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 environment and limit the potential harm to the ozone layer that can result from allowing refrigerant to escape into the atmosphere. We strictly adhere to a policy that promotes the recovery and limits the loss of refrigerant into the atmosphere.
Page 5: Table Of Contents
Thermo King S391 Screw Compressor with Loading Valves ....... . .
Page 6 Table of Contents Electrical Maintenance ..............53 Alternator (Australian Bosch) .
Page 7 Table of Contents Refrigeration Maintenance (continued) Liquid Line Solenoid Test ..............89 Liquid Injection Valve Test .
Page 8 Table of Contents Refrigeration Diagnosis ..............127 Refrigeration System Diagnosis .
Page 9: List Of Figures
List of Figures Figure 1: Compressor Serial Number Location ..........18 Figure 2: Unit Serial Number Locations .
Page 10 List of Figures Figure 59: Check Bleed Hole Diameter ............107 Figure 60: Check Piston Bleed Orifice .
Page 11: Safety Precautions
Safety Precautions General Practices Refrigerant 1. Always wear goggles or safety glasses. Although fluorocarbon refrigerants are classified Refrigerant liquid and battery acid can as safe refrigerants, certain precautions must be permanently damage the eyes. See First Aid observed when handling them or servicing a unit under Refrigeration Oil.
Page 12 Safety Precautions...
Page 13: Specifications
Specifications Engine Model TK 486 Number of Cylinders Cylinder Arrangement In-line vertical, number 1 on flywheel 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 13 quarts (12.3 liters) crankcase Fill to full mark on dipstick...
Page 14: Belt Tension
Tension No. on TK Gauge P/N 204-427 Alternator Belt Lower Fan Belt (Engine to Idler) Upper Fan Belt (Fan to Idler) Refrigeration System Compressor Thermo King S391 Refrigerant Charge—Type 19 lb (8.6 kg)—R-404A Compressor Oil Charge 2.8 quarts (2.7 liters)* Compressor Oil Type...
Page 15: Electrical Components
Specifications Electrical Components NOTE: Disconnect components from unit circuit to check resistance. Current Draw (Amps) Resistance—Cold Component at 12.5 Vdc (Ohms) Fuel Solenoid: Pull-in Coil 35 to 45 0.2 to 0.3 Hold-in Coil 24 to 29 Damper Solenoid High Speed (Throttle) Solenoid Intake Air Heater 0.14 Liquid Line Solenoid...
Page 16 Specifications...
Page 17: Design Features And Unit Photos
DAS (Data Acquisition System) • Sleep Mode Easy Switch Fuel Heater Frost Plug Heater 65 Amp Alternator Fresh Air Exchange Chrome Grills Remote Controls R:COM Automatic Data Transmission System Satellite Communications System Thermo King Bulkhead and Duct System Dealer Installed Synthetic Engine Oil...
Page 18: Serial Number Locations
Design Features and Unit Photos Serial Number Locations Nameplates on the on the bulkhead above Unit: compressor inside the curbside door, and on the top, roadside corner of evaporator. Stamped on an nameplate on the valve Engine: cover. Stamped on the plate above the oil Compressor: level sight glass.
Page 19: Unit Photos
Design Features and Unit Photos Unit Photos Figure 4: Front View...
Page 20: Figure 5: Back View
Design Features and Unit Photos Defrost Damper S391 Compressor TK 486 Engine Figure 5: Back View...
Page 21: Figure 6: Front View With Doors Open
Design Features and Unit Photos Top Access Door TK 486 Engine Condenser Fan S391 Compressor Radiator Cap (Coolant Fill) Fuel Filter Expansion Tank 10. Air Cleaner Subcooler/Condenser/Radiator Coil Top Access Door Pull Down Strap Top Access Door Latch Handle Figure 6: Front View with Doors Open...
Page 22: Figure 7: Engine Compartment
Design Features and Unit Photos Alternator Engine RPM Sensor Three-way Valve 12. Economizer Suction Service Valve Filter Drier 13. Loading Valve #1 Receiver Tank Sight Glass 14. Loading Valve #2 Fuel Injection Pump 15. Discharge Service Valve Hand Primer Pump 16.
Page 23: Figure 8: Control Panel
Design Features and Unit Photos Display Microprocessor Control Panel Computer Port Printer Port ON/OFF Switch Figure 8: Control Panel...
Page 24 Design Features and Unit Photos...
Page 25: Maintenance Inspection Schedule
Maintenance Inspection Schedule Every Every Annual/ Pretrip 1,500 3,000 4,500 Inspect/Service These Items Hours Hours* Hours Microprocessor • Run Pretrip Test (refer to Pretrip Test in the Operating Manual). Engine • Check fuel supply. • Check engine oil level. • •...
Page 26 Maintenance Inspection Schedule Every Every Annual/ Pretrip 1,500 3,000 4,500 Inspect/Service These Items Hours Hours* Hours Structural • • • • Visually inspect unit for fluid leaks. • • • • Visually inspect unit for damaged, loose or broken parts (includes air ducts and bulkheads).
Page 27: Unit Description
Unit Description General Description NOTE: A buzzer sounds when the unit is automatically preheating. The SB-400 is a one-piece, self-contained, diesel NOTE: The microprocessor has an OptiSet™ powered refrigeration-heating unit. The unit feature, which can lockout CYCLE-SENTRY mounts on the front of the trailer with the operation and force Continuous Run within a evaporator portion extending into the trailer.
Page 28: Data Logging
Heat Check Valve compatible laptop or desktop computer and 12. Receiver Tank Thermo King WinTrac 4.1 (or higher) software. The computer is connected to the Computer Port 13. High Pressure Relief Valve on the front of the control box. Detailed graph or 14.
Page 29: Figure 9: Refrigeration System Components
Unit Description Figure 9: Refrigeration System Components...
Page 30: Thermo King S391 Screw Compressor With Loading Valves
Thermo King S391 Screw Refrigeration System Compressor with Loading Valves The S391 screw compressor refrigeration system The unit features a Thermo King S391 screw is different from the reciprocating compressor compressor with loading valves. Some of the refrigeration system. Some of the characteristics...
Page 31: Sequence Of Operation
Unit Description • It has a liquid injection valve. The • Null (CYCLE-SENTRY operation only) microprocessor uses the liquid injection valve • Low Speed Heat to control the compressor temperature, discharge pressure, and compression ratio. • High Speed Heat • It has a condenser pressure bypass check valve •...
Page 32 Unit Description cooling cycle. The refrigerant flows through the The refrigerant boils off in the evaporator and the drier and arrives at a tee fitting located near the low pressure suction gas travels through the ETV. economizer expansion valve. Most of the The ETV regulates the suction pressure to the refrigerant enters the outer chamber of the compressor to vary capacity.
Page 33: Figure 10: High And Low Speed Cool
Unit Description High Pressure Gas Low Pressure Liquid High Pressure Liquid Low Pressure Gas Medium Pressure Liquid High Pressure Compressor Oil Medium Pressure Gas Engine Coolant Figure 10: High and Low Speed Cool...
Page 34 Unit Description At setpoints in the frozen range, the unit typically Modulated Cool enters modulated cool with LV1 and LV2 both Component Status closed. The microprocessor opens LV1 reduce the capacity, and closes LV1 to increase the capacity. Engine Speed 1450 rpm LV2 is always closed at setpoints in the frozen High Speed Solenoid...
Page 35: Figure 11: Modulated Cool With Lv1 Open
Unit Description High Pressure Gas Low Pressure Liquid High Pressure Liquid Low Pressure Gas Medium Pressure Liquid High Pressure Compressor Oil Medium Pressure Gas Engine Coolant Figure 11: Modulated Cool with LV1 Open...
Page 36 Unit Description Running Null Component Status Engine Speed 1450 rpm High Speed Solenoid LV1—Loading Valve #1 Off (Open) (Economizer Bypass Solenoid) LV2—Loading Valve #2 Off (Open) EWSV—Water Valve On (Open) LLSV—Liquid Line Solenoid On (Closed) PS—Pilot Solenoid Off (Closed) LIV—Liquid Injection Valve Off (Closed) Heat Check Valve Closed...
Page 37: Figure 12: Running Null
Unit Description High Pressure Gas Low Pressure Liquid High Pressure Liquid Low Pressure Gas Medium Pressure Liquid High Pressure Compressor Oil Medium Pressure Gas Engine Coolant Figure 12: Running Null...
Page 38 Unit Description through LV1 (economizer bypass solenoid), Low Speed Heat which is open (de-energized) during the Component Status heat/defrost cycle. Engine Speed 1450 rpm During the heat cycle there will be a small amount High Speed Solenoid of flow between the heat circuit and the suction LV1—Loading Valve #1 Off (Open) line through the heat orifice.
Page 39: Figure 13: Low Speed Heat
Unit Description High Pressure Gas Low Pressure Liquid High Pressure Liquid Low Pressure Gas Medium Pressure Liquid High Pressure Compressor Oil Medium Pressure Gas Engine Coolant Figure 13: Low Speed Heat...
Page 40 Unit Description The evaporator coil temperature must be below High Speed Heat 45 F (7 C) to allow defrost. When the Defrost Component Status Icon appears, the damper door is closed by the damper solenoid. Engine Speed 2200 rpm High Speed Solenoid A demand defrost cycle will occur if the LV1—Loading Valve #1 Off (Open)
Page 41: Special Start-Up Modes
Unit Description Special Start-up Modes Bucking Defrost The microprocessor uses special modes for Component Status conditions that usually exist only when the unit is Engine Speed 1450 rpm started. High Speed Solenoid Bucking Heat Mode LV1—Loading Valve #1 Off (Open) (Economizer Bypass Solenoid) Component Status...
Page 42: Compressor Temperature (Ctmp) System
Unit Description lower than normal for the first 5 minutes. This If this cannot be accomplished, the unit may shut mode will also occur in the service test modes that down to protect the compressor and other run the unit in cool. components.
Page 43: Alarm Codes
Unit Description Alarm Codes microprocessor will use the Compressor Temperature Control Auxiliary Mode to try to This unit has some alarm codes other units do not reduce the compressor temperature before have. The following text explains some of the shutting down on Code 82. alarm codes used in this unit.
Page 44 Unit Description...
Page 45: Operating Instructions
Most of the controls used to operate the unit are switch is in the Off position, the display will be located on the control panel. Refer to the SB-400 off and the display backlight will be off. The Operator’s Manual TK 51212 or the switch should always be placed in the Off position THERMOGUARD µP-VI Microprocessor for...
Page 46: Optional On/Off/Sleep Switch
Operating Instructions Optional On/Off/Sleep Switch Cool and Modulation Icons displayed at the same time indicate the unit is operating in This switch turns the unit on and off and also Running Null. places the unit directly into the Sleep Mode Appears when the unit is Heat Icon: without an exit time.
Page 47: Computer Port
[00] means printer port to print a report for the directly no codes are present. connected DAS sensors. Refer to the SB-400 Operator’s Manual TK 51212 of the DAS Data Pressing this key will execute a...
Page 48: Unit Operation
Operating Instructions A number of fuses, located on the relay Unit Operation Fuses: board, protect various circuits and components. See “Fuses” on page 56 for more information. Manual Pretrip Inspection (Before Starting Unit) The high pressure cutout is High Pressure Cutout: a pressure sensitive switch that is located in the The following Manual Pretrip Inspection should compressor discharge service valve.
Page 49: Starting Unit With Electronic Full Pretrip
Operating Instructions 7. STRUCTURAL. Visually inspect the unit for d. Press the key while PRE TRIP is NTER leaks, loose or broken parts and other damage. displayed. The condenser and evaporator coils should be • PRE LOAD will appear on the display clean and free of debris.
Page 50: Selection Of Operating Modes
Operating Instructions Selection of Operating Modes Examples of Products Normally Requiring Continuous Run Operation for Air Flow The Thermo King CYCLE-SENTRY system is designed to save refrigeration fuel costs. The • Fresh fruits and vegetables, especially savings vary with the commodity, ambient asparagus, bananas, broccoli, carrots, citrus, temperatures and trailer insulation.
Page 51: After Start Inspection
3. COMPRESSOR OIL. The compressor oil level should be visible in the sight glass. 4. Products should be pre-cooled before loading. Thermo King transport refrigeration units are 4. REFRIGERANT. Check the refrigerant designed to maintain loads at the temperature charge. See Refrigerant Charge in the at which they were loaded.
Page 52 Operating Instructions...
Page 53: Electrical Maintenance
Thermo King P/N terminal F2 to ground. Attempting to 204-615 (FLUKE 23) digital multimeter and a full-field the alternator by applying Thermo King P/N 204-613 amp clamp or an battery voltage to terminal F2 will cause equivalent. voltage regulator failure.
Page 54 Electrical Maintenance • Make sure the drive belts and pulleys of the b. Energize the run relay in the relay board charging system are in good condition and are test. The B pin is the excitation circuit and adjusted properly before testing the alternator. should be at 10 volts or higher.
Page 55 Electrical Maintenance NOTE: An alternator can easily exceed its 3. The ammeter reading indicates field current. rated output. An alternator MUST at least The following chart shows the field current for reach its rated output when full fielded. An each alternator with 12 volts applied to the alternator that has a defective rectifier diode field: may reach 75% of its rated output with a full...
Page 56: Battery
Electrical Maintenance Check Point for 2A Amperage Position for Full Fielding Jumper Figure 17: Full Field Test Battery Fuses Inspect/clean the battery terminals and check the A number of fuses, located on the relay board, electrolyte level during scheduled protect various circuits and components. The maintenance inspections.
Page 57: Fuse Link
Electrical Maintenance • Fuse 21 (25 amp) protects the circuit that Check the resistance of the air intake heater with provides power to the On/Off switch. an ohmmeter between the M6 terminal on the front of the heater and the screw on the back of •...
Page 58 Electrical Maintenance...
Page 59: Engine Maintenance
Coolant). The oil filter should be changed along with the The EMI package allows standard maintenance engine oil. Use a genuine Thermo King extended intervals to be extended to 3,000 hours, or 2 years, maintenance oil filter. whichever occurs first.
Page 60 Engine Maintenance Low Oil Pressure Flow Chart Oil Pressure Low Check Oil Level Oil Level Low Oil Level OK or High Add Oil Oil May Be Diluted Check Oil Pressure Change Oil and Filter Check Oil Pressure Oil Pressure OK Oil Pressure Low Oil Pressure OK Install Known Good Oil Pressure Gauge...
Page 61: Engine Cooling System
The following are the Extended Life Coolants 1. Prevents freezing down to -30 F (-34 C). currently approved by Thermo King for use in ELC units for five years or 12,000 hours: 2. Retards rust and mineral scale that can cause engine overheating.
Page 62: Antifreeze Maintenance Procedure
Engine Maintenance 2. Use Service Test Mode [LS.H] to place the CAUTION: Do not add “GREEN” or unit in low speed heat before the unit starts. “BLUE-GREEN” conventional coolant to This opens the water valve and allows the cooling systems using “RED” Extended coolant to drain from the economizer and its Life Coolant, except in an emergency.
Page 63: Bleeding Air From The Cooling System
Engine Maintenance Bleeding Air From The Cooling NOTE: If an engine runs with air trapped in the System block, the engine may be damaged. The high water temperature switch may not protect an Jiggle pin thermostats are original equipment on engine that has air trapped in the block, because units that have TK 482/486 engines.
Page 64: Engine Thermostat
Engine Maintenance 6. Check the coolant level and add coolant if The injection pump plungers are activated by a necessary. gear driven injection pump camshaft. The governor sleeve and weight assembly is mounted 7. Repeat steps 5 and 6 until the coolant level on the end of the pump camshaft.
Page 65: Figure 22: Engine Fuel System
Engine Maintenance Any major injection pump or nozzle repairs 3. Priming pump (hand) replacement or repair. should be done by a quality diesel injection 4. Fuel pump replacement or repair. service shop. The necessary service equipment and facilities are not found in most engine rebuild 5.
Page 66: Bleeding The Fuel System
Engine Maintenance Bleeding The Fuel System 3. Tighten the bleed screw and screw the priming pump handle back in. If the engine runs out of fuel, repairs are made to the fuel system, or if air gets into the system for 4.
Page 67: Engine Speed Adjustments
Engine Maintenance 1. Unscrew the fuel filter/water separator 3. Remove the ball joint from the eye bolt in the canister with a strap wrench. Drain, and high speed solenoid. dispose of properly. 4. Remove the boot from the high speed 2.
Page 68: Injection Pump Timing
Engine Maintenance Injection Pump Timing 5. Place the engine at top dead center of the compression stroke for the number one This timing procedure requires fuel pressure at the cylinder. Refer to steps a. through d. injection pump inlet. This can be accomplished by pumping the priming pump by hand, or by using a.
Page 69: Injection Pump Removal
Engine Maintenance 9. Energize the fuel solenoid by energizing the run relay [RUNR] with the Relay Board Test Mode. 10. Rotate the engine backwards (counterclockwise viewed from the water pump end) until the injection timing mark is positioned in the bottom of the timing mark access hole.
Page 70: Injection Pump Reinstallation
Engine Maintenance 2. Remove the cover plate from the gear case. 6. Remove the screw and adapter leaving the tool Remove the nut and lock washer which secure plate in place. This holds the gear in proper the gear to the injection pump shaft. Use a tooth alignment until the injection pump is shop rag to prevent the lock washer or nut re-installed.
Page 71: Fuel Solenoid
Engine Maintenance Fuel Solenoid 1. Use the microprocessor keypad to enter the Relay Board Test Mode. Refer to the The fuel solenoid is located on the end of the appropriate Microprocessor Diagnostic injection pump. It contains two coils: the pull-in Manual for specific information about the coil, and the hold-in coil.
Page 72: Figure 33: Fuel Solenoid Components
Engine Maintenance 7. Place a jumper wire between the black wire black wire (CH—pin C) in the fuel (CH—pin C) in the fuel solenoid connector solenoid connector. The resistance of the and a good chassis ground. hold-in coil should be 24 to 29 ohms. If the resistance of the hold-in coil is not in 8.
Page 73: Engine Valve Clearance Adjustment
Engine Maintenance 7. Install the new fuel solenoid. 8. Place the On/Off switch in the Off position after installing the fuel solenoid. Engine Valve Clearance Adjustment 1. Remove the rocker arm cover. 2. Remove the round cover (plug) from the timing mark access hole on the front of the bell housing.
Page 74: Crankcase Breather
Engine Maintenance Crankcase Breather 4. Use a feeler gauge to check the valve clearance on both valves for the number one The crankcase breather is located on top of the cylinder, the intake valve for the number two rocker arm cover. The crankcase breather system cylinder, and the exhaust valve for the number ducts crankcase gases formed in the crankcase three cylinder.
Page 75: Emi 3000 Air Cleaner
“EMI 3000.” It cannot be interchanged with air filters used on previous Thermo King trailer units, however it can be retrofit on previous units by using the EMI 3000 Air Cleaner Assembly.
Page 76: Alternator Belt Adjustment
Engine Maintenance Alternator Belt Adjustment Upper And Lower Fan Belt Adjustment The alternator belt tension should read 35 on the belt gauge. The upper fan belt should read 74 and the lower fan belt should read 67 on the belt tension gauge. 1.
Page 77: Fan Belt Removal And Installation
Engine Maintenance 2. Push in or pull out on the idler adjusting arm 2. Push the idler adjusting arm in and the idler to “center” the idler assembly between the assembly up. The upper belt should become belts and balance the tension equally between slack and slip down out of the idler pulley the upper and lower belts.
Page 78: Figure 41: Condenser Blower Alignment
Engine Maintenance 7. Push inward on the idler adjusting arm and slip the belt into the idler pulley groove. 8. Pull the idler adjusting arm forward and install the lower fan belt. AEA749 Blower Wheel Inlet Ring Alignment Mark Edge of Inlet Ring Figure 42: Condenser Blower Alignment...
Page 79: Refrigeration Maintenance
Refrigeration Maintenance NOTE: The following procedures involve 3. For some tests it is necessary to connect a servicing the refrigeration system. Some of these second compound gauge to the economizer service procedures are regulated by Federal, and suction service valve port. in some cases, by State and Local laws.
Page 80: Refrigerant Charge
Refrigeration Maintenance Refrigerant Charge 2. Use Service Test Mode [HS.C] to run the unit in High Speed Cool. Refer to the appropriate CAUTION: The S391 screw compressor Diagnostic Manual for specific information refrigeration system is sensitive to an about the Service Test Mode. overcharge of refrigerant.
Page 81: Moisture Indicating Sight Glass
Refrigeration Maintenance NOTE: If the ball and liquid level in the h. Close the hand valve on the refrigerant receiver sight glass drops during step 4, the tank when liquid appears in the receiver unit is not overcharged and it is not sight glass.
Page 82: Compressor Shaft Seal Leak Check
Refrigeration Maintenance NOTE: A leak detector cannot be used to check 3. Starting from below the seal cover, slowly the compressor shaft seal. The shaft seal in this move the probe up towards the compressor screw compressor is designed so that if it leaks, it shaft seal.
Page 83: Adding Compressor Oil
Refrigeration Maintenance Adding Compressor Oil 4. Pour the required amount of compressor oil into the compressor. Use oil from a capped 1. Close the main suction service valve, the contained. DO NOT use oil from an open economizer suction service valve, and the container.
Page 84: Compressor Pump Down
Refrigeration Maintenance Compressor Pump Down 6. To return the unit to service: a. Evacuate the compressor. NOTE: Never run the unit if the compressor oil is not visible in the sight glass. The compressor b. Open the discharge, main suction, and will not function properly if the compressor oil economizer suction service valves.
Page 85: High Pressure Cut In Switch (Hpci) Test
Refrigeration Maintenance 5. If the suction access port gauge was unable to pressures. If the discharge pressure rises above obtain an approximate 25 in. Hg vacuum (-85 425 psi (2930 kPa), the HPCI closes. This signals kPa) in step 3, but the compressor does pump the microprocessor that the discharge pressure is down in step 4, at least one of the following high.
Page 86: Three-Way Valve Condenser Pressure Bypass Check Valve
Refrigeration Maintenance fuel solenoid and shuts down the unit. The 3. Raise the discharge pressure of the microprocessor then records Alarm Code 10. Test compressor first by blocking the condenser the HPCO for the following symptoms: coil air flow by covering the roadside condenser grille with a piece of cardboard.
Page 87: Electronic Throttling Valve (Etv)
Refrigeration Maintenance 6. Isolate the low side by closing the economizer suction service valve and the main suction service valve while the unit is running. 7. Stop the unit. The pressures in the compressor should equalize. The discharge pressure and the pressure at the suction access port should then remain stable, indicating no leaks.
Page 88: Pressure Transducers
Refrigeration Maintenance The ETV has two internal coils. The Refer to Service Procedure G03A, the Electronic microprocessor operates the valve by energizing Throttling Valve (ETV) Test, and Alarm Code 89 the coils with a variable frequency ac signal. The in the THERMOGUARD µP-VI Microprocessor valve position can be monitored with the for Screw Compressor Applications Diagnostic key [ETV.P].
Page 89: Liquid Line Solenoid Test
Refrigeration Maintenance 6. Use Service Test Mode [LSC.U] to place the unit in Low Cool Unloaded. This opens LV2. The main suction pressure and the economizer suction pressure should both rise, and the discharge pressure should fall. The main suction pressure should stabilize a minimum of 5 psi (34 kPa) below the economizer suction pressure.
Page 90: Liquid Injection Valve Test
Refrigeration Maintenance Liquid Injection Valve Test a. If the suction pressure is above -5 psi (-34 kPa), the test will continue. See Use the following procedure to test the LIV step 5. (Liquid Injection Valve). b. If the suction pressure is below -5 psi 1.
Page 91: Heat Check Valve Test
Refrigeration Maintenance • The unit records Alarm Code 26 (Check 9. The hoses should be warming up and soon get Refrigeration Capacity) and either the heating almost as hot as the engine coolant. capacity or the cooling capacity is low. a.
Page 92: Compressor Test
Refrigeration Maintenance Compressor Test 2. Use Service Test Mode [HS.C] to run the unit in High Speed Cool. Refer to the appropriate The following symptoms often occur when the Diagnostic Manual for specific information compressor is failing and its capacity is low: about the Service Test Mode.
Page 93 Refrigeration Maintenance 2. Install a gauge manifold on the compressor NOTE: If you cannot raise the discharge and connect an extra compound gauge to the pressure to 400 psi (2758 kPa), make sure economizer suction service valve. Make sure you have at least 16 psi (110 kPa) of main the gauge attached to the economizer suction suction pressure.
Page 94: Figure 50: Remove Sump
Refrigeration Maintenance 15. Check and record the CTMP after about 15 c. Recover the refrigerant from the minutes with the unit in low speed cool and compressor. the box temperature as close as possible to d. Disconnect the service valves from the 20 F (-7 C).
Page 95 Refrigeration Maintenance Compressor Test Flow Chart Download DAS Alarm Codes 26, 32, 63, No Codes 81, or 82 CTMP Normal TPDF less than -10 F (-6 C) TPDF Normal High CTMP Return Unit to Service Continue to Monitor Install Gauges Run in Service Test High Speed Cool Check the Compressor Oil Level and Condition Oil Level OK...
Page 96 Refrigeration Maintenance Compressor Test Flow Chart (Continued) From Previous Page Run in Service Test High Speed Cool, Raise Discharge Pressure to 400 psi (2758 kPa), and Partially Close Main Suction Service Valve to Obtain Suction Pressure of 16 psi (110 kPa) Cannot Raise Discharge Pressure to 400 psi (2758 kPa) Can Raise Discharge Pressure to 400 psi (2758 kPa) with Main Suction Pressure of 16 psi (110 kPa)
Page 97: Refrigeration Service Operations
Refrigeration Service Operations Installation NOTE: It is generally good practice to replace the filter drier whenever the high side is opened 1. Slide the compressor into the unit. or when the low side is opened for an extended period of time. 2.
Page 98: Compressor Coupling Installation
Refrigeration Service Operations 4. Use the appropriate Allen tool to loosen the not fit easily into the keyway, it will push the coupling mounting screw. tapered components apart and the reduced friction could lead to slippage and premature failure. 5. Once the center screw has been loosened, back the head against the tool and it should The following procedure requires the key to be push the coupling off the crankshaft as you...
Page 99: Compressor Repair
Refrigeration Service Operations 3. Using no lubricants, set the coupling on the 8. Install the key in the keyway. As above, it crankshaft and align the keyways using the should fit with a light press fit requiring only a Keyway Tool (P/N 204-972). Insert the minimum of light tapping.
Page 100: System Clean-Up Procedures
Refrigeration Service Operations System Clean-up Procedures 4. Remove the compressor drain plug and drain the compressor oil. Measure the amount of oil If a compressor fails, contaminants can spread drained from the compressor and check the throughout the system via the compressor oil. In condition of the oil.
Page 101: Figure 54: Screw Compressor Clean-Up Kit (P/N 204-920) Installation
Refrigeration Service Operations 4. Mid-seat the economizer suction service d. Evacuate the air from the compressor and valve. Open the main suction and discharge the external filter. service valves. e. Mid-seat the economizer suction service 5. Run the unit for at least 1/2 to 1 hour in both valve.
Page 102: In-Line Condenser Check Valve
Refrigeration Service Operations In-line Condenser Check Valve 5. Pressurize the refrigeration system and test for leaks. This unit uses an in-line condenser check valve. 6. If no leaks are found, evacuate the system. The in-line check valve is not repairable and must be replaced if it fails.
Page 103: Filter Drier
Refrigeration Service Operations Evaporator Expansion Valve 2. Place the receiver tank in the unit and install the mounting bolts and nuts loosely. Position NOTE: The evaporator expansion valve and the the receiver tank so that the sight glass is economizer expansion valve are made by the clearly visible through the viewing hole in the same manufacturer.
Page 104: Checking Evaporator Expansion Valve Superheat
Refrigeration Service Operations 6. Open the refrigeration valves and place the 7. Check and record the suction pressure and the unit in operation. suction line temperature simultaneously. Take four readings at 2 minute intervals. 7. Test the unit to see that the expansion valve is properly installed and check the expansion 8.
Page 105: Three-Way Valve Repair
Refrigeration Service Operations 5. Remove the feeler bulb from the suction line clamp. Note the position of the feeler bulb on the suction line. 6. Unsolder the distributor from the expansion valve. 7. Unsolder the suction line from the evaporator circuit.
Page 106: End Cap Checks
Refrigeration Service Operations 4. Loosen the four 1/4 in. Allen head screws (DO NOT REMOVE OR CAP MAY POP OFF); use tool P/N 204-424 to break the gasket at each side of the center section. CAUTION: Do not force the tool into the brass or against the bolts.
Page 107: Assembly/Installation
Refrigeration Service Operations 3. With the piston pushed all the way back in its bore, use a strong light to look down the 0.089 in. (2.26 mm) hole towards the back of the piston and determine how much of the end of the hole is covered by the piston.
Page 108: Three-Way Valve Condenser Pressure Bypass Check Valve Repair
Refrigeration Service Operations 3. Install new gaskets on both sides of the seat. 9. Install the pilot solenoid line and pressurize Oil the gaskets in compressor oil before the system with refrigerant to check for leaks. installing. 10. If there are no leaks, evacuate the system and 4.
Page 109: Pilot Solenoid
Refrigeration Service Operations Installation 2. Place the valve in the unit and install the mounting bolts. The arrow on the valve 1. Coat the O-ring with compressor oil and indicates the direction of flow through the install it on the check valve stem. valve.
Page 110: High Pressure Relief Valve
Refrigeration Service Operations Installation 2. Recover the refrigerant remaining in the compressor. 1. Clean the tubes for soldering. 3. Disconnect the switch wire connector from the 2. Remove the solenoid coil from the solenoid main wire harness, and remove the switch valve.
Page 111: Discharge Pressure Transducer
Refrigeration Service Operations 3. Solder the refrigeration connections. 2. Install and tighten the suction pressure transducer and reconnect the wires. 4. Pressurize the refrigeration system and test for leaks. If no leaks are found, evacuate the 3. Pressurize the low side and check for leaks. If system.
Page 112: Figure 64: Electronic Throttling Valve
Refrigeration Service Operations c. Place the new valve body (and any tubes that were removed) in the same position from which the old one was removed. The new ETV could interfere with the evaporator access panel if it is not placed in the same position as the old one.
Page 113: Economizer Heat Exchanger
Refrigeration Service Operations Economizer Heat Exchanger CAUTION: The ETV may stick in the closed position if the stepper motor and Removal piston assembly is installed with the piston in the closed position. In the closed 1. Pump down and isolate the low side. Equalize position the bottom edge of the piston is the pressure to slightly positive and recover 1.5 in.
Page 114: Checking Economizer Expansion Valve Superheat
Refrigeration Service Operations Check/Adjustment Procedure 2. Remove the feeler bulb from the clamp on the suction line. Note the position of the feeler 1. Install a gauge manifold on the compressor. bulb on the suction line. Attach the low side gauge to the service port 3.
Page 115: Heat Check Valve Repair
Refrigeration Service Operations Heat Check Valve Repair 11. Check and record the economizer suction service valve pressure and the suction line temperature simultaneously. Take four Disassembly readings at 2 minute intervals. 1. Recover the refrigerant charge. 12. Calculate the superheat for each of the four 2.
Page 116: Liquid Injection Valve
Refrigeration Service Operations 2. Disassemble the check valve. 4. Solder the inlet and outlet connections. After the valve cools, install the coil and connect the 3. Unsolder the lines and remove the check wire connector to the main wire harness. valve.
Page 117: 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 mounting 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...
Page 118: Defrost Damper
Structural Maintenance Defrost Damper 4. If necessary, adjust Distance A to the proper dimension by loosening the locknut on the end Check the damper during scheduled maintenance of the solenoid plunger and turning the eye inspections for shaft wear, end play, and the bolt.
Page 119: Condenser And Evaporator Fan Location
Structural Maintenance 8. De-energize and energize the damper several 5. Pass a gauge wire completely around the times to make sure that the damper operates blower orifice to check for uniform clearance. correctly and seals properly. 6. Spin the blower by hand to check for blower 9.
Page 120: Fan Shaft Assembly
NOTE: The fan shaft assembly requires a 6. After all the parts are cleaned, inspect the special lubricant, Thermo King P/N 203-278. bearings and bearing races for wear or damage. Fan Shaft Assembly Overhaul 7.
Page 121: Idler Assembly
Department After the shaft has been removed, clean all the 0.020 in. (0.500 mm) Thermo King P/N 99-4231 parts in clean solvent. 0.007 in. (0.177 mm) Thermo King P/N 99-2902 4. Using a punch, remove the oil seal from the 0.005 in.
Page 122: Figure 73: Idler Assembly
Shims available from the Service Parts Department 0.020 in. (0.500 mm) Thermo King P/N 99-4231 0.007 in. (0.177 mm) Thermo King P/N 99-2902 0.005 in. (0.127 mm) Thermo King P/N 99-2901 AEA722...
Page 123: 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 124 Mechanical Diagnosis 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 125 Mechanical Diagnosis 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 Oil pressure low...
Page 126 Mechanical Diagnosis 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 127: Refrigeration Diagnosis
Refrigeration Diagnosis Refrigeration System Diagnosis Perform the Diagnosis Procedure and refer to the charts (see “Refrigeration Diagnosis Charts” on page 129) to help diagnose the refrigeration system. Use the THERMOGUARD µP-VI Microprocessor for Screw Compressor Applications Diagnostic Manual TK 51329 to diagnose the Alarm Codes that appear.
Page 128 Refrigeration Diagnosis b. Let the unit run until the box temperature d. High main suction pressure and a dry is at approximately 0 F (-18 C). If the box suction line suggest internal vapor leaks or temperature will not come down to 0 F low compressor capacity: This may be (-18 C), continue the procedure with the caused by the following: leaking...
Page 129: Refrigeration Diagnosis Charts
Refrigeration Diagnosis b. Check to see if the liquid line solenoid a. If the low side does not pump down but closes. If not, liquid line solenoid or its the compressor does pump down, at least circuits may be faulty. one of the following components may be leaking or defective: three-way valve, c.
Page 130 Refrigeration Diagnosis Possible Causes • • • • • Overcharge of refrigerant • • • • • • • • • Shortage of refrigerant • • • Air through condenser too hot (ambient) • • • Air flow through condenser restricted •...
Page 131 Refrigeration Diagnosis Possible Causes • Leaky receiver tank outlet valve • Leaky condenser check valve • • • Leaky heat check valve • • • Leaky loading valve #1 • Leaky liquid line solenoid • • Liquid line solenoid not closing •...
Page 132 Refrigeration Diagnosis...
Page 133: Refrigeration Diagrams
Refrigeration Diagrams High Pressure Gas Low Pressure Liquid High Pressure Liquid Low Pressure Gas Medium Pressure Liquid High Pressure Compressor Oil Medium Pressure Gas Engine Coolant Figure 75: High and Low Speed Cool...
Page 134: Figure 76: Modulated Cool With Lv1 Open
Refrigeration Diagrams High Pressure Gas Low Pressure Liquid High Pressure Liquid Low Pressure Gas Medium Pressure Liquid High Pressure Compressor Oil Medium Pressure Gas Engine Coolant Figure 76: Modulated Cool with LV1 Open...
Page 135: Figure 77: Running Null
Refrigeration Diagrams High Pressure Gas Low Pressure Liquid High Pressure Liquid Low Pressure Gas Medium Pressure Liquid High Pressure Compressor Oil Medium Pressure Gas Engine Coolant Figure 77: Running Null...
Page 136: Figure 78: Defrost And Heat
Refrigeration Diagrams High Pressure Gas Low Pressure Liquid High Pressure Liquid Low Pressure Gas Medium Pressure Liquid High Pressure Compressor Oil Medium Pressure Gas Engine Coolant Figure 78: Defrost and Heat...
Page 137: Index
Index discharge pressure transducer, replacement 111 discharge vibrasorber, replacement 102 air cleaner, EMI 3000 75 display, microprocessor 46 air heater 57 air restriction indicator 47, 75 alarm codes 43 alternator (Australian Bosch) 53 economizer expansion valve antifreeze checking superheat 114 changing 62 replacement 113 checking 62...
Page 138 Index idler assembly 121 receiver tank sight glass 47 overhaul 121 receiver tank, replacement 102 injection pump refrigerant charge 80 reinstallation 70 testing for an overcharge 80 removal 69 testing with a loaded trailer 80 timing 68 testing with an empty trailer 80 in-line condenser check valve 102 refrigerant leaks 81 inspection, unit 117...
Page 139: Wiring Diagram Index
Wiring Diagram Index Drawing No. Drawing Title Page 1E02367 Schematic Diagram 141-142 1E02371 Wiring Diagram 143-147...
Page 140 Wiring Diagram Index...