Thermo King T-680S Series Maintenance Manual
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Thermo King T-680S Series Maintenance Manual

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Maintenance Manual
T-680S, T-880S,
SB-210+
SB-210+
SB-210+
T-1080S Series
Additional text information
Additional text information
Additional text information
with SR-3
TK 55635-1-MM (Rev. 5, 11/16)
to be placed here
to be placed here
to be placed here
TK 5XXXX-X-PL
TK 5XXXX-X-PL
TK 5XXXX-X-PL

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Summary of Contents for Thermo King T-680S Series

  • Page 1 Maintenance Manual T-680S, T-880S, SB-210+ SB-210+ SB-210+ T-1080S Series Additional text information Additional text information Additional text information with SR-3 to be placed here to be placed here to be placed here TK 5XXXX-X-PL TK 5XXXX-X-PL TK 5XXXX-X-PL TK 55635-1-MM (Rev. 5, 11/16)
  • Page 2 T-680S, T-880S, T-1080S Series with SR-3 TK 55635-1-MM (Rev. 5, 11/16) Copyright © 2013 Thermo King Corp., Minneapolis, MN, U.S.A. Printed in U.S.A.
  • Page 3 Evacuation Station Operation and Field Application TK 40612 The information in this manual is provided to assist owners, operators and service people in the proper upkeep and maintenance of Thermo King units. Revision History Rev. 0 – 55635-1-MM (Rev. 0, 02/13) Original release.
  • Page 4 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. Thermo King’s warranty will not apply to any equipment which has been “so repaired or altered outside the manufacturer’s plants as,...
  • Page 5 Customer Satisfaction Survey Let your voice be heard! Your feedback will help improve our manuals. The survey is accessible through any internet-connected device with a web browser. Scan the Quick Response (QR) code or click or type the web address http://irco.az1.qualtrics.com/SE/?SID=SV_2octfSHoUJxsk6x to complete the survey.

  • Page 6: Table Of Contents

    Table of Contents Safety Precautions ..............11 General Practices .
  • Page 7 Table of Contents Heat/Defrost Mode ..............32 Operating Instructions for Standard HMI Control Panel .
  • Page 8 Table of Contents Diesel/Electric Menu ..............69 Adjust Brightness .
  • Page 9 Table of Contents Belts ................. . 116 Engine/Electric Motor (Jackshaft) Belt .
  • Page 10 Table of Contents Electronic Throttling Valve (ETV) Testing ........... . . 144 Electronic Throttling Valve (ETV) Replacement .
  • Page 11 Table of Contents Fanshaft Assembly ..............166 Disassembly .

  • Page 12: Safety Precautions

    Safety Precautions Thermo King recommends that all service be DANGER: Avoid engine operation in performed by a Thermo King dealer. However, confined spaces and areas or you should be aware of several general safety circumstances where fumes from the practices: engine could become trapped and cause serious injury or death.

  • Page 13: Auto Start/Stop

    CAUTION: Do not connect other manufacturer’s equipment or accessories DANGER: Do not use a Halide torch. to the Thermo King unit. This could result When a flame comes in contact with in severe damage to equipment and void refrigerant, toxic gases are produced.

  • Page 14: Refrigerant Oil Hazards

    Safety Precautions DANGER: Do not use oxygen (O ) or CAUTION: Do not expose the refrigerant oil to the air any longer than necessary. compressed air for leak testing. Oxygen The oil will absorb moisture, which results mixed with refrigerant is combustible. in much longer evacuation times and possible system contamination.

  • Page 15: Low Voltage

    Safety Precautions • If the microprocessor has a power switch, turn WARNING: Never work alone on high it OFF before connecting or disconnecting the voltage circuits in the refrigeration unit. battery. Another person should be nearby to shut off the unit and provide aid in the event of •...

  • Page 16: First Aid

    Safety Precautions First Aid, Electrical Shock • Components that could be damaged by welding sparks should be removed from the Take IMMEDIATE action after a person has unit. received an electrical shock. Get quick medical • Use normal welding procedures, but keep the assistance, if possible.

  • Page 17: Specifications

    Specifications Engine Model: T-680S and T-880S TK374F (Tier 4) T-1080S TK380F (Tier 4) Fuel Type No. 2 Diesel fuel under normal conditions No. 1 Diesel fuel is acceptable cold weather fuel Oil Capacity: T-680S and T-880S Crankcase & Oil Filter 9.0 quarts (8.5 liters) T-680S and T-880S w/Bypass Oil Filter 10.0 quarts (9.5 liters) Fill to full mark on dipstick...

  • Page 18: Belt Tension

    Battery Charging System 12 volt, 37 amp, brush type, Thermo King alternator Voltage Regulator Setting 13.8 to 14.4 volts @ 77 F (25 C) NOTE: Fuse F4 (Bypass resistor for Prestolite Alternator) must be removed for the Thermo King Alternator.

  • Page 19: Fuses

    HPCO Switch Circuit Power to CAN Connector J98 F4 Remove fuse F4 for units with Australian Bosch or Thermo King Alternators. Install fuse F4 for units with Prestolite Alternator. F10 When fuse F10 is installed in the right position the On/Off keys on the HMI turn the unit on and off. When fuse F10 is installed in the left position the unit will start and run without the HMI control panel.

  • Page 20: Electrical Standby (Model 50 Units Only)

    Specifications Electrical Standby (Model 50 Units Only) T-680S and T-880S Electric Motor and Overload Relay Voltage/Phase/Frequency Horsepower Kilowatts Full Load Overload Relay (amps) Setting (amps) 230/3/50 1460 17.0 230/3/60 1765 19.4 400/3/50 1460 460/3/60 1765 T-1080S Electric Motor and Overload Relay Voltage/Phase/Frequency Horsepower Kilowatts...

  • Page 21: Maintenance Inspection Schedule

    Maintenance Inspection Schedule Pretrip 1,200 2,000 Annual/ Inspect/Service These Items Hours Hours 3,000 Hours Microprocessor • Run pretrip test (see “Pretrip Test” in Operating Instructions Chapter). Engine • Check fuel supply. • • Check engine oil level. • • Check condition of belts. •...
  • Page 22 Maintenance Inspection Schedule Pretrip 1,200 2,000 Annual/ Inspect/Service These Items Hours Hours 3,000 Hours Electrical • Check controller for alarms. • Run pretrip test. • Check battery voltage. • Inspect battery terminals and electrolyte level. • Inspect wire harness for damaged wires or connections. •...

  • Page 23: Unit Description

    • Scroll Compressors, New Generation TK04 & TK06 The built-in CYCLE-SENTRY, an exclusive Thermo King feature, automatically starts and • ETV (Electronic Throttling Valve) stops the unit according to temperature demands. • Stainless Steel Condenser and Evaporator...

  • Page 24: Unit Options

    Unit Description Unit Options ELC (Extended Life Coolant) • Body Mount HMI Enclosure Systems The maintenance interval for ELC is five years or 12,000 hours. A nameplate on the coolant • DAS (Data Acquisition System) expansion tank identifies units with ELC (see •...

  • Page 25: Mechanics Hmi Control Panel

    Unit Description Mechanics HMI Control Panel The system monitors and maintains the compartment temperature, the engine block The Mechanics HMI Control Panel is available as temperature, and battery charge levels at a point a hand held diagnostic tool. It is used on units where quick, easy starts are possible.

  • Page 26: Cargolink™ (Optional)

    Unit Description CargoLink™ (Optional) • Electric Heater Strips • Auto Switching CargoLink™ is a wireless sensor system. The main components are the coordinator module, Engine Compartment interconnect harness, antenna, and wireless sensors. The coordinator module receives Components information from the wireless sensors through the The coolant level and Coolant Expansion Tank: antenna, and communicates with the controller...
  • Page 27 Unit Description The preheat buzzer sounds when Preheat Buzzer: Electric Motor Overload Relay (Model 50): the CYCLE-SENTRY system energizes the overload relay protects the electric standby motor. glow plugs. This should warn anyone near the unit The overload relay opens the circuit from the that the CYCLE-SENTRY system is about to contactor to the electric motor if the motor...
  • Page 28 Unit Description AMA828 Figure 5: Main Components Engine Oil Dipstick (on side of engine) Alternator Engine Scroll Compressor Coolant Expansion Tank Dehydrator (Filter-Drier) Electric Motor On/Off Switch Main Components in Figure 5...

  • Page 29: Refrigeration System Components

    Unit Description Refrigeration System Electronic Throttling Valve (ETV) Components This is an electronic valve that the microprocessor uses to control the suction pressure to the The refrigeration system in these units does not compressor. The ETV is a variable position valve have a three-way valve.

  • Page 30: Refrigeration System Diagrams

    Unit Description Suction Pressure Transducer Refrigeration System Diagrams This transducer supplies the suction pressure at The following pages show the refrigeration the compressor to the microprocessor. This system and examples of the refrigerant flow in the information is used by the microprocessor and various modes.

  • Page 31: Cool Mode

    Unit Description Cool Mode Solenoid and Check Valves The refrigerant flow in Cool Mode is a 1. Condenser Inlet Solenoid (CIS)-Open/ conventional refrigeration cycle. High pressure De-energized refrigerant vapor leaves the compressor and flows 2. Liquid Injection Solenoid (LIS)-Closed/ through the open CIS to the condenser where the De-energized but the microprocessor will refrigerant releases heat and condenses into high open it if necessary to control compressor...

  • Page 32: Purge Mode

    Unit Description Purge Mode Solenoid and Check Valves Purge Mode is similar to Condenser Evacuation 1. Condenser Inlet Solenoid (CIS)-Open/ Mode in previous systems. It is used to move the De-energized refrigerant out of the condenser into the 2. Liquid Injection Solenoid (LIS)-Closed/ accumulator when the unit shifts from Cool (or De-energized but the microprocessor will Null) to Heat or Defrost.

  • Page 33: Heat/Defrost Mode

    Unit Description Heat/Defrost Mode Solenoid and Check Valves The refrigerant flow in Heat/Defrost Mode is a 1. Condenser Inlet Solenoid (CIS)-Closed/ conventional hot gas heat cycle. The CIS is closed Energized and the HGS is open so high pressure refrigerant 2.

  • Page 34: Operating Instructions For Standard Hmi Control Panel

    Alarm Code 91 Check Electric Ready Alarm Code(s). Input occurs. It will also glow if a 15 pin Thermo King data cable is connected to the The lower row of numbers can display the serial port on the back of the controller (DPD).
  • Page 35 Operating Instructions for Standard HMI Control Panel The meaning of the display icons are shown in the table below. When this icon is present the upper display is showing the actual box temperature inside the truck box. When this icon is present the lower display is showing the current setpoint.

  • Page 36: Keys And Led Indicators

    This indicator will glow if Alarm Code 91 Check Electric Ready Input occurs. It will also light if a 15 pin Thermo King data cable is connected to the serial port on the back of the controller (DPD). Figure 12: Keys and LED Indicators The primary and secondary key uses are shown in the table below.
  • Page 37 Operating Instructions for Standard HMI Control Panel CYCLE-SENTRY/Continuous Key If the unit is turned on and is in Continuous Mode, pressing the CYCLE-SENTRY/CONTINUOUS Key will switch operation to CYCLE-SENTRY Mode and the amber LED indictor will glow. If the unit is running in CYCLE-SENTRY Mode, pressing this key will switch operation to Continuous Mode and the amber LED will turn off.

  • Page 38: Turning The Unit On And Off

    Operating Instructions for Standard HMI Control Panel Turning the Unit On and Off shown in the lower display. The box temperature shown in Figure 15 is 35.8 F (2.1 C) with a 35 F IMPORTANT: Verify the Base Controller (1.6 C) setpoint. On/Off Switch is turned on before turning on the HMI Control Panel.

  • Page 39: Changing The Setpoint

    Operating Instructions for Standard HMI Control Panel Changing the Setpoint From the Standard Display, press the UP ARROW Key and/or DOWN ARROW Key until the desired setpoint is shown. In Figure 18 the setpoint has been increased to 40 F (4.4 C) using the UP ARROW Key.

  • Page 40: Starting The Electric Motor

    Operating Instructions for Standard HMI Control Panel Switching from Diesel to WARNING: Never use starting fluid. Electric When the engine is preparing to start, the SR-3 Standard Truck HMI Control Panel will continue IMPORTANT: Applies to units with the Electric to display the Standard Display as shown in Standby Option only.

  • Page 41: Selecting Cycle-Sentry Or Continuous Mode

    Operating Instructions for Standard HMI Control Panel will glow, the Alarm Icon will glow and the box 4. Press the Standard Truck HMI Control Panel temperature and setpoint displays will disappear ON Key again to clear Alarm Code 91 Check as shown in Figure 23.

  • Page 42: Selecting The High Speed Lock-Out Feature

    Operating Instructions for Standard HMI Control Panel IMPORTANT: HIGH SPEED LOCKOUT amber LED indictor will glow. If the unit is running in CYCLE-SENTRY Mode, pressing this TIMER: If High Speed Lockout Mode is key will switch operation to Continuous Mode selected, the High Speed Inhibit Timeout feature and the amber LED will turn off.

  • Page 43: Alarms

    Operating Instructions for Standard HMI Control Panel IMPORTANT: During the defrost cycle, the box indicates that Alarm Code 127 Setpoint Not temperature will rise toward 50 F (10 C). This is Entered has been set. The lower display indicates normal and is caused by the defrost cycle that only one alarm code exists.

  • Page 44: Sending A Servicewatch Data Logger Start Of Trip

    Operating Instructions for Standard HMI Control Panel Conditions where Pretrip Tests are • Some alarms cannot be cleared using the not allowed Standard Truck HMI Control Panel. These alarms must be cleared by maintenance • Pretrip Tests are not allowed if any shutdown personnel from the Maintenance or Guarded alarms are present.

  • Page 45: Pretrip Test Considerations

    Operating Instructions for Standard HMI Control Panel • Heat Check - The ability of the unit to heat in low speed is checked. • Report Test Results - The test results are reported when the Pretrip Test is completed. If the Pretrip Test fails, alarm codes will exist to direct the technician to the source of the Figure 35: Pretrip Test...

  • Page 46: Pretrip Test Results

    Operating Instructions for Standard HMI Control Panel Fail Pretrip Test with Shutdown Alarms • A flashing Pretrip LED indicates that the Pretrip Test is being initialized. When the • If the unit fails the Pretrip Test with a Pretrip Test starts, the Pretrip LED will glow Shutdown alarm, the Alarm Icon will appear steady amber to indicate the test is in progress.

  • Page 47: Checking Truck Hmi Control Panel Software Revision And Serial Number

    Operating Instructions for Standard HMI Control Panel Checking Truck HMI Control Panel Software Revision and Serial Number The Standard Truck HMI Control Panel serial number and software revision can be displayed if necessary. To display the serial number and software revision press and hold the PRETRIP key for 5 seconds when the unit is turned off.

  • Page 48: Operating Instructions For Premium Hmi Control Panel

    Operating Instructions for Premium HMI Control Panel SR-3 Truck Premium HMI • Changes Setpoint Controller Description • Indicates Alarm Condition Exists • Displays and Clears Alarms Premium HMI Control Panel • Selects and Indicates CYCLE-SENTRY or The Premium Truck HMI (Human/Machine Continuous Mode Operation Interface) Control Panel is available as an option on SR-3 Truck applications.

  • Page 49: Keys

    Operating Instructions for Premium HMI Control Panel Figure 43: Soft Keys Figure 41: Display Soft Keys Keys Soft Key Description The four "soft" keys under the display are multi-purpose keys. Their function changes depending on the operation being performed. If a soft key is active the key function is shown in the display directly above the key.

  • Page 50: If More Than One Language Is Enabled

    Operating Instructions for Premium HMI Control Panel IMPORTANT: The ON key must be held down until the Thermo King Logo appears as shown in Figure 44. If the ON key is not held down long enough (approximately ½ second), the display may flicker but the unit will not start up.

  • Page 51: The Standard Display

    Operating Instructions for Premium HMI Control Panel Figure 51: Language Menu Figure 55: Standard Display When the unit is ready to run the Standard Display The CYCLE-SENTRY Icon in the upper right appears. corner of the display shows that the unit is operating in CYCLE-SENTRY Mode.

  • Page 52: Starting The Diesel Engine

    Operating Instructions for Premium HMI Control Panel Figure 61: Standard Display, New Setpoint Figure 58: Increase Setpoint IMPORTANT: If the setpoint is changed using The YES and NO soft keys confirm the setpoint the "+" or "-" keys, the change must be change.

  • Page 53: Starting The Electric Motor

    Operating Instructions for Premium HMI Control Panel WARNING: Never use starting fluid. After the motor is running the display returns to the Standard Display of temperature and setpoint. When the engine is preparing to start the HMI control panel will display the engine start screen, as shown in Figure 62.

  • Page 54: Switching From Electric To Diesel

    Operating Instructions for Premium HMI Control Panel Switching from Electric to Diesel Units equipped with the Electric Standby option only. If the Electric to Diesel Autoswitch Enabled Figure 70: Display is YES is selected feature in Guarded Access is set YES then the unit will automatically switch to Diesel Mode If unit operation is required the diesel engine will operation when standby power is turned off or is...

  • Page 55: Terminating A Defrost Cycle

    Operating Instructions for Premium HMI Control Panel Figure 73: Defrost Display Figure 74: High Speed Lockout Key The display will briefly show [PROGRAMMING Terminating a Defrost Cycle HIGH SPEED LOCKOUT - PLEASE WAIT]. The defrost cycle terminates automatically when the coil temperature is greater than or equal to 52 F (11 C) or the defrost timer expires.

  • Page 56: Selecting Cycle-Sentry Or Continuous Mode

    OK or LOW. Continuous Mode Oil Pressure - Displays the engine oil pressure as With Thermo King Truck unit applications, OK or LOW. CYCLE-SENTRY Mode or Continuous Mode operation is selected from the Main Menu - Mode Oil Level - Displays the engine oil level as OK or Submenu.

  • Page 57: Using The Sensors Key

    Operating Instructions for Premium HMI Control Panel • Purge Valve Data Logger Sensor 1 Temperature - Display the temperature of Data Logger Sensor 1. Using the Sensors Key Data Logger Sensor 2 Temperature - Display the temperature of Data Logger Sensor 2. The SENSORS key allows the operator to view the temperatures read by the unit temperature Data Logger Sensor 3 Temperature - Display the...

  • Page 58: Main Menu Choices

    Operating Instructions for Premium HMI Control Panel Main Menu Choices the operator to manually select electric mode operation. This feature does not appear if the unit LANGUAGE - If more than one language is does not feature optional Electric Standby or if the enabled, this will be the first menu item to appear.
  • Page 59 Operating Instructions for Premium HMI Control Panel • Languages currently supported by software The new language is confirmed, and then the revision 67xx are English, Japanese and Standard Display will appear in the new language Chinese. Other than the languages supported, as shown in Figure 88.

  • Page 60: Alarms

    When the unit is turned on the display will show • The remote indicator alarm light (if installed) the Thermo King Logo and then the "Configuring will display only a row of LEDs at the bottom. System" message. If log alarm(s) are present the...
  • Page 61 • If the alarm does not reoccur during the timed running interval with reduced performance, The Alarm Icon used in previous Thermo King the unit will return to full performance to controllers has been incorporated. If a Check determine if continued operation is possible.
  • Page 62 Operating Instructions for Premium HMI Control Panel • Alarm Code 92 Sensor Grades Not Set - If alarms are present, the quantity of alarms (if Clears when the sensor grade is changed from more than one) and the most recent alarm code number will be shown.

  • Page 63: Datalogger

    Operating Instructions for Premium HMI Control Panel To select a different Main Menu item press the NEXT key. To return to the Standard Display press the EXIT key. Important Alarm Notes • If an alarm will not clear, it may still exist. If the alarm is not corrected, it will not clear or Figure 100: Select Key may be immediately set again.

  • Page 64: Mode

    Operating Instructions for Premium HMI Control Panel User Programmable - The Total Run Reminder 2: number of hours before a Total Unit Run Time Maintenance Reminder 2 occurs. Total hours the controller Controller Power On: and HMI control panel have been turned on. User Programmable - number Pretrip Reminder : Figure 103: Menu Key...

  • Page 65: Selecting Cycle-Sentry Or Continuous Mode

    Operating Instructions for Premium HMI Control Panel Start Sleep Mode If enabled in Guarded Access, Sleep Mode is used to keep the engine warm and the battery charged when the unit is not in use. When the unit is in Sleep Mode the display will show "SLEEP"...

  • Page 66: Selecting Sleep Mode

    Operating Instructions for Premium HMI Control Panel The Turn Off/Turn On CYCLE-SENTRY screen will appear. In the display shown below, the unit is operating in CYCLE-SENTRY mode. Turning CYCLE-SENTRY mode off will result in the unit running in Continuous mode. Figure 115: Mode Menu IMPORTANT: If the unit is in CYCLE-SENTRY null and the mode is switched to Continuous...
  • Page 67 Operating Instructions for Premium HMI Control Panel The Language Menu or Alarm Menu will appear. Press the NEXT key as required to show the Mode Menu. When the Mode Menu is shown press the SELECT key. Figure 121: Sleep Mode Display To enter a Wake-up Time, verify the unit clock is set properly.

  • Page 68: Pretrip

    Operating Instructions for Premium HMI Control Panel the unit shut down a Full Pretrip Test with device amp checks will be performed. If the Pretrip Test is entered with the unit running in either diesel or electric mode a Running Pretrip Test is performed, but the device amps checks are not performed.
  • Page 69 Operating Instructions for Premium HMI Control Panel • To stop a Pretrip Test at any time, turn the unit • RPM Check - The engine RPM in high and low speed is checked during the Cool Check. off. Alarm Code 28 Pretrip Abort will be set. Other alarms may also be set, depending upon •...

  • Page 70: Diesel/Electric Menu

    Operating Instructions for Premium HMI Control Panel If the Pretrip Test results are CHECK or FAIL the problem should be diagnosed and corrected before the unit is released for service. Diesel/Electric Menu The Diesel Mode/Electric Standby menu allows Figure 132: Pretrip Test Display the operator to manually select diesel or electric •...

  • Page 71: Adjust Brightness

    Operating Instructions for Premium HMI Control Panel Electric Mode operation will briefly be confirmed. If unit operation is required the electric motor will start as shown previously in STARTING THE ELECTRIC MOTOR. Switching from Electric to Diesel - Units equipped with the Electric Standby option Figure 139: Display when YES is selected only If unit operation is required the diesel engine will...

  • Page 72: Time

    Operating Instructions for Premium HMI Control Panel Figure 142: + and - Keys Figure 146: + and - Keys The display will briefly show ADJUSTING BRIGHTNESS - PLEASE WAIT. Figure 143: Adjusting Brightness The display brightness is changed to the new setting.

  • Page 73: Electrical Maintenance

    F2 Terminal (Do Not Ground) B- Terminal (Negative Ground - CH Wire) Voltage Regulator and Brush Assembly S Terminal (Regulator Sense - 2 Wire) W Terminal (AC Output) L Terminal (Regulator Excite - 7K Wire) Figure 147: Thermo King Alternator Terminal and Component Locations...

  • Page 74: Interface Board Fuse F4

    King alternators. The voltage regulator on the charging system are in good condition and are Thermo King alternators will be damaged if the adjusted properly before testing the alternator. unit is turned On with the F4 fuse in place on Be sure the pulleys are the correct size.
  • Page 75 CAUTION: Energizing the circuit with should fall to normal unit load plus charge the resistor bypass fuse installed will current to the unit battery (typically 5-10 damage Thermo King alternators. Be sure amps). the resistor bypass fuse is removed for Thermo King alternators.

  • Page 76: Field Current Test

    Perform this test with the unit turned off. 1. Attach a clamp-on ammeter to the 2A wire near the B+ terminal on the alternator. 2. Energize the field on the Thermo King alternator by connecting a jumper wire between the F2 terminal and the B+ terminal.

  • Page 77: Fuses

    Light/Optional Power) Main Fuse (2 Circuit) Alternator Sense 7.5A HPCO/Run Circuit Power to CAN Connector J98 F4 Remove fuse F4 for units with Australian Bosch or Thermo King Alternators. Install fuse F4 for units with Prestolite Alternator. Figure 148: Base Controller...

  • Page 78: Base Controller Leds

    Electrical Maintenance Base Controller LEDs condition occurs, the Smart FET will turn off until the over-current condition no longer exists. It will The base controller has LEDs that indicate which then resume normal operation. A fuse is not outputs are energized. The LED is illuminated required.

  • Page 79: Glow Plugs

    Electrical Maintenance Testing the Flywheel (RPM) Sensor: 5. Reconnect the FS1 and FS2 wires to the sensor. The following equipment is required: If the flywheel sensor passes the above test, the • AC voltmeter capable of reading up to 10 sensor may be considered good.

  • Page 80: Unit Wiring

    Electrical Maintenance Condenser Fan Rotation NOTE: The cylinder head cover must be removed to access the glow plugs. The condenser fan is belt driven. On electric A shorted glow plug will show excessive current standby operation, check for correct fan rotation draw (more than 13 amps) during preheat, and by placing a small cloth or sheet of paper against may cause fuse F5 (40 A) to blow.
  • Page 81 Electrical Maintenance Inputs L1, L2 and L3 respectively. Operating power from 12 to 24 volts is supplied to the module via the 8 Input Description wire and CH wire. This Brown wire supplies standby power L1 When the voltage sensed rises above 165 volts to the phase select module.
  • Page 82 Electrical Maintenance Connector Pinout Tape the Black wire back onto itself. It is not used on single-phase installations. Pin Wire Description 11. Connect the plug on the short harness from the Power to Module phase select module. CH/CHV Chassis ground 12.

  • Page 83: Overload Relay

    Electrical Maintenance be on. If voltage is not present on either the 2. Use a small screwdriver to set the opening 7EB or 7EC output, replace the phase select amperage. See “Electric Motor and Overload module. Relay” in the “Specifications” chapter for the correct overload relay setting.
  • Page 84 Electrical Maintenance 4. Move the slide switch down until it clicks into place at the bottom of the slot (from which the tab marked “H” was removed). This sets the overload relay to reset automatically. Switch Clicks into Place at Bottom of Slot Figure 156: Move Switch Down The new overload relay is now set up correctly.

  • Page 85: Engine Maintenance

    “Specifications” chapter) and check the dipstick package do require regular inspection in level. Run the unit, and then recheck the oil level. accordance with Thermo King's maintenance recommendations. CAUTION: The fill port on top of the engine should not be used to add engine NOTE: The new EMI 2000 oil filters and new oil.

  • Page 86: Oil Filter Change

    Oil Filter Change Both oil filters should be changed along with the engine oil. Use genuine Thermo King extended maintenance oil filters. 1. Remove the filter. 2. Apply oil to rubber ring of new filter and install filter.

  • Page 87: Crankcase Breather System

    Engine Maintenance Crankcase Breather System The vacuum will increase as the air cleaner gets dirty and becomes more restrictive. Remove the The crankcase breather system ducts crankcase breather cover and the baffle plate and check to gases formed in the crankcase directly to the air make sure nothing is plugged or damaged.

  • Page 88: Engine Cooling System

    Engine Maintenance Engine Cooling System All water-cooled engines are shipped from the factory with a mixture of 50 percent permanent type antifreeze concentrate and 50 percent water General Description in the engine cooling system. The engine employs a closed, circulating type, This provides the following: pressurized cooling system.
  • Page 89 Engine Maintenance Engine Overflow Bottle Coolant Level Switch Coolant Temperature Sensor Expansion Tank Cap Radiator Expansion Tank Drain Cock Figure 162: Engine Cooling System Components for Units with Coolant Expansion Tank and Overflow Bottle (Starting 10/16)

  • Page 90: Elc (Extended Life Coolant)

    The following are the Extended Life Coolants The factory recommends the use of a 50/50 currently approved by Thermo King for use in percent antifreeze mixture in all units even if they ELC units for five years or 12,000 hours: are not exposed to freezing temperatures.

  • Page 91: Bleeding Air From The Cooling System For Units With Coolant Expansion Tank Only (Ending 10/16)

    Engine Maintenance Changing the Antifreeze Bleeding Air from the Cooling System for Units with Coolant 1. Run the engine until it is up to operating Expansion Tank Only (Ending 10/16) temperature. Stop the unit. Often when a self powered truck unit cooling 2.
  • Page 92 Engine Maintenance 5. Install a vacuum fill system and pull the 2. Open the bleed valve on the thermostat housing (see Figure 165). cooling system down to a full vacuum. (An air driven venturi vacuum system will achieve approximately 27 inches of mercury [hg] vacuum while a vane or piston vacuum pump will achieve 29 inches of mercury vacuum.
  • Page 93 Engine Maintenance fluctuation is OK and the system is full. If the NOTE: If the fill hose is allowed to pull air into the system, the system will be engine achieves the 14 psig (97 kPa) cooling under-filled. In this case, either lower the system pressure at an engine temperature of system coolant level back to the 5 inches less than 165 F (74 C) it passes the test and...
  • Page 94 Engine Maintenance Figure 172: Spill-Free Funnel Tool Bring coolant up to this level. CAUTION: Running the unit with the Figure 170: Fill Expansion Tank radiator cap removed and without the Spill-Free Funnel will cause significant 2. Open the bleed valve on the thermostat coolant from the bypass tube to overflow housing (see Figure 171).
  • Page 95 Engine Maintenance Figure 175: Cover Condenser Coil If Necessary Figure 174: Close-Up of Attached Spill-Free Funnel Tool e. Squeeze the upper radiator hose closed and open to vary the flow of coolant b. Lock the HMI on the Coolant Temperature through the radiator and help push air out in the Gauges Menu to read engine coolant of the radiator.
  • Page 96 Engine Maintenance 6. Start the system and monitor the coolant temperature until the unit reaches normal operating temperature of 160-165 F (71-74 C). 7. Shut the engine off and wait 3-5 minutes and check the pressure. If the pressure is at 14 psig or higher, the system is full of coolant and all the trapped air has been removed.
  • Page 97 Engine Maintenance Bleeding Air from the Cooling The cooling system capacities have increased and System for Units with Coolant are listed below. Expansion Tank and Overflow Bottle Unit Gallons Quarts Liters (Starting 10/16) Units with 3TNV74-F The cooling system in T-Series Truck Units has Engine, Coolant been updated.
  • Page 98 Engine Maintenance 2. Place a clamp on the engine to expansion tank the thermostat is open and any air trapped in upper hose to prevent coolant from flowing the cylinder head will be purged by the water pump circulation. through it from the expansion tank to the thermostat housing.

  • Page 99: Engine Thermostat

    Engine Maintenance Vacuum Fill Procedure See “Vacuum Fill Procedure” earlier in this manual. Engine Thermostat For the best engine operation, use a 160 F (71 C) thermostat year round. Float in Upper Position - Switch Closed Float in Lower Position - Switch Open Figure 179: Coolant Level Switch Testing the Coolant Level Switch You can test the switch in the unit by adjusting the...

  • Page 100: Coolant Level Switch For Units With Coolant Expansion Tank And Overflow Bottle (Starting 10/16)

    Engine Maintenance Testing the Coolant Level Switch Testing the switch in the unit is accomplished by adjusting the coolant level and also by removing the expansion tank from the unit by flipping the tank upside down and right side up. 1.

  • Page 101: Engine Fuel System

    53163 for injection nozzle testing and repair prechamber. procedures. The components of the fuel system are: Thermo King recommends that any major injection pump or nozzle repairs be done by a • Fuel tank (may be the truck fuel tank) quality diesel injection service specialty shop.
  • Page 102 Engine Maintenance Figure 182: Fuel and Oil System Components...
  • Page 103 Engine Maintenance Elbow - hose fitting (3/8) 16. Plug - pipe Kit - sleeve & eyelet (3/8) 17. Plug - pipe Nut (3/8) 18. Filter - oil bypass (EMI 2000) Hose (3/8 od) 19. Stud - bypass filter Adapter - oil line 20.

  • Page 104: Bleeding The Fuel System

    Engine Maintenance Bleeding the Fuel System Draining Water from Fuel Tank The fuel system will have to have the air bled out Water run through the system may damage the if the engine runs out of fuel, if repairs are made injection pump or nozzles.

  • Page 105: Electric Fuel Pump

    Engine Maintenance Electric Fuel Pump Assembly 1. Screw the fuel filter back into the pump Operation housing (finger tight). The electric fuel pump must be mounted next to 2. Place the fuel filter bowl gasket in place and the fuel tank. This pump is designed to push rather hand tighten (or 100 in-lb [11.3 N•m]) the fuel than pull fuel.
  • Page 106 Engine Maintenance TDC mark on the flywheel lines up with the timing mark on the starter mounting plate. Injection Timing Marks Top Dead Center Mark for Number 1 Cylinder Index Timing Mark on Starter Mounting Plate Figure 186: Timing Marks Number One Cylinder Injection Line b.

  • Page 107: Injection Pump Removal And Installation

    Engine Maintenance a. Pull the top of the injection pump away from the engine to advance the timing. b. Push the top of the injection pump toward the engine to retard the timing. 12. Tighten the injection pump mounting nuts and recheck the timing.
  • Page 108 Engine Maintenance NOTE: The injection pump gear assembly is made of two pieces, the flange and the gear. Do not loosen or remove the four bolts that fasten the gear to the flange because that changes the timing. 5. Use a suitable puller to loosen the injection pump gear from the injection pump shaft.

  • Page 109: Fuel Limit Screw

    Engine Maintenance 5. Install the injection pump timing cover on the gear case cover, and reinstall all components removed previously to facilitate the injection pump removal. Injection Pump Injection Pump Gear Mounting Nut Gear Case Lock Washer Gear Case Cover Injection Pump Gear Injection Pump Timing Cover O-Ring...
  • Page 110 Engine Maintenance NOTE: The fuel solenoid may be removed from the injection pump to visually check its operation. The fuel solenoid must be energized when it is re-installed in the injection pump. If it is not, the plunger and the linkage may not line up correctly and the fuel solenoid will not function properly.

  • Page 111: Engine Speed Adjustments

    Engine Maintenance pin C) in the fuel solenoid connector. The 4. Use the Mechanics/Premium HMI Control resistance of the pull-in coil should be 0.2 Panel to enter the Interface Board Test Mode. to 0.3 ohms. If the resistance of the pull-in Refer to the appropriate Microprocessor coil is not in this range, replace the fuel Diagnostic Manual for specific information...

  • Page 112: Adjust Engine Valve Clearance

    Engine Maintenance 3. If the engine speed is not correct, loosen the Make the engine speed adjustments with the engine fully warmed up. jam nuts at both ends of the high speed adjuster in the throttle linkage. Low Speed Adjustment 4.
  • Page 113 Engine Maintenance On the three cylinder engines the order for the flywheel timing marks is 1, 2, 3, but the firing order is 1, 3, 2. The reason for this is that the engine fires every 240 degrees of crankshaft rotation.
  • Page 114 Engine Maintenance 8. Check and adjust both valves for the number 3 cylinder. 9. Place the engine at top dead center of the compression stroke for the number 2 cylinder. a. Rotate the engine in the normal direction of rotation (counterclockwise viewed from the flywheel end) until the top dead center timing mark for the number 2 cylinder on AGA148...

  • Page 115: Engine Mounts

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

  • Page 116: Restraining Mount (Snubber) Adjustment

    Engine Maintenance Bracket - engine (upper rear) Washer - belleville Bracket - engine (compressor side) 10. Flatwasher Bracket - engine (door side) Screw - plate & bracket (socket head) 12. Chain - 3 links Washer - belleville 13. Bolt - eye 1/2 in. Sealer - thread 14.

  • Page 117: Belts

    Engine Maintenance Belts The unit uses only two belts to transfer power from the engine and the electric motor to the alternator, compressor, and evaporator fans. Engine 10. Compressor Pulley Clutch Scroll Compressor Engine/Electric Motor (Jackshaft) Belt 12. Evaporator Fan Pulley (Compressor Side) Evaporator Fan Pulley (Engine Side) 13.

  • Page 118: Engine/Electric Motor (Jackshaft) Belt

    Engine Maintenance Engine/Electric Motor (Jackshaft) 7. Take a straight edge, place it against the side Belt of the muffler can and mark the frame as shown below. This is the unloaded engine The engine/electric motor (jackshaft) belt is a 3V position.
  • Page 119 Engine Maintenance 9. Tighten the pulley mounting nut. NOTE: The washer on the restraining mount (snubber) should not go below the bracket 10. Check the orientation of the restraining mount side wall height. If it does, the restraining (snubber) eye-bolt because the ‘eye’ is offset. mount (snubber) will be over-compressed.

  • Page 120: Electric Motor (Jackshaft)/ Compressor Belt

    Engine Maintenance Electric Motor (Jackshaft)/ Water Pump Belt Compressor Belt The water pump pulley is a split type. Adjust the The electric motor (jackshaft)/compressor belt is a tension by adding or removing shims between the pulley sheaves. See “Specifications” for the polyvee stretch belt that also drives the compressor side evaporator fan and the alternator.

  • Page 121: Refrigeration Service Procedures

    See the diagram of the Thermo King Evacuation Moisture in the system will produce acid and Station (Figure 210 on page 121) and note the other contaminants that lead to compressor location of the valves and other components.
  • Page 122 Refrigeration Service Procedures AGA654 Iso-Valve To 110 Vac Power Calibration Standard 10. Vacuum or Micron Gauge Thermistor Charging Port Two Stage Vacuum Pump Figure 210: Evacuation Station...
  • Page 123 Refrigeration Service Procedures 100 Microns 500 Microns 1000 Microns 2500 Microns 5000 Microns 20,000 Microns Atmospheric Pressure Calibration Adjustment Screw Example: Meter needle shown at calibration position when Calibration Standard specifies 0.15 mm Hg. Figure 211: Vacuum Gauge...

  • Page 124: Set Up And Test Of Evacuation Equipment

    Refrigeration Service Procedures Set Up and Test of Evacuation NOTE: Dirty vacuum pump oil or a defective Equipment vacuum pump will prevent a low micron reading. Hoses and fittings can be isolated NOTE: See the previous two pages for the individually to identify leaks.

  • Page 125: Unit Evacuation

    Refrigeration Service Procedures 4. Mid-seat the receiver tank outlet valve and 3. The Maintenance Menu Hourmeters will appear. Press the NEXT key as required to suction service valve, and install the valve show Evacuation Test. When the Evacuation stem caps. Test is shown press the SELECT key.

  • Page 126: Unit Charging

    Refrigeration Service Procedures Leak Moisture Should the needle show a pressure rise but Isolate the pump from the system by closing the proper valve. Watch the movement of the vacuum finally level off to practically a constant mark, gauge needle. If the needle continues to rise, this is an indication that the system is vacuum this is an indication that a leak exists in the unit tight but is still too wet, requiring additional...

  • Page 127: Refrigerant Gauge Removal

    Refrigeration Service Procedures Refrigerant Charge valve. Control the liquid flow so the suction pressure increases approximately 20 to 25 psig (138 to 172 kPa). Testing the Refrigerant Charge with an Empty Box (Controlled Check) 9. Add refrigerant until the system has the recommended refrigerant charge (see unit If the unit has an insufficient charge of refrigerant, serial number nameplate or the...

  • Page 128: Checking Compressor Oil

    Refrigeration Service Procedures To check compressor oil level with an ambient air in the receiver tank sight glass, the unit may temperature below 50 F (10 C): be low on refrigerant. Perform a Controlled Check. Run the unit through a complete Defrost cycle. After completing the Defrost cycle, run the unit NOTE: If the ball floats, there is sufficient on Cool for ten minutes.

  • Page 129: Low Side Pump Down

    Refrigeration Service Procedures Low Side Pump Down compressor is probably faulty if it cannot raise the discharge pressure by 100 psig (689 kPa) CAUTION: Do not pull scroll compressor or to 375 psig (2586 kPa). into a vacuum below 10 in. Hg vacuum NOTE: It may be necessary to remove the (-34 kPa) to perform routine maintenance upper grille insert to cover the condenser.

  • Page 130: R404A

    Pumps used with other Thermo King refrigerants Compressor Oil may be used but extreme care should be taken to Thermo King Corporation has chosen to use a prevent contamination of R404A systems with compressor oil called Polyol Ester (POE)—also other refrigerants.

  • Page 131: Refrigerant Recovery

    Gauge manifold sets that show the correct pressure-temperature relationship should be used. Gauge manifolds and manifold hoses used with other Thermo King refrigerants maybe used but extreme care should be taken to prevent contamination of the R404A systems with other refrigerants.

  • Page 132: Refrigeration System Component Locations

    Refrigeration Service Procedures Refrigeration System The following drawings show the locations of various refrigeration system components. Component Locations Figure 219: Condenser Refrigeration Component Locations...
  • Page 133 Refrigeration Service Procedures Suction Access Port 13. Dehydrator (Filter-Drier) Electronic Throttling Valve (ETV) 14. High Pressure Relief Valve Suction Service Valve 15. Receiver Tank Outlet Valve Compressor 16. Receiver Tank Sight Glass Suction Pressure Transducer 17. Receiver Tank High Pressure Cutout Switch (HPCO) 18.

  • Page 134: Accumulator Replacement

    Refrigeration Service Procedures Accumulator Replacement 3. Note the discharge pressure on the high pressure gauge. Removal 4. Cover the condenser and check the discharge pressure. The compressor should be able to 1. Pump down the low side and equalize the increase the discharge pressure by at least 100 pressure to slightly positive.
  • Page 135 Refrigeration Service Procedures 5. Pressurize the system and test for refrigerant leaks. 6. If no leaks are found, replace the liquid line drier then evacuate the system. 7. Replace the compressor/electric motor belt and adjust the tension. 8. Recharge the unit with the proper refrigerant. 9.
  • Page 136 Refrigeration Service Procedures Pulley Bolt (Torque to 18 to 22 ft-lb (24 to 30 N•m) 10. Baffle Pulley Compressor Temperature Sensor Shaft Seal Cover 12. Oil Drain Plug Shaft Seal Assembly 13. Sight Glass Oil Filter 14. Screen Cover Oil Filter Spring 15.

  • Page 137: Compressor Shaft Seal Change Procedure

    Thermo King recommends changing the compressor shaft seal when there is a major system interruption, such as component replacement or total loss of refrigerant charge. When the shaft seal is changed, Thermo King also recommends changing the compressor oil and oil filter. AGA576...
  • Page 138 Refrigeration Service Procedures NOTE: The following illustration shows the seal 13. Use seal installation tool (P/N 204-995) to install the bellows squarely on the shaft. Clean installation tool being used on a reciprocating the seal installation tool and place it on the compressor seal cover.

  • Page 139: Compressor Oil Filter Replacement

    Measure amount of interruption, such as component replacement or oil drained from compressor. total loss of refrigerant charge. When the oil filter is changed, Thermo King also recommends 4. Remove two screws and oil drain cap from changing the oil. compressor.

  • Page 140: Compressor Temperature Sensor Testing

    Replacement the purge check valve. NOTE: Thermo King recommends changing the 1. Attach a gauge manifold to the suction service compressor temperature sensor whenever the valve and the discharge service port. Attach...

  • Page 141: Condenser Inlet Solenoid (Cis) Test

    Refrigeration Service Procedures 7. Use the Mechanics/Premium HMI Control accumulator inlet. Low loss fittings must be Panel to enter the Interface Board Test Mode. used on the hoses connected to the discharge Refer to the appropriate Microprocessor service port and the suction access port. Diagnostic Manual for specific information 2.

  • Page 142: Condenser/Radiator Coil Replacement

    Refrigeration Service Procedures 1. Connect a high pressure gauge to the discharge service port to monitor the discharge pressure. 2. Start the unit while watching the discharge pressure. • If the unit stops before the discharge pressure rises to the HPCO opening pressure (see “Specifications”), it is probably a plugged discharge strainer or faulty HPCO.

  • Page 143: Dehydrator (Filter-Drier) Replacement

    Refrigeration Service Procedures 6. Connect the coolant hoses to the radiator and 3. Check the discharge pressure on the gauge refill the engine cooling system with the 50/50 attached to the discharge service port. It antifreeze/water solution. should be within the range shown for the DPR setting in the “Specifications”...

  • Page 144: Discharge Pressure Transducer Testing

    Refrigeration Service Procedures Discharge Pressure Transducer 1. Connect a high pressure gauge to the discharge service port to monitor the Testing discharge pressure. The discharge pressure transducer is located on 2. Start the unit while watching the discharge the discharge line near the discharge strainer. It pressure.

  • Page 145: Electronic Throttling Valve (Etv) Testing

    Refrigeration Service Procedures Electronic Throttling Valve (ETV) Testing The ETV is controlled and monitored by the SR-3 Microprocessor Control System. Alarm Code 89 (Check Electronic Throttling Valve Circuit) indicates a possible problem with the ETV. Refer to the appropriate Microprocessor Diagnostic Manual for information about testing the ETV.
  • Page 146 Refrigeration Service Procedures WARNING: If the ETV is stuck in the closed position, much of the refrigerant charge may be trapped in the evaporator. If you hear refrigerant begin to flow through the valve when the stepper motor and piston assembly are loosened, unscrew the Old Style ETV stepper motor and piston assembly no more than four turns, or unscrew the four screws on the...

  • Page 147: Installation Of Service Kit

    Refrigeration Service Procedures Installation of Service Kit b. Screw the new stepper motor and piston assembly into the valve body. NOTE: Do not connect the ETV harness or ETV to main wire harness and turn the unit on before c. Torque the nut to approximately 118 ft-lb the stepper motor and piston assembly is (160 N•m).

  • Page 148: Reassembly Of Piston And Stepper Motor On Old Style Etv

    Refrigeration Service Procedures 2. Insert the piston into the piston nut. You must align the rectangular shaft on the piston with the rectangular hole in the piston nut to allow the piston to be inserted into the piston nut. ARA2504 Figure 234: Align Arrowhead Marks c.

  • Page 149: Installation Of Complete Etv Assembly

    Refrigeration Service Procedures Evaporator Coil Replacement 7. Continue to turn the piston and piston nut onto the stepper motor until they are tight. Torque the piston nut and stepper motor to 37 ft-lb (50 Removal N•m). 1. Recover the refrigerant charge. Installation of Complete ETV 2.

  • Page 150: Installation

    Refrigeration Service Procedures Heat Exchanger Replacement 5. Remove the expansion valve mounting bolt and remove the expansion valve from the unit. NOTE: It unlikely that the heat exchanger is defective. Carefully review your refrigeration Installation system diagnosis to eliminate all other system 1.

  • Page 151: High Pressure Cutout Switch (Hpco) Test

    Refrigeration Service Procedures 5. Solder suction line connection to the evaporator coil. 6. Solder the liquid line to the expansion valve. 7. Solder the equalizer line to the suction line. 8. Pressurize the system and check for leaks. 9. If no leaks are found, replace the liquid line drier then evacuate and dehydrate the system.

  • Page 152: Installation

    Refrigeration Service Procedures Installation 3. Front seat the receiver tank outlet valve and allow the low side to pump down to 0 to 5 in. 1. Apply a refrigerant Loctite to the threads of Hg vacuum (0 to -17 kPa). the HPCO.

  • Page 153: Removal

    Refrigeration Service Procedures 2. Run the unit in low speed cool until the system pressures stabilize. 3. Front seat the suction service valve and allow the compressor to pump down to 0 to 5 in. Hg vacuum (0 to -17 kPa). CAUTION: Do not run scroll compressor in a vacuum for more than 1 minute.

  • Page 154: Installation

    Refrigeration Service Procedures 7. Check the temperatures of the refrigeration 3. Remove liquid injection solenoid mounting bolts and remove the liquid injection solenoid lines on each side of the PV by hand. A from the unit. temperature difference between the two sides of the PV indicates it is leaking.

  • Page 155: Receiver Tank Replacement

    Refrigeration Service Procedures Solenoid Valve Replacement components: hot gas solenoid, liquid injection solenoid, purge valve, or receiver tank pressure check valve. Removal 7. Check the temperatures of the refrigeration 1. Recover the refrigerant charge. lines on each side of the receiver tank pressure 2.

  • Page 156: Suction Pressure Transducer Testing

    Refrigeration Service Procedures Suction Pressure Transducer Testing The suction pressure transducer is located on the suction adapter on top of the compressor. It supplies pressure information to the SR-3 Microprocessor Control System. Alarm Code 87 (Check Suction Pressure Sensor) indicates a possible problem with the suction pressure transducer.

  • Page 157: Clutch Maintenance

    Clutch Maintenance Centrifugal Clutch The centrifugal clutch has three belt grooves and its engagement speed is 600 ± 100 RPM. AGA127 Figure 243: Front View and Cross Section...
  • Page 158 Clutch Maintenance aea558 (3 belt grooves) Screw Grease Seal Washer Roller Bearing Inner Race Snap-Ring Pulley Housing Ball Bearing Elastic Stop Nuts (6) Large & Small Spacers Connector Link (6) Rolling Bearing Spring (6) Lockwasher (12) Shoe Assembly (3) Bushing (6) Screws (6) Figure 244: Centrifugal Clutch...

  • Page 159: Clutch Inspection

    2. Use a Continental Elite Gauge to check the condition of the Engine/Electric Motor Belt. 3. Contact the Thermo King Service Department if you cannot find a supplier for the Continental Elite Gauge. Figure 247: Clutch Removed from Failed Engine...
  • Page 160 Clutch Maintenance • If a strobe light is available, check for slip Slightly less than 1/16 inch gap between shoes in the unit. Some slip is planned. and pulley face – consistent for all shoes • Start Up • Slow slip rate to protect against rust bonding.

  • Page 161: Clutch Maintenance

    Clutch Maintenance Clutch Maintenance 3. Remove housing from hub by supporting hub (in a minimum of three places) in spoke area, Using an inspection mirror, inspect the clutch and pressing on the housing shaft. The inner every 1000 hours of operation or yearly, race of the roller bearing will remain on the whichever occurs first.

  • Page 162: Assembly Procedure (Using New Bearings And Seal)

    Clutch Maintenance 7. Press bushings out of hub. Figure 251: Bushing Removal 8. Remove inner race of roller bearing from the housing shaft. Figure 252: Bushing Insertion NOTE: This race had Loctite applied and was pressed in place. A puller will be *DO NOT USE SOAP OR OIL TO required to remove it.
  • Page 163 Clutch Maintenance 6. Apply Mobil (see Tool Catalog) grease to roller bearing and fill cavity between large and small spacers. A small amount of grease should also be applied to the seal lip and space between the seal and roller bearing. 7.

  • Page 164: Structural Maintenance

    Structural Maintenance Unit and Engine Mounting Bolts Cleaning Methods (listed in order of recommended method) Periodically check and tighten all unit and engine • Take a cloth or towel and wipe the air side of mounting bolts. Torque the unit mounting the coil going with the fins, across the tubes.

  • Page 165: Fan Location

    Structural Maintenance Fan Location When mounting the fan and hub assembly on the fanshaft, position the assembly in the orifice as follows for proper fan performance: • For the ten-blade condenser fan, position the fan with 50 percent of the blade width to the air discharge side.

  • Page 166: Plastic Defrost Damper

    Structural Maintenance Plastic Defrost Damper The blade pivots of the ends of the plastic damper blade are not adjustable. However, the position of the damper can be adjusted if necessary by adjusting the position of the eye bolt in the damper solenoid.

  • Page 167: Fanshaft Assembly

    Structural Maintenance Fanshaft Assembly The unit is equipped with one-piece fanshaft assemblies that contain tapered roller bearings in a sealed oil reservoir. A fanshaft assembly does not require any maintenance. There is a level plug and a fill plug, but they are not normally utilized except after removal and repair of the fanshaft assembly.
  • Page 168 Structural Maintenance 2. After draining the oil from the housing, 4. Using a punch, remove the oil seal from the remove the four retaining bolts from the evaporator end of the assembly. With the seal bearing retainer cap. removed, clean the housing in solvent. Figure 265: Removing Oil Seal 5.

  • Page 169: Reassembly

    Structural Maintenance Reassembly 3. Install a new oil seal after replacing the bearing race and splash guard. 1. Install the new bearings on the shaft with a pipe in the same way they were removed. NOTE: Tape shaft holes or keyway to prevent seal damage.

  • Page 170: Jackshaft Assembly

    Structural Maintenance Jackshaft Assembly 6. Torque the bolts in a criss-cross pattern in equal steps to 80 in.-lbs (9.04 N•m). The unit is equipped with a jackshaft that contains special sealed bearings. The jackshaft bearings should be checked when the belts are replaced. Spin the jackshaft with the belts removed and listen.

  • Page 171: Reassembly

    Structural Maintenance Reassembly CAUTION: To prevent damage to the bearings, use bearing drivers (or other suitable tools) on the bearing races when installing the bearings. NOTE: Place a thin layer of grease (Mobil 28 or its equivalent) on the inner and outer bearing races before assembly.

  • Page 172: 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 173 Mechanical Diagnosis Condition Possible Cause Remedy Engine does not reach full power Air or dirt in fuel system Repair Fuel line leaks Tighten connections of fuel lines. If necessary, replace damaged lines Speed adjustment wrong Adjust speed Electric fuel pump does not run Check voltage.
  • Page 174 Mechanical Diagnosis Condition Possible Cause Remedy Engine runs hot Engine coolant is low Add coolant slowly while engine is in operation Dirty or plugged radiator Clean radiator Cooling system heavily scaled Clean cooling system Water pump leaks Repair or replace water pump Worn or loose belt Replace belt or adjust Cylinder head gasket leaks (bubbles...
  • Page 175 Mechanical Diagnosis Condition Possible Cause Remedy Battery is not recharging Loose alternator belt Tighten belt Loose connections in electrical Check all electrical connections and system charging system Worn brushes in alternator Repair Voltage regulator faulty Replace Battery defective Replace Alternator defective Repair or replace Dirty battery terminals Clean and retighten...

  • Page 176: Electric Standby (Optional) Diagnosis

    Electric Standby (Optional) Diagnosis Condition Possible Cause Remedy Unit turned On—Microprocessor Battery discharged Charge or replace battery display does not come on Faulty battery cable connections Clean battery cables Fuse F21 blown Check for short circuits and replace fuse Fuse F2 blown Check for short circuits and replace fuse Open circuit...
  • Page 177 Electric Standby (Optional) Diagnosis Condition Possible Cause Remedy Contact chatter Low battery voltage Check voltage condition. Check momentary voltage dip during starting—low voltage prevents magnet sealing Defective or incorrect coil Replace coil Poor contact in control circuit Check auxiliary switch contacts and overload relay contacts.

  • Page 178: 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 179 Refrigeration Diagnosis Possible Causes • • • • Restricted line on the high side • • • • Restricted drier • Defrost damper stays open • • • Defrost damper stuck closed • Suction service valve back seated • • •...

  • Page 180: Index

    Index AC components 79 Defrost 24 accumulator replacement 133 defrost damper alternator 72 plastic 165 field current test 75 defrost mode 32 general diagnostic and warranty evaluation dehydrator (filter-drier) 142 procedure 73 Design Features 22 identification 72 diagnosis, mechanical 171 load test 73 diagnosis, refrigeration 177 antifreeze...
  • Page 181 Index filter-drier 142 first aid 15 phase select module 79 electrical shock 15 Preheat Buzzer 26 engine coolant 15 purge check valve refrigerant 15 test 139 refrigerant oil 15 purge mode 31 flywheel RPM sensor 77 purge valve (PV) fuel filter replacement 103 test 153 fuel limit screw 108 fuel solenoid 108...
  • Page 182 Index Unit Options 23 wiring 79 wiring diagrams index 182...

  • Page 183: Wiring And Schematic Diagrams Index

    Wiring and Schematic Diagrams Index Dwg No. Drawing Title Page 2E24812 Schematic Diagram 183-184 2E24811 Wiring Diagram 185-189...
  • Page 184 Schematic Diagram - Page 1 of 2...
  • Page 185 Schematic Diagram - Page 2 of 2...
  • Page 186 Wiring Diagram - Page 1 of 5...
  • Page 187 Wiring Diagram - Page 2 of 5...
  • Page 188 Wiring Diagram - Page 3 of 5...
  • Page 189 Wiring Diagram - Page 4 of 5...
  • Page 190 Wiring Diagram - Page 5 of 5...
  • Page 191 Ingersoll Rand’s Climate Solutions sector delivers energy-effi cient HVACR solutions for customers globally. Its world class brands include Thermo King, the leader in transport temperature control and Trane, a provider of energy effi cient heating, ventilating and air conditioning systems, building and contracting services, parts support and advanced controls for commercial buildings and homes.

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