PCV) system ducts (See Figure 2-63, Measuring Crankcase Pressure, from gases formed in the crankcase directly to the intake. Harm- Overhaul Manual - di 2.2 and se 2.2, TK 8009-3; pg. 33.) ful vapors that would otherwise collect in the crankcase and Use a 127 to 254 mm (5 to 10 in.) Magnehelic Gauge to contaminate the oil, or escape to the outside, are now drawn...

  • Page 62: Engine Air Cleaner (Filter)

    Engine Maintenance (Rev. 12/03) GOOD AGA153 Air Intake Manifold Crossover Hose (Side View) Valve Cover Crossover Hose Alignment Checking Oil Level NOTE: Care should be taken when using the dipstick to measure engine oil level. The PCV system will cause oil to be thrown out when the dipstick is removed.

  • Page 63: Belts

    Engine Maintenance (Rev. 12/03) BELTS Upper and Lower Fan Belt Adjustment The upper fan belt should read 74 and the lower fan belt Belts should be regularly inspected during unit pretrip should read 67 on the belt tension gauge. inspections for wear, scuffing or cracking. Belt tension should also be checked during scheduled maintenance NOTE: Both the upper and lower fan belts are adjusted at inspections.
  • Page 64 Engine Maintenance (Rev. 12/03) aea709 Upper Fan Belt Condenser Fan Pulley Condenser Fan Condenser Inlet Ring Idler Assembly Belt Guide Lower Fan Belt Engine Pulley Idler Adjusting Arm 10. Alternator Belt Model 30 Belt Arrangement...
  • Page 65 Engine Maintenance (Rev. 12/03) Installation Lift the belt up over the condenser blower wheel and remove it from the unit. Slip the belt into the groove of the idler pulley. Push the idler adjusting arm back in toward the unit. Installation Slip the belt over the condenser blower wheel and place Slip the belt onto the pulley groove on the engine.
  • Page 66 Engine Maintenance (Rev. 12/03) Torque the blower hub clamping bolts to 24 N•m (18 ft-lb). Seat the upper belt in the blower wheel pulley groove. Push inward on the idler adjusting arm and slip the belt into the idler pulley groove. Pull the idler adjusting arm forward and install the lower fan belt.

  • Page 67: Refrigeration Maintenance

    Refrigeration Maintenance NOTE: The following procedures involve servicing the refrigeration system. Some of these service procedures are regu- lated by Federal, and in some cases, by State and Local laws. In the USA all regulated refrigeration service procedures must be performed by an EPA certified technician, using approved equipment and complying with all Federal, State and Local laws.
  • Page 68 Testing for an Overcharge Perform a refrigerant level check and repeat the over- charge test. Use the following procedure to identify a Thermo King unit with an excessive refrigerant charge: If the liquid level is low, add refrigerant as follows: Install a calibrated gauge manifold on the compressor.

  • Page 69: Refrigerant Leaks

    Refrigeration Maintenance (Rev. 12/03) ARA035 Colored Ring Moisture Indicating Sight Glass A system has to run for at least 15 minutes to change the color of the indicator ring after the moisture content of the ARA115 system has been changed. For example, evacuating a system to remove the moisture will not change the color of the indi- Sight Glass cator ring until the system has been recharged and then...

  • Page 70: High Pressure Cutout Switch (Hpco)

    Refrigeration Maintenance (Rev. 12/03) To add compressor oil pump down the compressor and equalize the pressure to slightly positive. Disconnect the compressor oil filter return line from the top of the compres- sor and add the oil. Reattach the oil filter return line to the compressor.
  • Page 71 Refrigeration Maintenance (Rev. 12/03) When the unit is running on defrost or heat, if the condenser To check the operation of the valve: pressure is higher than the discharge pressure, the check Remove the condenser pressure bypass check valve cap valve opens and the condenser pressure is bled off until it from the three-way valve.

  • Page 72: Electronic Throttling Valve (Optional)

    Refrigeration Maintenance (Rev. 12/03) ELECTRONIC THROTTLING VALVE (OPTIONAL) The optional Electronic Throttling Valve (ETV) is a vari- able position valve operated by a stepper motor. The ETV is located in the suction line between the evaporator and the heat exchanger. The ETV system also uses discharge and suction pressure transducers, and a hot gas bypass valve.

  • Page 73: Hot Gas Solenoid (Optional)

    Refrigeration Maintenance (Rev. 12/03) HOT GAS SOLENOID (OPTIONAL) The hot gas solenoid (or hot gas bypass valve) is used in conjunction with the electronic throttling valve to reduce the capacity of the unit during modulation. This normally closed solenoid valve is located in the refrigeration line that connects the discharge line to the hot gas line.

  • Page 75: 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. COMPRESSOR Installation Slide the compressor into the unit. Removal Place the compressor in position, install the compressor Pump down the low side and equalize the pressure to...

  • Page 76: Compressor Coupling Removal (Model 30)

    Refrigeration Service Operations (Rev. 12/03) Compressor Coupling Removal To prevent the tool and crankshaft from rotating, use one of the compressor to engine mounting screws to pin (Model 30) the tool to the flange. If a nut is used to prevent the bolt After the compressor has been removed from the unit, from falling out, the nut should not be tightened.

  • Page 77: Compressor Coupling Installation (Model 30)

    Refrigeration Service Operations (Rev. 12/03) Compressor Coupling Installation (Model 30) In a tapered fit joint the entire twisting load should be han- dled by the friction fit between the two tapered parts. The key is only a backup and is used to index the parts correctly. When a taper fit is machined and assembled properly a key is not needed.

  • Page 78: Condenser Coil

    Refrigeration Service Operations (Rev. 12/03) Install the key in the keyway. As above, it should fit with CONDENSER COIL a light press fit requiring only a minimum of light tap- Removal ping. Do not install the key into the keyway beyond the front face of the coupling.

  • Page 79: Discharge Vibrasorber

    Refrigeration Service Operations (Rev. 12/03) DISCHARGE VIBRASORBER CONDENSER CHECK VALVE REPLACEMENT Removal Removal Recover the refrigerant charge. Recover the refrigerant charge. Heat the connections on the vibrasorber until the vibra- sorber can be removed. Place a heat sink on the check valve. CAUTION: Use a heat sink, P/N 204-584 or Unsolder the lines and remove the check valve.

  • Page 80: Bypass Check Valve

    Refrigeration Service Operations (Rev. 12/03) BYPASS CHECK VALVE Remove the high pressure relief valve from the receiver tank. Removal Unbolt the mounting brackets and remove the receiver Pump down the low side and equalize the pressure to tank from the unit. slightly positive.

  • Page 81: Expansion Valve Assembly

    Refrigeration Service Operations (Rev. 12/03) Install the new drier and tighten the mounting hard- Clean the suction line to a bright polished condition. ware. Install the feeler bulb clamps and the feeler bulb on the side of the suction line in its former position. The feeler Install and tighten the inlet nut.

  • Page 82: Evaporator Coil

    Refrigeration Service Operations (Rev. 12/03) Remove the mounting bolts that hold the heat Clean the suction tube to a brightly polished condition. exchanger on the bulkhead. Install the feeler bulb clamps and the feeler bulb on the side of the suction line in its former position. The feeler Disconnect the equalizer line from the suction line.

  • Page 83: Accumulator

    Refrigeration Service Operations (Rev. 12/03) Pressurize the low side and test for leaks. If no leaks are Installation found, evacuate the low side. Place the accumulator in the unit and tighten the mounting bolts and nuts. Clean the suction line to a bright polished condition. Install the feeler bulb on the side of the suction line in Solder the inlet and outlet suction lines to the accumu- its former position.
  • Page 84 Refrigeration Service Operations (Rev. 12/03) CAUTION: Do not force the tool into the brass NOTE: The valve body cannot be reconditioned. Seat or against the bolts. positions change and improper sealing will result. Gasket Tool P/N 204-424 Remove the four bolts from the valve. Remove the top cap and spring.
  • Page 85 Refrigeration Service Operations (Rev. 12/03) Use the three-way valve seal installation tool P/N 204-1008 to install a new seal on the piston. This prevents the seal from being stretched and damaged. Place the tapered tool over the piston. Lubricate the seal with refrigeration oil. Slide the seal onto the tapered tool with the spring side facing away from the piston.
  • Page 86 Refrigeration Service Operations (Rev. 12/03) Line up the passageways in the cap and body. Failure to Unscrew the check valve stem by using a screwdriver line up the holes will result in improper operation of the in the slot provided. valve.

  • Page 87: Pilot Solenoid

    Refrigeration Service Operations (Rev. 12/03) Installation Pressurize the refrigeration system and test for leaks. If no leaks are found, evacuate the system. Prepare the suction hose and tube fittings for soldering by cleaning thoroughly. Recharge the unit. Solder the vibrasorber to the suction service valve. PILOT SOLENOID CAUTION: Use a heat sink or wrap vibra- sorber with wet rags to prevent damaging the...

  • Page 88: Discharge Pressure Transducer (Optional)

    Refrigeration Service Operations (Rev. 12/03) HIGH PRESSURE RELIEF VALVE SUCTION PRESSURE TRANSDUCER (OPTIONAL) Removal Removal Recover the refrigerant charge. Pump down the low side and equalize pressure to Unscrew and remove the high pressure relief valve. slightly positive. Installation Disconnect the wires and remove the suction pressure transducer.
  • Page 89 Refrigeration Service Operations (Rev. 12/03) CAUTION: Unscrew the large nut. Do not If the complete ETV assembly is being replaced, unsol- unscrew the small nut. der and remove the valve body. It may be necessary to unsolder the tubes above or below the valve body to WARNING: If the ETV is stuck in the closed obtain enough clearance to remove the valve body.

  • Page 90: Compressor Oil Filter Change

    Refrigeration Service Operations (Rev. 12/03) Lubricate the piston and threads on the new stepper ARA167 motor and piston assembly with refrigeration oil. Screw the new stepper motor and piston assembly into the valve body. Torque the nut to approximately 100 ft-lb (136 N•m). Hold the valve body with backup wrench to prevent damage to the refrigeration tubing.

  • Page 91: Hot Gas Solenoid Valve (Optional)

    Refrigeration Service Operations (Rev. 12/03) Coat the new O-rings with clean compressor oil and HOT GAS SOLENOID VALVE (OPTIONAL) place them in the ORS fittings on the ends of the new Removal compressor oil filter. Recover the refrigerant charge. Fasten the new compressor oil filter in place with the clamp.

  • Page 93: 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 60 ft-lb (81 N•m). Torque the engine mounting bolts to 150 ft-lb (203 N•m). UNIT INSPECTION Inspect the unit during pre-trip inspection and scheduled maintenance inspections for loose or broken wires or hard-...

  • Page 94: Defrost Damper

    Structural Maintenance (Rev. 12/03) DEFROST DAMPER To adjust the damper: Remove the damper assembly from the evaporator. Check the damper during scheduled maintenance inspec- tions for shaft wear, end play, and the ability to stop the air Disconnect the damper link from the eye bolt. flow.

  • Page 95: Condenser And Evaporator Fan Location

    Structural Maintenance (Rev. 12/03) Check Distance A, the distance from the shoulder on Condenser Fan Blower the solenoid to the center of the hole in the eye bolt. Loosen the condenser inlet ring (spinning) on the con- Distance A should be 2.75 in. (69.85 mm) with the denser coil bulkhead.

  • Page 96: Fan Shaft Assembly Overhaul

    NOTE: The fan shaft assembly requires a special lubri- Check the radial clearance by passing a wire com- cant, Thermo King P/N 203-278. pletely around the circumference of the inlet rings and the blower wheel. Fan Shaft Assembly Overhaul Torque the blower hub bolts to 18 ft-lb (24 N•m).
  • Page 97 Use the original shims and replace the Shims available from the Service Parts Department: O-ring if needed. 0.020 in. (0.500 mm) Thermo King P/N 99-4231 Install the retainer cap assembly over the shaft, then 0.007 in. (0.177 mm) Thermo King P/N 99-2902 install the bolts.

  • Page 98: Idler Assembly

    Structural Maintenance (Rev. 12/03) After correct end-play is obtained, add oil for the bear- To remove the shaft from the assembly, tap the opposite ings. end of the shaft with a soft hammer. After the shaft has been removed, clean all the parts in clean solvent. Lock the assembly in a vise with the vent facing up.
  • Page 99 Check the condition of the O-ring used on the plugs and replace if necessary. Install the top and side 0.020 in. (0.500 mm) Thermo King P/N 99-4231 plugs. Clean up any spillage. 0.007 in. (0.177 mm) Thermo King P/N 99-2902 Place the assembly on the workbench with the vent up.

  • Page 101: Mechanical Diagnosis

    Mechanical Diagnosis CONDITION POSSIBLE CAUSE REMEDY Engine will not crank Electrical problem Check and repair electrical system Defective starter solenoid Replace solenoid Defective starter Repair starter Water in cylinders Check for hydrostatic lock. Remove injectors and turn engine slowly Starter motor turns but engine Starter clutch defective Replace does not crank...
  • Page 102 Mechanical Diagnosis (Rev. 02/03) CONDITION POSSIBLE CAUSE REMEDY 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 Speed adjustment wrong Adjust speed Insufficient fuel volume leaving filter Check for dirty filter or air in system...
  • Page 103 Mechanical Diagnosis (Rev. 02/03) CONDITION POSSIBLE CAUSE REMEDY Engine runs hot Dirty radiator Wash radiator Coolant level is low Add coolant Cooling system heavily scaled Cleaning cooling system Cylinder head gasket leaks Replace cylinder head gasket. Use correct gasket Faulty thermostat Check or replace thermostat Loose or worn water pump belt Replace belt...
  • Page 104 Mechanical Diagnosis (Rev. 02/03) ENGINE EMITS EXCESSIVE SMOKE WHITE SMOKE BLACK SMOKE BLUE SMOKE Fuel is not burning Excessive Fuel to Air Ratio Oil Consumption • Air or water in fuel • Type of fuel used • Poor compression • Incorrect timing •...

  • Page 105: 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 106 Refrigeration Diagnosis (Rev. 12/03) 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 107: Defrost And Heating Cycle

    Defrost and Heating Cycle 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 Drier Heat Exchanger Expansion Valve Feeler Bulb Equalizer Line...

  • Page 108: Refrigeration Cycle

    Refrigeration Cycle 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 Drier Heat Exchanger Expansion Valve Feeler Bulb Equalizer Line Distributor...

  • Page 109: Cool Cycle With Electronic Throttling Valve (Optional)

    Cool Cycle with Electronic Throttling Valve (Optional) 1. Compressor 2. Discharge Service Valve 3. Discharge Vibrasorber 4. Discharge Line 5. Three-way Valve 6. Three-way Valve Bypass Check Valve 7. Condenser Coil 8. Condenser Check Valve 9. High Pressure Relief Valve 10.

  • Page 110: Heat/Defrost Cycle With Electronic Throttling Valve (Optional)

    Heat/Defrost Cycle with Electronic Throttling Valve (Optional) 1. Compressor 2. Discharge Service Valve 3. Discharge Vibrasorber 4. Discharge Line 5. Three-way Valve 6. Three-way Valve Bypass Check Valve 7. Condenser Coil 8. Condenser Check Valve 9. High Pressure Relief Valve 10.

  • Page 111: Index

    Index Electronic Throttling Valve (ETV) 11 Electronic Throttling Valve (Optional) 62 Accumulator Replacement 73 Electronic Throttling Valve Replacement 78 After Start Inspection 28 Engine Air Cleaner 52 Air Restriction Indicator 25 engine coolant 6, 7 Alternator 31 Engine Cooling System 38 Antifreeze Maintenance Procedure 38 Engine Lubrication System 37 Engine Maintenance 37...
  • Page 112 Index (Rev. 02/03) Maintenance Inspection Schedule 5 Selection of Operating Modes 27 Manual Pretrip Inspection 26 Serial Number Locations 15 Mechanical Diagnosis 91 Setpoint/Mode Key Buzzer 26 Mounting Bolts, Engine 83 SMART REEFER µP-VI Microprocessor 9 Specifications 1 Starting Unit With Electronic Full Pretrip 26 Oil Change 38 Suction Pressure Transducer Replacement 78 Oil Filter Change 38, 80...

  • Page 113: Wiring Diagrams And Schematics

    SB-100/190 Schematic Diagram — Page 1 of 2...
  • Page 114 SB-100/190 Schematic Diagram — Page 2 of 2...
  • Page 115 SB-100/190 Wiring Diagram — Page 1 of 5...
  • Page 116 SB-100/190 Wiring Diagram — Page 2 of 5...
  • Page 117 SB-100/190 Wiring Diagram — Page 3 of 5...
  • Page 118 SB-100/190 Wiring Diagram — Page 4 of 5...
  • Page 119 SB-100/190 Wiring Diagram — Page 5 of 5...

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