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Maintenance Manual

SB-210+
SB-210/SB-310
Additional text information
to be placed
TK 51586-2-MM (Rev.here
1, 03/05)

TK 5XXXX-X-PL
Ingersoll Rand’s Climate Solutions sector delivers energy-efficient HVACR solutions for
customers globally. Its world class brands include Hussmann, a manufacturer of refrigeration
and food merchandising solutions, Thermo King, the leader in transport temperature control
and Trane, a provider of energy efficient heating, ventilating and air conditioning systems,
building and contracting services, parts support and advanced controls for commercial
buildings and homes.

Distributed by:

Thermo King Corporate
314 West 90th Street
Minneapolis, MN 55420
Direct (952) 887-2200

TK 51586-2-MM

©2011 Ingersoll Rand Company
Printed in U.S.A.

SB-210/SB-310
TK 51586-2-MM (Rev. 1, 03/05)

Copyright© 2004 Thermo King Corp., Minneapolis, MN, U.S.A. Printed in
U.S.A.

The maintenance information in this manual covers unit models:
System SB-210 30 Base (920190) SB-210 30 Base (002158)
System SB-210 30 ETV (920044) SB-210 30 ETV (002117)
System SB-210 50 (920045) SB-210 50 (002118)
System SB-310 30 (920046) SB-310 30 (002119)
System SB-210 30 Base Tier 2 (920378) SB-210 30 Base Tier 2 (002202)
System SB-210 30 ETV Tier 2 (920379) SB-210 30 ETV Tier 2 (002203)
System SB-210 50 Tier 2 (920380) SB-210 50 Tier 2 (002204)
System SB-310 30 Tier 2 (920381) SB-310 30 Tier 2 (002205)
For further information, refer to:
SB-210/SB-310 Operator’s Manual TK 51585
SB-210 Parts Manual TK 51584
SB-210 with Tier 2 Engine Parts Manual TK 52936
SB-310/310R Parts Manual TK 51609
SB-310/310R with Tier 2 Engine Parts Manual TK 52863
SR-2 Microprocessor Control System Diagnostic Manual TK 51727
TK482 and TK486 Engine Overhaul Manual TK 50136
X214, X418, X426 and X430 Compressor Overhaul Manual TK 6875
Diagnosing TK Refrigeration System TK 5984
Tool Catalog TK 5955
Evacuation Station Operation and Field Application TK 40612
ElectroStatic Discharge (ESD) Training Guide TK 40282
The information in this manual is provided to assist owners, operators and service people in the proper upkeep
and maintenance of Thermo King units.

This manual is published for informational purposes only and the information so provided should
not be considered as all-inclusive or covering all contingencies. 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. Thermo King’s warranty will not apply to any
equipment which has been “so repaired or altered outside the manufacturer’s plants as,
in the manufacturer’s judgment, to effect its stability.”

No warranties, express or implied, including warranties of fitness for a particular
purpose or merchantability, or warranties arising from course of dealing or usage of
trade, are made regarding the information, recommendations, and descriptions
contained herein. Manufacturer is not responsible and will not be held liable in contract
or in tort (including negligence) for any special, indirect or consequential damages,
including injury or damage caused to vehicles, contents or persons, by reason of the
installation of any Thermo King product or its mechanical failure.

2

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. service personnel must be aware of Federal regulations concerning the use of refrigerants and the certification of technicians. We strictly adhere to a policy that promotes the recovery and limits the loss of refrigerant into the atmosphere. In addition. Recover Refrigerant At Thermo King. For additional information on regulations and technician certification programs. contact your local Thermo King dealer. 3 .

4 .

. . . . . . . . . . . 20 Maintenance Inspection Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 First Aid. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Unit Protection Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 General Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Safety Precautions . . . . . . . . . . . . . . . . . 16 First Aid. . . . . . . . . . . . . . Electrical Shock . . . . . . . . . . . . . . . . . . 14 Electrical Hazards . . . . . . . . . . . . 26 CYCLE-SENTRY Start-Stop Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Welding Precautions . . . . . . . . . . . . . . . . 15 Low Voltage . . . . . 23 Unit Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 Manual Pretrip Inspection (Before Starting Unit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Electrical Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 First Aid. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Electric Heater Strips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 5 . . . . . . . . . . . . . . . . . . . . 13 Battery Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Table of Contents List of Figures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 Turning Unit On . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 First Aid . 21 Unit Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Operating Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Diesel Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Electric Motor and Overload Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 HMI Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Refrigerant Oil Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 FreshSet . . . . . . . . . . . . . . . 26 Data Logging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Standby Power Cord Requirements . . . . 41 Turning Unit Off . . . 15 Microprocessor Service Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Serial Number Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 Temperature Watch Display . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Electronic Throttling Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 OptiSet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 High Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Belt Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Opening the Secondary Door Latch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Design Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 Microprocessor On/Off Switch . . . . . . . . . . . . . . . . . 39 Unit Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Thermo King X430L Reciprocating Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Opening the Front Doors . . 33 Operating Instructions . . . . . . . . . . . . . . . . Refrigerant Oil . . . . . . . . . . . . . . . . 14 Refrigerant Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 SMART REEFER 2 (SR-2) Control System . . . . . . 16 First Aid. . . . . . . . . . . 19 Electrical Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Refrigeration System . . . . . . . 20 Electrical Standby (Model 50 Units Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Sequence of Operation . . . . . . . . . . . . 25 SMART REEFER 2 (SR-2) Control System . . . . . . . . . . . 29 Engine Compartment Components . . . . . . . . . . 42 Standard Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Unit Photos . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 Alternator (Australian Bosch) Model 30 . . . . 49 Viewing Gauge Readings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 Fuse Link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Viewing Sensor Readings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 Post Trip Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 Language Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 Engine Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72 Unit Wiring . . . . . . 75 Auto Phase System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72 Battery Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 Oil Filter Change . . . . . . . . . . . . . 80 ELC (Extended Life Coolant) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 Electrical Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 Wire Harness Routing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 SMART REEFER 2 (SR2) Microprocessor Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 Antifreeze Maintenance Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 Low Oil Pressure . . . . 87 6 . . . . 59 Pretrip Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 Electric Standby Operation . . . . . . . . . . . . . . . . . . . 86 Bleeding the Fuel System . . . . . . . . . . . . . . . . . . . . . . 54 Alarms Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 Loading Procedure . . . . . . . . . . . . . . . . . . . . 78 Engine Oil Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 Engine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Changing the Setpoint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Starting the Unit on Electric Standby Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 Selecting CYCLE-SENTRY or Continuous Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82 Engine Thermostat . 81 Bleeding Air from the Cooling System . . . . . . . . . . . . . . . . . . 51 Navigating the Main Menu . . . . . . . . . . . . . . 62 Electric Standby/Diesel Mode . . . . . . . . . . . . . . . . . . . . . 56 Hourmeters Menu . 55 Datalogger Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77 EMI 3000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 Terminating a Defrost Cycle . . . . . . . . . . . . . . . . 74 AC Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 Fuel Return Line Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 Time Display . . . . . . 77 Engine Change . . . . . . . . . . . . . . . . . . . . . 66 Post Load Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 Adjust Brightness Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 Mode Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 Selection of Operating Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 Engine Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Table of Contents Standard Display Variations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 Initiating a Manual Defrost Cycle . 83 Fuel Line Routing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 Charging System Diagnostic Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 After Start Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . 74 Air Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 Starting the Diesel Engine . . . . . . . . . . . . . . . . . . 67 Alternator (Prestolite) Model 50 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 Electrical Contactors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 Engine Lubrication System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 Charging System Diagnostic Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . 101 Engine Valve Clearance Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110 Model 50 Compressor Belt Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105 EMI 3000 Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120 Refrigerant Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130 Evaporator Coil . . 88 Fuel Filter/Water Separator Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131 Accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121 High Pressure Cutout Switch (HPCO) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125 Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123 Hot Gas Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111 Model 50 Fan Belt Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119 Testing The Refrigerant Charge With An Empty Trailer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131 Three-Way Valve Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106 Air Restriction Indicator . . . . . . 129 Filter Drier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121 Three-Way Valve Condenser Pressure Bypass Check Valve . . . . . . . . . . . . 132 Removal/Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104 Positive Crankcase Ventilation (PCV) Tier 2 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133 Assembly/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97 Fuel Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113 Drive Bushing Replacement . . . . . . . . . . . . . . . 134 Three-Way Valve Condenser Pressure Bypass Check Valve Repair . . . . . . . . . . . . . . . . . . . . . . . . . . 114 Dowel Pin Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129 Receiver Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126 Condenser Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98 Trochoid Feed Pump Tier 2 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103 Crankcase Breather Tier 1 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . 92 Injection Pump Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129 Expansion Valve Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127 Discharge Vibrasorber . . . . . . . . . . . . . . . 108 Model 30 Fan Belt Replacement . . . . . . . . . . . . . . . . . . 100 Cold Start Device Tier 2 Engine . . . . . . . 119 Testing the Refrigerant Charge with a Loaded Trailer . . . . 88 Injection Pump Timing Tier 1 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119 Refrigerant Charge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89 Injection Pump Timing Tier 2 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125 Compressor Coupling Removal (Model 30) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119 Testing for an Overcharge . . . . . . . . . . . . . . . . . . . . . . . . . . . 128 In-Line Condenser Check Valve . 120 Checking Compressor Oil . . . . . . . . . . . 109 Model 50 Belt Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128 Bypass Check Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112 Clutch (Model 50) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Table of Contents Draining Water from Fuel Tank . . 95 Injection Pump Reinstallation . . . . . . . . 124 Refrigeration Service Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130 Heat Exchanger . . 88 Fuel Filter/Water Separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122 Electronic Throttling Valve (ETV) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106 Belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119 Moisture Indicating Sight Glass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123 Pressure Transducers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107 Model 30 Belt Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88 Engine Speed Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116 Refrigeration Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125 Compressor Coupling Installation (Model 30) . . . . . . . . . . . . . 132 End Cap Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128 Condenser Check Valve Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106 Starters . . . . . . . . . . . . . . .

. . . . . . . . . . 159 Cool Cycle With Mechanical Throttling Valve . . . . . . . . . . . . . . . . . . . . 161 Heat/Defrost Cycle With Electronic Throttling Valve . . . . . . . . . 136 Suction Vibrasorber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149 Idler Assembly Overhaul . . . . . . . . . . 140 Disassembly . . 141 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137 Suction Pressure Transducer . 145 Condenser. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146 Condenser and Evaporator Fan Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147 Fan Shaft Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142 Compressor Oil Filter Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145 Defrost Damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151 Electric Standby Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145 Unit Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142 Checking Compressor Oil Pressure . . . . . . . . . . . . . . . . . . . . 162 Index . . . . . 148 Fan Shaft Assembly Overhaul . . . . . . . . 143 Structural Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160 Cool Cycle With Electronic Throttling Valve . . . . . . . . . . . . 143 Priming New Compressor Installations . . . . . . . . . . . . . . . . . . . . . 145 Unit Installation . . . . . . . . . . . . . . . . 141 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . and Radiator Coils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138 Mechanical Throttling Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136 High Pressure Cutout Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137 High Pressure Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142 Hot Gas Solenoid Valve . . . . . . . . . . . . . . . . . . . . . 155 Refrigeration Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . 145 Defrost Drains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147 Evaporator Fan Blower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Table of Contents Pilot Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148 Idler Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147 Condenser Fan Blower . . . . . . . . . . . . . . . . . . . Evaporator. . . . . . . . . . . . . . . . . . . . . . . 159 Heat/Defrost Cycle With Mechanical Throttling Valve . . . . . . . . . 145 Unit and Engine Mounting Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137 Discharge Pressure Transducer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137 Electronic Throttling Valve (ETV) . . . . . . . . . . . . . . . . . . 163 Diagram Index . . . . . . . . . . . . 149 Mechanical Diagnosis . . . . . . . . . . . . . . . . 157 Refrigeration Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

55 Figure 46: Viewing and Clearing Alarms Screen Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Figure 24: Standard Display . . . . . . . . . . . . . . . . . . 61 Figure 58: Standard Display . . . . 55 Figure 47: Standard Display . . . . . . . . 43 Figure 26: Standard Display Variations . . . . . . . . . . . . . . . . . . . . . . . 46 Figure 31: Changing Mode . . . . . 58 Figure 53: Viewing Hourmeters Screen Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 Figure 56: Standard Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 Figure 39: Soft Keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Figure 10: Unit Serial Number Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . .List of Figures Figure 1: SB-210/SB-310 Front View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 Figure 45: Standard Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 Figure 30: Changing the Setpoint Screen Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Figure 17: Control Box With Service Door Open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Figure 15: Front View with Doors Open (Model 50) . . . . . . . . . . . . . . . . . . . . . . . . . Other Engines Similar) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Figure 23: Turning Unit Off Screen Sequence . . . . . . . . . . . . . . . 56 Figure 49: Printer Port Location . . . . . 41 Figure 22: Press Off Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Figure 6: Door Latch Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 Figure 55: Selecting Mode Screen Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 Figure 52: Standard Display . . . . . . . . . . . . . . 25 Figure 5: HMI Controller and Data Ports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Figure 29: Changing Setpoint . . . . 62 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Figure 9: Compressor Serial Number Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Figure 3: TK486V (TK486VH is Similar) Tier 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 Figure 25: Temperature Watch Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Figure 28: Electric Standby Detected Screen . . . . . . . . . . 51 Figure 40: Viewing Sensors Screen Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Figure 13: Back View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Figure 12: Front View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 Figure 42: Main Menu Choices . . . . . 39 Figure 19: Dedicated and Soft Keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 Figure 18: SR-2 HMI Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 Figure 35: Initiating Manual Defrost Screen Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 Figure 41: Accessing Main Menu . . . . . 49 Figure 36: Viewing Gauges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 Figure 43: Standard Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Figure 14: Front View with Doors Open (Model 30) . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 Figure 21: Turning Unit On Screen Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 Figure 51: Print Report Screen Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Figure 4: Compressors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 Figure 44: Change Language Screen Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 Figure 57: Selecting Sleep Mode Screen Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 Figure 34: Initiating a Manual Defrost Cycle . . . . . . . . . . . . . . . . . . 57 Figure 50: Standard Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 Figure 32: Screen Sequence for Changing from CYCLE SENTRY Mode to Continuous Mode . . . . . . . . . 29 Figure 7: Opening Secondary Door Latch . . . . 50 Figure 37: Viewing Gauges Screen Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Figure 11: Engine Serial Number Location Tier 1 Engine Shown Tier 2 Engine Similar . . . . . . . . . . . . . . . . . . . 58 Figure 54: Standard Display . . . . . . . . . . . . . . . . . . . . . . 50 Figure 38: Viewing Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 Figure 48: Start of Trip Screen Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Figure 2: TK486E (TK486EH is Similar) Tier 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 Figure 27: Electric Power Receptacle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 Figure 33: Screen Sequence for Changing from Continuous Mode to CYCLE-SENTRY Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Figure 8: Engine Compartment Components (TK486E Shown. . . . . . . . . . . . . . . . . . . . . . 40 Figure 20: Press On Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Figure 16: High Voltage Tray (Model 50 Only) . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . 97 Figure 110: Fuel Solenoid Location Tier 1 Engine . . . . . . . . . . 73 Figure 71: Interface Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98 Figure 111: Fuel Solenoid Location Tier 2 Engine . . . . . . . . . . . . . . . 100 Figure 114: Trochoid Feed Pump Location . . . 64 Figure 62: Programming Electric Standby Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101 Figure 117: Cold Start Device . . . . . . . . . . . . . . . . 88 Figure 86: Tier 1 Engine Speed Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89 Figure 87: Tier 2 Engine Speed Adjustments . .List of Figures Figure 59: Pretrip Test Screen Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95 Figure 106: Tier 1 Index Mark Alignment . . . . . . . . . . . . . . . . . . . . 87 Figure 85: Filling Fuel Filter/Water Separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93 Figure 100: Injection Angle Mark . . . . . . . . . . . . . 95 Figure 105: Tier 1 Index Mark Location . . . . . . . . 85 Figure 80: Fuel Return Line Replacement Decal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 Figure 66: Check Points for Alternator Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92 Figure 95: Marking Gear Case . . . . . . . . . . . . . . . . 82 Figure 78: Tier 1 Engine Fuel System . . . . . . . . . 91 Figure 91: Correct Injection Timing Mark Alignment for SB-210 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 Figure 69: Tier 1 Wire Harness Routing . . . . . . . . . . . . . . . . 86 Figure 82: Fuel Tank . . . . . . . 64 Figure 61: Programming Diesel Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 Figure 89: Top Dead Center One and Four . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 Figure 67: Full Field Test . . . . . . . . . . . . . . . . . . . . . 94 Figure 102: Examples of Injection Pump Index Mark Alignment with Injection Angle Sticker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96 Figure 109: Injection Pump Gear Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87 Figure 84: Tier 2 Injection Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 Figure 65: Time and Date Screens . . 74 Figure 73: High Voltage Tray . . . . 96 Figure 107: Tier 2 Index Mark Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 Figure 68: Prestolite Terminal Locations . . . . . . . . . . . . . . . . . . . . . . . . 102 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77 Figure 75: Tier 2 Engine . . . . . . . . . . . . . . . . 87 Figure 83: Tier 1 Injection Pump . . . . . . . . . . . 90 Figure 90: Timing Mark Alignment . 86 Figure 81: Fuel Return Line Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 Figure 64: Adjusting Display Brightness Screen Sequence . . . . . . . . . . . . 91 Figure 92: Correct Injection Timing Mark Alignment for SB-310 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91 Figure 93: Tier 2 Index Mark Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 Figure 63: Standard Display . . . . . . . . . . . 98 Figure 112: Fuel Solenoid Connector Pin Identification . . . . . . . . . . . . . . . . 94 Figure 101: Injection Pump Serial Number Location . . . . . . . 73 Figure 70: Tier 2 Wire Harness Routing . . . . . . . . . . . . . . . . . . 77 Figure 76: ELC Nameplate Located On Expansion Tank . . . . . . . . . . . . . . . 92 Figure 94: Tier 2 Index Mark Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 Figure 116: Trochoid Feed Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94 Figure 103: Timing Mark Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93 Figure 98: Removing Injection Pump Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 Figure 74: Tier 1 Engine . . . . . . . . . 93 Figure 99: Injection Angle Mark Location . . . . . . . . . . . . . . . . . . . . 93 Figure 97: Injection Angle Sticker . 74 Figure 72: Air Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92 Figure 96: Place Injection Angle Sticker on Gear Case . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96 Figure 108: Tier 2 Index Mark Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89 Figure 88: Component Location . 84 Figure 79: Tier 2 Engine Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 Figure 60: Standard Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 Figure 77: Engine Cooling System . . . 95 Figure 104: Align Flat Sides of Crankshaft Gear with Flat Sides of Inner Rotor in Timing Gear Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 Figure 115: Trochoid Feed Pump Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101 Figure 118: Remove Engine Coolant Fitting . . . . . . . . . . . . . . . . . . . 99 Figure 113: Fuel Solenoid Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141 Figure 165: Throttling Valve Reassembly . . . . . . . . . 116 Figure 139: Pressing New Dowel Pin Into Flywheel Using Manual Pin Tool 204-1117 . . . . . . . . . . . . . . . . . . . . . . . . 106 Figure 128: Air Restriction Indicator . . . . . . . . . . . . . . . . . . . . 103 Figure 122: Adjusting the Valve Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114 Figure 136: Old Style Drive Bushing . . . . . . . . . . . . . 102 Figure 120: Clean Piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114 Figure 137: Press Old Bushings Out Of Hub With Tool 204-1116 . . . . . 110 Figure 133: Model 50 Belt Arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126 Figure 147: Keyway Tool P/N 204-972 . . . . . . . . . . . . . 121 Figure 143: High Pressure Cutout Manifold . . . . . . . . . . . . . 140 Figure 162: Inspect Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148 Figure 172: Idler Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117 Figure 140: Driving New Dowel Pin Into Flywheel With Impact Pin Tool 204-1118 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141 Figure 164: Inspect for Damage . . . . . . . . . . . 113 Figure 135: New Style. . . . . . . . . 115 Figure 138: Press New Bushing Into Hub With Tool 204-1116 . . . . . . . . . . . . . . . . . 104 Figure 124: Tier 2 PCV Components . . . . . . . . . . . . . . . . . . . . . . . . . . . 145 Figure 168: Defrost Damper Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142 Figure 166: Compressor Oil Filter . . . . . 102 Figure 121: Top Dead Center One and Four . . . . . . . . . . . . . . . . . . . . . 130 Figure 151: Three-Way Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134 Figure 156: Check Seat Orifice . . . . . . . . 150 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127 Figure 148: Compressor Coupling Installation . . . . 117 Figure 141: Moisture Indicating Sight Glass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133 Figure 153: Piston and Stem Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122 Figure 145: Electronic Throttling Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147 Figure 170: Evaporator Fan Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132 Figure 152: Gasket Tool P/N 204-424 . . . . . . . . . . . . . . . . . . . . . 135 Figure 159: Electronic Throttling Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106 Figure 129: Tier 1 Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128 Figure 150: Location of Expansion Valve Bulb . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141 Figure 163: Inspect for Wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143 Figure 167: Unit and Engine Mounting Bolts . . List of Figures Figure 119: Remove Cold Start Device . . . . . . . . . . . . . . . . . . . . . . . . . . . 104 Figure 123: Tier 1 Crankcase Breather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123 Figure 146: Compressor Coupling Removal Tool . . 105 Figure 125: Tier 2 PCV System . . . . . . . . . . . . . . . 111 Figure 134: Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106 Figure 130: Tier 2 Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106 Figure 127: EMI 3000 Air Filter Element . . . . . . 135 Figure 158: Teflon Check Valve Assembly . . . . . . . 134 Figure 155: Check Piston Bleed Orifice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146 Figure 169: Condenser Blower Alignment . . . . . . . . . . . . . . . . 127 Figure 149: Cross Section of In-line Condenser Check Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147 Figure 171: Fan Shaft Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133 Figure 154: Check Bleed Hole Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bonded Drive Bushing . . . . . 139 Figure 161: Mechanical Throttling Valve Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107 Figure 131: Model 30 Belt Arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105 Figure 126: EMI 3000 Air Cleaner Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120 Figure 142: Checking Compressor Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138 Figure 160: Stepper Motor and Piston Assembly with Piston in Fully Open Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121 Figure 144: Three-way Valve Condenser Pressure Bypass Check Valve . . . . . . . . . . . . . . . . . . . . . . . 108 Figure 132: Condenser Blower Alignment . . . . . . . . . . . . . . . . 134 Figure 157: Seal Installation with Tool P/N 204-1008 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

List of Figures 12 .

resulting in suffocation and incorrect bolt lengths can damage possible death. personal injury. General Practices WARNING: Use extreme caution when DANGER: Do not operate the compressor drilling holes in a unit. contact with moving belts. causing serious injury or possible death. equipment. drain it. The symbol appears next to a point that is particularly important WARNING: Make sure your gauge manifold hoses are in good condition DANGER: Denotes the possibility of before using them. Defective gauge equipment WARNING: Denotes the possibility of can damage components or cause serious serious equipment damage or serious injury. Holes might with the discharge service valve closed. oil and battery acid can personal injury. Observe the manufacture’s safety caution when working with refrigerant or labels and warnings. Then flush it with respiratory irritants. Before applying heat to a produces toxic gases that are severe cooling system. 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. Loose clothing might boil off the water. 13 . pulleys or hot surfaces. Never let them come in serious injury or death. DANGER: Refrigerant in the presence of WARNING: Do not apply heat to a closed an open flame. Improper torque and depletion. such as a CAUTION: Make sure all mounting bolts cargo area or garage. clothing and ethylene glycol is flammable and can tools clear of fans when working on a unit ignite if the antifreeze is heated enough to that is running. fire or explosion. However. DANGER: Never apply heat to a sealed WARNING: Exposed coil fins can cause refrigeration system or container. fans. Refrigerant are tight and are the correct length for displaces air and can cause oxygen their applications. Holes This condition increases internal pressure. water and drain the water.Safety Precautions Thermo King recommends that all service be DANGER: Avoid engine operation in performed by a Thermo King dealer. minor to severe equipment damage or Refrigerant liquid. spark or electrical short cooling system. WARNING: Always wear goggles or safety CAUTION: Denotes the possibility of glasses when working on a unit. Heat lacerations. a certified Thermo King technician. WARNING: Be careful when using ladders or scaffolding to install or service DANGER: Do not inhale refrigerant. permanently damage your eyes. Antifreeze contains water and ethylene glycol. drilled into electrical wiring can cause a which can cause an explosion. weaken structural components. See “First Aid” on page 16. a refrigeration system in any confined area with a limited air supply. entangle moving pulleys or belts. Service work on the increases internal pressure. Use a unit. The DANGER: Keep your hands. which might evaporator or condenser coils is best left to cause an explosion.

Battery Removal CAUTION: When transferring refrigerant. damage. out of direct sunlight and away from intense heat. Certification is required to work on refrigeration refrigerant must be in liquid state to avoid systems. Oxygen oil to the air any longer than necessary. Heat increases pressure CAUTION: Store refrigerant oil in an inside storage containers. CAUTION: Wipe up spills immediately. moisture contamination. DANGER: Do not use a Halide torch. To prevent irritation. DANGER: Do not use oxygen (O2 ) or CAUTION: Do not expose the refrigerant compressed air for leak testing. possible equipment damage. which can cause approved sealed container to avoid them to burst. CAUTION: Use dedicated equipment to prevent contaminating systems with the DANGER: Store refrigerant in proper wrong type of oil. serious injury. toxic gases are produced. If there are sufficient refrigerant oil. This order is important because the frame is Refrigerant Oil Hazards grounded to the negative battery terminal. Avoid positive side and the frame simultaneously will prolonged or repeated contact with cause sparks or arcing. even death. freezing anything it contacts. The oil can battery to the frame. first when installing a battery. an your hands and clothing thoroughly after explosion might occur. causing equipment handling the oil.Safety Precautions NOTE: In the USA. If the negative terminal is still connected. containers. When a flame comes in contact with CAUTION: Do not mix refrigerant oils refrigerant. Metal objects contacting the cause serious eye injuries. Be careful when handling refrigerant to protect your skin from frostbite. Connect the positive terminal (+) the earth’s upper ozone layer. mixed with refrigerant is combustible. These gases can cause suffocation. wash hydrogen gases emitted from the battery. Refrigerant oil can damage paints and CAUTION: Refrigerant in a liquid state rubber materials. which results in much longer evacuation times and WARNING: Wear butyl lined gloves when possible system contamination. EPA Section 608 CAUTION: When being transferred. 14 . evaporates rapidly when exposed to the atmosphere. The oil will absorb moisture. Refrigerant damages battery. handling refrigerant to help prevent frostbite. a complete WARNING: Protect your eyes from circuit exists from the positive terminal of the contact with refrigerant oil. use a process that prevents or DANGER: Disconnect the negative greatly restricts refrigerant from escaping battery terminal (-) first when removing a into the atmosphere. CAUTION: Use the correct oil in Thermo King systems to avoid damaging Refrigerant Hazards equipment and invalidating its warranty. because that can cause system damage. even death.

in the event of an straps are available from most electronic electrical accident. an accident. Some capacitors hold a components. Another person should be nearby to shut • Avoid wearing clothing that generates static off the unit and provide aid in the event of electricity (wool. Safety Precautions Electrical Hazards WARNING: Do not wear jewelry. energized conductors. it OFF before connecting or disconnecting the battery. rubber. WARNING: Never work alone on high voltage circuits in the refrigeration unit. • Leave electronic components in their antistatic packing materials until you’re ready to use them. WARNING: Use caution when working with electrical circuits that contain • Avoid unnecessary contact with the electronic capacitors. polyester. significant charge that might cause burns • Store and ship electronic components in or shocks if accidentally discharged. Low Voltage • After servicing any electronic components. Never hold uninsulated metal a microprocessor control system to avoid tools near exposed. Use burns. equivalent) with the lead end connected to the insulated gloves and cable cutters should microprocessor’s ground terminal. Even tiny amounts of tools because you might accidentally touch current can severely damage or destroy electronic a high voltage source. These be near your work area. 24 volts dc). • Wear a wrist strap (P/N 204-622 or its WARNING: Safety glasses. sure capacitors are discharged before working on electrical circuits. nylon. equipment distributors.). Microprocessor Service Precautions WARNING: Do not make rapid moves Take precautions to prevent electrostatic when working on high voltage circuits in discharge when servicing the microprocessor and refrigeration units. WARNING: Control circuits used in check the wiring for possible errors before refrigeration units are low voltage (12 to restoring power to the unit. WARNING: Use tools with well insulated Observe the following precautions when servicing handles. turn otherwise. such as tools. components. until a meter and wiring diagram indicate • If the microprocessor has a power switch. • Disconnect power to the unit. DO NOT wear these straps with power applied to the unit. 15 . ground with metal objects. Do not grab for falling its related components. watches or rings because they increase the risk of High Voltage shorting out electrical circuits and DANGER: Lethal amounts of voltage are damaging equipment or causing severe present in some electrical circuits. but the large amount of amperage • Never use a battery and a light bulb to test available from the alternator can cause circuits on any microprocessor-based severe burns if accidentally shorted to equipment. extreme care when working on an operating refrigeration unit. Make antistatic bags and protective packaging. This voltage is not dangerous. Refer to the appropriate microprocessor diagnosis manual and WARNING: Treat all wires and the Electrostatic Discharge Training Guide (TK connections as if they were high voltage 40282) for more information. etc. damaging electronic components.

Refrigerant Oil Observe the following precautions when welding EYES : Immediately flush with water for at least to avoid damaging electronic components. eyes with large amounts of water. start CPR (cardio pulmonary resuscitation). respiration. sterile. likelihood of stray welding currents passing through any electronic circuits. INGESTION: Do not induce vomiting. This will reduce the assistance. EYES : For contact with liquid. it OFF before connecting or disconnecting the INGESTION: Do not induce vomiting. protect the frozen area and safety glasses. battery. Remove contaminated TOUCH the victim. Wrap burns with dry. First Aid. portion of the unit or the vehicle to which it is if necessary. but keep the Take IMMEDIATE action after a person has ground return electrode as close to the area received an electrical shock. rope. by either shutting off the power or removing the victim. CALL A PHYSICIAN. Immediately contact local poison control center or • Components that could be damaged by physician. 16 . CALL A PHYSICIAN. if possible. a belt or coat to pull or SKIN: Flush area with large amounts of warm push the victim away from the current. allowed to flow through the unit’s electronic circuits. Refrigerant cutters. Stay with victim until emergency attached. with soap and water. switch them OFF. Rescuers should wear insulated gloves In the event of frostbite. Wash skin • If the microprocessor has a power switch. After bulky dressing to protect from infection. immediately flush If the victim must be removed from a live circuit. The ensuing flash can cause burns and maintain respiration. PHYSICIAN.Safety Precautions Welding Precautions INHALATION: Move victim to fresh air and use CPR (cardio pulmonary resuscitation) or Take precautions before electrically welding any mouth-to-mouth resuscitation to restore breathing. Wash contaminated clothing before immediately check for signs of a pulse and reuse. blindness. If the power cannot be shut off. Ensure that welding currents are not personnel arrive. 15 minutes. material. • Disconnect all wire harnesses from the First Aid. the wire First Aid should be cut with an non-conductive tool. current flowing through the victim’s body. and avoid looking at wires from further injury. Do not apply heat. warm the area rapidly and being cut. If no pulse is present. Immediately contact local poison control center or physician. First Aid. You will receive a shock from clothing and shoes. turn with soap and water. Call for emergency medical assistance. welding sparks should be removed from the unit. such as a wood-handle axe or thickly insulated cable First Aid. respiration might be restored by using mouth-to-mouth resuscitation. Wash skin the control box. CALL A separating the victim from power source. The source of the shock must be quickly stopped. Engine Coolant microprocessor. DO NOT water. EYES : Immediately flush with water for at least • If there are any electrical circuit breakers in 15 minutes. Electrical Shock • Use normal welding procedures. CALL A pull the victim away with a non-conductive PHYSICIAN. • Close the control box. Use wood. If a pulse is present. Get quick medical being welded as practical. • Disconnect power to the unit.

(0. Number of Cylinders 4 Cylinder Arrangement In-line vertical.010 in.15 to 0. (0. 2 diesel fuel under normal conditions No.006 to 0. number 1 on flywheel end Firing Order 1-3-4-2 Direction of Rotation Counterclockwise viewed from flywheel end Fuel Type No.3 liters) crankcase Fill to full mark on dipstick Oil Type API Classification CI-4 or better (ACEA Rating E3 or better for Europe) Oil Viscosity 5 to 122 F (-15 to 50 C): SAE 15W-40 -13 to 104 F (-25 to 40 C): SAE 10W-40 -13 to 86 F (-25 to 30 C): SAE 10W-30 -22 to 32 F (-30 to 0 C): SAE 5W-30 Engine rpm: SB-210 Low Speed Operation 1450 ± 25 rpm SB-210 High Speed Operation 2200 ± 25 rpm SB-310 Low Speed Operation 1450 ± 25 rpm (1720 ± 25 rpm with High Capacity Fresh Option) SB-310 High Speed Operation 2600 ± 25 rpm Engine Oil Pressure 18 psi (127 kPa) minimum in low speed 45 to 57 psi (310 to 390 kPa) in high speed Intake Valve Clearance 0. 1 diesel fuel is acceptable cold weather fuel Oil Capacity 13 quarts (12.600 to 22. 1 cylinder) TK486V and TK486VH (Tier 2) See “Injection Pump Timing Tier 2 Engine” on page 92. 1 cylinder) TK486EH (Tier 1) 11 degrees BTDC (timed on No.000 psi (19.600 to 20.100 to 3.15 to 0.25 mm) Valve Setting Temperature 70 F (21 C) Fuel Injection Timing: TK486E (Tier 1) 10 degrees BTDC (timed on No. Fuel Injection Nozzle Opening Pressure: TK486E and TK486EH (Tier 1) 2.010 in.300 psi (21.25 mm) Exhaust Valve Clearance 0.006 to 0.600 kPa) TK486V and TK486VH (Tier 2) 3.Specifications Engine Model: SB-210 Ending Second Quarter 2005 TK486E (Tier 1) SB-210 Starting Second Quarter 2005 TK486V (Tier 2) SB-310 Ending Second Quarter 2005 TK486EH (Tier 1) SB-310 Starting Second Quarter 2005 TK486VH (Tier 2) See “Diesel Engine” on page 24 and the photos on page 25 to identify the engine in the unit.600 kPa) Low Oil Pressure Switch (Normally Closed) 17 ± 3 psi (117 ± 21 kPa) Engine Coolant Thermostat 180 F (82 C) 17 .800 to 3.

alternator. which is “RED” Use a 50/50 concentration of any of the following equivalents: Chevron Dex-Cool Texaco ELC Havoline Dex-Cool® Havoline XLC for Europe Shell Dexcool® Shell Rotella Saturn/General Motors Dex-Cool® Caterpillar ELC Detroit Diesel POWERCOOL® Plus CAUTION: Do not add “GREEN” or “BLUE-GREEN” conventional coolant to cooling systems using “RED” Extended Life Coolant. on TK Gauge P/N 204-427 Alternator Belt 61 Lower Fan Belt (Engine to Idler) 67 Upper Fan Belt (Fan to Idler) 74 Model 50 Alternator Belt 29 Compressor Drive Belts 79 Fan Belt 74 Water Pump Belt 35 18 . the coolant must be changed after 2 years instead of 5 years. If conventional coolant is added to Extended Life Coolant.5 quarts (7. belts to electric standby motor.Specifications Engine Engine Coolant Type ELC (Extended Life Coolant). alternator. belts to fans. fans. and water pump Belt Tension Model 30 Tension No. and water pump Model 50 Centrifugal clutch to compressor. Coolant System Capacity 7. except in an emergency.1 liters) Radiator Cap Pressure 7 psi (48 kPa) Drive: Model 30 Direct to compressor.

Battery Charging 12 volt. 37 amp. group C31. (950 CCA recommended for Battery operation below -15 F [-26 C]) Fuses See “Fuses” on page 73.3 kg)—R404A Compressor Oil Charge 4. oil level should be noted or the oil removed from the compressor should be measured so that the same amount of oil can be added before placing the replacement compressor in the unit. Electrical Control System Voltage 12. brush type alternator Voltage Regulator Setting 13.9 kg)—R404A SB-310 16 lb (7. The Bosch alternator has the word “BOSCH” on the end opposite the pulley (see Figure 68 on page 71). Specifications Refrigeration System Compressor Thermo King X430L Refrigerant Charge—Type: SB-210 13 lb (5.5 Vdc One. 12 volt.3 qt (4.8 to 14.1 liters)* Compressor Oil Type Polyol Ester type P/N 203-513 Mechanical Throttling Valve Setting 27 to 29 psi (186 to 200 kPa) (Units without ETV) Heat/Defrost Method: Engine Operation Hot gas Electric Operation Hot gas and electric heater strips High Pressure Cutout 470 +7/-35 psi (3241 + 48/-241 kPa) Automatic reset @ 375 ± 38 psi (2586 ± 262 kPa) * When the compressor is removed from the unit. 19 .2 volts @ 77 F (25 C) NOTE: Fuse F4 (Bypass Resistor for Prestolite Alternator) must be removed for the Bosch Alternator.

0 10.Specifications Electrical Components NOTE: Disconnect components from unit circuit to check resistance.5 Vdc (Ohms) Fuel Solenoid: Pull-in Coil 35 to 45 0.9 4.3 Air Heater 89 0.0 10.7 17. up to 75-foot length 20 .4 1755 37.5 24 to 29 Damper Solenoid 5.1 11. 25 to 50-foot length 230/3/60 6 AWG Power Cable.7 2.2 to 0.1 Starter Motor: TK486E and TK486EH (Tier 1) 250-375* TK486V and TK486VH (Tier 2) 350-475* * On-the-engine cranking check.2 High Speed (Throttle) Solenoid 2. 75-foot length 460/3/60 10 AWG Power Cable.9 20 Electric Heater Strips Number 3 Watts 1000 watts (each) Resistance 48 ohms (each) Standby Power Cord Requirements Supply Circuit Breaker: 230/3/60 70 amps 460/3/60 40 amps Extension Cord Size: 230/3/60 8 AWG Power Cable.8 40 460/3/60 14.3 Hold-in Coil 0. Bench test is approximately 140 amps.4 1755 18. Electrical Standby (Model 50 Units Only) Electric Motor and Overload Relay Voltage/Phase/Frequency Horsepower Kilowatts rpm Full Load Overload Relay (amps) Setting (amps) 230/3/60 14. Component Current Draw (Amps) Resistance—Cold at 12.14 Pilot Solenoid 0.0 Electronic Throttling Valve: Coil A (Red [EVA] and Blue [EVB] Wires) — 20 to 35 Coil B (Black [EVC] and White [EVD] Wires) — 20 to 35 Hot Gas Bypass Valve 1.

— Replace fuel return lines between fuel injection nozzles every 10.000 hours or two years (whichever occurs first) if indicator has not reached 25 in. • • • • Check operation of damper door (closes on defrost initiation and opens on defrost termination). Engine • Check fuel supply. • • • • Listen for unusual noises.000 hours.000 hours. • Change engine oil and oil filter (hot). — Change ELC (red) engine coolant every 5 years or 12. • Replace fuel filter/water separator. • • • Inspect wire harness for damaged wires or connections.000 hours. • Check engine mounts for wear. on high speed (should display “OK”).). • • • Drain water from fuel tank and check vent. 204-427).000 4.Maintenance Inspection Schedule Pretrip Every Every Annual/ Inspect/Service These Items 1. Requires oil with API Rating CI-4 or better (ACEA Rating E3 for Europe). etc. • Inspect electric motor. • • • Check and adjust engine speeds (high and low speed). Electrical • • • Inspect battery terminals and electrolyte level.000 hours.500 3. • • • Inspect/clean fuel transfer pump inlet strainer (prefilter). • Inspect alternator wire connections for tightness. Units equipped with ELC have an ELC nameplate on the expansion tank (see page 80). vibrations.500 Hours Hours* Hours Microprocessor • Run Pretrip Test (see “Pretrip Tests” on page 62). 21 . whichever occurs first. • • • • Inspect belts for condition and proper tension (belt tension tool No. — Test fuel injection nozzles at least every 10. *3. • • • • Check engine oil pressure hot. • Check engine oil level. • Check air cleaner restriction indicator (change filter when indicator reaches 25 in. replace bearings yearly or every 6. Replace EMI 3000 air cleaner element (see “EMI 3000 Air Cleaner” on page 106) at 3.000 hours or two years.

• • • Check all unit and fuel tank mounting bolts. • • • Check for proper suction pressure.000 hours or two years. hoses. • Check compressor efficiency and pump down refrigeration system. • • • Check evaporator damper door adjustment and operation.000 4.500 3. — Replace dehydrator and check discharge and suction pressure every two (2) years. • • • Clean entire unit including condenser and evaporator coils and defrost drains. • Check compressor oil level and condition. whichever occurs first. *3.500 Hours Hours* Hours Refrigeration • • • • Check refrigerant level. etc.Maintenance Inspection Schedule Pretrip Every Every Annual/ Inspect/Service These Items 1. 22 . brackets. lines. Structural • • • • Visually inspect unit for fluid leaks. loose or broken parts (includes air ducts and bulkheads). • • • Inspect tapered roller bearing fanshaft and idlers for leakage and bearing wear (noise). • • • • Visually inspect unit for damaged.

air cooling/heating unit operating under the control of a SMART REEFER 2 (SR-2) programmable microprocessor controller. Figure 1: SB-210/SB-310 Front View 23 .Unit Description Unit Overview The Thermo King SB-210/SB-310 is a one piece. diesel powered. Designed for engine operation at a high speed of 2600 rpm. The SB-210/SB-310 features cooling and heating using a quiet running engine from the Thermo King TK486 engine family. The unit mounts on the front of the trailer with the evaporator extending through an opening in the front wall. self-contained. The SB-210 and SB-310 are available in the following three models: • SB-210 30: Cooling and heating on diesel engine operation. AJA1617 • SB-310 30: High capacity cooling and heating on diesel engine operation. • SB-210 50: Cooling and heating on diesel engine operations and electric standby operation.

water cooled. direct injection diesel Standard Unit Color ● ● ● engines.Unit Description Design Features SB-210/SB-310 Key SB-210 SB-210 SB-310 Features & Options Model Model Model The following chart lists key design features and 30 50 30 options.The engine is coupled directly to the White compressor on the Model 30. alternator. Belts transmit power to the unit Directional Air Delivery ● ● ● fans. The engine in the SB-310 Liter) was changed from a TK486EH to a TK486VH. Aluminum Undermount ● ● ● The engine in the SB-210 was changed from a Fuel Tank 50 Gal. Vibration Isolation ● ● ● In the second quarter of 2005 the engines in these System units changed to meet EPA Tier 2 requirements. ❍ ❍ ❍ The TK486V and TK486VH are EPA Tier 2 12V dc engines. Special Color Grills ❍ ❍ ❍ ● Standard Features Fresh Air Exchange ❍ ❍ ❍ ❍ Option/Factory Installed i-Box™ Interface ❍ /❏ ❍ /❏ ❍ /❏ ❏ Option/Dealer Installed R:COM™ Automatic ❍ /❏ ❍ /❏ ❍ /❏ Data Transmission SB-210/SB-310 Key SB-210 SB-210 SB-310 System Features & Options Model Model Model 30 50 30 FleetWatch™ Data ❏ ❏ ❏ Manager SMART REEFER ● ● ● SR-2 Controller TracKing™ Satellite ❏ /❍ ❏ /❍ ❏ /❍ Communications Kit OptiSet™ with ● ● ● FreshSet™ TracKing™ Cellular TBA TBA TBA Programmable Modes Communications Kit ETV (Electronic ❍ ● ● PrimAir™ bulkhead ❏ ❏ ❏ Throttling Valve) and duct system ServiceWatch™ ● ● ● Rear Remote Control TBA TBA TBA CargoWatch™ ❍ ❍ ❍ CargoWatch™ Accessories: EMI-3000 ● ● ● • Door Switches ❍ /❏ ❍ /❏ ❍ /❏ High-Capacity ● ● ● Condenser Coil • Temperature Sensor ❍ /❏ ❍ /❏ ❍ /❏ Kits Whisper Quiet ❍ ● ● Technology • Humidity Sensor ❍ /❏ ❍ /❏ ❍ /❏ Kits Easy-access door ● ● ● design • Fuel Level Sensor ❍ /❏ ❍ /❏ ❍ /❏ Kits Composite Exterior ● ● ● Panels Megatech Battery. (186 TK486E to a TK486V. 65 Amp. 12V ❏ ❏ ❏ Long-Life ● ● ● Coolant/Silicone Diesel Engine Hoses The Thermo King TK486 family of engines are Remote Status Light ❍ ● ● 4-cylinder. Fuel Heater ❍ ❍ ❍ The TK486E and TK486EH are EPA Tier 1 Frost Plug Heater ❍ ❍ ❍ engines. and water pump. Alternator. A centrifugal clutch Standard Grille Color ● ● ● transfers power from the engine to the compressor Black on the Model 50. 24 .

The higher injection pressure Electronic Throttling Valve atomizes the fuel more efficiently. See “Maintenance the compressor. Mechanical Throttling Valve (No ETV) Figure 4: Compressors The Electronic Throttling Valve (ETV) is a variable position valve operated by a stepper 1 motor. The ETV system also uses a hot gas bypass valve like the one used with the modulation valve in other units. There are some other differences (see “Engine Change” on page 77). Mono-Plunger and Distributor Injection Pump Figure 3: TK486V (TK486VH is Similar) Tier 2 25 . 1 2 1 1. 1. In-Line Injection Pump 1. The Tier 1 engines use an The unit is equipped with a Thermo King X430L in-line injection pump. Discharge and suction pressure transducers supply pressure information to the microprocessor control system. but the periodic You can tell if the unit has an ETV by looking at maintenance is the same.0 cu. Suction Valve Adapter (Has ETV) Figure 2: TK486E (TK486EH is Similar) Tier 1 2. The (492 cm3) displacement. on the Model SB-210 30 and standard on the Models SB-210 50 and SB-310 30. Units with an ETV have a suction Inspection Schedule” on page 21. which reduces The Electronic Throttling Valve (ETV) is optional the emissions. The microprocessor controls the electronic throttling valve directly. Units without an ETV have a mechanical throttling valve. valve adapter. in. The Tier 2 engines use a reciprocating compressor with 30. Unit Description The main difference between a Tier 1 engine and Thermo King X430L Reciprocating a Tier 2 engine is the fuel injection pump (see the Compressor following photographs). mono-plunger and distributor injection pump. The ETV is located in the suction line between the evaporator and the heat exchanger. The ETV replaces both the throttling valve and the modulation valve used in other units. mono-plunger and distributor injection pump uses a higher injection pressure than the in-line injection pump.

This lowers the engine temperature while still allowing continued unit operation. temperature. pre-programming of the unit modulation valve. SR-2 integrates the following functions: the engine will start and run until the block • Changing setpoint and operating mode temperature is above 90 F (32 C). NOTE: The SR-2 controller provides a wide range of control and programming flexibility. algorithm provides an additional measure of protection against high discharge pressures and WARNING: The unit can start at any time possible compressor damage. Press the OFF key on the shutdowns in high ambient temperatures by HMI control panel and place the allowing continued operation of the unit at a microprocessor On/Off switch in the Off temporarily reduced refrigeration capacity. Refer to TK 51727 the SR-2 Microprocessor Control SMART REEFER 2 (SR-2) Control System Diagnostic Manual for information System about controller programming. CYCLE-SENTRY Amps (typically 5 amperes). sensor and hourmeter CYCLE-SENTRY Battery Voltage (typically 12. and battery charge levels at a The SR-2 is a microprocessor control system condition where quick. engine block location and function of each control. also prohibit certain modes of operation. The CYCLE-SENTRY Start-Stop fuel saving Discharge Pressure Protection: This protection system provides optimum operating economy. Modulation Control: The ETV system replaces the However. designed for a transport refrigeration system. It will prevent without warning.2 readings volts) and Diesel CYCLE-SENTRY mode is • Initiating Defrost cycles selected. which is located inside the lower roadside service door. This allows the information about the SR-2 controller. The If the block temperature falls below 30 F (-1 C). refrigeration system to fully utilize the power capabilities of the engine under varying CYCLE-SENTRY Start-Stop Controls conditions. It is clearly visible refrigeration system as follows: through an opening in the lower roadside service Suction Pressure Control: The suction pressure door. It is used to operate the unit. It will reduce the load on the shuts down the unit after those conditions are engine by temporarily reducing refrigeration satisfied. If the battery voltage falls to the programmed limit selected by • Viewing gauge. The modulation control controller may prohibit operation in certain algorithm operates much the same as modulation temperature ranges within some modes and may on other units. The HMI control panel is mounted on the 26 . protection algorithm protects the engine from high The CYCLE-SENTRY system automatically coolant temperature shutdowns and possible starts the unit on microprocessor demand. The microprocessor components are located inside the control box. The microprocessor is connected to an HMI (Human Machine Interface) Control Panel. WARNING: Do not operate the unit until The system automatically monitors and maintains you are completely familiar with the the compartment temperature.Unit Description The ETV system provides enhanced control of the face of the control box. position before inspecting or servicing any Engine Coolant Temperature Protection: This part of the unit. the engine will start and run until the charge rate falls below that programmed by • Viewing and clearing alarms. control algorithm is the primary control used to See the Operating Instructions Chapter for more obtain maximum capacity. and engine damage. easy starts are possible. capacity.

Figure 5: HMI Controller and Data Ports Sequence of Operation ServiceWatch™: ServiceWatch™ is standard When the Microprocessor On/Off switch is turned equipment. • Preheat indicator buzzer. Temperature in the sensor readings. If the ServiceWatch data. switches can be installed. the LCD codes and compartment temperatures as they display is illuminated and shows the setpoint and occur and at preset intervals. optional sensor readings. during unit operation. 27 . If the typically used to analyze unit performance. the unit will always operate laptop or desktop computer and Thermo King the same way. See “Printing a Trip Report” on page 57. the the ServiceWatch Port to downloaded the unit will start and stop automatically. Refer to TK 51727 1. If optional temperature sensors are installed. FreshSet modifies and adjusts unit airflow operation to control temperature and to maximize protection of cargo. OptiSet™ is standard equipment. It records operating events. ServiceWatch Port Diagnostic Manual for configuration instructions. downloaded the CargoWatch data. to ten setpoints or setpoint ranges. Optiset can be programmed for up WinTrac 4. A printer can also be used to print a report of the • Variable preheat time. the unit will start and run automatically. Up to • Offers either CYCLE-SENTRY or six temperature sensor/probes and four door Continuous Run operation. FreshSet is a demand base temperature control for fresh products. Continuous mode has been selected. Unit Description Features of the CYCLE-SENTRY system are: CargoWatch™: CargoWatch™ data logging requires the installation of optional sensors. OptiSet Data Logging Optiset™ is a group of programmable functions There are two separate data loggers. FreshSet FreshSet™ is included in OptiSet. Use the CargoWatch Port to control. This assures that when a particular the control box using an IBM® PC compatible setpoint is selected. while keeping operating costs to a minimum. See “Viewing • Battery Sentry keeps batteries fully charged Sensor Readings” on page 51. This information is the return air temperature. their readings • Maintains minimum engine temperature in are displayed as Datalogger Sensor (1-6) low ambient conditions. This allows an 1 2 entire fleet to be configured to match customers’ needs (up to 10 preset conditions).4 (or higher) software. CargoWatch also logs • Controller regulated all season temperature the setpoint. alarm on and Controller ON key is pressed. Refer to TK 51727 the SR-2 Microprocessor Control System Diagnostic Manual for configuration instructions. Use CYCLE-SENTRY mode has been selected. CargoWatch Port the SR-2 Microprocessor Control System 2. The data is that control how the unit will operate with specific downloaded through the data ports on the front of setpoints.

The unit uses hot be in. Heat and Defrost consists of hot to automatically initiate timed or demand defrost gas delivered to the evaporator coil distributor. It does not differences between the return air temperature. 4. and either low speed or high speed as determined by Manual. and coil temperature used to increase the Heat and Defrost capacities exceed certain limits. The In diesel operation the diesel engine operates at methods of Defrost initiation are Automatic. The unit will Defrost in Automatic Defrost: The controller is programmed low speed only. the microprocessor. cycles as often as every 30 minutes if required. 8 or 12 • Defrost hours. cycles. 6. These • High Speed Heat timers can be set for intervals of 2. • Low Speed Modulated Heat (ETV units only) The evaporator coil temperature must be below 45 F (7 C) to allow defrost. and the • Null (CYCLE-SENTRY operation only) coil temperature is below 45 F (7 C). Diesel Operation Manual Defrost: In Manual Defrost Mode. it is difficult to predict which refrigerant to defrost the evaporator coils. Therefore. Electric evaporator heaters are also discharge air temperature. The unit will Cool or Heat in either high or low speed. Demand defrost cycles occur if the drive motor operates at a single speed. • Defrost (Hot Gas and Electric Heat) 28 . the operator initiates a defrost cycle.Unit Description Operating Modes Defrost The microprocessor uses a complex program to Frost gradually builds-up on evaporator coils as a determine which operating mode the unit should result of normal operation. and melts the frost. • Defrost Interval In Range with Fresh Setpoint Electric Operation (standard setting 6 hours) In electric operation the microprocessor will • Defrost Interval Not In Range with Fresh select the operating mode from the following: Setpoint (standard setting 4 hours) • Cool • Defrost Interval In Range with Frozen • Modulated Cool Setpoint (standard setting 6 hours) • Null (CYCLE-SENTRY operation only) • Defrost Interval Not In Range with Frozen Setpoint (standard setting is 6 hours) • Modulated Heat (Hot Gas only) This feature allows a shorter Defrost interval to be • Hot Gas Heat used when the unit is out of range during a • Full Heat (Hot Gas and Electric Heat) pull-down and more frequent Defrost cycles may be beneficial. the unit is running in Continuous or CYCLE-SENTRY mode (or shut • Low Speed Modulated Cool (ETV units only) down in CYCLE-SENTRY Null mode). Hot operating mode the unit should be in by refrigerant gas passes through the evaporator coil comparing the setpoint to the box temperature. 6. The unit can enter defrost during electric operation. or 12 hours. • Low Speed Heat The following four defrost timers are used. 4. The controller can be programmed to initiate timed defrost cycles at intervals of 2. the operating mode from the following: NOTE: The unit will not perform a Manual • High Speed Cool Defrost cycle unless the unit has been turned on • Low Speed Cool with the ON key. See “Initiating a In diesel operation the microprocessor will select Manual Defrost Cycle” on page 49. The water flows through collection drain tubes onto the ground. run in Null. In electric operation (Model 50 units only) the 8.

The defrost interval may need to Later model units are equipped with a secondary be changed if the unit will not hold the door latch. The unit will stay in defrost until the evaporator coil temperature rises to 58 F (14 C). Slam the door to close it. reach between the initiated on demand. Unit Description Normally. Spring Latch will not close properly. These units also have a secondary door compartment temperature at setpoint. Spring Catch Figure 7: Opening Secondary Door Latch 1 2 1. longer defrost timer intervals are used Opening the Secondary Door Latch for colder loads. Door Latch 2. Use a longer defrost interval if defrost is not being After opening the door latch. Opening the Front Doors Pull the door latch handle to open the doors and 2 access the engine compartment. 2. the engine will start when defrost is initiated. Secondary Door Latch Nameplate Figure 6: Door Latch Location 29 . front doors and lift the spring latch over the spring catch while opening the door. Use a shorter defrost interval if defrost is frequently being initiated on demand. Do not push the door closed while holding the door latch handle open or the door 1. 1 If the unit is in CYCLE-SENTRY Null mode. latch nameplate located below the front doors.

Other Engines Similar) 30 . Compressor Sight Glass 15. without warning. Engine Oil Dipstick: Use the engine oil dipstick to WARNING: The unit can start at any time check the engine oil level. 1 9 2 10 3 11 4 12 5 13 6 14 7 15 16 8 17 AJA1921 1. Engine Oil Filter 17. Receiver Tank Sight Glass: Use this sight glass to check the level of refrigerant in the receiver tank. Throttle Solenoid 5. service the air filter. Engine Oil Dipstick 8. Receiver Tank Sight Glass 4.Unit Description Engine Compartment Compressor Oil Sight Glass: Use this sight glass Components to check the compressor oil level. Press the button on the bottom of the restriction indicator to reset after servicing the air cleaner. Discharge Service Valve 12. Engine RPM Sensor 14. Low Engine Oil Pressure Switch 7. Press the Off key on the CAUTION: Make sure the engine is HMI control panel and place the turned off before attempting to check the microprocessor On/Off switch in the Off engine oil. intake manifold. Alternator Figure 8: Engine Compartment Components (TK486E Shown. Suction Service Valve 11. Battery Tray 9. Three-Way Valve 2. Hand Primer Pump 6. visually. See the Refrigeration Maintenance Chapter for the correct The following maintenance items can be checked procedure. Air Filter Restriction Indicator: The air filter See the Refrigeration Maintenance Chapter for the restriction indicator is attached to the engine correct procedure. When the diaphragm indicates 25. Filter Drier 3. Air Filter Restriction Indicator 10. Engine Starter Motor 13. position before inspecting any part of the unit. Compressor Oil Filter 16.

The valve is non-repairable and requires no adjustment. If the valve fails to reseat properly. Low Oil Level Switch: The low oil level switch closes if the oil drops below an acceptable level. time. temperature. High Pressure Relief Valve: This valve is designed to relieve excessive pressure in the refrigeration system. interface board to protect circuits and components.. recover the refrigerant charge and replace the valve. replace it by replacing the the overload relay. the microprocessor shuts the unit down and records alarm code 66. The high voltage tray is positive battery cable. If it stays closed for a specified closes if the coolant level drops below an time. Preheat Buzzer: The preheat buzzer sounds when Engine Coolant Temperature Sensor: The the controller energizes the preheat relay. 31 . If it stays closed for a specified time. the switch opens the circuit to the run relay to stop the unit. the microprocessor records alarm code 37. The valve is a spring-loaded piston that lifts off its seat when refrigerant pressure exceeds 500 psi (3447 kPa). The located in the positive battery cable. This microprocessor uses the engine coolant warns anyone near the unit that the controller is temperature sensor to monitor the engine coolant about to start the engine. High Pressure Cutout Switch: The high pressure cutout switch is located on the compressor discharge manifold. The microprocessor will record Alarm Code 10. If the compressor discharge pressure becomes excessive. See “Fuses” on page 73 for more information. If the the reset button on the high voltage tray to reset fuse link burns out. the microprocessor shuts the unit down and acceptable level. If it stays closed for a specified records alarm code 19. Press protects the electric system from a short. The the microprocessor might also The overload relay opens the circuit to the electric shut the unit down. If the engine coolant temperature rises above an acceptable level. The valve could possibly leak refrigerant after it has relieved excess pressure. located behind the lower access panel on the Fuses: Various fuses are located on the controller compressor side of the unit. possibly 18. The fuse link microprocessor will record Alarm Code 90.g. The valve will reseat when the pressure drops to 400 psi (2758 kPa). the Overload Relay—Manual Reset (Model 50): An microprocessor records alarm code 41 and overload relay protects the standby electric motor. motor if the motor overloads for any reason (e. Unit Description Unit Protection Devices Low Oil Pressure Switch: The low oil pressure switch closes if the oil pressure drops below an Coolant Level Switch: The coolant level switch acceptable level. low line voltage or improper power supply) while Fuse Link (Current Limiter): The fuse link is the unit is on electric standby operation. It is located on the receiver tank. Tapping the valve lightly may help the valve reseat and seal properly.

Unit Description Serial Number Locations Unit: Nameplates on the bulkhead above the compressor inside the curbside door. 1 1 AJA1617 1. Serial Number Location Figure 10: Unit Serial Number Locations 1 1. Serial Number Location Figure 11: Engine Serial Number Location Tier 1 Engine Shown Tier 2 Engine Similar 32 . Compressor: Stamped between the cylinders on the front end above the oil pump. and on the roadside of the evaporator. 1 Engine: See the engine identification plate located on the engine valve cover. Serial Number Location Figure 9: Compressor Serial Number Location 1.

Unit Description Unit Photos AJA1617 Figure 12: Front View 33 .

TK486E Engine (Other Engines Similar) Figure 13: Back View 34 . Defrost Damper 2. X430L Compressor 3.Unit Description 1 AJA1930 3 2 1.

TK486E Engine (Other Engines Similar) Figure 14: Front View with Doors Open (Model 30) 35 . X430L Compressor 2. Expansion Tank 7. Air Cleaner 4. Condenser Fan 5. Unit Description 1 2 3 7 6 AJA1931 5 4 1. Fuel Filter/Water Separator 3. Condenser Coil 6.

Fuel Filter/Water Separator 4. Expansion Tank 7. Condenser Coil 6. X430L Compressor 3. Condenser Fan 5. Air Cleaner Figure 15: Front View with Doors Open (Model 50) 36 .Unit Description 1 2 3 8 7 4 6 5 1. TK486E Engine (Other Engines Similar) 8. Electric Motor 2.

Phase Selector 4. Heaters Contactor 3. Unit Description 1 2 3 4 AJA1932 1. Overload Relay 2. Drive Motor Contactors Figure 16: High Voltage Tray (Model 50 Only) 37 .

Unit Description 38 .

ServiceWatch Port Figure 17: Control Box With Service Door Open Figure 18: SR-2 HMI Control Panel Microprocessor On/Off Switch This switch supplies or removes electrical power to the microprocessor. its function will be shown in the 3 display directly above the key. 4 5 1. CAUTION: The unit can start at any time without warning. which is located inside the TK 51585 and the SR-2 Microprocessor Control lower roadside service door. The microprocessor components are located Refer to the SB-210/310 Operator’s Manual inside the control box.Operating Instructions SMART REEFER 2 (SR-2) HMI Control Panel Control System Use the HMI control panel to operate the unit. Microprocessor 5. The display is capable of used to retrieve data from the data logging system. CargoWatch Port 2. If a 2 soft key is active. It is located on the left side of the control box. The CargoWatch and ServiceWatch ports are touch sensitive keys. The four keys on the left and right sides of the display are dedicated keys. Interface) Control Panel. Press the OFF key on the HMI control panel and place the microprocessor On/Off switch in the Off position before inspecting or servicing any part of the unit. Control Box 4. HMI Control Panel On/Off Switch 3. The four keys under the display are “soft” 1 keys. The microprocessor System Diagnostic Manual TK 51727 for more is connected to an HMI (Human Machine information. The function of “soft” keys change depending on the operation being performed. It is used to operate the The HMI control panel has a display and eight unit. 39 . showing both text and graphics.

If a soft It is shown in Figure 19 and is described in detail key is active. Soft Keys Figure 19: Dedicated and Soft Keys Control Panel Keys The four keys on the left and right sides of the display screen are “dedicated keys” (see Figure 19). On Key: Press this key to turn the unit on. The Thermo King Logo screen will appear briefly. Off Key (Dedicated Key) 2. 40 . The display will then show the Standard Display of box temperature and setpoint when the unit is ready to run. Then the HMI control panel will enter the power-down sequence. the operation being performed. shown in the display directly above the 3 key. it’s function will be later in this chapter. Defrost Key (Dedicated Key) • Select/Exit 5. current box temperature operating information. Their functions are listed below. Continuous/CYCLE-SENTRY Mode Key (Dedicated Key) • Clear/Help 6. Their function changes depending on The default display is called the Standard Display. Display • Up/Down 4. Off Key: Pressthis key to turn the unit off. Typical soft key applications: 2 4 1 • Set Point 5 • Gauges • Sensors AJA1850 • Menu 6 • Next/Back • Yes/No 1. On Key (Dedicated Key) • +/– 3. The engine will stop immediately. are multi-purpose keys (see Figure 19).Operating Instructions Control Panel Display Mode Key: Press this key to switch back and forth between the The display is used to supply unit information to CYCLE-SENTRY mode and the the operator. system temperatures and The four “soft” keys under the display other information as selected by the operator. Continuous Run mode. Defrost Key: Press this key to initiate a Manual Defrost cycle. This information includes setpoint. unit gauge readings.

Add coolant in the the first display to appear. Press the ON key. On Key guarantee engine operation to the next check 2. Logo. CAUTION: Do not remove expansion tank cap while coolant is hot. Display point. While the pretrip inspection is not a substitute for regularly scheduled maintenance inspections. The wires and terminals should be free of corrosion. If conventional coolant is added to Extended Life Coolant. Check the defrost drain hoses and fittings to make sure they are open. cracks or moisture. The condenser and evaporator coils should be clean and free of debris. Operating Instructions Unit Operation Turning Unit On Complete the following steps to turn on the unit: Manual Pretrip Inspection (Before Starting Unit) 1. expansion tank. CAUTION: Do not add “GREEN” or “BLUE-GREEN” conventional coolant to cooling systems using “RED” Extended Life Coolant. The following Manual Pretrip Inspection should 2 be completed before starting the unit and loading 1 the trailer. except in an emergency. the coolant must be changed after 2 years instead of 5 years. loose or broken parts and other damage. Structural: Visually inspect the unit for leaks. Make sure all the doors are latched securely. Alarm Code 37 temperatures it may take up to 15 seconds for indicates low coolant. Fuel: The diesel fuel supply must be adequate to 1. Figure 20: Press On Key Engine Oil: The engine oil level should be at the FULL mark with the dipstick turned (threaded) 2. Never overfill. it is an important part of the preventive maintenance program designed to head off operating problems and breakdowns before they happen. Belts: The belts must be in good condition and adjusted to the proper tensions. The display briefly shows a Thermo King into oil pan. Coolant: The engine coolant must have antifreeze NOTE: With extremely cold ambient protection to -30 F (-34 C). Battery: The terminals must be clean and tight. Electrical: The electrical connections should be securely fastened. Figure 21: Turning Unit On Screen Sequence 41 .

The “System is Powering Down” Screen will briefly appear. Display Figure 22: Press Off Key 2. Press the OFF key. 3. 1. 5. The “Diesel Engine Starting” Screen briefly 1 appears as the engine preheats and starts. The engine will immediately shut off. The Off Screen will briefly appear. Off Key 2. The screen goes blank when the unit power is off. 6. Figure 23: Turning Unit Off Screen Sequence 4. The “Configuring System” Screen briefly Turning Unit Off appears while communications are established Complete the following steps to turn unit off: between the microprocessor and the HMI control panel.Operating Instructions 3. The Standard Display showing box 2 temperature and setpoint briefly appears. The Standard Display showing box temperature and setpoint reappears when the unit is running. 42 . 5. 4. 1.

1 2 1. showing any of the following variations is still The Standard Display shows the box temperature considered a Standard Display. Menu Soft Key Figure 25: Temperature Watch Display 43 . A display appears if no other display function is selected. and setpoint. See Figure 26. The box temperature is measured by The top of the display will show that the unit is the controlling sensor. Degrees Fahrenheit non-use (when no keys are pressed). The temperature can be controlling sensor during modulation. The Figure 26: Standard Display Variations Temperature Watch Display shows the same box temperature and setpoint but in larger fonts. CYCLE-SENTRY mode. Cooling The Standard Display defaults to the Temperature 5. Heating 3. Degrees Celsius Temperature Watch Display 4. This creates easy operator viewing from a distance. An arrow pointing The setpoint shown is 35 F.5 F. Celsius (C). Operating Instructions Standard Display Standard Display Variations The Standard Display is the default display. The top of the display upwards indicates the unit is heating. Service/Alarm Message Watch Display after about 2-1/2 minutes of 6. Box Temperature 3. Continuous or CYCLE-SENTRY Figure 24: Standard Display 2. The arrow pointing down indicates the unit is cooling. Setpoint 1. 1 3 1 3 2 4 2 5 4 6 1. It The Standard Display has variations. Cooling 4. An arrow shows the unit is operating in the pointing downwards indicates the unit is cooling. To return to the Standard Display press the MENU soft key (or any of the other three soft keys that are not assigned). It may also display a programmed to use the discharge air sensor as the service/alarm message. The return air sensor is the operating in either CYCLE-SENTRY or controlling sensor except when the controller is Continuous Mode. Temperature Watch Display 2. CYCLE-SENTRY 2. The box displayed in degrees Fahrenheit (F) or degrees temperature shown below in Figure 24 is 35.

Allow the unit to run for a minimum of 30 minutes (longer if possible) before loading Unit Fails To Start the trailer. See “Viewing Gauge approximately 10 seconds after pressing the last Readings” on page 50. The controller will go through the start up screens and then after a 10 second delay the unit will start automatically. minutes of operation. Repeat the procedure. 7. Clear all alarms. mode. See “Pretrip Tests” on page 62. the trailer interior. Pre-Cooling: Make sure that the setpoint is at the NOTE: Run a pretrip test if the unit has not been desired temperature. If not. See “Initiating a Manual Defrost Cycle” on Sequence” on page 55. the engine will preheat and start the GAUGES soft key. 3. check the compressor oil level using the procedure in the Refrigeration WARNING: Never use starting fluid. need for the engine to run. turn the unit off. on page 46. This will remove the frost that builds up 2. indicate a positive charge amperage rate to the battery. refrigerated load. take the following steps. Press the OFF key to tun the unit off. discharge condition. A negative (-) number indicates a See “Turning Unit On” on page 41. Determine and correct the cause for not starting. See “Viewing and Clearing while running the unit to pre-cool the trailer. If the engine will still not start. See “Changing the Setpoint” used recently. 44 .Operating Instructions Starting the Diesel Engine After Start Inspection Diesel engine preheats and starts automatically in After the unit is running. The engine will preheat and start if Oil Pressure: Check the engine oil pressure by necessary when the unit is turned on. If the engine does not start and the alarm message This provides a good test of the refrigeration “UNIT NOT RUNNING .SERVICE system while removing residual heat and the moisture from the trailer interior to prepare it for a REQUIRED” appears on the top of the display. 5. Check for and correct any alarm conditions. page 49. The Engine Oil Pressure CYCLE-SENTRY mode if there is no current Display should indicate OK not LOW. Maintenance Chapter. The engine pressing the GAUGES soft key. Press the ON key to turn the unit on. CAUTION: The engine may start Compressor Oil: The compressor oil level should automatically any time the unit is turned be visible in the compressor sight glass after 15 on. check the following both Continuous Mode and CYCLE-SENTRY items to confirm that the unit is running properly. See “Viewing Gauge preheat and start will be delayed in Readings” on page 50. Defrost: When the unit has finished pre-cooling 1. Alarms Screen Sequence” on page 55. 6. The Amps Display should key. If a key or sequence of keys are pressed on the controller before the Ammeter: Check the ammeter reading by pressing engine starts. manually initiate a Defrost See “Viewing and Clearing Alarms Screen cycle. 4.

3. Check for and correct any alarm conditions. If the unit still does not start. If a screen asking if you wish to switch to unit is supplied by an electric motor connected to Electric Standby appears. 1. Connect the unit electric power receptacle to electric power as well as be powered by the an appropriate electric power supply. press the YES soft a high voltage power source. During Electric Standby operation. Press the controller ON key. 45 . or disconnecting high voltage power cords. AMA35 2. The electric power receptacle continuously in Continuous Mode. Press the Controller ON key. If the microprocessor determines that the unit CAUTION: Do not start the electric drive should cool or heat. This feature allows the unit to operate on 2. Figure 28: Electric Standby Detected Screen 5. Press the Controller OFF key. Model 50 units are equipped with Electric Standby. power to the 4. See “Viewing and Clearing Figure 27: Electric Power Receptacle Alarms Screen Sequence” on page 55.SERVICE REQUIRED” appears on the top of the display. supply are turned off before connecting or disconnecting a power cord. the appropriate screens motor unless the diesel engine is will appear and the electric motor will start. 3. It completely stopped. repeat the above follows: steps. Make sure the unit and the power page 44). unit is connected to live electric power and the controller is turned on. is usually mounted on the front of the trailer 6. may not start if the return air sensor Electric Power Receptacle: The electric power temperature is within a few degrees of receptacle is used to connect the unit to an setpoint. or if WARNING: Units equipped with electric the unit was in Electric Standby when it was standby may start at any time when the turned off. take the following steps. Starting the Unit on Electric Standby Operation 4. CAUTION: Always turn the electric power supply off when handling. See “Viewing and Clearing Alarms Screen Sequence” on page 55. This screen does not appear if the is shown on a decal on the unit’s electric power controller is programmed to automatically receptacle. Complete an After Start Inspection (see below the unit. The required voltage key. Operating Instructions Electric Standby Operation 1. Start the unit on Electric Standby operation as 5. Unit Fails to Start If the electric motor does not start and the alarm message “UNIT NOT RUNNING . switch from Diesel to Electric Standby. standard diesel engine. connecting. Press the controller OFF key to make sure the unit is turned off. The electric motor cycles on and off appropriate electric power source for electric in CYCLE-SENTRY Mode and runs standby operation. Clear all alarms.

2. Press the SETPOINT soft key on the Standard Display. 1. the setpoint will not be changed and the display will return to the Standard Display. 2.soft keys to change the setpoint reading. 6. “Setpoint Not Entered”. 4. 2 5. the setpoint change made with the “+” or “-” soft keys will be accepted. The Standard Display appears with setpoint Figure 29: Changing Setpoint changed to the new setpoint. To change the setpoint complete the following steps. See Figure 30. The “New Setpoint Is XX” Screen briefly 1. See Figure 30. If YES Key was pressed If NO Key was pressed SETPOINT Key + or – Key YES or NO Key Figure 30: Changing the Setpoint Screen Sequence 46 . Setpoint Soft Key 7. The “Current NOTE: This generates an Alarm Code 127 Setpoint” Screen appears. See Figure 30. See Figure 30. Begin at the Standard Display. See Figure 29. See Figure 30. Press the YES OR NO soft key accordingly as described below. See Figure 30. accepted. Press the + or . See Figure 30.Operating Instructions Changing the Setpoint 3. Standard Display appears. • If the NO key is pressed the setpoint change press the MENU soft key once to return to the made with the “+” or “-” soft keys will not be Standard Display. If the Temperature Watch Display is showing. and the following screens will appear. The “Programming New Setpoint” Screen will appear. 1 • If the YES soft key was pressed.

• Fresh flowers and foliage. sweet corn. 47 . Operating Instructions Selection of Operating Modes The Thermo King CYCLE-SENTRY system is designed to save refrigeration fuel costs. broccoli. citrus. strawberries. Examples of products normally requiring Continuous Run Operation for air flow: • Fresh fruits and vegetables. Examples of products normally acceptable for CYCLE-SENTRY Operation: • Frozen foods (in adequately insulated trailers) • Boxed or processed meats Poultry • Fish • Dairy products • Candy • Chemicals • Film • All non-edible products. The savings vary with the commodity. green peas.Use the following guidelines to select the proper operating mode to protect the commodity you are transporting. spinach. ambient temperatures and trailer insulation. carrots. Consult your grower or shipper if you have any questions about the operating mode selection of your type of load. etc. Certain highly sensitive products normally require continuous air circulation. peaches. bananas. However. • Non-processed meat products (unless pre-cooled to recommended temperature). not all temperature controlled products can be properly transported using CYCLE-SENTRY operation. lettuce. The above listings are not all inclusive. especially asparagus.

The Standard Display appears and the bar on top of screen reads the new mode. When Continuous mode is selected. The “Programming Continuous Mode” or “Programming CYCLE-SENTRY Mode” Screen briefly appears. See Figure 32 and Figure 33. Press the MODE key. Press the MODE key again to change the unit back to the previous mode. 4. 1. See Figure 31. See Figure 32 and Figure 33. Complete the following steps to change modes: NOTE: The mode can also be changed using the Mode Menu Screen in the Main Menu. The “New System Mode is Continuous” Screen or the “New System Mode CYCLE-SENTRY” Screen briefly appears. 3. Shows Mode Selected 2. See Figure 32 and Figure 33.Operating Instructions Selecting CYCLE-SENTRY or Continuous Mode When CYCLE-SENTRY mode is selected the unit will start and stop automatically to maintain the setpoint. 48 . keep the engine warm. and the battery charged. 1 2 Figure 32: Screen Sequence for Changing from CYCLE SENTRY Mode to Continuous Mode 1. Mode Key Figure 31: Changing Mode 2. Figure 33: Screen Sequence for Changing from Continuous Mode to CYCLE-SENTRY Mode 5. the unit will start automatically and run continuously to maintain setpoint and provide constant airflow. See “Selecting CYCLE-SENTRY or Continuous Mode” on page 59.

The “Programming Defrost” Screen briefly 30 minutes. The bar indicator in the figure shows that the Defrost cycle is 50% complete. See Figure 35. check the 5. terminates Defrost because the evaporator coil temperature fails to reach 58 F (14 C). turning the unit off. When the Defrost cycle is complete the display returns to the Standard Display. but can be set for 3. A “Defrost Unavailable” Screen briefly appears. Use the following steps to initiate a Manual Defrost: 1. The “Defrost” Screen briefly appears.). The bar unit to see if it is working properly. Press the DEFROST key. If the unit is prevented from going into a Manual Defrost (IE: Coil temperature more than 45 F (7 C) or on economy mode etc. is normally set for 45 minutes. Defrost Key Terminating a Defrost Cycle Figure 34: Initiating a Manual Defrost Cycle The Defrost cycle will terminate automatically when the coil temperature reaches 58 F (14 C) or 2. Manual Defrost is also available if the unit is running and the coil temperature is less than 45 F (7 C). The “Defrost Started” Screen briefly appears. The display returns to the Standard Display. NOTE: If the defrost timer consistently See Figure 35. See Figure 35. Defrost can also be terminated by appears. Standard Display 2. 4. See Figure 34. 49 . indicator will fill in showing time remaining to complete the Defrost cycle. Other features such as door switch settings may not allow Manual Defrost to be initiated. A modified Standard Display appears. See when the defrost timer expires. Operating Instructions Initiating a Manual Defrost Cycle Defrost cycles are usually initiated automatically based on time or temperature. or 1 2 Figure 35: Initiating Manual Defrost Screen Sequence 1. The defrost timer Figure 35. See Figure 35.

NOTE: Units without an Electronic Throttling Valve (ETV) will not display the Discharge Pressure. Pressure. Begin at the Standard Display. Menu. Use the following steps to view the gauge Coolant Level. Figure 36: Viewing Gauges 5. Suction Pressure. If no keys are pressed within 30 seconds. readings: Battery Voltage. Press the LOCK soft key to display any Gauge 2. Press the GAUGES soft key to enter the Gauges Overload. Heater Output. ETV Position. Diesel/Electric Relay. Gauges Soft Key Screen for an indefinite period. and ETV Position. the 1 screen will return to the standard display. Press BACK or NEXT soft keys to scroll through following gauges: Coolant Temperature. Run Relay. Selecting I/O enters a group of screens press the MENU soft key once to return to the that show the status (On or Off) of the High Standard Display. Press the EXIT soft key to return to the Standard Display. Engine Oil Pressure. Standard Display Screen 4. Amps. Speed Relay. Suction Pressure. Engine RPM. Discharge 1. See Figure 37. See Figure 36. Press the key again to unlock the screen. and Hot Gas Bypass. See “Electronic Throttling Valve” on page 25 for more information about the ETV and how to tell if the unit has 2 an ETV. I/O. Defrost Damper. BACK Key BACK Key GAUGES Key BACK Key NEXT Key BACK Key NEXT Key BACK Key NEXT Key BACK Key NEXT Key BACK Key NEXT Key BACK Key NEXT Key BACK Key NEXT Key NEXT Key NEXT Key Figure 37: Viewing Gauges Screen Sequence 50 .Operating Instructions Viewing Gauge Readings 3. and If the Temperature Watch Display is showing. 1. Electric 2.

The controller will 2. temperature goes below a certain point in extremely cold ambient temperatures. Begin at the Standard Display. Operating Instructions Viewing Sensor Readings • Optional Datalogger Sensor 1-6 Temperatures – The Datalogger Sensor Use the following steps to view the sensor Temperature screens display dashes (– – –) readings. 1. Press the SENSOR soft key to enter the Sensor turn the HMI display heater on if this Menu. Sensors Soft Key Figure 38: Viewing Sensors 1 2 3 4 3. Lock Soft Key 4. the screen will return to the Standard Display. unless optional sensors are installed. 1 See Figure 39 and Figure 40. Press the LOCK soft key to display any sensor • Control Discharge Air Temperature screen for an indefinite period. Standard Display 2. If no keys are pressed within 30 seconds. Press the EXIT soft key to return to the Standard • Temperature Differential – The Display. • Board Temperature Sensor – The Board If the Temperature Watch Display is showing. See Figure 38. Press the BACK or NEXT soft keys to scroll 1. • Evaporator Coil Temperature • Ambient Air Temperature • Spare 1 Temperature 51 . Press the key again to unlock the screen. Temperature Sensor displays the press the MENU soft key once to return to the temperature of the PC board inside the Standard Display. Back Soft Key through the following sensor screens: 2. Next Soft Key • Control Return Air Temperature Figure 39: Soft Keys • Display Return Air Temperature 4. Exit Soft Key 3. Temperature Differential is the difference between the Control Return Air Temperature and the Control Discharge Air Temperature. HMI control panel. 2 1. • Display Discharge Air Temperature 5.

Operating Instructions BACK Key BACK Key SENSORS Key BACK Key NEXT Key BACK Key NEXT Key BACK Key NEXT Key BACK Key NEXT Key BACK Key NEXT Key BACK Key NEXT Key BACK Key NEXT Key BACK Key NEXT Key BACK Key NEXT Key BACK Key NEXT Key BACK Key NEXT Key BACK Key NEXT Key NEXT Key NEXT Key Figure 40: Viewing Sensors Screen Sequence 52 .

For detailed information controller is programmed to activate more than on each menu area. Press the MENU soft key. see the individual one language. See page 65. Time: Allows the operator to view the Time and Date. See page 59. Next Soft Key 5. Adjust Brightness: Allows the operator to Figure 41: Accessing Main Menu adjust the display intensity as required by conditions. Back Soft Key 8. Operating Instructions Navigating the Main Menu Does not appear unless more than LANGUAGE one language activated. Pretrip: Allows the operator to run a Pretrip. See page 54. The Main Menu choices are 1. Language Menu: This menu only appears if the shown in Figure 42. Electric Standby/Diesel Mode (Model 50 Only): This menu only appears on Model 50 units. 5 4 3 2 7. 3. 2. PRETRIP 2. See page 62. See page 55. down through the main menu areas. Alarms Menu: Shows any active alarms and allows alarms to be cleared. Figure 42: Main Menu Choices 5. Press the EXIT soft key. See page 66. 53 . Mode Menu: Allows the operator to change unit operating modes between CYCLE-SENTRY mode and Continuous Run mode. 4. Hourmeters Menu: If enabled. English is the default language. See Figure 41 and Figure 42. Press NEXT and BACK soft keys to scroll up or ELECTRIC STANDBY/DIESEL Does not appear on Model 30 units. displays are shown in the selected language. ADJUST BRIGHTNESS 4. Menu Soft Key 4. See page 56. and start Sleep mode. Begin at the Standard Display. Select Soft Key allows the operator to manually select Electric 2. HOURMETERS If the Temperature Watch Display is showing. See page 64. 9. 6. See page 58. All other subsequent following pages of this manual. Use the following steps to access these menu areas: DATALOGGER 1. allows the operator to view the hourmeter displays. 3. Exit Soft Key Standby or Diesel operation. 5. press the MENU soft key once to return to the MODE Standard Display. See Figure 41. It allows the operator to select explanations of each menu item on the which language is used. To return to the Main Menu Choices Standard Display. The Time is displayed in 24 hour military time. It 1. Press the SELECT soft key to access a specific TIME menu area when shown on the display screen. Datalogger Menu: Allows the operator to view 1 the datalogger displays. See Figure 41. The Main Menu contains individual menu areas that allow the operator to view information and ALARMS modify unit operation. 3.

programming will appear on this menu. Hungarian. software revisions 65xx and 66xx are identical. Other than will appear. Polish. Danish. When the desired language is shown. Press the MENU soft key on the Standard soft key to select a different main menu item.Operating Instructions Language Menu If the Language feature is activated in the controller programming. Press the + or . 9. Portuguese. The languages available are dependant on the 1. The display will return to the Standard Standard Display. languages supported. 3. The “PROGRAMMING Diagnostic Manual TK 51727 for information LANGUAGE-PLEASE WAIT” Screen briefly about programming the controller. Begin at the Standard Display. Refer to the SR-2 Microprocessor Control System 7. Dutch. German. See Figure 44. See Figure 44. Screen briefly appears. Czech. Display. Spanish. Italian. 4. Languages currently supported by software revision 65xx are Figure 43: Standard Display English. Arabic and Hebrew. Turkish. Norwegian and Finnish. The display returns to Language Menu press the MENU soft key once to return to the Screen. press the YES soft key to confirm the choice. Greek. Only languages that have been activated in the controller 6. French. 5. an alternate language can be selected from the Language Menu. Press the SELECT soft key to choose the Language Menu Languages currently supported by software revision 66xx are English. Press the NEXT 2. Russian. See Figure 44. Menu Soft Key HMI control panel software revision. appears. Press the EXIT soft key to return to the Standard Display. The default language is English. Screen. Romanian. Display if no keys are pressed. If the Temperature Watch Display is showing. The “LANGUAGE SELECTED IS XXX” 1. To select an alternate language: 8. MENU Key YES Key Figure 44: Change Language Screen Sequence 54 . The Language Menu Screen appears. The “NEW LANGUAGE WILL BE” Screen Swedish.soft keys to select the desired language. After a 1 new language is chosen all displays will appear in that language. Bulgarian.

For additional information regarding the alarm appears. If a serious alarm occurs. 203. 8. Press the NEXT soft key until the Alarm Menu 9. MENU Key NEXT Key SELECT Key SELECT Key CLEAR Key Figure 46: Viewing and Clearing Alarms Screen Sequence 55 . Menu as follows: 6. Menu Soft Key the Guarded Access Menu. Microprocessor Control System Diagnostic Manual TK 51727 for information about diagnosing alarm codes. 1 NOTE: Some alarms (3. If alarms are present. Refer to the SR-2 Microprocessor Control System Diagnostic Figure 45: Standard Display Manual TK 51727 for more information. and the most recent alarm code number will If the Temperature Watch Display is showing. Press the EXIT soft key to Alarms are viewed and cleared using the Alarm return to the Standard Display. the unit will be shut 2. Refer to the SR-2 will appear. To clear an alarm press the CLEAR soft key. If there is more than one alarm. the quantity of alarms 1. shown on the display press the HELP soft key. load. Press the MENU soft key on the Standard down to prevent damage to the unit or the Display. 7. 4. If no alarms are present. If this occurs. and 204) cannot be cleared in the Alarms Menu. 3. Operating Instructions Alarms Menu 5. the display will show that the unit is shut down and display the alarm code that caused the shutdown. Standard Display. They must be cleared in the Maintenance Menu or 1. Press the SELECT soft key. press the MENU soft key once to return to the press the NEXT soft key to view each alarm. 74. 4. The Alarm Display A help message will appear. Begin at the Standard Display. the “No Alarm” Screen is shown. be shown.

Press the SELECT soft key on the Datalogger covers manual initiation. See Figure 48. 2. Menu appears. SELECT Key SELECT Key SELECT Key Figure 48: Start of Trip Screen Sequence 56 . Standard Display. Menu Soft Key the cargo is being loaded. For more information on Menu.Operating Instructions Datalogger Menu The Datalogger Menu is used to initiate a start of trip. The following procedure 4. The Start Of Trip marker then shows when the trip started in the Figure 47: Standard Display data that is downloaded or printed from the datalogger. HTTP://WWW. Press the NEXT soft key until the Datalogger through the use of WinTrac datalogging software. 1 Initiating a Start of Trip A “Start Of Trip” places a marker in the datalogger memory. The “Start Trip” Screen will appear. Press the SELECT soft key. See Figure 47. The WinTrac 5.BLUETREE. 6. A Start Of Trip Marker has been inserted into press the MENU soft key once to return to the the datalogger memory. Begin at the Standard Display. A Start Of Trip can be initiated 3. If the Temperature Watch Display is showing. or manually in the field. or to print a trip report. see the WinTrac User Manual included with the WinTrac software. Press the SELECT soft key to initiate a start of 1. trip. Press the MENU soft key on the Standard Display. The “Start Of Trip” User Manual is also available on the Internet at Screen will appear. It is typically initiated when 1. 7. datalogging.IE.

ServiceWatch Port 6. This procedure prints the CargoWatch datalogger It is typically mounted between the record directly to a handheld printer. Press the SELECT soft key to print a trip report. If no press the MENU soft key once to return to the sensors are connected. Figure 49: Printer Port Location 7. Press the NEXT soft key. the printed record shows Standard Display. Connect the printer to the 6-pin printer port soft key to print a delivery report. 4. Press the NEXT soft key until the Datalogger Menu appears. record shows things such as the unit and controller identification numbers. Operating Instructions Printing a Trip Report NOTE: The printer port can be mounted so it is accessible without opening the control box. Begin at the Standard Display. Press the NEXT soft key to go to the “Trip Ticket” Screen. dates and times. connected to the CargoWatch data logger. See Figure 51. SELECT Key SELECT Key SELECT Key NEXT Key NEXT Key SELECT Key Figure 51: Print Report Screen Sequence 57 . Press the MENU soft key on the Standard 3 Display. Printer Port Screen will appear. See Figure 50. the setpoint. Press the SELECT soft key on the Datalogger 1. 1 1 1. The printed CargoWatch Port and the ServiceWatch Port. The “Print/View” 3. CargoWatch Port Menu. and data from the optional sensors If the Temperature Watch Display is showing. Press the SELECT 1. The “Start Trip” Screen will appear. Press the SELECT soft key. 2. the same things without the sensor data. 2. 8. located inside the control box. 5. The “Delivery Ticket” Screen will appear. Menu Soft Key 2 Figure 50: Standard Display 3.

Engine Hours. Press the SELECT soft key to enter the Menu as follows: Hourmeters Menu. Total Run Time Hours. Hourmeters can be viewed in the Hourmeters 4. The default setting for Model 30 units is to display the Total Hours and Engine Hours. Press the NEXT and BACK soft keys to view the If the Temperature Watch Display is showing. Refer to the SR-2 Figure 52: Standard Display Microprocessor Control System Diagnostic Manual TK 51727 for information about 3. BACK Key BACK Key SELECT Key BACK Key NEXT Key BACK Key NEXT Key BACK Key NEXT Key BACK Key NEXT Key BACK Key NEXT Key BACK Key NEXT Key BACK Key NEXT Key BACK Key NEXT Key BACK Key NEXT Key NEXT Key NEXT Key Figure 53: Viewing Hourmeters Screen Sequence 58 . Press the MENU soft key on the Standard Display. and Electric Run Hours. The Hourmeters are programmable to be visible or hidden in the controller. See Figure 53. press the MENU soft key once to return to the Standard Display. Hourmeters that are hidden are not displayed. Menu appears. 5. hourmeter displays. The Hourmeters Menu will not appear if 1. Press the NEXT soft key until the Hourmeters programming the controller. Begin at the Standard Display. but they do count hours. Hourmeters that are visible are displayed. The default setting 1 for Model 50 units is to display Total Hours.Operating Instructions Hourmeters Menu 2. Menu Soft Key all hourmeters are hidden. 1.

But. Press SELECT soft key to enter the Mode Menu. Press the SELECT soft key. Operating Instructions Mode Menu 2. Mode Key 3. 2 CAUTION: If the unit is in CYCLE-SENTRY null and the mode is 3 switched to Continuous mode. Selecting CYCLE-SENTRY or Continuous 3. Menu Soft Key Figure 54: Standard Display SELECT Key SELECT Key SELECT Key Figure 55: Selecting Mode Screen Sequence 59 . 7. Press the MENU soft key on the Standard Display. you can also switch modes in the Mode Menu as follows: 5. 1. Begin at the Standard Display. The display then returns to the Mode Menu. If the Temperature Watch Display is showing. 1 Press the SELECT soft key again to change the mode again. CYCLE-SENTRY and Continuous Run is to press See Figure 55. 1. the Mode key (see page 48). The easiest way to switch between 4. 6. to switch between modes. the unit will start automatically. Standard Display. Shows Current Mode 2. The new mode is then confirmed for 10 press the MENU soft key once to return to the seconds. Press the NEXT soft key until the Mode Menu Mode appears.

engine warm and/or the battery charged. Then press the YES soft key at the away. Electric mode. 60 . it keeps the compartment temperature immediately enter Sleep mode. In Electric mode will resume normal operation and control the unit starts and stops as necessary to maintain to setpoint. You now choose to program a Sleep mode keep the unit engine warm in cold ambient Wake-up Time or simply enter Sleep mode conditions. If a Wake-up Time is 9. example Monday has been chosen. Press SELECT soft key to enter the Mode Menu. See Figure 57. the operator can also program an unit is to restart in normal operation. Press the YES soft key to confirm the minute. Sleep mode starts and stops the unit as required to keep the unit battery in a charged condition and 7. 4. near the ambient temperature when the unit is a. 5. To enter a Wake-up Time verify that the unit When Sleep mode is entered. Standard Display. The display will now prompt you for the hour 1. 1 12. This is useful in extremely cold weather unit will start and stop as required to keep or when the unit is to be out of service for an engine warm and/or the battery charged. extended time. In this example 18:37 hours has been chosen. Sleep mode does not maintain setpoint. Sleep mode does not maintain the Sleep mode operates in both Diesel mode and compartment temperature. In If the Temperature Watch Display is showing. The display will now prompt you for the Display. Figure 56: Standard Display 13. Press the SELECT soft key to start the Sleep mode. battery charge only. Press the + or . In this automatic Pretrip Test when the unit restarts. 8. Select Sleep Mode as follows: 10. Begin at the Standard Display. The display will show “SLEEP” and the running. The display will now prompt you to “Run A Pretrip On Wake-Up?” Press YES soft key or the NO soft key accordingly and the display will show the unit is programming the Sleep 1. 2. the unit is to restart in normal operation. Sleep mode does not maintain immediately. Press the EXIT soft key to exit Sleep mode and stop as required to maintain engine or turn the unit off and back on. automatically restart and run normally at the determined time. Press the YES soft key to confirm the hour.soft keys to select the day the programmed. the operator can clock is set properly (see “Time Display” on program an automatic Wake-up Time up to a week page 66). minute the unit is to restart in normal operation. Press the NEXT soft key as required to display the Sleep Mode Screen. In Diesel mode the unit will start b. the unit will “Program A Wake-Up Time?” Screen. Press the NO soft key to setpoint. Using this feature. The display will show “SLEEP” and the unit 3. The unit temperature and battery charge. Press the NEXT soft key until the Mode Menu will start and stop as required to keep the appears. Press the MENU soft key on the Standard 11. press the MENU soft key once to return to the Note that 24 hour “military time” is used. Press the YES soft key to confirm the day. this example 18:00 hours has been chosen. Menu Soft Key mode.Operating Instructions Selecting Sleep Mode 6.

the unit will resume normal operation and control to setpoint. After the Pretrip is the unit off and back on. To exit Sleep mode before the selected (in this example 18:37 hours) and perform a Wake-up time press the EXIT soft key or turn Pretrip (if selected). The unit will restart at the programmed time 15. The unit will resume complete the test results will be displayed and normal operation and control to setpoint. SELECT Key then NEXT Key YES Key SELECT Key YES Key YES Key YES Key or NO Key YES Key Figure 57: Selecting Sleep Mode Screen Sequence 61 . Operating Instructions 14.

a Defrost cycle is initiated. direct the technician to the source of the The Full Pretrip test proceeds in the order shown problem. a Defrost cycle is initiated. The controller • Heat Check . • Cool Check – The ability of the unit to cool in 2. • Heat Check . is running in the Diesel Mode. the engine and before the unit starts. • Defrost – If the coil temperature is below 45 F 1. If test results A Full Pretrip occurs when Pretrip is initiated are Check or Failed. the unit. low speed is checked. before pressing the MENU soft key on the Standard Display. Menu Soft Key Figure 58: Standard Display 62 . (7 C). If the unit is running. “CHECK” or “FAILED” when the Pretrip is completed. Pretrip Test. 1. The Pretrip A Running Pretrip occurs when Pretrip is initiated Menu allows the operator to select and initiate a after the engine or electric motor is running. The Pretrip Test. • Report Test Results – The test results are Full Pretrip reported as “PASS”. Test on a loaded trailer.Operating Instructions Pretrip Tests Running Pretrip A Pretrip test verifies unit operation. Press the ON key to turn the unit on. There are two different Pretrip Tests. Running Pretrip test proceeds in the order shown the Full Pretrip and the Running Pretrip. alarm codes will exist to direct the technician to the source of the problem. If test results 1 are Check or Failed. “CHECK” or “FAILED” when the Pretrip is completed. the engine CAUTION: Monitor the return air RPM in high and low speed is checked during temperature when performing a Pretrip the Cool Check.The ability of the unit to heat in may not maintain setpoint during the low speed is checked. To initiate a Full Pretrip press the MENU soft • RPM Check (Diesel Mode only) – If the unit key as soon as the Standard Display appears is running in the Diesel Mode. alarm codes will exist to before the engine or electric motor starts running. 3. A Running Pretrip • Engine or Electric Motor Start – The engine or can also be initiated by starting at step 3 with the electric will start automatically. • Report Test Results – The test results are reported as “PASS”. RPM in high and low speed is checked during To initiate a Running Pretrip let the unit start the Cool Check. • Any alarms are present • RPM Check (Diesel Mode only) – If the unit • The unit is in Sleep mode. press the OFF key to stop (7 C).The ability of the unit to heat in low speed is checked. Pretrip or a Running Pretrip. below: The Pretrip Tests can be run in either Diesel or • Defrost – If the coil temperature is below 45 F Electric mode. below: • Amp Checks – Each electrical control Initiating a Pretrip Test component is energized and the current drawn Use the following procedure to initiate a Full is confirmed to be within specification. unit running. Pretrip Tests are not allowed if: • Cool Check – The ability of the unit to cool in low speed is checked.

When all tests are complete. number of tests completed out of a total of 26. If the Pretrip Test results are Check or Failed 6. 8. Test progress is measured by the service. The soft keys may be used during the Pretrip Stopping a Pretrip Test Test to select the Hourmeter. The Pretrip display appears. In a Full Pretrip. accompanying alarm codes will direct the technician to the cause of the problem. when the non-running tests Other alarm codes may also be generated. 5. This will generate Alarm Code 28–Pretrip Abort. See Figure 59. The top line of the problem should be diagnosed and the display indicates which test the unit is corrected before the unit is released for performing. completion. “CHECK” or “FAILED”. Press the NEXT soft key until the Pretrip Screen If the results are Check or Failed. Turn the unit off to stop a Pretrip Test at any time. the appears. If “FAILED” appears. 7. the unit will shut down. Gauge or Sensor menus. Operating Instructions 4. SELECT Key Figure 59: Pretrip Test Screen Sequence 63 . the results are reported as “PASS”. Press the SELECT soft key to start a Pretrip. This is are complete the unit will start automatically normal when the Pretrip test is stopped before and continue with the running tests.

64 . See Figure 61 and Figure 62. Press the NEXT soft key until the Electric Standby/Diesel Mode Screen appears. Press the MENU soft key on the Standard Display. Begin at the Standard Display. NOTE: Manual selection is the default setting for both Electric Standby and Diesel Mode.Operating Instructions Electric Standby/Diesel Mode The Electric Standby/Diesel Mode display allows the operator to manually select Electric Standby or Diesel Mode operation. Select Electric Standby or Diesel Mode as follows: 1. 1 Figure 62: Programming Electric Standby Mode 1. Figure 61: Programming Diesel Mode A screen asking if you wish to switch to Diesel Mode will appear if standby power is disconnected when in Electric Standby. Menu Soft Key Figure 60: Standard Display 3. 4. Press the SELECT soft key to select the mode shown on the display. The unit can also be programmed to automatically select Electric SELECT Key Standby operation when standby power is available and Diesel Mode operation if standby power fails or is removed. 2. SELECT Key If the Temperature Watch Display is showing. A screen asking if you wish to switch to Electric Standby will appear if the unit is connected to standby power when in the Diesel Mode. Refer to the SR-2 Microprocessor Control System Diagnostic Manual TK 51727 for information about programming the controller. press the MENU soft key once to return to the Standard Display.

Begin at the Standard Display.soft keys to select the desired brightness. press the MENU soft key once to return to the SELECT Key Standard Display. The selected level appears on the screen. See Figure 64. 5. If the Temperature Watch Display is showing. 2. The Adjust Brightness Main Menu Screen reappears and if no keys are pressed the Standard Display appears. + Key 1 1. 4. Menu Soft Key YES Key Figure 63: Standard Display 3. Figure 64: Adjusting Display Brightness Screen Sequence 65 . See Figure 64. Operating Instructions Adjust Brightness Menu Adjust the display brightness as follows: 1. This example shows changing screen brightness from low to medium. Press the NEXT soft key until the Adjust Brightness Menu appears. 7. Press the YES soft key to enter the new brightness level. Press the MENU soft key on the Standard Display. Press the + or . 6.

Operating Instructions

Time Display 2. Spot check and record load temperature while
loading. Especially note any off-temperature
The time and date can be viewed but not changed
product.
through the time display. The time and date are
changed by programming the controller. Refer to 3. Load the product so that there is adequate
the SR-2 Microprocessor Control System space for air circulation completely around the
Diagnostic Manual TK 51727 for information load. DO NOT block the evaporator inlet or
about programming the controller. View the time outlet.
and date as follows:
4. Products should be pre-cooled before loading.
1. Begin at the Standard Display. Thermo King transport refrigeration units are
If the Temperature Watch Display is showing, designed to maintain loads at the temperature
press the MENU soft key once to return to the at which they were loaded. Transport
Standard Display. refrigeration units are not designed to pull hot
loads down to temperature.
2. Press the MENU soft key on the Standard
Display.
Post Load Procedure
3. Press the NEXT soft key until the Time Display
1. Make sure all the doors are closed and locked.
appears.
2. Start the unit if it was shut off to load (see
4. Press the SELECT soft key to view the time and
“Turning Unit On”).
date.
3. Make sure the setpoint is at the desired setting.
1
4. One-half hour after loading, manually initiate
a Defrost cycle. If the evaporator coil sensor
temperature is below 45 F (7 C), the unit will
2 Defrost. The microprocessor will terminate
Defrost automatically when the evaporator
coil temperature reaches 58 F (14 C) or the
MENU Key then NEXT Key
unit has been in the Defrost mode for 30 or 45
minutes (depending on setting).

Post Trip Checks
SELECT Key 1. Wash the unit.
2. Check for leaks.
3. Check for loose or missing hardware.
4. Check for physical damage to the unit.
1. Standard Display
2. Menu Soft Key
Figure 65: Time and Date Screens

Loading Procedure
1. Make sure the unit is turned off before
opening the doors to minimize frost
accumulation on the evaporator coil and heat
gain in the trailer. (Unit may be running when
loading the trailer from a warehouse with door
seals.)

66

Electrical Maintenance

Alternator (Australian Bosch)
Model 30 CAUTION: The F4 fuse must be removed
from the interface board on units
Charging System Diagnostic equipped with the Australian Bosch
Procedures alternator. The voltage regulator will be
damaged if the unit is turned On with the
NOTE: Units manufactured with F4 fuse in place on the Interface board.
CYCLE-SENTRY and alternators with integral
regulators MUST use replacement alternators Complete the following checkout procedure
with integral regulators. before replacing the voltage regulator or the
alternator.
CAUTION: Full-fielding alternators • When testing alternators use accurate
with the integral regulator is equipment such as a Thermo King
accomplished by installing a jumper from P/N 204-615 (FLUKE 23) digital multimeter
terminal F2 to ground. Attempting to and a Thermo King P/N 204-613 amp clamp
full-field the alternator by applying or an equivalent.
battery voltage to terminal F2 will cause
voltage regulator failure.

1. Check Point for 2A Amperage 3. Check Point for Sense Circuit and
Excitation Circuit Voltages
2. Check Point for B+ Voltage 4. Position for Full Fielding Jumper

Figure 66: Check Points for Alternator Test

67

Electrical Maintenance

• Make sure the drive belts and pulleys of the b. The B pin is the excitation circuit and
charging system are in good condition and are should be at 10 volts or higher. If not,
adjusted properly before testing the alternator. check the excitation circuit (7K or
Worn belts and pulleys or loose belts will equivalent) in the alternator harness and in
lower the output of the alternator. the main wire harness.
• The battery must be well charged, the battery 8. If battery voltage is present on the sense and
cable connections must be clean and tight, and excitation circuits, connect the alternator
the 2A and excitation circuits must be harness to the voltage regulator and check the
connected properly. voltage on the B pin in the two pin connector
on alternator harness. The voltage should be
NOTE: All voltage readings should be taken
0.7 to 1 volt using the interface board test.
between the negative battery terminal, or a good
chassis ground, and the terminals indicated, a. No voltage or a voltage reading below 0.7
unless stated otherwise. volts indicates that the rotor or the voltage
regulator may be shorted. Perform the
1. Check to make sure that the F4 fuse has been
field current test to further isolate the
removed from the interface board. If not, it
problem.
must be removed, however, the voltage
regulator has probably already been damaged. b. A voltage reading above 3 volts indicates
that the field circuit may be open or have
2. Press the OFF key to turn the unit off.
high resistance. The brushes or the rotor
3. Check the battery voltage. If the battery are probably defective.
voltage is less than 12 volts, the battery must
9. Attach a clamp-on ammeter to the 2A wire
be charged or tested to determine if it should
connected to the B+ terminal on the alternator.
be replaced.
10. Connect a voltmeter between the B+ terminal
4. Check the voltage at the B+ terminal on the
and a chassis ground.
alternator. Battery voltage must be present. If
not, check the 2A circuit. 11. Start the unit and run it in high speed.
5. Disconnect the alternator harness from the 12. Connect a jumper wire between the F2
voltage regulator by carefully pushing on the terminal and a chassis ground. This will full
spring clip to release the plug lock. field the alternator.
6. Press the ON key to turn the unit on. Access
the Service Test Mode screens in the CAUTION: DO NOT full field the
Maintenance Menu before the unit starts. alternator for more than seven seconds
Energize the run relay in the interface board while checking the meter readings, or the
test. See the appropriate Diagnostic Manual electrical system may be damaged.
for specific information about the Service Test 13. Check the amperage in the 2A wire and record
Mode. the reading. Check the voltage at the B+
7. Check the voltage at the A pin and at the B pin terminal and continue to observe this voltage
in the two pin connector on the alternator for a few seconds to see if it increases,
harness. decreases, or stays the same. Note the change
in voltage and record the voltage reading.
a. The A pin is the battery sense circuit and
should be at battery voltage. If not, check Amperage in the 2A wire =____amps.
the sense circuit (2 or equivalent) in the Voltage at the B+ terminals =____volts.
alternator harness and in the main wire
harness. The voltage at the B+ terminal should be 13 to
18 volts and the amperage in the 2A wire
should be at least as high as the rated output of
the alternator.

68

Electrical Maintenance

NOTE: An alternator can easily exceed its 2. Connect a jumper wire between the F2
rated output. An alternator MUST at least terminal on the alternator and a chassis
reach its rated output when full fielded. An ground, and note the ammeter reading.
alternator that has a defective rectifier diode
3. The ammeter reading indicates field current.
may reach 75% of its rated output with a full
The following chart shows the field current for
field.
each alternator with 12 volts applied to the
14. Stop the unit. field:
15. Use the readings obtained previously to Field Current
determine the problem by referring to the Alternator Rating @ 12 Volts
Diagnosis Chart. 37 Amp 3.5 to 4.5 Amps
NOTE: This assumes that the alternator did 65 Amp 4.0 to 5.0 Amps
not charge properly prior to the full field test.
a. No field current or a low field current
Field Current Test (Checks the field indicates an open circuit or excessive
windings, brushes and slip rings) resistance in the field circuit. Replace the
voltage regulator and brush assembly,
Press the OFF key to turn the unit off before inspect the slip rings and repeat the test. If
performing this test. the brushes are not the problem, replace
1. Attach a clamp-on ammeter to the 2A wire the rotor or the alternator.
near the B+ terminal on the alternator. b. High field current indicates a short in the
field circuit. Repair or replace the
alternator.

Diagnosis Chart
Amperage in 2A Voltage at B+ Problem/Solution
At or above rated output At or above battery voltage and Voltage regulator defective / Replace
increasing voltage regulator and brush assembly
Approximately 60% of Approximately equal to battery voltage Rectifier diode defective / Repair or replace
rated output and does not change, or rises slightly alternator
Low or no output Less than or equal to battery voltage Stator windings, field windings, brush or
and decreasing diode defective / Perform Field Current
Test to check brushes and field coil, or
replace alternator

69

Electrical Maintenance 1. Check Point for 2A Amperage 2. Position for Full Fielding Jumper Figure 67: Full Field Test 70 .

Attempting to full-field the alternator by applying battery voltage to terminal F2 will cause voltage regulator failure.Terminal 2. with integral regulators. POS—B+ Terminal 3. terminal F2 to ground. If the F4 fuse is not in Procedures place. 2 3 1 4 7 5 6 AGA219 1. • When testing alternators use accurate equipment such as a Thermo King CAUTION: Full-fielding alternators P/N 204-615 (FLUKE 23) digital multimeter with the integral regulator is and a Thermo King P/N 204-613 amp clamp accomplished by installing a jumper from or an equivalent. VOLT SENSE Terminal 7. the alternator will not charge properly. EXC Terminal 5. AC TAP Terminal Figure 68: Prestolite Terminal Locations 71 . Electrical Maintenance Alternator (Prestolite) Model 50 NOTE: The F4 fuse must be installed on the interface board on units equipped with the Charging System Diagnostic Prestolite alternator. REG—D+ Terminal 4. F2 Terminal 6. NOTE: Units manufactured with Complete the following checkout procedure CYCLE-SENTRY and alternators with integral before replacing the voltage regulator or the regulators MUST use replacement alternators alternator. NEG—B.

Worn belts and pulleys or loose belts will lower the output of the alternator. Check the voltage at the B+ terminal on the • The battery must be in good condition alternator. Check the battery voltage. Press the ON key to turn the unit on. Check the voltage at the VOLT SENSE amperage draw by the unit control terminal on the alternator. weather. If there is LOW or NO output. They must be be replaced. check the 2 circuit.Electrical Maintenance • Make sure the drive belts and pulleys of the 11. not. The minimum specific gravity should be 7. If the battery voltage is less than 12 volts. output) indicates the alternator is good but NOTE: All voltage readings should be taken the voltage regulator needs replacement. See the appropriate Diagnostic Manual can be the cause of an ammeter indicating for specific information about the Service Test discharge due to lack of initial excitation of the Mode. clean and tight. Connect a jumper wire between the F2 charging system are in good condition and are terminal and a chassis ground. Units with Tier 1 engines use 2-gauge 10. If not.235. the unless stated otherwise. Units with Tier 2 engines use 0-gauge battery 9. negative battery cables and 4-gauge positive battery cables. it must be • Check the alternator brushes. Battery voltage must be present. Battery voltage circuits. 6. installed in order for the alternator to charge properly. 2. not. alternator even after the unit has been boosted for starting. Battery voltage must be present. Press the OFF key to turn the unit off. Full alternator output (the alternators rated connected properly. Access Battery the Service Test Mode screens in the Inspect/clean the battery terminals and check the Maintenance Menu before the unit starts. field the alternator. CAUTION: Never apply battery voltage to • The battery must be well charged. Attach a clamp-on ammeter to the 2A wire Battery Cables connected to the B+ terminal on the alternator. and will occur. 8. • Properly tension the alternator belt. the battery terminal F2 or voltage regulator failure cable connections must be clean and tight. Check the voltage at the EXC terminal on the 1. 4. the chassis ground. Start the unit and run it in high speed. This will full adjusted properly before testing the alternator. However. check the EXC circuit. alternator is probably faulty. the 2A and excitation circuits must be a. • Check for excessive or unusual 5. 72 . 3. • Check the 2A circuit from the alternator to the battery. Connect a voltmeter between the B+ terminal cables to ensure reliable starting in extremely cold and a chassis ground. Check to make sure that the F4 fuse is in place not charging: on the interface board. electrolyte level during scheduled Energize the run relay in the interface board maintenance inspections. the battery must • Check battery cable connections and be charged or tested to determine if it should the alternator ground. A dead or low battery test. must be present. Add distilled water as necessary to alternator. following items are potential causes for 1. or a good b. If maintain the proper water level. and the terminals indicated. check the 2A circuit. If and must accept a charge. between the negative battery terminal. If not.

Fuse Size Function F1 1A HPCO Switch Circuit F2 15A 2AB Power F3 40A Fuel Sol Pull-In/Starter Circuit F4 None No Fuse . Wire Harness In Front Of Starter Wire Harness Routing 2. See the SR-2 Microprocessor Controller Diagnostic Manual for a complete list of the size 1 and function of the fuses. Unit Wiring Inspect the unit wiring and the wire harnesses during scheduled maintenance inspections for loose. Wire Harness Behind Starter F8 5A CAN Connector J12 Figure 69: Tier 1 Wire Harness Routing F9 5A CAN Connector J14 F10 10A 8X Power (Install fuse in upper position) F11 10A Electric Clutch (Not Used) F12 5A CAN Connector J13 F13 2A 8FC Circuit (Remote Lights) 73 . The wire harness is routed behind the starter on the Tier 1 engine. which is attached to the starter. The wire harness is attached to a harness routing protect various circuits and components. on the interface board is located inside the control box. Harness Routing Bracket The wire harness routing across the front of the Figure 70: Tier 2 Wire Harness Routing engine is different for the Tier 1 and Tier 2 engines. The bracket. Tier 2 engine. Electrical Maintenance Make sure to use the 0-gauge battery cables when replacing the battery cables for a Tier 2 engine. chaffed or broken wires to protect against unit malfunctions due to open or short circuits. located on the interface board. A number of fuses. 1.All Prestolite Alternators F5 60A Preheat Circuit (Slow Burn Fuse) F6 15A Damper and High Speed Circuits F7 2A 8FP Circuit – CAN bus 1. The wire harness is Fuses routed in front of the starter on the Tier 2 engine.All Bosch Alternators 2A 2A Fuse . 1 2 Refer to the unit Parts Manual for the correct part numbers. Do not use the 0-gauge battery cables on Tier 1 engines because the battery cables are sized to match the starter performance.

100 amps. 1 AEA693 1. F10 When fuse F10 is installed in the upper position the On/Off keys on the HMI turn the unit on and off. Check the resistance of the air intake heater with an ohmmeter between the M6 terminal on the front of the heater and the screw on the back of the heater (or the heater case). M6 Terminal Figure 72: Air Heater Figure 71: Interface Board Fuse Link SMART REEFER 2 (SR2) Microprocessor Controller The fuse link is located in the positive battery cable. or if the current draw is more than F15 The device identified as F15 is a poly switch. just before the engine is started. The resistance should be 0. Check the current draw of the heater with a clamp-on ammeter at the H1 wire near the M6 terminal on the front of the heater. The air heater is Bosch Alternator. check for a grounded 2 wire before replacing service information about the Microprocessor the fuse link. During preheat the current draw should be approximately 70 amps. 74 . These over-current devices reset automatically and are not replaceable. The heater is probably defective if the resistance When fuse F10 is installed in the lower position the is more than 0.14 ± 0. Replace this fuse link by replacing Controller and the related components. the positive battery cable. It heats the intake air to help the F4 Remove fuse F4 for Model 30 units with Australian engine start in cold weather. The fuse link protects the electrical system See the SR-2 Microprocessor Control System from a short in the 2 circuit.Electrical Maintenance Fuse Size Function Air Heater F15 P/S On/Off Relay The air heater is mounted on the open end of the F20 2A Alternator Sense intake manifold. If the fuse link burns Diagnostic Manual TK 51727 for complete out.2 ohms and the current draw is less unit will start and run without the HMI control panel.02 ohms. Install fuse F4 for Model 50 units energized by the microprocessor during preheat. with Prestolite Alternator. than 60 amps.

and 5 in the power receptacle. switch the Brown wire and the Black wire from the PSM at the 1. If the f. and Brown should be energized by a minimum of 10 Vdc. care when testing the unit. Lethal voltage potentials can exist on c. The PSM correctly. If all of the wiring is correct. and L3 CAUTION: Model 50 units use high on the heater contactor and both motor voltage ac for electric standby operation. and the unit wiring. connected respectively to terminals 3. 75 . d. Turn the electric power supply Off and check heater contactor: Black to L1. Contactor MC1 is wired to and tight. T2A. L2. Periodically inspect all contactor points for pitting or corrosion and repair or replace as necessary. T2A. Take connected respectively to terminals T1. a. phase sequence of the power supply to correspond L2. terminals T1. and L3 should be connected respectively to terminals L1. 4. and Black wire Electric Standby has been selected in the to terminal L3. Auto Phase System h. T2. across the coil. Electrical Maintenance AC Components b. Wires T1A. See the appropriate wiring Brown to L3. schematics and to Figure 73. and L3 on MC1. T2 & T8. and the two motor contactors PSM and the wire harness should be clean (MC1 and MC2). correctly. Blue. and T3A should be connected respectively to terminals T3. Operator Menu. If the electric motor now runs diagrams. T2A. and T3A should be connections in the high voltage box. and Black should be The Auto Phase system automatically adjusts the connected respectively to terminals L1. and T3A should be Test the contactor points by checking the voltage connected respectively to terminals T1. with the wiring of the electric motor. appropriate precautions and use extreme T2. 1. and T3 on the overload Test the contactor coil by checking the voltage relay. The contactor coil should be g. is energized and the system is operating. Check MC1 and MC2 to make sure that one of them is not faulty (contacts stuck closed). Contactor MC2 is j. Blue to L2. e. Wires T1 & T7. and T3 on the overload relay. that Blue wire to terminal L2. Wires T1A. The main components of the system are the phase selection i. and T3 & T9 voltage drop across a set of points is more than 15 should be connected respectively to Vac. Troubleshooting the Auto Phase System 3. Make sure that the unit is turned On. Blue. senses the phase sequence at the heater contactor and energizes the appropriate motor contactor. 2. Wires Black. Wires Brown. it is probably wired incorrectly. and T3 on MC1. and the relays If the electric motor runs backwards (unit airflow and contactors are acceptable. contactors. drop across each set of points when the contactor T2. The three wires from the PSM should be If the electric motor does not run at all: connected to the heater contactor terminals as follows: Brown wire to terminal L1. L2. Electrical Contactors T2. and that the power supply is connected and turned On. replace the contact points as a set. Wires L1. and T1 on MC2. The electric motor must be wired wired to change the phase sequence. but the electric incorrect): motor still runs backwards. The 9-pin wire connector between the module (PSM). Wires T1A. retain the phase sequence.

Check for battery voltage at the 7EB and 7EC wires at the PSM. 4. If not. the PSM is faulty. and L3. the 2AB circuit. Check the CH circuit at MC1 and MC2 for 4. Overload Relay motor contactors. 6. the 2 circuit. 3. 9. If the CH circuits and BLK wires do have continuity to CH. 3. The BLK wires must have continuity. Check the continuity of the BLK wires on the motor contactors. the contactor that has battery voltage present at 7EB (MC1) or at 7EC (MC2) is faulty. and the battery. Also make sure that the microprocessor display is 3 on and that the microprocessor is calling for Heat or Cool. the fuse link. the F2 fuse. HC—Heaters Contactor continuity. the Microprocessor On/Off switch. the run relay (K1). MC2—Motor Contactor continuity to a chassis ground. 4 5. If the CH 5. L2.Electrical Maintenance 2. check the 7E circuit. the 1 diesel/electric relay (K5). Check for battery voltage at the 7EB terminal on MC1 and at the 7EC terminal on MC2. 2 the 8 circuit. Battery voltage should be present. 76 . check the CH wires. Check for battery voltage (12 volts) at the 7EA wire to the PSM. Check the continuity of the RED wires on the 1. Battery voltage should be present on one of these wires when the correct AC voltage is present on L1. Figure 73: High Voltage Tray 8. If not. MC1—Motor Contactor circuits do not have continuity to a chassis ground. check the continuity of ARD077 the 7EB and 7EC wires. check the CH wire for continuity. Battery voltage should be present at one of these terminals. If there is no continuity to the CH circuit. PSM—Phase Selection Module 7. Check the CH wire to the PSM for continuity to the CH circuit (chassis ground). If 5 battery voltage is not present. The RED wires must have 2.

Engine Maintenance Engine Change In the second quarter of 2005 the engines in these units changed to meet EPA Tier 2 requirements. 77 . The Tier 1 engines use an in-line injection pump. The Tier 1 and Tier 2 engines share many common parts. The Tier 2 engines use a mono-plunger and distributor injection pump. The mono-plunger and distributor injection pump uses a higher injection pressure 1. The engine in the SB-210 was changed from a TK486E to a TK486V. The TK486E and TK486EH are EPA Tier 1 engines. The TK486V and TK486VH are EPA Tier 2 engines. however the following major parts are new on the Tier 2 engine: • Cylinder Head Assembly 1. In-Line Injection Pump • Injection Nozzles Figure 74: Tier 1 Engine • Injection Pump • Oil Pump • Pistons 1 • Piston Rings • Starter • Water Pump The most noticeable difference between a Tier 1 engine and a Tier 2 engine is the fuel injection pump (see the following photographs). which reduces the emissions. The higher injection pressure atomizes the fuel more Figure 75: Tier 2 Engine efficiently. Mono-Plunger and Distributor Injection Pump than the in-line injection pump. The engine in the SB-310 1 was changed from a TK486EH to a TK486VH.

78 . then tighten 1/2 turn more.Engine Maintenance EMI 3000 Engine Oil Change EMI 3000 is an extended maintenance interval The engine oil should be changed according to the package that is standard equipment on this unit. Maintenance Inspection Schedule. engine oil. See the Specifications chapter for the correct type of oil. Start the unit and check for leaks. Remove the filter. The engine oil (black with gold lettering) level should be at the FULL mark with the • API Rating CI-4 Mineral Oil (ACEA Rating dipstick turned (threaded) into the oil pan. NOTE: Units equipped with the EMI 3000 1. Engine Lubrication System The TK486 family of engines use a pressure lubrication system. Oil Filter Change The EMI package allows standard maintenance The oil filter should be changed along with the intervals to be extended to 3. Run the • New EMI 3000-Hour Dual Element Oil Filter unit. Refill the pan with 13 quarts (12. • Five Year or 12.000 Hour ELC (Extended Life Coolant). Drain the oil The EMI 3000 package consists of the following only when the engine is hot to ensure that all the key components: oil drains out. or 2 years. and install the filter.000 hours. It is important to get as much of the oil out as Assembly and Air Cleaner Element possible because most of the dirt particles are • New EMI 3000-Hour Fuel Filter (black with contained in the last few quarts of oil that drain gold lettering) out of the pan. keep unit and trailer level so all the oil can flow from the oil • New EMI 3000-Hour Cyclonic Air Cleaner pan. Use a genuine Thermo King extended whichever occurs first. package do require regular inspection in accordance with Thermo King's maintenance 2. and then recheck the oil level. with the oil filters and air cleaners previously 4. used in trailer units. Never E3 for Europe) overfill. maintenance oil filter. Apply oil to the rubber ring of the new filter recommendations. NOTE: The new EMI 3000 oil filters and new 3. Refer to the TK482 and TK486 Engine Overhaul Manual TK 50136 for a detailed description of the engine lubrication system. When changing oil. Tighten the filter until the rubber ring makes EMI 3000 air cleaners are NOT interchangeable contact.3 liters) and check the dipstick level.

and engine speed. Use the following “Low Oil Pressure Flow viscosity. a faulty oil 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 Check Oil Pressure Oil Pressure OK Oil Pressure Low Remove Oil Pump (Access the oil pump by removing the crankshaft pulley. usually be traced to the lack of oil.) Check Oil Pump Tolerances Check Oil Pressure Control Valve for Broken Spring or Sticking Piston Reinstall Oil Pump Check Oil Pressure Oil Pressure OK Oil Pressure Low Pull Engine Remove Oil Pan Check Inlet Screen and Intake Pipe Pressure Check Engine for Internal Leaks 79 . oil pump. the sound shield and the timing gear cover. or worn bearings. Low oil pressure is not normally caused by a faulty oil Oil pressure is affected by oil temperature. Engine Maintenance Low Oil Pressure pressure regulating valve. Low oil pressure can Chart” to help diagnose low oil pressure.

Retards corrosion (acid) that can attack • Texaco ELC (nitrite free) accumulator tanks. the coolant must be changed after 2 years instead of 5 years. water tubes.Engine Maintenance Engine Cooling System The engine employs a closed. • Havoline Dex-Cool (With nitrites) 4. The pump draws the coolant from the side of the radiator. A nameplate on the coolant expansion • Saturn/General Motors Dex-Cool. pressurized cooling system. If conventional coolant is added to Extended Life Coolant. of the current GREEN or BLUE-GREEN CAUTION: Do not add “GREEN” or colored coolants. NOTE: The new engine coolant. Retards rust and mineral scale that can cause ELC units for five years or 12. currently approved by Thermo King for use in 2. • Caterpillar ELC. fan and thermostat. Texaco Extended Life Coolant.000 hours: engine overheating. A thermostat mounted in the coolant outlet line from the cylinder head to the radiator automatically maintains coolant temperature within the specified temperature range. except in an emergency. • Chevron Dex-Cool 3. “BLUE-GREEN” conventional coolant to cooling systems using “RED” Extended Life Coolant. circulates it through the cylinder block and head and returns it to the radiator. Provides lubrication for the water pump seal. All water cooled engines are shipped from the factory with a 50 percent permanent type AJA1947 antifreeze concentrate and 50 percent water mixture in the engine cooling system. circulating type. • Havoline Dex-Cool (nitrite free) • Shell Dexcool ELC (Extended Life Coolant) • Shell Rotella ELC has been phased into all trailer units equipped with engines from the TK486 engine • Havoline XLC (Europe) family. tank identifies units with ELC. is RED in color instead • Detroit Diesel POWERCOOL Plus. radiators and core plugs. Correct engine temperatures are controlled and maintained by a radiator. The coolant is circulated through the system by a belt driven centrifugal pump. Prevents freezing down to -30 F (-34 C). Figure 76: ELC Nameplate Located On Expansion Tank This provides the following: The following are the Extended Life Coolants 1. 80 .

Changing the Antifreeze 1. Run clear water into the radiator and allow de-ionized or distilled water is recommended it to drain out of the block until it is clear. If using ELC concentrate. Loosen the water pump belt. Check the water antifreeze mixture in all units even if they are not pump bearing for looseness. If 100 percent full strength concentrate is used. clamp tightness. This antifreeze mixture will provide the required corrosion 6. Do not mix antifreeze stronger than 8. The factory recommends the use of a 50/50 5. exposed to freezing temperatures. and c. (whichever occurs first). Stop the unit. Open the engine block drain to drain the become worn out and must be replaced by water and flushing solution. Open the engine block drain (located behind the starter) and completely drain the coolant. Close the block drain and install a commercially available radiator and block Antifreeze Maintenance Procedure flushing agent.000 hours coolant.) -30 F (-34 C). Engine Maintenance NOTE: The use of 50/50 percent pre-mixed CAUTION: Avoid direct contact with hot Extended Life Coolant (ELC) is recommended to coolant. Change ELC (red) engine CAUTION: Avoid direct contact with hot coolant every five years or 12. gasket shows any signs of deterioration. Inspect all hoses for deterioration and hose about ELC. Inspect the radiator cap. Inhibitors c. b. 81 . over tap water to insure the integrity of the cooling system is maintained. Otherwise go to 3. mix one gallon of Checking the Antifreeze ELC concentrate and one gallon of de-ionized Check the solution concentration by using a or distilled water in a container to make a temperature compensated antifreeze hydrometer 50/50 mixture. assure that de-ionized water is being used. Observe the coolant color. If the coolant is dirty. and operate the unit in accordance with instructions of the As with all equipment containing antifreeze. temperatures. Maintain a minimum of 50 not give a true 50/50 mixture because the percent permanent type antifreeze concentrate and exact cooling system capacity may not always 50 percent water solution to provide protection to be known. (Extended Life Coolant)” for more information 4. This procedure may testing antifreeze. changing the antifreeze. Replace if necessary. 2. Run clear water into the radiator. proceed with a. (Do not add antifreeze and or a refractometer (P/N 204-754) designed for then add water to the unit. Replace the cap if the protection and lubrication for the water pump. Refill the radiator with the 50/50 antifreeze 68 percent permanent type coolant concentrate mixture and make sure to bleed the air from and 32 percent water for use in extreme the cooling system as needed. 7. flushing agent manufacturer. and allow it with ELC (red) engine coolant. periodic inspection on a regular basis is required to verify the condition of the antifreeze. b. Do not mix green or blue-green engine coolant 3. See “ELC to drain out of the block until it is clear. a. Run the engine until it is up to its normal operating temperature.

Aluminum Expansion Tank (Ending 05/2004) 9. Expansion Tank Cap 7. The high block. DO Jiggle pin thermostats are original equipment on NOT START THE ENGINE WITHOUT units that have engines from the TK486 engine BLEEDING THE AIR OUT OF THE family. has been trapped in the block. Thermostat 5. Jiggle pin thermostats make it unnecessary BLOCK. Radiator 3. If approximately half of the Cooling the high water temperature switch is designed to System Capacity (see Specifications) seems to fill protect an engine from overheating due to the cooling system after it has been drained. Water Pump 4. Loosen the plug on the back of the water pump below the thermostat cover until coolant comes out of the plug fitting. the engine may be damaged. Normally.5 qt (1. all but about 1. Radiator Cap 10.Engine Maintenance 2 4 5 1 6 7 3 10 9 8 1. 82 . Thermostat Housing Figure 77: Engine Cooling System Bleeding Air from the Cooling CAUTION: IF YOU SUSPECT THAT System AIR IS TRAPPED IN THE BLOCK. to bleed the air out of the engine block because NOTE: If an engine runs with air trapped in the they keep air from being trapped in the engine block. Bleed the air out of the block using the following procedure: 1. because drained.4 liters) of water temperature switch may not protect an coolant drain out of the cooling system when it is engine that has air trapped in the block. Plastic Expansion Tank (Starting 05/2004) 6. Coolant Level Sensor 2. Coolant Level Switch 8. air failures in the cooling system.

off-center on the filter head. necessary. all sent back to the fuel tank in the return line. The stabilizes. Check the coolant level and add coolant if fitting on the filter head to the injection pump. The fuel lines inside the unit are installed and Tier 2 engines use a mono-plunger and distributor routed at the factory. Engine Maintenance 2. Engine Fuel System Fuel Line Routing Tier 1 engines use an in-line injection pump. It bleeds off air. Start the unit on low speed heat. • Inlet strainer (prefilter) • Priming pump • Fuel transfer pump • Fuel filter/water separator • Injection pump • Injection nozzles The priming pump is used to manually draw fuel from the tank up to the fuel pump if the unit should run out of fuel. Two orifices in the filter head control goes back into the system is approximately the pressure in the fuel system by allowing a equal to the amount of coolant that came out certain amount of fuel to return to the tank. Make sure that the amount of coolant that separator. Repeat steps 5 and 6 until the coolant level pressure. orifice is located in the center of the filter head. injection nozzle overflow For the best engine operation. Engine Thermostat Injection pump leakage. Pour coolant into the system until it appears to Fuel is drawn from the fuel tank and through the be full. Do not change the factory routing of The components of the fuel system are: the fuel lines inside the unit. tank connect to the fittings on the bottom of the unit frame. Filtered fuel passes through a line from the outlet 6. See the fuel line • Fuel tank routing diagrams in the Diagrams Chapter. The injection pump forces the fuel. Tighten the plug. The fuel lines from the fuel injection pump. use a 180 F (82 C) and excess fuel from the fuel filter orifice are then thermostat year-round. One of the system. Operation 3. 83 . The fuel transfer pump delivers fuel to the fuel filter/water 4. through the injection nozzles. let it run for bleeds off water. prefilter by the fuel transfer pump. injection nozzles atomize the fuel as it is injected directly into the combustion chambers. It 5. at a very high 7. and then shut it off. The other orifice is located two minutes.

Filter Head 6. Priming Pump 4. Fuel Transfer Pump system when engine is not running.) 2. Check Valve (Keeps air from entering fuel 5. Inlet Strainer (Prefilter) 3.Engine Maintenance 2 1 3 4 5 8 7 6 1. Fuel Filter/Water Separator Figure 78: Tier 1 Engine Fuel System 84 . In-line Injection Pump 7. Bleed Screw 8.

Fuel Filter/Water Separator 4. Priming Pump 3.) 2. Fuel Transfer Pump system when engine is not running. Change the will usually not require major service repairs fuel filter/water separator regularly and clean the between engine overhauls. Therefore. prefilter on the inlet side of the fuel transfer pump. Mono-plunger and Distributor Injection Pump Figure 79: Tier 2 Engine Fuel System Maintenance Contamination is the most common cause of fuel system problems. 85 . the fuel must be clean and fuel relatively trouble-free and if properly maintained tanks must be free of contaminants. Filter Head 6. Engine Maintenance 1 2 3 4 7 5 6 1. Bleed Screw 7. to ensure best The injection pump and fuel transfer pump are operating results. Check Valve (Keeps air from entering fuel 5.

Normal conditions are considered to be the use of clean high quality fuel. 4 The following procedures can be done under field conditions: 3 1. following precautions to prevent dirt from 1. possible. The decal is located near the unit 86 . Fuel tank and filter system maintenance. The date and engine hours must be (and repaired if necessary) at 10. 2. no used oil blending. Install the end cap and clamp. Refer to the TK482 and TK486 Overhaul Manual TK 50136 for injection nozzle Figure 80: Fuel Return Line Replacement Decal testing and repair procedures. the short fuel entering the system: return lines between the injection nozzles. Larger Clamp 5. and 1. Work in a relatively clean area whenever pump. Discard the old clamps. the long fuel return line from the injection nozzle to the banjo fitting on the injection 2.000 hour entered on the decal when the fuel return lines are intervals when used in normal conditions. The necessary service equipment and facilities are not found in most engine rebuild 3 shops because of the large investment required.Engine Maintenance NOTE: The injection nozzles should be tested serial plate. Cap all fuel lines. clamps. Use the following procedure to replace the fuel Whenever the fuel system is opened. to obtain the straightest routing for the long This decal is was added to production units in return line. 3. fuel injection nozzles should be changed every 10. and a decal like the one shown below. 2 3 Any major injection pump or nozzle repairs should be done by a quality diesel injection service shop. and regular maintenance of the fuel system according to the Maintenance Inspection Schedule. Injection line replacement. end cap. 2. Priming pump (hand) replacement or repair. Long Fuel Return Lines 7. 4. Figure 81: Fuel Return Line Replacement 2. return lines. January of 2005. It may (P/N 10-368) contains new return lines. Complete the work in the shortest possible 1 time. The return line kit 4. the end cap. Smaller Clamps 8. 5 3. and fuel 9. 3 5. Injection pump timing. Remove the clamps. Fuel transfer pump replacement or repair. Engine speed adjustments. End Cap 4. Note that the end cap has a larger OD than the other hoses The fuel return lines (hoses) and end cap on the and requires the larger clamp. 1. Short Fuel Return Lines 6.000 engine operating hours. changed. take the return lines and end cap. Nozzle spray pattern testing and adjustment. Minor rebuilding of nozzles. Bleeding air from the fuel system. 3. Fuel Return Line Replacement 3. Install the fuel return lines and clamps. be necessary to adjust the banjo fitting slightly an end cap.

Bleed Screw 2. 6. If the vent becomes clogged. Loosen the injection lines at the injection nozzles. Loosen the bleed screw on the Tier 2 injection pump about one turn. Tighten the bleed screw and screw the priming pump handle back in. and this increases the tendency for air to enter the system. the air must be bled out of the fuel system. a partial vacuum develops in the tank. 87 . 5. Crank the engine until fuel appears at the nozzles. NOTE: MAKE SURE the fuel tank vent is kept open. 4. Loosen the bleed screw on the Tier 1 injection Figure 84: Tier 2 Injection Pump pump about two turns. 3. Bleeding the Fuel System If the engine runs out of fuel. Stand Pipes 4. Tighten the injection lines. Be sure all the fittings are tight and check for 1 leaks. Fuel Gauge Figure 82: Fuel Tank 2 To bleed air from the fuel system: 1. Bleed Screw 2. 6. Vent (Optional) 3. Unscrew the priming pump handle and manually prime the fuel system until air bubbles are no longer visible in the fuel coming out of the bleed screw. Drain Plug 2. or if air gets into the system for any other reason. 2. Write the date and engine hours on the decal. Anti-Siphon Screen 5. Engine Maintenance 5. repairs are made to the fuel system. Priming Pump 1 2 Figure 83: Tier 1 Injection Pump 1 5 4 AEA751 3 1. Priming Pump 1. 2 1.

Damage to the fuel system will subsequently cause more expensive 1 2 damage to the engine. Remove the ball joint from the eye bolt in the high speed solenoid. Bleed the air out of the fuel system. Drain. 2. A large accumulation of water in the bottom of the fuel tank will stop a diesel engine. Drain the water off after the fuel tank and unit have remained idle for an hour. Shut the unit off. Place a container under the fuel tank to catch the draining water and fuel. from the fuel and returns it to the fuel tank. Install the drain plug. Screw the new canister on hand-tight. tighten another 1/4 turn. Use the Service Test Mode to run the unit in Schedule. purge the air from the canister. 4. adjusting the speed: clean or replace the vent. Remove the boot from the high speed solenoid. Bleed the air out of the nozzles. Through one of the small openings in the top a few minutes. and dispose of properly. or of the canister. Check the fuel inlet strainer. 1. Clean the filter head seal surface. This will procedure. 2. Lubricate the canister seal with clean fuel. If the water and fuel do not correct engine speed. injection pump or nozzles. 2. fill the new fuel filter/water starts but stops in a few minutes. 2. Push the check valve open Figure 85: Filling Fuel Filter/Water Separator with a small screw driver to drain the tank. Check the The fuel filter/water separator removes water speed. Check the speed. 3. high speed and check the high speed rpm. Draining Water from Fuel Tank 5. Check the speed. Do not fill canister through the center hole. Using a Water run through the system may damage the strap wrench. 1. Unscrew the fuel filter/water separator 2600 ± 25 rpm for the SB-310. Let the water and fuel drain into the container until no water is visible in the fuel draining When the diesel engine fails to maintain the from the tank. Fuel Filter/Water Separator 3. canister with a strap wrench. Remove the drain plug from the bottom of the 1.Engine Maintenance 7. Do Not Fill Through Center Hole NOTE: Some fuel tanks have a check valve in the drain plug fitting. Start the engine and observe the engine run for 4. 4. 3. Fuel Filter/Water Separator Replacement High Speed Replace the fuel filter/water separator at intervals according to the Maintenance Inspection 1. the vent may be plugged. check the following before drain freely. Water should be drained off during scheduled maintenance inspections to prevent breakdowns. Fill Through Small Opening fuel tank. repeat the separator canister with clean fuel. If so. ARA160 2. 88 . It should be 2200 ± 25 rpm for the SB-210 and 1. Make the engine speed adjustments with the engine fully warmed up. If the engine fails to start. Engine Speed Adjustments 3.

or by using an electric fuel pump to supply fuel to the fuel 1 2 3 4 5 pump inlet. Speed Control Rod 5. Boot 3. 1. Replace the ball joint. When the speed is correct. Low Speed Adjustment Screw 2. Tighten the jam nut and recheck the speed. ARA112 1. High Speed Solenoid Low Speed 2. Ball Joint 4. Turn the plunger eye bolt clockwise to increase the speed and counterclockwise to decrease the speed. It should be 1450 ± 25 rpm (1720 ± 25 rpm for SB-310 units with High Injection Pump Timing Tier 1 Engine Capacity Fresh). NOTE: If the correct speed cannot be set close enough with half turns of the eye bolt. This can be accomplished by pumping the priming pump by hand. use the Allen wrench to turn the plunger in smaller increments. Ball Joint 1. Press the OFF key to turn the unit off. The index marks on either side of this hole and the timing marks on the flywheel are used to check the injection pump timing. 2. Remove the round cover (plug) from the timing mark access hole on the front of the bell housing. Loosen the jam nut on the low speed adjustment screw. Engine Maintenance 5. Use the Service Test Mode to run the unit in low speed. Boot 3. 4. High Speed Solenoid 2. start the unit and check the speed. Speed Control Rod 5. This timing procedure requires fuel pressure at the 3. 1. Low Speed Adjustment Screw Figure 86: Tier 1 Engine Speed Adjustments 89 . Pull the plunger out of the solenoid enough to loosen the jam nut. injection pump inlet. 6. An Allen wrench placed in 1 2 3 4 5 the hex opening in the face of the plunger will keep the plunger from turning. Adjust the screw to obtain the Figure 87: Tier 2 Engine Speed Adjustments correct speed. tighten the jam nut and replace the solenoid boot.

Refer to steps a.0 in. water pump end) until the 1-4 timing mark on the flywheel lines up with the index 9. Press the ON key to turn the unit on. 90 . If the rocker arms are tight. Rotate the engine backwards (counterclockwise viewed from the water pump end) until the 10 degree BTDC (before top dead center) timing mark is positioned in the bottom of the timing mark access hole. Test Mode. Disconnect the 8S wire from the starter cylinder at the flywheel end of the engine. solenoid to prevent the engine from cranking when the unit is turned On.Engine Maintenance 1 1 2 AEA701 1. If the rocker arms are loose. the number one cylinder. There are two injection timing marks. 5. Index Mark 2. lines at the injection nozzles to prevent the d. Rotate the engine in the normal direction detailed information about the Service Test of rotation (clockwise viewed from the Mode. Refer to the appropriate Microprocessor Diagnostic Manual for a. The 10 degree BTDC timing mark is a horizontal line stamped on the flywheel approximately 1. through d. Energize the fuel solenoid by energizing the mark in the timing mark access hole. the engine is at top dead center of the compression CAUTION: Loosen all of the injection stroke for the number one cylinder. run relay with the Interface Board Test Mode. 10. the engine is at possibility of the engine firing while it is top dead center of the exhaust stroke for being rotated. 7. Use the keypad to enter the Interface Board cylinder. number one cylinder. Rotate the engine 3. Timing Mark Access Hole cylinder to see if they are loose. Number One Cylinder Injection Line b. NOTE: The number one cylinder is the 6. Remove the injection line for the number one 360 degrees to place the engine at top dead cylinder from the delivery valve on the center of the compression stroke for the injection pump and from the injection nozzle. Top Dead Center Mark for 1 and 4 ARA113 2 Figure 89: Top Dead Center One and Four 1. Check the rocker arms on the number one 2. Place the engine at top dead center of the compression stroke for the number one 8. Remove the rocker arm cover. Figure 88: Component Location c. 4.

10 Degree BTDC Timing Mark align with the midpoint between the two Figure 90: Timing Mark Alignment timing marks on the flywheel. a. 3. 14. On the SB-310 the index mark should 3.2 in. Stop as soon as you see the fuel rise. 12. [2. Slowly turn the engine in the normal direction 3 of rotation until you see the fuel rise in the end of the delivery valve holder. 12 Degree BTDC Timing Mark b.The 12 degree BTDC timing mark is a horizontal 1 2 line stamped on the flywheel approximately 1. 11. Index Mark 2. Index Mark 2. 10 Degree BTDC Timing Mark Figure 91: Correct Injection Timing Mark Alignment for SB-210 1. 10 Degree BTDC Timing Mark Figure 92: Correct Injection Timing Mark Alignment for SB-310 15. Index Mark timing mark on the flywheel should be 2. 13. 16. 91 . 3 1 2 3 1. (30 mm) before the top dead center mark. loosen the mounting nuts on the studs that fasten the injection pump to the engine and rotate the injection pump to change the timing. Check position of the timing marks. 12 Degree BTDC Timing Mark aligned with the index mark on the side of the timing mark access hole.1 in. Use a clean towel to remove the fuel from the top end of the delivery valve holder. On the SB-210 the 10 degree BTDC 1. Repeat steps 10 through 14 to recheck the timing. Engine Maintenance (25 mm) before the top dead center mark. Pump the priming pump by hand a few times. 1 or energize the electric fuel pump if an electric 2 fuel is being used. If the timing is off by more than 1 degree (0.5 mm]). 12 Degree BTDC Timing Mark 3.

Push the top of the injection pump toward the engine to retard the timing. Tighten the injection pump mounting nuts and recheck the timing. b. install the rocker arm cover. 17. install the injection line for the number one cylinder. Existing Index Mark on Gear Case mark on the injection pump is usually aligned 3. It is not necessary to use this timing procedure when 2 removing and reinstalling the original injection 1 pump. Repeat steps 10 through 17 until the timing is correct. tighten the other injection lines and reconnect 1 2 the 8S wire to the starter solenoid when finished with the procedure. Index Mark on Injection Pump 2. align the index marks on the 3 injection pump and the gear case as they were before removing the injection pump.Engine Maintenance a. Index Marks Figure 93: Tier 2 Index Mark Location 92 . 18. Index Mark on Injection Pump injection pump and the gear case. Make New Mark on Gear Case If Needed with the index mark on the gear case. 1. The index 2. Clean the area with brake cleaner or 95). Place an injection angle sticker on the gear case so the center line on the sticker is aligned with the index mark on the injection pump. Pull the top of the injection pump away from the engine to advance the timing. something similar. An injection angle sticker is provided with the new injection pump. 1 1. Install the cover in the timing mark access hole. If not. Index Mark on Gear Case Injection Pump Timing Tier 2 Engine Figure 94: Tier 2 Index Mark Alignment Use this timing procedure when installing a new injection pump on a Tier 2 engine. Before removing the old injection pump. make a mark on gear case in line with the Figure 95: Marking Gear Case index mark on the injection pump (see Figure 2. note the alignment of the index marks on the 1. In that case. 1.

The injection angle mark in the following photographs is 67. Remove Nut and Lock Washer Figure 96: Place Injection Angle Sticker on Gear Case Figure 98: Removing Injection Pump Gear 4. The injection pump gear assembly is made of three pieces. Record the injection angle marked on the old injection pump (see the following photographs). Remove the old injection pump. the flange. Engine Maintenance 1 1 2 1 1 1 2 1. Index Mark on Injection Pump 1. That equals an injection angle of 6.7 Degrees Figure 97: Injection Angle Sticker 85 8. Injection Angle Sticker 2. Add a decimal point before the last digit of the injection 3 angle mark to get the injection angle. The injection angle mark is 0. NOTE: Remove the injection pump gear by removing the nut and lock washer that secure the injection pump gear assembly to the injection pump shaft.0 Degrees Mark Examples 2.5 Degrees located on the side of the pump facing the 1 engine. Center Line (0 Degrees Mark) Injection Angle Mark Injection Angle 3.7 degrees. Injection Angle Mark Figure 99: Injection Angle Mark Location 93 .5 Degrees 3. 1. the gear. Do Not Loosen or Remove These Four Bolts 2. Use the injection pump gear tool P/N 204-1011 to 1 remove the injection pump gear without removing the timing gear cover (see “Injection Pump Removal”). +1. –1. Do not loosen or remove the four bolts that fasten the gear to the flange because that changes the timing.0 Degrees Mark 67 6. The injection angle mark on the pump 2 does not use a decimal point. 1. and the transfer pump cam.

Injection Pump Index Mark at –0. Install the injection pump gear. Torque the nut to 58 to 65 ft-lb (78 to 88 N•m).6 Degrees angle. Figure 101: Injection Pump Serial Number Location 5. The injection pump serial number is located on the bottom of the sticker on the 2. 6.jp) with the 2 injection pump serial number or the engine serial number and they will provide the injection 1. make sure the timing marks on the timing gears are aligned as shown below. Injection Pump Index Mark at +1. It helps to install the idler gear last 1.7 – 6.7 Injection Pump (Degrees) = Injection Angle Difference = +1.8 Degrees injection pump.co. 1 1. Injection Angle Mark 1 Figure 100: Injection Angle Mark NOTE: If you cannot read the injection angle mark. Figure 102: Examples of Injection Pump Index Mark Alignment with Injection Angle Sticker 1 8. NOTE: If the timing gear cover was removed to remove the injection pump gear.jp and Hisashi Hamada at hisashi_hamada@yanmar.5 6. lock washer. Calculate the injection angle difference by subtracting the injection angle of the old injection pump from the injection angle of the new injection pump. and nut. Install the new injection pump on the gear case and position it so the index mark on the injection pump is aligned with the mark equal to the injection angle difference on the injection angle sticker (see the following examples).6 (Degrees) 94 . contact Yanmar (e-mail both Koichi Sawada at koichi_sawada@yanmar. Record the injection angle marked on the side of the new injection pump.1 Injection Pump (Degrees) – Injection Angle of Old – 6.8 = –0.co. Injection Pump Serial Number when aligning the timing marks. Examples Injection Angle of New 8. Tighten the injection pump mounting nuts when the index mark is aligned as necessary with the injection angle sticker.Engine Maintenance 7.

fuel pump. The inner rotor of the oil pump fits around the crankshaft gear. On the 4 Tier 1 engine. Fuel Injection Pump Gear index mark on the gear case. On the Tier 2 2. mark it so the 4. Flat Side on Crankshaft Gear Figure 104: Align Flat Sides of Crankshaft Gear with Flat Sides of Inner Rotor in Timing Gear Cover 95 . the gear must be separated from the pump. NOTE: The oil pump is located in the timing gear cover on Tier 2 engines. crankshaft pulley. it will not be necessary to remove the belts. the index mark on the injection pump is usually aligned with the center (long) 1. Idler Gear engine. Camshaft Gear is usually aligned with the single index mark on the gear case. Timing Gear Cover 6. Flat Sides on Inner Rotor 7. 1. Index Marks 6 Figure 105: Tier 1 Index Mark Location 1. See Figure 109 “Injection Pump Gear Tool” on page 97. If not. Oil Pump Cover 3. Make sure that the flat sides of the inner rotor are aligned with the flat sides on the crankshaft gear when installing the timing gear cover. Inner Rotor 5. the index mark on the injection pump 3. 1 2 5 3 4 7 1 1. Crankshaft Gear 2. Crankshaft Gear injection pump can be returned to the same Figure 103: Timing Mark Alignment position when it is reinstalled. Outer Rotor 4. crankshaft seal or front plate. Note the alignment of the index marks on the injection pump and the gear case. Using tool P/N 204-1011. Engine Maintenance 3 Injection Pump Removal 1 2 The injection pump drive gear will not fit through the gear housing when removing the pump.

Center Index Mark on Gear Case 2. NOTE: The injection pump gear assembly is made of three pieces. Attach the gear to the tool plate with the screws provided with the tool plate. Insert the adapter into the tool plate and rotate to provide a solid position to force the injection pump shaft from the gear. Caution should be made to align the screw over the center of the injection pump shaft. also supplied with the tool plate. Use a shop rag to prevent the lock washer or nut from falling into the gear case. Use the hardware from the cover plate to Figure 107: Tier 2 Index Mark Location attach the tool plate (with the marked side pointing up and out) to the gear case. Index Mark on Gear Case Figure 106: Tier 1 Index Mark Alignment Figure 108: Tier 2 Index Mark Alignment 2. Remove the cover plate from the gear case. Align the threaded holes in the injection pump gear with the two holes in the tool plate by rotating the engine crankshaft.Engine Maintenance 1 2 1 2 1. 6. Index Mark on Injection Pump 2. the flange. the gear. 3. Index Mark on Injection Pump 1. fuel lines. Remove the nut and lock washer which secure the gear to the injection pump shaft. harness and mounting hardware from the injection pump. Do not loosen or 1 remove the four bolts that fasten the gear to the flange because that changes the timing. 5. Index Marks 4. and the transfer pump cam. Thread the long screw supplied with the tool plate into the small end of the adapter. Remove the starter for clearance. 96 . 1. Remove the throttle linkage.

Tool Long Screw 3. Tool Short Screw 4. Fasten the cover plate to the gear case and and the gear case like they were in step 1 of reinstall all components removed previously “Injection Pump Removal”. Tier 1 Injection Pump 6. 1 3 4 2 5 6 9 8 7 1. or 58 to 65 ft-lb (78 to 88 N•m) on the with previously removed hardware. see the appropriate injection pump tooth alignment until the injection pump is timing procedure to set the timing. Cover Plate Bolt Figure 109: Injection Pump Gear Tool 97 . to prevent the lock washer or nut keyway in the gear. Remove the hardware holding the gear to the tool plate. to 43 to 51 ft-lb (59 to 69 N•m) on the Tier 1 2. Take care to make sure the from falling into the gear case. with the lock washer and nut. Make sure Tier 2 engine. Torque the nut key mates with the keyway. 3. Secure the gear to the injection pump shaft 1. to align the index marks on the injection pump 5. Engine Maintenance 7. This holds the gear in proper installed. Remove the screw and adapter leaving the tool NOTE: If a different injection pump is being plate in place. rotating the shaft to mate the key with the as before. then remove the tool plate. Secure the injection pump to the gear case engine. Tier 2 Injection Pump 7. Tool Plate 5. Position the injection pump shaft into the gear. Injection Pump Reinstallation 4. Cover Plate 9. re-installed. to facilitate injection pump removal. Adapter 2. Gear Case 8. Use a shop rag.

The pull-in coil must be energized to move the If you suspect that the engine does not run injection pump governor linkage to the fuel on because the fuel solenoid is not operating position. If the approximately 35 to 45 amps at 12 volts. the plunger and the linkage may not line up correctly and the fuel solenoid will not function properly. It contains two coils: the pull-in require 35 to 45 amps to turn on the fuel. their fuses. If the fuel solenoid is not operating properly. controlled by the microprocessor through the fuel solenoid pull in relay (K6). 4. it has enough power to energize the fuel 12 volts. Fuel Solenoid operation. The pull-in appropriate Microprocessor Diagnostic coil must be de-energized after a few seconds to Manual for specific information about the keep it from being damaged. Once the injection pump governor correctly. If it is not. The pull-in coil is Interface Board Test Mode. De-energize the run relay with the Interface Board Test Mode. If the relays. This energizes the fuel solenoid. 1 1. and the associated circuits.Engine Maintenance Fuel Solenoid Testing the Fuel Solenoid The fuel solenoid is located on the end of the NOTE: The fuel solenoid pull-in coil will injection pump. Energize the run relay with the Interface Board Test Mode. The battery has enough power to crank the engine hold-in coil draws approximately 0. The fuel solenoid relay is 1 momentarily energized when the run relay is energized with the Interface Board Test Mode. The coil. solenoid pull-in coil. This de-energizes the fuel solenoid. Fuel Solenoid Figure 111: Fuel Solenoid Location Tier 2 Engine 98 . 3. The fuel solenoid must be energized when it is re-installed in the Figure 110: Fuel Solenoid Location Tier 1 Engine injection pump. 5.5 amps at over. fuses and circuits are acceptable. and the hold-in coil. Refer to the until the 8D circuit is de-energized. The pull-in coil draws unit’s battery must be in good condition. which makes a definite click when energized. 2. 1. NOTE: The fuel solenoid may be removed ARA112 from the injection pump to visually check its 1. Use the microprocessor keypad to enter the the hold-in coil will keep it in fuel on position Interface Board Test Mode. the fuel solenoid pull in relay (K6). which makes a definite click when de-energized. 6. use the following procedure: linkage has been moved to the fuel on position. check the run relay (K1). Disconnect the fuel solenoid wire connector from the main wire harness. Repeat steps 2 and 3 a few times to check the operation of the fuel solenoid. use steps 6 through 9 to isolate and check the fuel solenoid.

Test the pull-in coil by momentarily placing a solenoid connector. If in the fuel solenoid connector and the positive the resistance of the hold-in coil is not in battery terminal. Engine Maintenance b. make a definite click when the pull-in coil is energized and should click again when the Fuel Solenoid Replacement pull-in coil is de-energized. the plunger and 9. NOTE: The fuel solenoid must be energized when it is installed. replace the fuel solenoid. 99 . If the hold-in coil does not function 7. Energize the hold-in coil by placing a fuel solenoid will not function properly. jumper between the red wire (8D—pin A) 6. Test the hold-in coil. Connector Pin Identification d. Connect the new fuel solenoid wire connector to the main wire harness. the white wire (8DP—pin B) for more than a few seconds. De-energize the hold-in coil by removing 2. O-ring is positioned correctly during installation to avoid damage and leaks. The fuel solenoid should this range. check the resistance of the pull-in coil by placing 3. The fuel solenoid should make a definite click when the pull-in coil is energized. replace the fuel solenoid. an ohmmeter between the white wire 4. 2. 1. b. If the resistance of the pull-in Relay Test Mode. between the red wire (8D—pin A) and the black wire (CH—pin C) in the fuel 8. If the pull-in coil does not energize. the linkage may not line up correctly and the a. The appropriate Microprocessor Diagnostic resistance of the pull-in coil should be 0. Press the ON key to turn the unit on. 1. White (8DP) the jumper from the red wire (8D—pin A) and the positive battery terminal. go to step 9.3 ohms. Red (8D) c. The fuel 3. Refer to the pin C) in the fuel solenoid connector. Black (CH) solenoid should make a definite click Figure 112: Fuel Solenoid when the hold-in coil is de-energized. Disconnect the fuel solenoid wire connector NOTE: The pull-in coil will draw 35 to 45 from the main wire harness and remove the amps so do not leave the jumper connected to old fuel solenoid. coil is not in this range. Place a jumper wire between the black wire properly.2 Manual for specific information about the to 0. Make sure that the positive battery terminal. If not. Place the O-ring in the groove in the end of in the fuel solenoid connector and the the fuel injection pump. Momentarily energize the pull-in coil by placing a jumper between the white wire (8DP—pin B) in the fuel solenoid connector and the positive battery terminal. a. Energize the fuel solenoid by energizing the run relay with the Interface Board Test Mode. check the resistance of the (CH—pin C) in the fuel solenoid connector hold-in coil by placing an ohmmeter and a good chassis ground. The resistance of the jumper between the white wire (8DP—pin B) hold-in coil should be 24 to 29 ohms. If the pull-in coil does energize. Use the microprocessor keypad to enter the (8DP—pin B) and the black wire (CH— Interface Board Test Mode. but should not click when the AEA633 pull-in coil is de-energized. 5.

The trochoid feed pump supplies fuel to the injection pump at a pressure of 65 to 87 psi (450 to 600 kPa). Remove the trochoid feed pump from the above 94 psi (650 kPa). 2. Groove in Fuel Injection Pump Figure 113: Fuel Solenoid Components 7. Install the new fuel solenoid. Place new O-rings on the new trochoid feed pump and make sure it is clean. Use the following procedure to replace the trochoid feed pump. AEA635 1. Trochoid Feed Pump Figure 114: Trochoid Feed Pump Location 100 . 2. Replace the trochoid feed pump if the engine oil is being diluted with fuel and a faulty injection nozzle or fuel transfer pump is not the cause. Allen Head Screws (Do Not Remove) shown below. 8.Clean the area on the injection pump from which the trochoid feed 2 pump was removed. 1. Some engine oil might leak out of the injection pump when the trochoid feed pump is removed. Check the outlet 1 2 1 pressure of the trochoid feed pump by removing the plug and attaching a pressure gauge to the port 1. Hex Head Screws You will have to make an adaptor to attach a Figure 115: Trochoid Feed Pump Removal pressure gauge. injection pump. NOTE: The gear on the trochoid feed pump 1 is lubricated with engine oil. Trochoid Feed Pump Outlet Pressure Port 2. The plug has M12x1.Engine Maintenance If the seal in the trochoid feed pump fails.25 threads. The trochoid feed pump does not need to be timed when it is installed. it could allow some fuel to leak into the engine oil. Fuel Solenoid the trochoid feed pump to the injection pump. A faulty injection nozzle or fuel transfer pump can also dilute the engine oil with fuel. Remove the four hex head screws that attach 1. 3. 3. O-ring Do not remove the two Allen head screws. Trochoid Feed Pump Tier 2 Engine The Tier 2 engine has a trochoid feed pump on the fuel injection pump. Press the OFF key to turn the unit off after installing the fuel solenoid. Replace the trochoid feed pump if the outlet pressure is below 59 psi (410 kPa) or 2.

then check the engine rpm on the fuel injection pump. Plunger (Extended) 1 Figure 117: Cold Start Device 1. start device because that will damage it. The plunger Gauges Menu to check the coolant is extended and the injection timing is normal at temperature and engine rpm. When the engine coolant temperatures above 41 F (5 C). Remove the banjo bolt that fastens the engine coolant fitting to the cold start device. The engine rpm should has a plunger that retracts at engine coolant be approximately 100 rpm higher than normal temperatures below 41 F (5 C) to advance the (see Specifications). Torque the hex head screws to 6 to 2. Let the engine run to warm up and use the injection pump to change the timing. Install and tighten four hex head screws that attach the trochoid feed pump to the injection 1. injection timing approximately 2 degrees. difficult to start the engine in cold weather. Engine Maintenance 1 1 1. Replace the cold start device if the engine rpm does not drop approximately 100 rpm when NOTE: Do not pull the plunger out of a cold the engine warms up. The Tier 2 engine has a cold start device located 3. Use a backup wrench on the cold start device if necessary. 2. coolant temperature must be below 32 F (0 C) to start the procedure. coolant temperature rises above 41 F (5 C). pump. The engine injection pump. 101 . (to enter the Gauges Menu) and check the coolant temperature to make sure it is below Cold Start Device Tier 2 Engine 32 F (0 C). The plunger controls the position of a piston in the 4. The cold start device in the Gauges Menu. Cold Start Device Replacement 1. Let the engine start. Drain the engine coolant. Press the GAUGES key before the engine starts 7 ft-lb (8 to 10 N•m). O-Rings Checking Cold Start Device Operation Figure 116: Trochoid Feed Pump Use the following procedure to check the 4. Check the operation of the cold start device if it is the engine rpm should drop back to normal. 5. Place the new trochoid feed pump on the operation of the cold start device. Press the ON key to turn the unit on.

Coolant Hoses to Cold Start Device O-ring in the injection pump fitting. Remove the cold start device from the injection pump fitting. Refill the engine cooling system and make sure to bleed the air from the cooling system. Piston 1. Cold Start Device 2. Injection Pump Fitting Figure 119: Remove Cold Start Device 4. Install the coolant fitting and banjo bolt on the on the injection pump fitting if necessary. 3. Use a backup wrench 6. cold start device. Torque Figure 118: Remove Engine Coolant Fitting the cold start device to 22 to 26 ft-lb (30 to 35 N•m). Install the new cold start device with a new 3. Banjo Bolt Figure 120: Clean Piston 2. 102 . Engine Coolant Fitting 5. Torque the banjo bolt to 16 to 18 ft-lb (22 to 25 N•m). 7. 1 2 1.Engine Maintenance 1 2 1 3 1. Make sure the piston inside the injection pump fitting is clean.

2. CAUTION: Loosen all of the injection lines at the injection nozzles to prevent the possibility of the engine firing while it is being rotated. Valve Adjustments and Cylinder Configurations Rear Front Flywheel End Pulley End Cylinder No. on the flywheel lines up with the index mark in the timing mark access hole. 2. through d. Place the engine at top dead center of the 1. If the rocker arms are loose. Index Mark compression stroke for the number one cylinder. the engine is at top dead center of the exhaust stroke for the number one cylinder. 1 cylinder is at TDC on compression stroke Piston in No. Rotate the engine in the normal direction of rotation (clockwise viewed from the b. Remove the round cover (plug) from the timing mark access hole on the front of the bell housing. the engine is at top dead center of the compression stroke for the number one cylinder. c. Top Dead Center Mark for 1 and 4 Figure 121: Top Dead Center One and Four a. 4 cylinder is at TDC on compression stroke 103 . d. AEA701 3. Rotate the engine 360 degrees to place the engine at top dead center of the compression stroke for the number one cylinder. Remove the rocker arm cover. Engine Maintenance Engine Valve Clearance Adjustment 1 2 1. Refer to steps a. If the rocker arms are tight. Check the rocker arms on the number one water pump end) until the 1-4 timing mark cylinder to see if they are loose. 1 2 3 4 Valve arrangement E I E I E I E I Piston in No.

Engine Maintenance 4. and tighten the 6.006 to 0. keep the crankcase pressure from getting too low. Rotate the engine one full turn (360°) in the normal direction of rotation (clockwise viewed from the water pump end). (0. The valve clearance for both rocker arm cover. and align the 1-4 timing mark on the flywheel with the 6 index mark in the timing mark access hole. Figure 123: Tier 1 Crankcase Breather 104 . the cover for the timing mark access hole. vacuum will increase as the air cleaner gets dirty and becomes more restrictive. Air Restriction Indicator 5.25 mm). and the exhaust valve for the number The crankcase breather is located on top of the three cylinder. Use a feeler gauge to check the valve Crankcase Breather Tier 1 clearance on both valves for the number one Engine cylinder. The crankcase breather system the intake valve and the exhaust valve should ducts crankcase gases formed in the crankcase be 0. NOTE: The breather hose must be routed so it slopes down from the crankcase breather to the intake manifold. This prevents condensation from collecting in the breather hose.) 9. The condensation can plug the breather hose if it collects and freezes in the hose. The tighten the locknut. Intake Manifold 10. Hold the adjustment screw in place and 279 mm) H2O of vacuum at 2200 rpm. Intake Air Heater fuel injection lines when finished. Crankcase Breather number three cylinder. Check and adjust the exhaust valve for the 2. A positioned squarely on the top of the valve restrictor is placed in the breather hose to limit the stem. Replace the valve stem cap if it shows gas flow from the crankcase to the air intake and significant wear. The crankcase breather and the breather hose should be inspected when the air cleaner element is replaced to make sure they are not plugged or damaged. Adjust the valves if necessary by loosening Normal crankcase pressures with a new air the locknut and turning the adjustment screw cleaner are 5 to 10 in. the intake valve for the number two cylinder. Replace the rocker arm cover. vacuum at 1450 rpm and 7 to 11 in. or escape to the outside. 1 2 3 AEA705 Figure 122: Adjusting the Valve Clearance 7. Recheck the valve clearance. 4. are stem cap is in good condition and is drawn back into the engine and burned. 5. (127 to 254 mm) H2O of until the valve clearance is correct. to prevent freezing. 8. and both valves for the number four cylinder. Insulation (Covers breather Hose stroke for the number four cylinder. Restrictor number two cylinder. Harmful vapors that would otherwise collect in the crankcase and NOTE: Check to make sure that the valve contaminate the oil.010 in. directly to the air intake. the intake valve for the 3.15 to 0. (178 to 6. 5 4 This is top dead center of the compression 1.

Intake Manifold 4. To prevent intake manifold pressure. Baffle Breather 3. restricting the flow to maintain a even in the presence of ring wear or a restricted constant. the PCV diaphragm expands into the with a constantly regulated crankcase pressure passageway. Baffle Plate 3. It uses a spring and PCV system. Valve Cover 6. Spring 6.6 to 6. slightly positive crankcase pressure. 3 The following items can effect the crankcase 4 pressure readings. as air cleaner restriction increased. To Breather Hose Figure 125: Tier 2 PCV System 105 . Spring 5. Diaphragm 8 Breather Hose Figure 124: Tier 2 PCV Components 1 2 6 3 5 4 Unrestricted Position Partially Restricted Fully Restricted Position 1. In the unrestricted position. to maintain vacuum and flow would increase in the breather a constant flow of crankcase gas regardless of the hose to lower the crankcase pressure. Diaphragm 4. Push Rod Passages 2. Plate 7. diaphragm. 8 Crankcase Typical Cause Pressure Effect Increase Piston Rings Stuck or Worn Decrease Air Cleaner Dirty or Plugged Increase Breather Hose Plugged with Dirt or Ice Decrease PCV Diaphragm Torn Increase PCV Diaphragm Frozen to Seat in Valve 6 5 7 1. located in the valve cover. This results in a system this. Engine Maintenance Positive Crankcase Ventilation The following schematic illustrates the PCV (PCV) Tier 2 Engine operation. Baffle Plate 2. Normal crankcase pressures with a new air 1 cleaner are approximately 1. (40 to 2 170 mm) of H2O positive pressure. Diaphragm Cover 5. air cleaner.7 in. Without a Ventilation (PCV) system. gas flow exits the crankcase via the push rod passages and The Tier 2 engine has a Positive Crankcase flows past the orifice and diaphragm.

The Tier 2 starter requires heavier battery cables (see “Battery Cables” in the Electrical Maintenance chapter). Dust Ejector Must Point Down When Installed Figure 127: EMI 3000 Air Filter Element Air Restriction Indicator Excessive restriction of the air intake system reduces the flow of air to the engine affecting horsepower output. An air restriction indicator is installed in the air intake manifold. AEA710 Figure 128: Air Restriction Indicator Starters The Tier 1 and Tier 2 engines use different starters. Visually inspect the restriction indicator periodically to assure the air filter is not 106 . The Tier 2 starter does fit on the Tier 1 engine. whichever occurs first. Replace the EMI indicator after servicing the air filter.Engine Maintenance EMI 3000 Air Cleaner restricted. however it can be retrofit on previous units by using the EMI 3000 Air Cleaner Assembly. of vacuum. 1 ARA190 1. fuel consumption and engine Figure 129: Tier 1 Starter life. Press the The EMI 3000 air cleaner is a dry element air reset button on the bottom of the restriction cleaner used in late model units. Identify the starters by looking at the Figure 126: EMI 3000 Air Cleaner Assembly through bolts. of vacuum. 3000 air cleaner element when the air restriction indicator reads 25 in. The EMI 3000 air cleaner element has a nameplate that reads “EMI 3000.000 hours or 2 years.” It cannot be interchanged with air filters used on previous Thermo King trailer units. Service the air filter when the yellow diaphragm indicates 25 in. or at 3. The Tier 1 starter does not fit on the Tier 2 engine because it is too long. The Tier 2 starter has external through bolts. but the Tier 1 starter does not. The Tier 2 engine has a more powerful ARA189 starter to ensure reliable starting in extremely cold weather. Do not try to put a Tier 1 starter on a Tier 2 engine.

not in a notch. 1. Using belt tension gauge. When the unit is turned on. Make sure the hook is on the face of the belt. External Through Bolt Figure 130: Tier 2 Starter NOTE: Do not attempt to remove or install belts without loosening adjustments. it can start at any time without warning. P/N 204-427. Belts that are too loose will whip and belts that are too tight put too much strain on the belt fibers and bearings. Install the belt gauge in the center of the longest belt span. CAUTION: Turn the unit off before performing maintenance or repair procedures. Use an average of three readings. 107 . Press the plunger so the hook will engage the belt. Then read the dial. Belt tension should also be checked during scheduled maintenance inspections. CAUTION: Do not attempt to adjust belts with the unit running. scuffing or cracking. is the best method of checking belts for tightness. Belts that are installed by prying over pulleys will fail prematurely due to internal cord damage. Engine Maintenance Belts Belts should be regularly inspected during unit pre-trip inspections for wear. Release the plunger with a quick 1 motion and without pulling on the belt.

to adjust the belt to 61 on the belt tension 1. Alternator Belt 6. The alternator belt tension should read 61 on the NOTE: Both the upper and lower fan belts are belt gauge. Idler Adjusting Arm 5. Condenser Fan 10. 3. Condenser Fan Pulley 9. Engine Pulley 3. replace adjusting arm bolt. Idler Assembly Pivot Bolt 12. adjusted at the same time in one procedure.Engine Maintenance 2 3 4 1 13 5 6 7 12 8 9 11 9 10 1. 1. Upper Fan Belt 8. Move the alternator on the adjusting arm slots procedure). Loosen the idler assembly pivot bolts and the gauge. 108 . Tighten the adjusting arm bolt and alternator pivot bolt. Belt Guide Figure 131: Model 30 Belt Arrangement Model 30 Belt Adjustments Upper and Lower Fan Belt Adjustment The upper fan belt should read 74 and the lower Alternator Belt Adjustment fan belt should read 67 on the belt tension gauge. the belt (see Fan Belt Removal and Installation 2. Idler Adjusting Arm Bolt 4. idler adjusting arm bolts. Condenser Inlet Ring 11. Lower Fan Belt 2. Idler Assembly 13 Idler Adjusting Arm Pivot Bolt 7. Loosen the alternator pivot bolt and the NOTE: If a fan belt is loose or damaged.

Tap the blower wheel with a soft hammer to and the support bracket slots. Pull the idler adjusting arm back OUT and inlet ring lines up with the alignment mark on adjust the belts to the proper tension. idler mounting bracket. The upper both idler assembly pivot bolts. clearance between the blower wheel and 2. 3. Engine Maintenance 2. Tighten the idler assembly pivot bolts and the 4. 5. Loosen the idler adjusting arm bolts and 5. loosen the upper idler support bracket mounting bolts to free up the 4. Slip the belt over the condenser blower wheel 1. Loosen both idler adjusting arm bolts and both wheel back to provide 1/2 in. 2. Check the radial clearance between the blower idler adjusting arm bolts. Slip the belt onto the pulley groove on the hammer. Push the idler adjusting arm in and the idler to “center” the idler assembly between the assembly up. Check the main idler retainer nut clamping bolts. Loosen the two condenser fan hub to the shaft assembly. Check around the entire circumference to the inlet Upper Fan Belt ring and blower wheel (see “Condenser and Evaporator Fan Location” in the Structural Removal Maintenance chapter). diameter bolt Lower Fan Belt into the end of the fan shaft. for belt adjustment. 3. remove that are installed by prying over pulleys will fail the small access panel located on the prematurely due to internal cord damage. Torque the blower hub clamping bolts to remove the lower fan belt (see Lower Fan Belt 18 ft-lb (24 N•m). Push the idler adjusting arm IN. belt will come off the engine pulley. engine. The lower fan condenser fan inlet ring. Slip the belt into the groove of the idler pulley. 109 . wheel and inlet ring with a gauge wire. 1. the condenser fan inlet ring using a soft 3. assembly for proper alignment between the nut 5. Pull the idler adjusting arm OUT. NOTE: Do not attempt to remove or install the NOTE: If the condenser fan does not slide belts without loosening the adjustments. Move the 6. and place it in the condenser fan pulley. the blower wheel. Push in or pull out on the idler adjusting arm 2. Removal). Push the idler adjusting arm back in toward 2. Drive the blower 1. condenser coil header above the expansion tank. Position the blower wheel so the edge of the 4. (13 mm) idler assembly pivot bolts. Belts on the fan shaft with light tapping. Drive the condenser blower wheel out toward the unit. Lift the belt up over the condenser blower arm OUT far enough to clear the roadside wheel and remove it from the unit. Thread a 1/4-20 x 1 in. Tighten both idler adjusting arm bolts and 3. fan belt should slip off the idler pulley as the idler pulley hub clears the curbside idler NOTE: If the idler assembly binds when moving mounting bracket. Tighten the bolt Removal and washer down on the condenser fan hub to loosen the blower wheel. 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. drive the blower wheel up the fan shaft to provide 1/2 in. groove. (13 mm) clearance between the Model 30 Fan Belt Replacement blower wheel and the inlet ring. Installation Installation 1.

With the proper belt tension adjustment. 4 Water Pump Belt Adjustment The water pump belt tension should be 35 on the belt tension gauge. Alternator Belt Adjustment 1. Remove the bolts from the water pump pulley. Move the hex nuts on the compression spring adjustment screw to adjust the belt tension to 79 on the belt tension gauge. Loosen the back-up hex nut on the belt 8. 110 . adjusting arm bolt. Loosen the alternator pivot bolt and the 3. 1. slip the belt into the idler pulley groove. 4. 1 2 2. Move the idler pulley assembly to adjust the belt tension gauge. Edge of Inlet Ring Figure 132: Condenser Blower Alignment Fan Belt Adjustment Model 50 Belt Adjustments The fan belt tension should read 74 on the belt tension gauge. Tighten the adjusting arm bolt and alternator pivot bolt. Alignment Mark 5. 1. 2. belt tension to 74 on the belt tension gauge. AEA749 3. screw.Engine Maintenance 6. Loosen the idler pulley mounting bolts. Inlet Ring pulley. Tighten the mounting belts on the water pump 2. 1. Push inward on the idler adjusting arm and belt tension gauge. 2. The alternator belt tension should read 29 on the 2. tighten the back-up hex nut to the adjustment hex nut on the compression spring adjustment screw. Blower Wheel 4. Pull the idler adjusting arm forward and install tensioner compression spring adjustment the lower fan belt. The belt tension should read 35 on the belt tension gauge. 1. Remove the pulley sliding section and add or remove shims to adjust the belt tension. Move the alternator on the adjusting arm slot to adjust the belt to 29 on the belt tension gauge. Tighten the idler pulley mounting bolt. The compressor drive belts should read 79 on the 7. 3. 3 3. 3. Reinstall the belt on the pulley and replace the sliding pulley section on the pulley. Seat the upper belt in the blower wheel pulley Compressor Belt Adjustment groove.

Place the compressor in position and install 1. Condenser Inlet Ring 9. Condenser Fan 8. 5. Tighten the back-up hex nut on the belt 3. Electric Motor 2. 4. Engine Maintenance 1 2 3 12 11 4 5 10 7 9 6 8 AGA223 1. Water Pump Belt 12. adjustment screw to relieve belt tension. Fan Belt 11. Loosen the back-up hex on the belt tensioner the mounting bolts. 3. Removal 2. Move the hex nuts on the compression spring tension compression spring adjustment screw. Support the compressor and unbolt the adjustment to tighten the belts to 79 on the compressor form the flywheel housing (leave belt tension gauge. Adjust the hex nuts on the compression spring 2. Idler Pulley 10. 4. the refrigeration lines connected). Belt Tension Adjustment Idler 5. Install the belts on the clutch pulley through the gap between the clutch and the flywheel. Alternator Figure 133: Model 50 Belt Arrangement Model 50 Compressor Belt Installation Replacement 1. Swing the compressor assembly away from the flywheel housing. Remove the belts through the gap between the clutch and the flywheel. compression spring adjustment screw. Compressor Belts 4. Alternator Belt 6. Condenser Fan Pulley 7. Compressor Pulley 3. 111 .

5. 4. remove the small access panel located on the condenser coil header above the expansion tank. Loosen the idler pulley mounting bolts. Loosen the two condenser fan hub to the shaft 9. 1. 2. 3. Torque the blower hub clamping bolts to prematurely due to internal cord damage. (13 mm) clearance between the blower wheel and condenser fan inlet ring. Tap the blower wheel with a soft hammer to drive the blower wheel up the fan shaft to provide 1/2 in. Lift the belt up over the condenser blower wheel and remove it from the unit. Check around the entire circumference to the inlet 112 . Drive the blower wheel back to provide 1/2 in. (18 ft-lb) 24 N•m. Seat the upper belt in the blower wheel pulley Removal groove. enough slack to remove the belt from the idler 8. See Figure 132 “Condenser Blower Alignment” on page 110. Place the belt in the idler and electric motor 2. 6. Tighten the bolt and washer down on the condenser fan hub to loosen the blower wheel.Engine Maintenance Model 50 Fan Belt Replacement ring and blower wheel (see “Condenser and Evaporator Fan Location” in the Structural NOTE: Do not attempt to remove or install the Maintenance chapter). Thread a 1/4-20 x 1 in. Slip the belt over the condenser blower wheel and place it in the condenser fan pulley. Move the idler pulley assembly to adjust the and the electric motor. NOTE: If the condenser fan does not slide on the fan shaft with light tapping. diameter bolt into the end of the fan shaft. Installation 1. Position the blower wheel so the edge of the inlet ring lines up with the alignment mark on the blower wheel. 4. 3. belt tension to 74 on the belt tension gauge. Move the idler pulley assembly to obtain pulleys. belts without loosening the adjustments. clamping bolts. Drive the condenser blower wheel out toward the condenser fan inlet ring using a soft hammer. Tighten the idler pulley mounting bolt. 7. (13 mm) clearance between the blower wheel and the inlet ring. Belts that are installed by prying over pulleys will fail 5. Check the radial clearance between the blower wheel and inlet ring with a gauge wire.

or damage. 1. Friction Shoe Mounting Bolt 5. Loosen the back-up hex nut and move the hex nuts on the compression spring adjustment 5. To to the clutch. Engine Maintenance Clutch (Model 50) NOTE: The refrigeration lines may be removed from the compressor to allow more Periodically inspect the clutch for worn bearings. 11 10 9 8 7 AGA338 6 5 4 3 2 1 1. Special Washer 8. Pulley 6. press the pulley out access to the clutch. Remove the clutch with a clutch puller. of the bearing. Spring 2. Mounting Bolt Plate 4. Clutch Mounting Bolt 7. Hub Figure 134: Clutch 113 . Remove the compressor from the bell housing crankshaft for wear. and turn the compressor to provide better 8. Snap Ring 9. 6. Remove the key from the compressor compressor from the bell housing studs. Bearing 10. Support the compressor and unbolt the 7. 2. To disassemble the clutch. Friction Shoe 3. belts. crankshaft and inspect the key and the 3. Remove the clutch mounting bolt and special screw to relieve the tension on the compressor washer. burrs. movement of the compressor for better access worn friction shoes and for broken springs. Lock Nut 11. Remove the compressor belts. inspect the clutch: 4.

Remove the compressor. press the pulley into 1. Remove the springs from the friction shoes. 2 b. Torque the lock nuts to 30 to 35 ft-lb (41 to 47 N•m). Elastomer the bearing. Remove the snap ring and press the bearing out of the hub. Loosen the compressor drive belt(s). It is when the clutch is installed.Engine Maintenance 9. Place the clutch on the compressor crankshaft. 10. Remove the lock nuts from the friction 2 shoe mounting bolts. To replace the bearing: a. Torque the clutch mounting “Dowel Pin Replacement” on page 116. Replace the springs if they are worn or with 8-pin clutches. Attach the new friction shoes to the hub with the mounting bolt plate. 18. The design of the new style drive bushing requires 15. heat-treated dowel pin. Use a soft hammer to tap the friction shoe mounting bolts out of the hub and remove 1. To assemble the clutch. 1. Bonded Drive Bushing bolts. (1. 1 11. See mounting bolt. Outer Steel Sleeve 13. 16. 114 . 2. Figure 136: Old Style Drive Bushing align the keyways (use Keyway Tool 204-972). should be used to replace the old style drive CAUTION: Do not place the key on the bushings and dowel pins. Press the new bearing into the hub and install the snap ring. b. 17. a. bonded drive bushing was introduced in July 2004 in model 50 trailer units b. bolt to 90 ft-lb (122 N•m).4 mm).6 to 2. broken. compressor away from the bell housing and turn the compressor to access the clutch. imperative the old style dowel pins are replaced 14. c. 2. Readjust the compressor drive belts. A new style. Install and tighten the flatwashers. that the following procedure be used to replace the drive bushings. Install the special washer and the clutch with the new heat-treated dowel pins. To replace the friction shoes: 1 a. the clutch because the key might be NOTE: The new bushing must be mated with a pushed out of place behind the clutch newly designed. and the lock nuts. Replace the friction shoes if the linings are worn to a thickness of less than 1/16 to Drive Bushing Replacement 3/32 in. Elastomer them from the friction shoes. and insert the key to be flush with The new style drive bushings and dowel pins the end of the crankshaft. or pull the lockwashers and nuts on the studs. 12. Use 8-Pin and Bushing compressor crankshaft before installing Replacement Kit 70-208. Inner Fiber Sleeve d. Inspect the friction shoes and springs. Reinstall the compressor on the bell housing studs. Reinstall the compressor drive belts. 2. the mounting Figure 135: New Style.

mounting bolts out of the hub. hub/coupling about 1/8 in. exceeding the time limit. installed within 2 minutes of when the adhesive was applied. Engine Maintenance Support the compressor so it is not hanging NOTE: The Loctite adhesive has a working from the vibrasorbers if you are not removing time of 2 minutes so the bushing must be it. 10. Remove the lock nuts from the friction is applied all over the bushing before it is shoe mounting bolts. 2 1 1. “Start fit” the bushing in the clutch slightly if the pressure is released too soon. Remove the clutch mounting bolt and special install the bushings one at a time to avoid washer. and remove the mounting bolts and the friction shoes. (3 mm) to make sure it fits in the hole and does not hang up on NOTE: Let the Loctite adhesive cure for at something. Use the straight pin end of the Clutch Bushing the new bushing into the hub (from side of the Removal/Installation Tool 204-1116 to press hub that faces the flywheel) until the cup the old bushings out of the clutch hub (see contacts the hub (see Figure 138). the compressive force stored in the rubber will cause it to slip out 8. The adhesive will 5. “Start fit” the bushing in the side least 1 hour at 70 F (21 C) before running of the hub/coupling that faces the flywheel. otherwise. Hold the Figure 137). a. Put a thick ring of Loctite adhesive 203-535 the bearing. the adhesive will begin to cure before the bushing can be pressed c. squeegee up the entire length of bushing as it is pressed into the hole. The components can be reassembled immediately. started in the hole. Remove the clutch pulley by pressing it out of 9. It is not necessary to remove the around the bottom of the new bushing before bearing to replace the drive bushings. Remove the springs from the friction shoes. Straight Pin End 2. Clean the holes from which the bushings were seconds to allow the adhesive time to set removed. the unit. pressing it into place. Cupped End Figure 137: Press Old Bushings Out Of Hub With Tool 204-1116 115 . 4. Apply the adhesive and 3. WARNING: If a thin coating of adhesive b. and remove the clutch. Use the cupped end of the Clutch Bushing Removal/Installation Tool 204-1116 to press 6. tool against the hub/coupling for 10 to 15 7. sufficiently. Remove the friction shoes. Use a soft hammer to tap the friction shoe completely into place.

Use the Manual Pin Tool 204-1117 or the the clutch because the key might be Impact Pin Tool 204-1118 to press or drive the pushed out of place behind the clutch new dowel pins into the flywheel.Engine Maintenance 1 2 1. 22. 17. on the outside of the dowel pins or on the and friction shoe mounting bolts. hardened (black) dowel pins. replace the dowel pins in the flywheel with new. Inspect the clutch components before 20. Press the clutch pulley into the bearing. 21. Adjust the compressor drive belts. If the clutch had old style drive bushings. 15. inside of the drive bushings. Install the compressor on the bell housing reassembling the clutch and replace them if studs. Install the friction shoes. 16. CAUTION: Do not place the key on the compressor crankshaft before installing 3. (29. Clean Holes 2. Lubricant between the dowel pins and drive bushings 13. Place the clutch on the compressor crankshaft. Install and tighten the flatwashers. Cupped End Figure 138: Press New Bushing Into Hub With Tool 204-1116 11. The end of when the clutch is installed. Remove the flywheel. Press the old dowel pins out of the flywheel. 116 . NOTE: Do not place any kind of lubricant 12. Install the springs on the friction shoes. 2. the end of the crankshaft. 14. and insert the key to be flush with 1. lockwashers. mounting bolts to 35 ft-lb (47 N•m). 19. 18. align the keyways (use Keyway Tool Dowel Pin Replacement 204-972). Torque the lock nuts on the friction shoe will cause premature wear.15 in. See “Dowel Pin Replacement” on page 116. mounting bolt plate. each dowel pin should be 1. Install the compressor drive belts. Install the special washer and the clutch mounting bolt.2 mm) from the outer face of the flywheel. necessary. Torque the clutch mounting bolt to 90 ft-lb (122 N•m). and nuts on the studs.

Install the compressor and adjust the drive belts.15 in. Drive Dowel Pin In Until Tool 204-1118 Hits Flywheel 2. (29. Engine Maintenance 5. Install the flywheel mounting bolts. Torque 1 2 the flywheel mounting bolts to 65 ft-lb (88 N•m). Outer Face Of Flywheel Figure 140: Driving New Dowel Pin Into Flywheel With Impact Pin Tool 204-1118 4. Press Dowel Pin In Until Flush With Tool 204-1117 2. Dowel Pin 3. 1. Outer Face Of Flywheel Figure 139: Pressing New Dowel Pin Into Flywheel Using Manual Pin Tool 204-1117 2 3 1 1. Dowel Pin 3.2 mm) 6. Install the flywheel and align it with the dowel pin in the end of the crankshaft. 3 1. 117 .

Engine Maintenance 118 .

Testing for an Overcharge 3. and refrigerant is not visible in the receiver tank in some cases. can be raised by covering the roadside the evaporator will be “starved” and the box condenser grille with a piece of cardboard to temperatures will rise even though the unit is block condenser air flow. operating. it If the unit has an insufficient charge of refrigerant. the unit is low on refrigerant. If service procedures are regulated by Federal. Refer to the appropriate Refrigerant Charge Diagnostic Manual for specific information about the Service Test Mode. 4. Under these conditions. Run the unit on high speed cool until the air in Diagnostic Manual for specific information the box is at 0 F (-18 C). In the USA all regulated refrigeration service Testing the Refrigerant Charge with procedures must be performed by an EPA a Loaded Trailer certified technician. Use the Service Test Mode to run the unit in high speed cool. Check suction pressure. refrigerant should be tank sight glasses with the following conditions visible in the receiver tank sight glass. Refer to the appropriate King unit with an excessive refrigerant charge: Diagnostic Manual for specific information about the Service Test Mode. sight glass. Place a test box over the evaporator. sight glass. Use the microprocessor thermometer to monitor the return air temperature. laws. 2. refrigerant should be servicing the refrigeration system. Testing The Refrigerant Charge With 3. The discharge pressure should be at least 275 4. By allowing the box about the Service Test Mode. State and Local 1. 2. The charge may be determined by psi (90 to 165 kPa). the unit is low on refrigerant. using approved equipment and complying with all Federal. you will be able to maintain 0 F (-18 C). The suction pressure should be 13 to 18 psi reduce the box temperature to approximately (90 to 124 kPa). Some of these visible in the receiver tank sight glass. If the pressure is below this. the unit may not cool properly and the suction and discharge pressure 5. Install a calibrated gauge manifold on the compressor. Install a gauge manifold.Refrigeration Maintenance NOTE: The following procedures involve 8. 7. 119 . Build up and maintain 275 psi (1896 kPa) of An Empty Trailer head pressure. Cool the compartment to the lowest refrigerant charge decreases. Use the Service Test Mode to run the unit in Use the following procedure to identify a Thermo high speed cool. 3. to leak a small amount. block condenser airflow. Observe discharge pressure and cover the psi (1896 kPa). overcharge of refrigerant. Under these conditions. it condenser to increase the discharge pressure can be raised by covering a portion of the approximately 75 to 100 psi (500 to 690 kPa) condenser grille with a piece of cardboard to above observed pressure. by State and Local laws. inspection of the refrigerant through the receiver 6. 60 F (16 C) or colder. 2. If the unit has an temperature required. Install a gauge manifold. The suction pressure will drop as the 4. Operate the unit in high speed cool long enough to stabilize system pressures and 6. If the pressure is below this. It should be 13 to 25 may be high. If established: refrigerant is not visible in the receiver tank 1. Use the Service Test Mode to run the unit in high speed cool. Refer to the appropriate 5. 1.

the unit is not tank when the liquid level approaches the overcharged and it is not necessary to top of the receiver sight glass. indicating sight glass. Remove the condenser cover to rapidly reduce discharge pressure. 2 2. d. Operate the unit in high speed cool. valve. Moisture Indicating Sight Glass 6. complete the procedure. Floating Ball 3. the liquid level will rise. ring until the system has been recharged and then operated for at least 15 minutes. Observe the receiver tank sight glass and the The receiver tank is equipped with a moisture unit discharge pressure. 5. the unit • Chartreuse = Caution most likely has an overcharge of • Yellow = Wet refrigerant. Mid seat the compressor suction service moisture content of the system has been changed. Connect a refrigerant tank to the gauge manifold service line and purge the line. The refrigerant level should be adjusted. 1 To adjust the refrigerant level: 1. Inspect for signs of oil leakage. approximately 50 psi (345 kPa). g. When the discharge pressure stabilizes. Repeat the overcharge test. A system has to run for at least 15 minutes to change the color of the indicator ring after the b. moisture content of the refrigerant. Close the hand valve on the refrigerant glass drops during step 4. Observe the suction pressure and slowly Refrigerant Leaks open the gauge manifold low pressure hand valve to allow liquid refrigerant to Use a reliable leak detector that is suitable for flow into the compressor suction service R-404A to leak test the refrigeration system. Set the refrigerant tank for liquid removal moisture will not change the color of the indicator and open the hand valve.5 mm) thick. 120 . the liquid (2. 1. Colored Ring follows: Figure 141: Moisture Indicating Sight Glass a. • Green = Dry b. which is the first sign of a leak in the refrigeration system. If the liquid level will not drop. 4. Control the liquid flow so the suction pressure increases approximately 20 psi NOTE: It is normal for compressor shaft seals to (138 kPa). Stop the unit and remove some refrigerant with an approved refrigerant recovery device. Perform a refrigerant level check and repeat AEA672 the overcharge test. The color of the ring indicates the level in the receiver tank should drop. but it is not completely reliable. If the liquid level is low.Refrigeration Maintenance NOTE: If the liquid level in the receiver sight h.1 in. The outer edge of the sight 7. evacuating a system to remove the c. add refrigerant as 2. have a slightly oily film. Maintain a discharge pressure of at least 275 psi (1896 kPa) while adding refrigerant. For example. f. valve. e. By the time the discharge pressure drops glass has a colored ring approximately 0. a.

The oil should be 1/4 to 1/2 up in the sight glass. High Pressure Cutout Switch (HPCO) The HPCO is located on the compressor discharge manifold. observe the oil level. 1. 552X3 Figure 143: High Pressure Cutout Manifold 121 . NOTE: Use refrigeration compressor oil ONLY. components in the refrigeration system have been Reattach the oil filter return line to the removed for service or replacement. Operate the unit on cool with a 20 psi (138 kPa) minimum suction pressure and a 185 psi (1275 kPa) minimum discharge pressure for 15 minutes or more. To check compressor oil level with an ambient air temperature above 50 F (10 C): Install a gauge manifold on the compressor. rework a gauge manifold as shown in Figure 143 “High Pressure Cutout Manifold” and use the following procedure. O-Ring (33-1015) R-404A. Evacuate the compressor before opening the service valves. Sight Glass black jacketed thick wall #HCA 144 hose with Figure 142: Checking Compressor Oil a 900 psig (6204 kPa) working pressure rating. To check compressor oil level with an ambient air temperature below 50 F (10 C): Run the unit through a complete defrost cycle. After the unit has maintained the above conditions for 15 minutes. ARA115 1. Relief Valve (66-6543) Polyol Ester P/N 203-513 is required for 2. run the unit on cool for ten minutes. Connect the gauge manifold to the compressor discharge service valve with a heavy duty. To test the HPCO. If the box is empty. compressor. The compressor oil should be checked when there Disconnect the compressor oil filter return line is evidence of oil loss (oil leaks) or when from the top of the compressor and add the oil. Adapter Tee Weather Head No. The oil should be 1/4 to 1/2 up in the sight glass. If the discharge pressure rises above 1 470 psig (3241 kPa). 1. you can run the unit on the heat cycle instead of the defrost cycle. 3. Observe the oil level. the HPCO opens the HPCO circuit to the run relay and stops the unit. Refrigeration Maintenance Checking Compressor Oil To add compressor oil pump down the compressor and equalize the pressure to slightly positive. After completing the defrost cycle.

shut the unit off immediately. gently turn the check compressor first by blocking the condenser valve stem in until the valve is front seated. the three-way valve The low side gauge will raise slightly. Three-Way Valve Condenser Pressure Bypass Check Valve A three-way valve condenser pressure bypass check valve is used in this unit. The gauges will equalize. Check Valve higher than the condenser pressure. If this does not raise compressor. the check valve opens and the condenser Pressure Bypass Check Valve pressure is bled off until it drops to the level of the discharge pressure. finally shifts to cool when the temperature rise 7.Refrigeration Maintenance 2. The check valve is closed when the unit is running on cool. This check valve controls the bypass flow of refrigerant gas between the condenser inlet line and the compressor discharge line. increase the engine speed by 4. or whenever the discharge pressure is 1. if the 3. shifting from heat to cool. Cooling Position condenser pressure is higher than the discharge Figure 144: Three-way Valve Condenser pressure. puts the unit into high speed. Close (front seat) the receiver tank outlet overriding the throttle solenoid. 6. Operate the unit on cool and pump down the improve the three-way valve response time when low side to 20 in. Heating/Defrost Position When the unit is running on defrost or heat. See “End Cap high side gauge will drop to approximately Checks” in the Refrigeration Service Operations zero. This should valve. If the HPCO does not open to de-energize the run relay and stop the unit. 3. Chapter. The end cap should be checked. Stop the unit. Raise the discharge pressure of the 2. it must be replaced. coil air flow by covering the condenser grille 3. To check the operation of the condenser pressure bypass check valve: 122 . The purpose of the valve is to 5. Do not allow the discharge pressure to exceed 477 psig (3289 kPa). Use the Service Test Mode to run the unit in 1. the discharge pressure to the cutout level of the HPCO. The condenser and suction If a three-way valve does not shift back to cool pressures should remain stable. increase the discharge pressure enough to cause the HPCO to cut out. indicating no immediately after the pilot solenoid closes. Install a gauge manifold set on the with a piece of cardboard. and leaks. Using a screwdriver. valve cap from the three-way valve. Remove the condenser pressure bypass check high speed cool. 4. Shift the three-way valve to the heat position. 2. Hg (-68 kPa) of vacuum. CAUTION: If the discharge pressure reaches 477 psig (3289 kPa).

remove the gauges and return the unit to 2 normal operation. 4 3 The Electronic Throttling Valve (ETV) is a variable position valve operated by a stepper ARD078 motor. The gauges will remain in this position. Replace the cap on the condenser pressure bypass check valve. The valve position seals properly toward the condenser and the should be 0 at the start of the test when the valve condenser pressure bypass check valve seals is fully closed. See “Electronic Throttling Valve” in the Refrigeration Service Operations chapter of this NOTE: Valve stem MUST be back seated manual for removal and installation procedures. 9. should rise indicating the condenser pressure bypass check valve is properly releasing Refer to the SR-2 Microprocessor Control System condenser pressure into the discharge tube and Diagnostic Manual TK 51727 for complete evaporator. The ETV test can also be performed using the Service Test Mode. 10. 11. 123 . It is standard on the SB-210 50 and SB-310 30. and should go to a higher value properly. below 10 F (-12 C). a Refer to the SR-2 Microprocessor Control System frozen expansion valve. Open the receiver tank return outlet valve. 3. The Figure 145: Electronic Throttling Valve valve position can be monitored with the GAUGES key. and a hot gas bypass valve. during normal unit operation. information about the testing and operation of the ETV. Valve Body The ETV has two internal coils. These pressures can be the refrigeration system pressures did not respond monitored with the GAUGES key. Both gauges opened. if the three-way valve ETV during the ETV test. The suction pressure should decrease while the valve is fully closed. Zero (0) indicates the valve is fully Pressure Transducers closed and 800 indicates the valve is fully open. The microprocessor ignores the test results if information about the testing and operation of the the box temperature or the ambient temperature is pressure transducers. The ETV is located in the suction line between the evaporator and the heat exchanger. system problem such as low refrigerant level. 1 Electronic Throttling Valve (ETV) The Electronic Throttling Valve (ETV) is optional on the SB-210 30. Refrigeration Maintenance 8. Outlet The ETV system also uses discharge and suction 2. 1. This may be caused by readings by comparing them to the readings on a a malfunction of the ETV or by a refrigeration gauge manifold set attached to the compressor. Stepper Motor pressure transducers. The 4. Inlet microprocessor operates the valve by energizing the coils with a variable frequency ac signal. when the valve is opened. Alarm Code 89 indicates to the microprocessor. or a restriction in suction Diagnostic Manual TK 51727 for more line. Check the as expected during the test. Back seat condenser pressure bypass check and should begin to increase when the valve is valve stem against the snap ring. Use the GAUGES key to check the operation of the approximately zero. The discharge pressure transducer and the suction The microprocessor tests the ETV if required pressure transducer supply pressure information when the unit is started.

124 . See the Refrigeration Service Operations chapter of this manual for removal and installation procedures. The hot gas solenoid is energized (opened) at full modulation. Refer to the SR-2 Microprocessor Control System Diagnostic Manual TK 51727 for information about testing the hot gas solenoid. This normally closed solenoid valve is located in the refrigeration line that connects the discharge line to the hot gas line. The hot gas solenoid is de-energized (closed) when modulation is discontinued.Refrigeration Maintenance Hot Gas Solenoid The hot gas solenoid (or hot gas bypass valve) is used in conjunction with the electronic throttling valve to reduce the capacity of the unit during modulation.

Attach the tool to the coupling with the prevent dust.. Place the compressor in position. Support the compressor and remove the compressor mounting bolts from the flywheel housing. Recover the refrigerant remaining in the compressor. install the compressor belts on Model 50 units. use the short spacers with shallow compressor NOTE: When the compressor is removed mounting flanges and the longer set for deeper from the unit. 125 . Slide the compressor into the unit. 1. etc. 7. service procedures are regulated by Federal. procedures must be performed by an EPA certified technician. and in some cases. 5. and In the USA all regulated refrigeration service install the mounting bolts. use the appropriate Allen tool coupling pins are clear. Lift the service valves out of the way. should be measured so that the same amount of oil can be added before placing the replacement compressor in the unit. Loosen the compressor belts on Model 50 units. Compressor 3. Keep the compressor ports covered to 2.Refrigeration Service Operations NOTE: The following procedures involve Installation servicing the refrigeration system. Two compressor. Tighten the compressor belts on Model 50 units. 4. Front seat the discharge and suction service valves. After the compressor has been removed from 9. 9. the pilot solenoid valve line. using approved equipment NOTE: The compressor drive coupling or and complying with all Federal. and remove the provided with removal tool P/N 204-991 to compressor belts from Model 50 units. by State and Local laws. Install the service valves using new gaskets soaked in compressor oil. Disconnect the high pressure cutout switch. Operate the unit at least 30 minutes and then inspect the oil level in the compressor. flanges. the oil level should be noted. evacuate the compressor. dirt. 3. sets of spacers are provided with the tool. which are 180 degrees apart. If no leaks are found. the pilot solenoid line. Pump down the low side and equalize the pressure to slightly positive. from falling into the provided socket head screws and spacers. Check the refrigerant charge and add refrigerant if needed. loosen the center bolt which holds the coupling to the compressor shaft. Add or 6. 8. Some of these 1. 6. Unbolt the discharge and suction service valves from the compressor. in either of two positions. 5. Back seat the suction and discharge service valves. 2. and remove the compressor oil filter. 10. The side with the countersunk holes or the oil removed from the compressor should be toward the coupling. Connect the high Removal pressure cutout switch. Compressor Coupling Removal (Model 30) 8. Pressurize the compressor and test for refrigerant leaks. State and Local clutch will only slide onto the coupling pins laws. and install the compressor oil filter. 2. Remove the compressor from the front of the unit. Slide the compressor to the left until the the unit. 4. 7. 1. remove oil if necessary.

used to index the parts correctly. push the coupling off the crankshaft as you continuing turning the center screw in a Use the following procedure to install a counter-clockwise direction. To prevent the tool and crankshaft from needed. Socket Head Bolts (supplied with tool) 8. use one of the compressor to engine it may be worse than no key at all! If the key does mounting screws to pin the tool to the flange.Refrigeration Service Operations 3. if the key is not installed correctly rotating. it will push the If a nut is used to prevent the bolt from falling tapered components apart and the reduced friction out. Engine Mounting Flange Figure 146: Compressor Coupling Removal Tool 126 . the nut should not be tightened. could lead to slippage and premature failure. Compressor Coupling Installation brake cleaner or the like). (Model 30) 2. cannot hold the tapers apart when the final bolt back the head against the tool and it should torque is applied. In a tapered fit joint the entire twisting load oxidation and other surface imperfections. lacquer thinner. Coupling 5. When a taper fit is machined and assembled properly a key is not 1 2 3 8 4 5 7 6 AGA1059 1. Short Spacers (supplied with tool) 7. should be handled by the friction fit between the Dress with crocus cloth if necessary and two tapered parts. Coupling Removal Tool (P/N 204-991) 4. fitted after the tapers are pulled together with 20 ft-lb (27 N•m) torque. Long Spacers (supplied with tool) 6. In fact. 4. 10 mm Allen Tool (for large shaft compressor) 2. Use the appropriate Allen tool to loosen the The following procedure requires the key to be coupling mounting screw. Using this tool compressor coupling on the compressor will prevent the coupling from popping off crankshaft. The key is only a backup and is re-clean as required. Once the center screw has been loosened. Clean the compressor shaft taper and coupling hold it in place. bore taper with a solvent that leaves no oily residue (such as naphtha. not fit easily into the keyway. This insures that the key 5. 5/16 Allen Tool (for small shaft compressors) 3. because the center bolt and flatwasher will 1. Inspect both mating surfaces for burrs.

Spray a corrosion inhibitor (such as spray the key (P/N 55-9024). If 4. Re-install the bolt and heavy flat washer and used as a lapping tool to clean the snug the bolt down by hand. A key can be Figure 148: Compressor Coupling Installation coated with fine lapping compound and 9. As above. Refrigeration Service Operations 3. Removal 6. If the key does not prevents moisture from wicking into the joint fit properly. Key tapped flush with outside face of coupling. set the coupling on the key into the keyway beyond the front face crankshaft and align the keyways using the of the coupling. Washer the tool does not fit. 127 . 90 ft-lb (122 N•m). Using no lubricants. Compressor Coupling or Clutch coupler or crankshaft and the tool does not fit easily there is a problem with one of 2. should fit with a light press fit requiring only a Remove the mounting clamps from the minimum of light tapping. Torque the bolt to keyways. Remove the Keyway Tool and check the fit of 10. 4. Torque bolt to 90 ft-lb (122 N•m) keyway and then drop the coupler on. 7. If tapped in farther it may Keyway Tool (P/N 204-972). Spray this area with corrosion inhibitor after and it will hold the taper in the coupler off assembling. Re-install the coupling and align the keyways 1. This minimum of light tapping. the taper on the shaft. 5. with the Keyway Tool. Install the key in the keyway. Check both keyways for burrs or corrosion. 2. Do not install the condenser inlet line. Recheck the fit as shown above. Condenser Coil 5. Remove the condenser coil mounting bolts. remove the coupler and inspect and causing corrosion. flat washer and bolt and pre-torque to 20 ft-lb Unbolt and remove the expansion tank from (27 N•m). the condenser coil frame. gently move the coupling on the shaft while pressing the tool into the keyway. Do not tap key any farther into keyway. Drain engine coolant from the expansion tank. When the key fits properly. Insert the cause the coupling to move off center on the tapered end of the tool into the keyway and shaft. Install the 3. Recover the refrigerant charge. Open the roadside condenser fan grille. 8. the keyways and key for burrs or other problems. the keyways! Do not remove the coupler and place the key in the crankshaft 3. Do not install the key at this time. remove the coupling and key from the shaft. This will 1 align the keyway in the crankshaft with the 2 keyway in the coupler. 3 AGA333 Figure 147: Keyway Tool P/N 204-972 5 4 AGA1254 CAUTION: If you are assembling a used 1. Remove the bolt and washer. it 4. the key will not fit. It should fit into the paint) on the exposed part of the shaft and the keyway with a light press fit requiring only a joint between the shaft and the coupling.

Unsolder the inlet line and liquid line In-Line Condenser Check Valve connections. Place the check valve in position. mounting bolts. 128 . Recover the refrigerant charge. 2. This unit uses an in-line condenser check valve. 4. Solder the inlet and outlet connections. Pressurize the refrigeration system and test for leaks. Valve 7. Place a heat sink on the check valve.Refrigeration Service Operations 5. Spring Discharge Vibrasorber Figure 149: Cross Section of In-line Condenser Check Valve Removal 1. P/N 204-584 1. or wrap the vibrasorber with wet rags to 1. P/N 204-584 prevent damage to the neoprene seal. or wrap the vibrasorber with wet rags to 2. Charge the unit with the proper refrigerant and 3. 3. The arrow 3. check the compressor oil level. Clean the tubes for soldering. A heat sink must be used on 1. Heat the connections on the vibrasorber until the vibrasorber can be removed. 1. Recharge the unit with proper refrigerant and 3. If no on the valve body indicates the direction of leaks are found. Solder the vibrasorber connections. 3. Installation The in-line check valve is not repairable and must be replaced if it fails. Prepare the vibrasorber and tubing fittings by Installation cleaning thoroughly. Place the coil in the unit and install the in place to prevent damage to the neoprene seal. Condenser Check Valve Replacement 2. Lift the coil from the unit. evacuate the system. Recover the refrigerant charge. Clean the fittings for soldering. Solder the inlet line and liquid line connections. refrigerant flow through the valve. 5. check valve when it is being soldered in place to CAUTION: Use a heat sink. Pressurize the system and test for leaks. 1. Install the clamps on the condenser inlet line. prevent damaging the vibrasorber. AEA648 6. prevent damaging the vibrasorber. Unsolder the lines and remove the check Installation valve. If no leaks are found. 4. Removal CAUTION: Use a heat sink. NOTE: A heat sink must be used on the in-line 2. Install the engine coolant expansion tank and refill half way with engine coolant. evacuate the system. the in-line check valve when it is being soldered 2. Valve Seat check the compressor oil. 4. Neoprene Seal 8. 4. Place a heat sink on the check valve. Close the roadside condenser fan grille. 2.

2. Bypass Check Valve 2. outlet. 7. Release a small amount of refrigerant to purge the receiver tank. Loosen the mounting hardware and remove Receiver Tank the drier. hardware. Use a heat sink on the with a back-up wrench on the hex behind the bypass check valve. Use a heat sink on the 5. receiver tank. valve lines to the receiver tank. Recharge the unit with proper refrigerant and 1. Solder the inlet. If no leaks are found. 4. Unsolder and remove the bypass check valve sink on the bypass check valve. evacuate the 1. Recharge the unit with proper refrigerant. Position the receiver tank so that the sight glass is 2. outlet. Solder the bypass check valve onto the receiver tank. Removal Installation 1. Install the high pressure relief valve in the check the compressor oil. Open the bypass service valve and place the 2. Pressurize the low side and test for leaks. Tighten the receiver tank mounting hardware bypass check valve. If no leaks are found. If no 1. unit in operation. Unbolt the mounting brackets and remove the leaks. inlet fitting. 3. securely. Install the new drier and tighten the mounting sink on the bypass check valve. the mounting bolts and nuts loosely. Disconnect the nuts at the ends of the drier. Unsolder the bypass check valve line from the mounting bracket. 2. evacuate the system. evacuate the system. Close the bypass service valve. and bypass check bypass check valve. 1. Pressurize the refrigeration system and test for 5. 4. 6. Then tighten the outlet nut. 3. Solder the bypass check valve onto the system. Pressurize the refrigeration system and check for leaks. Use a heat 2. Unsolder the inlet. Removal 3. Install and tighten the inlet nut. Installation 7. clearly visible through the viewing hole in the 3. 1. Pump down the low side and equalize the 3. 129 . Place the receiver tank in the unit and install pressure to slightly positive. Pump down the low side and equalize the leaks are found. bypass check valve. Hold the drier from the receiver tank. the air through the drier. from the receiver tank. receiver tank from the unit. Use a heat sink on the bypass check valve. receiver tank. Place the new O-rings in the ORS fittings on the ends of the drier. pressure to slightly positive. Solder the bypass check valve line to the bypass check valve. Installation 6. Use a heat 4. Use a heat sink on the bypass Removal check valve. and bypass check valve lines from the receiver tank. Remove the high pressure relief valve from 4. Refrigeration Service Operations 5. Recover the refrigerant charge. Unsolder and remove the bypass check valve 3. Use a heat sink on the 4. Use a heat sink on the Filter Drier bypass check valve.

exchanger on the bulkhead. Disconnect the equalizer line from the suction line. Remove the evaporator access panels. Side View 4. Connect the inlet liquid line and solder the distributor to the expansion valve. the feeler bulb on the side of the suction line 2. Connect the equalizer line to the suction line. Removal 4. Pump down the low side and equalize the pressure to slightly positive. 7. Pressurize the low side and test for leaks. 2. properly installed. Disconnect the inlet liquid line and unsolder 5. Heat Exchanger 3. Clean the suction line to a bright polished 1. Remove the mounting bolts that hold the heat tape. leaks are found. 1. Install and bolt the expansion valve assembly 8. Expansion Valve Assembly Removal 1. If no leaks are found. Remove the upper and lower evaporator in its former position. Replace the access panels. If no the distributor from the expansion valve. Note AEA713 the position of the feeler bulb on the suction line.Refrigeration Service Operations 5. Disconnect the equalizer line from the suction line. 6. make good contact with the suction line or operation will be faulty. Install the feeler bulb clamps and pressure to slightly positive. 3. 7. Open the refrigeration valves and place the Installation unit in operation. Note the position of the feeler bulb on the side of the suction line. Remove the expansion valve mounting bolt 6. Unsolder the suction line at the evaporator coil end. Wrap with insulating 3. Remove the expansion valve feeler bulb from the suction tube. and remove the expansion valve from the unit. evacuate the low side. Remove the feeler bulb from the clamp. The feeler bulb must access panels. 5. 130 . Figure 150: Location of Expansion Valve Bulb 5. 1. End View 2. Disconnect the liquid outlet line from the expansion valve. Pump down the low side and equalize the condition. 4. 6. Pressurize the system and inspect for leaks. Test the unit to see that the expansion valve is in the unit. 2. open the refrigeration valves and place the unit in operation.

Disconnect the sensors. Seal the openings through the bulkhead with putty when the refrigerant lines Installation have cooled off. Solder the hot gas line and suction line 5. Unsolder the distributor from the expansion valve. Open the refrigeration valves and place the unit in operation. Replace the roadside and curbside evaporator tape. 2. bulkhead. 1. Solder the suction line connection to the housing and install the mounting bolts. Remove the feeler bulb from the suction line clamp. 9. Place the heat exchanger assembly in the evaporator housing and install the mounting 7. Solder the liquid inlet and the suction outlet 8. Place the evaporator coil in the evaporator 4. Replace the evaporator access panels. Check the refrigerant charge unit in operation. 5. Install the feeler bulb on the side of 8. lift and slide the line connections on the condenser side of the coil from the housing. 2. Pressurize the low side and test for leaks. Open the refrigeration valves and place the 10. evacuate the low side. condenser side of the bulkhead. make good contact with the suction line or the operation will be faulty. 9. Pump down the low side and equalize the 1. Remove the upper and lower evaporator inlet liquid line connections from the access panels. Slide the heat exchanger assembly out of the evaporator housing. evacuate the low side. Replace and connect the sensors. pressure to slightly positive. Note the position of the feeler bulb on Installation the suction line. If no leaks are found. Pump down the low side and equalize the pressure to slightly positive. 6. Remove the roadside and curbside evaporator putty from around the lines before unsoldering access panel mounting channels. Connect the distributor to the expansion valve. in its former position. 1. Clean the suction line to a bright polished condition. Remove the mounting bolts. 6. The feeler bulb must Wrap with insulating tape. Wrap with insulating 7. access panel mounting channels. Unsolder the hot gas line and the suction line hardware loosely. Clean the tubes for soldering. The condition. access panels. Clean the suction tube to a brightly polished the suction line in its former position. 131 . 7. Install the feeler bulb clamps and feeler bulb must make good contact with the the feeler bulb on the side of the suction line suction line or its operation will be faulty. valve. 9. and the liquid outlet line to the expansion 3. 6. Tighten the heat exchanger mounting hardware securely. the connections. from the evaporator coil. Add as required. Unsolder the remaining outlet suction line and 2. Pressurize the low side and test for leaks. Replace the upper and lower evaporator 8. 3. 4. If no leaks are found. evaporator coil. 5. Remove any 3. Connect the equalizer line to the suction line connections to the evaporator coil. Refrigeration Service Operations 8. Evaporator Coil Accumulator Removal Removal 1. 4. and the compressor oil.

Spring 10. Gaskets should occur. Stem Assembly the copper tubing to separate the three sections 5. Seat NOTE: The three-way valve can be repaired in the unit if leakage or damage to the Teflon seals 3. If no leaks are found. 2. Clean the exterior surface of the valve. 132 . 3. Check Valve 9. Recover the refrigerant charge. 6. CAUTION: Use a heat sink or wrap vibrasorber with wet rags to prevent damaging the vibrasorber. Seal 12. Connect the tee fitting and lines to the accumulator. Unbolt and remove the accumulator from the unit. 4. Bottom Cap Figure 151: Three-Way Valve Removal/Disassembly 1. Installation 1. 3. Screen of the valve without unsoldering any tubes. 4. AEA714 Three-Way Valve Repair 1. Open the refrigeration valves and place the unit in operation. CAUTION: Use a heat sink or wrap vibrasorber with wet rags to prevent damaging the vibrasorber. Piston 11. Unsolder the inlet and outlet suction lines from the accumulator. Check the refrigerant charge and the compressor oil. Pressurize the low side and test for refrigerant leaks. Remove the line from the three-way valve to the pilot solenoid. 3. 5. Add as required. Cap 7. Solder the inlet and outlet suction lines to the accumulator. 2. Disconnect the tee fitting from the accumulator tank. Clip 2. There is usually enough give in 4. End Cap 8.Refrigeration Service Operations 2. evacuate the low side. Place the accumulator in the unit and tighten the mounting bolts and nuts.

spring. c. Stem assembly. See Service Bulletin T&T 260 for more information. 2. Deburr the hole in the check valve piston bore. All end caps. 3. A used drill bit can be modified to use as a deburring tool. Remove the screen. Remove the spring clip which secures the 3. Internal Spring in Seal stem to the piston. the cap gasket face to the check valve piston bore discharge line must be removed at the as shown. the end cap. End cap. Retaining Clip 8. Remove the condenser pressure bypass check valve snap ring.26 mm]) drill 10. 5 2 4 3 AGA1069 Figure 152: Gasket Tool P/N 204-424 AGA1066 5. Seat positions change and 4. reconditioned. use tool P/N 204-424 to break the gasket at each side of the center section. [2. 1. Refrigeration Service Operations 4. Loosen the four 1/4 in. Allen head screws (DO NOT REMOVE OR CAP MAY POP OFF). The following parts will be discarded: Check Valve Bleed Hole Diameter a. Use a number 43 (0. Slide piston off the stem. Connecting Groove in Stem 5. Remove the seat and stem assembly. Connecting Notch in Piston 7. and piston from b. sealing and support surface. sealing and support area. If any particles drop from bit to check the size of the hole from the end the screen into the discharge line. as follows. should be checked b. stem. sealing surface. If the drill does not go all the way into the NOTE: The valve body cannot be bore. improper sealing will result. Inspect the following parts for wear or damage: End Cap Checks a. c. Figure 153: Piston and Stem Parts 9. Remove the four bolts from the valve. 2. 4. even new ones. All gaskets. Seal Groove in Piston 6. Piston seal. Bottom cap. 1. Seat. drill the hole completely through. 133 .089 in. 1 CAUTION: Do not force the tool into the brass or against the bolts. Remove the end cap and spring. compressor.

Check for Burr Here Figure 155: Check Piston Bleed Orifice 1.033 in. use a strong light to look down the 1 0. Use a paper clip bent into a 90 degree 1.089 in. Number 66 Drill Check Valve Piston Check Figure 156: Check Seat Orifice 1. Make sure you can feel the piston 2.033 in. working against the spring. charge pressure is higher than condenser pressure because the flow is restricted. Use a number 66 (0. Carefully check to see that the drill projects behind the piston. spring. With the piston pushed all the way back in its bore.84 mm) holes located Piston Bleed Orifice Check in the three-way valve seat (center section). Number 66 Drill 1 2.033 in. NOTE: When front seating a condenser bypass check valve DO NOT over-tighten the stem! Excessive torque will deform the piston and the deformed piston can increase the hole blockage. Leave the stem back seated against the snap the valve.84 mm)! Whenever 2 you disassemble a three-way valve you should check that all three of the holes are drilled cleanly. and snap ring (Kit Assembly/Installation P/N 60-163). Install the new stem in the bottom cap. Reassemble the end cap using a new check valve piston. 1. Install the screen in the bottom cap. Do not enlarge this hole. pressure is higher than discharge pressure because gas will flow to the discharge line instead of 2. reassemble 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. If the piston covers more than three-quarters of the hole replace the end cap. Only one is used depending on how the valve is config- 1. stem. Number 43 Drill Seat (Center Section) Orifice Check Figure 154: Check Bleed Hole Diameter There are three 0.84 mm]) drill bit to check the orifice in the bleed hole from ured. Do not enlarge this 1 hole larger than 0. angle to push the check valve piston back in its bore.Refrigeration Service Operations 3. (0. 134 . (2. (0. [0. After cleaning and inspecting all parts. If the hole is too small the valve down into the groove and that there are no will be slow to shift from heat to cool when dis- burrs at the end of the hole in the groove. If the hole is too large the valve will be slow the gasket surface to the groove in the bottom to shift from heat to cool when the condenser of the piston bore. 1. ring.

use care slot. 9. P/N 204-1008 to install a new seal on the 10. Pipe 5. 1. O-ring 2. While removing the stem. with spring clip. If there are no leaks. Line up the passageways in the cap and body. 5. Stem 1. This prevents the seal from being recharge with the proper refrigerant. Tapered Tool 2. Snap Ring 5. Install the bolts and tighten in rotating Oil the gaskets in compressor oil before sequence. Install the pilot solenoid line and pressurize 4. 3 4 5 AEA715 ARA166 1. 6. Lubricate the seal with refrigeration oil. valve operation. Recover the refrigerant charge. Torque to 160 in-lb (18 N•m). Spring 3. Use the pipe to hand press the seal onto Removal the piston. Remove the spring and piston. The open part of the clip NOTE: The spring and piston are held in by should be on the opposite side of the piston the stem. Press by Hand 4. Inspect the check valve seat in the three-way Failure to line up the holes will result in valve. 1 2. Seal Figure 158: Teflon Check Valve Assembly Figure 157: Seal Installation with Tool P/N 204-1008 4. Run the unit to check for proper three-way a. Cap 6. c. 6. Slide the seal onto the tapered tool with Three-Way Valve Condenser the spring side facing away from the Pressure Bypass Check Valve piston. installing. stretched and damaged. Unscrew the check valve stem by using a 5. Piston 4. Use the three-way valve seal installation tool the system with refrigerant to check for leaks. 2 3. Refrigeration Service Operations 3. 7. 8. Place the piston slot on the stem and secure screwdriver in the slot provided. improper operation of the valve. evacuate the system and piston. Repair d. Unscrew the condenser pressure bypass check valve cap from the three-way valve. Install the spring and end cap. Remove the snap ring. Install new gaskets on both sides of the seat. so the spring and piston are not lost. b. 11. 135 . Piston 3. Place the tapered tool over the piston.

Pressurize the refrigeration system and test for leaks. If no leaks are found. 5. Open the refrigeration valves and place the 3. and install the assembly into the check valve 6. to the accumulator and remove the vibrasorber NOTE: The valve stem must be back seated from the unit. 8. Place the valve in the unit and install the mounting bolts. Solder the vibrasorber to the suction service system. and snap ring. and check the compressor oil. Screw the check valve stem into the three-way valve until the snap ring can be installed. Coat the O-ring with compressor oil and proper direction. Coat the sealing area in the cap with compressor oil. Installation 7. Unsolder the suction vibrasorber from the 6. 1. Install the snap ring. If replacement parts are needed. unit in operation. fittings for soldering by cleaning the thoroughly. If no leaks are found. Remove the mounting bolts and remove the valve. Coat the entire assembly with compressor oil system. 4. CAUTION: Use a heat sink or wrap vibrasorber with wet rags to prevent Pilot Solenoid damaging the vibrasorber. Install the coil and connect the wires. Solder the refrigeration lines to the valve. Remove the coil from the valve. Pressurize the refrigeration system and test for piston towards the spring. during normal unit operation. 2. evacuate the 2. Removal 4. Unscrew (back seat) the check valve stem suction service valve. 1. The arrow on the valve Installation indicates the direction of flow through the valve. 3. leaks. Solder the suction vibrasorber connection to Removal the accumulator. 2. Prepare the suction vibrasorber and tube the three-way valve. Recover the refrigerant charge. O-ring. Recharge the unit with the proper refrigerant seat in the three-way valve. If 2. 4. 9. 2. Recharge the unit with the proper refrigerant. spring. Unsolder the refrigeration lines. install it on the check valve stem. a kit Installation P/N 60-163 must be used which includes the 1. CAUTION: The piston must be inserted with the flat side against the valve seat to Suction Vibrasorber ensure proper sealing. valve. valve stem. 136 . Make sure that the arrow points in the 1. 5. evacuate the system. Unsolder the connection against the snap ring. evacuate the 3. Pump down the low side and equalize pressure to slightly positive. 3. piston. install and tighten the cap on 1. other end of the spring with the hole in the 5. Disconnect the wires and remove the coil from no leaks are found.Refrigeration Service Operations 7. the valve. Insert the spring into the hole in the check valve stem and then install the piston on the 4. Pressurize the low side and check for leaks.

Apply a refrigerant Loctite to the threads of pressure cutout switch from the compressor the discharge pressure transducer. evacuate the the high pressure cutout switch. Install and tighten the high pressure cutout 4. Install and tighten the high pressure relief 5. 4. 1. 2. 3. Recharge the unit with the proper refrigerant and check the compressor oil. Recover the refrigerant charge. Disconnect the wires and remove the 2. Recover the refrigerant charge. system. 2. If valve. open the refrigeration Suction Pressure Transducer service valves and place the unit in operation. 2. Front seat the discharge and suction service discharge pressure transducer. 2. Pressurize the low side and check for leaks. 2. Refrigeration Service Operations High Pressure Cutout Switch Discharge Pressure Transducer Removal Removal 1. Installation 3. 137 . system. Apply a refrigerant Loctite to the threads of leaks. Removal 2. If no leaks are found. evacuate the low side. Recharge the unit with the proper refrigerant switch and reconnect the wires. Apply a refrigerant Loctite to the threads of Installation the suction pressure transducer. Install and tighten the suction pressure high pressure relief valve. 4. pressure transducer. Unscrew and remove the high pressure relief Installation valve. 3. and check the compressor oil. Pump down the low side and equalize pressure to slightly positive. Install and tighten the discharge pressure transducer and reconnect the wires. transducer and reconnect the wires. 3. Pressurize the refrigeration system and test for 6. Installation 3. evacuate the unit in operation. Pump down the low side and equalize the 1. discharge manifold. Disconnect the wires and remove the high 1. If no leaks are found. Pressurize the refrigeration system and test for 1. pressure to slightly positive. Disconnect the wires and remove the suction 1. valves. no leaks are found. If no leaks are found. Open the refrigeration valves and place the leaks. Pressurize the compressor and test for leaks. Apply a refrigerant oil to the O-ring of the 4. Recover the refrigerant remaining in the compressor. Removal High Pressure Relief Valve 1.

Stepper Motor 4. 5 4. ARA168 The torque on the nut is approximately 100 ft-lb (136 N•m). proceed as follows: tank outlet valve.Refrigeration Service Operations Electronic Throttling Valve 2 (ETV) 1 Removal 1. Harness 5. Pump down the low side and equalize the pressure to slightly positive. It may be necessary to unsolder the tubes If you hear refrigerant begin to flow above or below the valve body to obtain through the valve when the stepper motor enough clearance to remove the valve body. Hold the valve body with 1. Remove the evaporator access panels. unsolder and remove the valve body. Clean the tubes for soldering. and recover the refrigerant assembly from the valve body on the new charge. Remove the clip and disconnect the ETV 4 harness connector from the stepper motor. Clip unscrew the small nut. Note the position of the valve body so the new unscrew the stepper motor and piston one will be placed in the same position. Figure 159: Electronic Throttling Valve WARNING: If the ETV is stuck in the 5. Valve Body refrigeration tubing. If the complete ETV assembly is being closed position. and piston assembly are loosened. much of the refrigerant replaced. refrigerant is trapped and must be recovered. Midseat the receiver tank a. Unscrew the large nut that attaches the stepper motor and piston assembly to the valve body. 3 2. Screw the stepper 1. If the suction position as the old one. Large Nut backup wrench to prevent damage to the 2. Attach a refrigerant recovery step 2. The assembly no more than four turns and new ETV could interfere with the evaporator check the suction (low side) pressure on access panel if it is not placed in the same the gauge manifold. If an ETV service kit (stepper motor and motor and piston assembly back into the piston assembly) is being installed. 138 . Do not 3. Connector CAUTION: Unscrew the large nut. b. assembly may then be removed. If a complete ETV assembly is being device to the service port on the receiver installed. The stepper motor and piston ETV assembly. Remove the stepper motor and piston outlet valve. 3. charge may be trapped in the evaporator. pressure has increased from the pressure to which it was equalized after the low side Installation pump down. go to valve body.

Hold the valve body with backup wrench to prevent damage to the refrigeration tubing. 2 8. The 1. Install the evaporator access panels. Lubricate the piston and threads on the new retracts to open and extends to close. Pressurize the low side and test for leaks. 9. Place the new valve body (and any tubes CAUTION: The ETV may stick in the that were removed) in the same position closed position if the stepper motor and from which the old one was removed. 0. (38 mm) from the bottom edge of arrow on the valve body must point up. In in the fully open position. Check the operation of the ETV. Use a heat piston assembly and use the evacuation sink on the valve body to prevent damage. Check the stepper motor and piston assembly evacuation mode. The piston assembly is installed with the piston new ETV could interfere with the in the closed position. 7. 5. 6. Connect the ETV harness connector to the (19 mm) stepper motor. Bottom Edge of Brass Nut 10. If no leaks are found. The piston 3. connect the from the evaporator to the heat exchanger. Screw the new stepper motor and piston ARA167 assembly into the valve body. Solder the tubing connections.25 in. Do not tighten the small nut. stepper motor and piston assembly with NOTE: The ETV cannot be opened refrigeration oil. information about placing the unit in the 2. If there is any doubt about which is the direction of refrigerant flow the position of the piston. mode in the Service Test Mode to place the piston in the fully open position.5 in. Take care when making the connection. disconnect the an open position the bottom edge of the piston ETV harness from the stepper motor and is 0.75 in. Open the refrigeration valves and place the Figure 160: Stepper Motor and Piston Assembly with Piston in Fully Open Position unit in operation. 139 .75 to 1. ETV harness to the stepper motor and d. Refer to e. Refrigeration Service Operations c. evacuate the low side. CAUTION: Tighten the large nut. The connector attaches to the 1 ETV in only one position. manually. 4. After placing the piston to make sure the piston is an open position. the brass nut. bottom edge of the brass nut. Torque the nut to approximately 100 ft-lb (136 N•m). Install the clip and secure it with a band wrap. 1. (19 to 32 mm) from the piston assembly. In the closed evaporator access panel if it is not placed position the bottom edge of the piston is in the same position as the old one. Bottom Edge of Piston 11. See the following CAUTION. 2. Allow the valve body to cool before the SR-2 Microprocessor Controller installing the stepper motor and piston Diagnostic Manual TK 51727 for assembly.

Bellows End 12. Gasket .Rubber 9. Spring . Flatwasher 11. Gasket .Valve to Compressor 8. Bellows & Shaft . Removal 4. Cap .Adjusting 14. Plate .Piston 4. O-ring 17.Bellows 15.Mtg Plate 10.Cotter 6. Piston 3. O-ring . 3. Unbolt and remove the throttling valve from 1. Housing Figure 161: Mechanical Throttling Valve Assembly 140 . Remove the suction service valve.Piston 7. Recover the refrigerant remaining in See Figure 161 for an illustration of the the compressor. Pump down the low side and equalize the the unit. Shim . Nut .Adjusting 5. Screw .Assy 16.End Plate 13.Refrigeration Service Operations Mechanical Throttling Valve 2.Piston Housing 2. Pin . AEA717 1. mechanical throttling valve assembly. pressure to slightly positive. Housing . Spring . Front seat the discharge and suction service valves.

Remove the cotter pin from the castle nut and remove the nut. Inspect Cap Figure 164: Inspect for Damage 2. spring and tighten the castle nut until it is firmly seated against the bottom of the piston. CAUTION: This end cap is under slight spring pressure. Clean the parts that will be reused. 4. Break the gasket free and remove the end cap. Remove the piston end cap (round end). Shims Figure 162: Inspect Parts Reassembly 7. and b. Inspect all the parts. place the shims in the end cap (use same c. 2. Oil the gasket. Center the spring on the bellows shoulder. Refrigeration Service Operations Disassembly 1. Bellows end cap for damage in the pilot number as removed). Install the piston. 141 . a. 3. place with the vent hole closest to the outlet opening of the valve housing. 3. install it on the housing. Note the number of shims next to the cap. 3. Tighten the end cap in hole. Remove the spring and piston. 4. 2. Install the bellows with the O-ring in the housing. Inspect for Damage 1. Inspect for Wear 5. 1. NOTE: The bellows is normally replaced. 8. These can be reused. 1. 1. Inspect Spring 9. Remove the bellows. Piston and cap for wear (scuff marks). Loosen all the bolts on the bellows end cap. Body for stripped threads. Figure 163: Inspect for Wear 6.

) valves. Install the throttling valve using a new O-ring 4. Pressurize the compressor and check for leaks. Installation 1. Removal 8. compressor oil filter. shims under the spring. ends of the new compressor oil filter. Recover the refrigerant charge. Figure 165: Throttling Valve Reassembly The compressor oil filter should be changed when the drier is replaced. 1. Adjust the setting by adding or removing from the compressor. Recharge the unit with proper refrigerant and check the compressor oil. Fasten the new compressor oil filter in place compressor. AEA716 6. Install the suction valve. 7. Front seat the discharge and suction service Specifications Chapter for the setting. Open the refrigeration valves and place the 7. Remove the coil and place the valve in position. Disconnect the wires and remove the coil for 9. The throttling valve will have to be pressure to slightly positive. Insert cotter pin This unit is equipped with a compressor oil filter. evacuate the 6. then back Compressor Oil Filter Change off 1 turn only. If no leaks are found. Back off the castle nut. Hold the oil filter with back-up Installation wrench on the hex behind the ORS fitting. 5. Oil the gasket and install the end cap. evacuate the system. 142 . 2. with the clamp. Pump down the low side and equalize the 8. Clean the tubes for soldering.Refrigeration Service Operations 5. operate the system. 1. Tighten castle nut to bottom. and check the compressor oil filter for leaks. Bolt the throttling filter. 5. 6. install the coil. recalibrated on operating unit. Open the service valves. 3. Evacuate the compressor and filter to a maximum of 500 microns to remove trapped 1. If no leaks are found. 1. the valve. Recover the remaining refrigerant 9. valve to the compressor. 2. 3. Unsolder the lines and remove the valve. Disconnect the oil lines from the compressor oil filter. oil and place them in the ORS fittings on the 3. 4. Remove the clamp and the compressor oil soaked in compressor oil. 4. Insert the cotter pin. Pressurize the refrigeration system and test for leaks. Solder the inlet and outlet connections. Coat the new O-rings with clean compressor 2. air. 3. Attach and tighten the oil lines to the unit in operation. one full turn only. (See the 2. Hold the oil filter with a back-up wrench on the hex behind the ORS Hot Gas Solenoid Valve fitting. After the valve cools.

oil pressure access port minus the suction pressure below the throttling valve. The net oil pressure should be at least 20 psi (138 kPa). Attach the low pressure gauge of a gauge varies with the suction pressure in the compressor. Refrigeration Service Operations 4. Priming New Compressor Installations Thermo King remanufactured compressors have had a special break in process to assure that the oil pump is primed. manifold to the fitting on the side of the Therefore. 1. Attach the low pressure gauge of a gauge solenoids are disconnected and the engine manifold to the fitting on the side of the does not start. Subtract the suction pressure below the throttling valve from the pressure at the oil pressure access port to get the net oil pressure. Disconnect the wires to the fuel solenoid. The oil pressure at the oil pressure access port 2. This procedure must be followed to prevent premature pump failure in any compressor that AEA718 has had an oil pump installed. and broken in. port and the suction pressure below the throttling valve while the engine is 143 . Turn the unit on and let the engine crank (or below the throttling valve. first check the compressor oil level. Clear these alarm codes as throttling valve. Use the following 3. This fitting allows you to necessary. crank the engine) for 30 seconds. The following procedure is recommended. monitor the suction pressure in the compressor 5. Attach a suitable oil pressure gauge to the oil solenoid. especially a compressor that has been stored for any length of Figure 166: Compressor Oil Filter time. pressure access port on the compressor oil NOTE: The microprocessor will probably filter. The net oil pressure is the pressure at the below the throttling valve. Attach a suitable oil pressure gauge to the oil Checking Compressor Oil pressure access port on the compressor oil Pressure filter. record some alarm codes because the 2. procedure to check the compressor oil pressure. 4. pressure access port and the suction pressure a. we need to calculate the “net oil throttling valve. functioning. This fitting allows you to pressure” to determine the actual compressor oil monitor the suction pressure in the compressor pressure. Disconnect the wires to the high speed 1. then check the compressor oil pump and relief valve. but do not 3. If the net oil pressure is low. Note the pressure at the oil pressure access below the throttling valve. Pressure at Oil Pressure Access Port – Suction Pressure Below Throttling Valve = Net Oil Pressure 5. Start the unit and note the pressure at the oil crank the engine for more than 30 seconds. but not required for factory-remanufactured compressors.

144 . then check the compressor oil pump and relief valve. The compressor oil pump is now primed and broken in. but do not re-connect the high speed solenoid wires. Run the engine on high speed for at least five more minutes. re-connected the fuel solenoid wires. Start unit and run the engine on low speed for at least five minutes. If the compressor does not develop at least 10 psi (96 kPa) of net oil pressure in the first 30 seconds. If the net oil pressure is above 20 psi (138 kPa) for this period. If 10 psi (96 kPa) of net oil pressure still does not develop. stop the unit and re-connect the high speed solenoid wires. 6. allow the starter to cool for a few minutes and the crank the engine again for 30 seconds. first check the compressor oil level. 7. 8.Refrigeration Service Operations cranking. Subtract the suction pressure below the throttling valve from the pressure at the oil pressure access port to get the net oil pressure. As soon as the compressor develops 10 psi (96 kPa) of net oil pressure. b.

extension. NOTE: The nuts for mounting the unit should be elastic stop nuts (Nylock type).g.. accessible using an impact wrench with a 10 in. If possible. Torque the unit mounting bolts to 60 ft-lb extension. ball-type swivel and a deep-well socket. NOTE: The nuts for mounting the unit should be elastic stop nuts (Nylock type). 150 ft-lb (203 N•m).Structural Maintenance Unit and Engine Mounting Bolts Unit Installation Check and tighten all unit and engine mounting All nuts that hold the unit to the trailer are bolts during scheduled maintenance inspections. Clean dirty coils with compressed air or a pressure washer. Evaporator. Torque the engine mounting bolts to socket. Repair bent fins and any other noticeable damage. Defrost Drains Clean the defrost drains during scheduled maintenance inspections to be sure the lines remain open. Check Bolts for Tightness Figure 167: Unit and Engine Mounting Bolts 145 . ball-type swivel and a deep-well (81 N•m). ARA106 1. and Radiator Coils Clean the coils during scheduled maintenance inspections. leaves or plastic wrap) that reduces the air flow. Be careful not to bend the fins when cleaning a coil. blow the air or water through the coil in the direction opposite the normal airflow. Unit Installation ARA104 1 All nuts that hold the unit to the trailer are accessible using an impact wrench with a 10 in. Remove any debris (e. Condenser.

Eye Bolt 2. Tighten the solenoid mounting bolts 2.75 in. Check Distance A. de-energized. Mounting Bolts 7.85 mm) with the solenoid damper from sticking closed. If 1.Structural Maintenance Defrost Damper 4. Distance A 2. Open Position 9. (69. Energize the solenoid (apply 12 volts dc) and check the damper blade to make sure that both To adjust the damper: edges contact the damper housing. Stop 6. 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. the top and bottom edges with the solenoid plunger bottomed out. (69. Damper Link Figure 168: Defrost Damper Adjustment 146 . Adjust the damper blade stops so they contact hole in the eye bolt. Remove the damper assembly from the necessary. This keeps the in. when both edges of the damper blade contact 3. Position the damper so that air flow is stopped on 5. Connect the damper link to the eye bolt. the distance from the the damper housing. 6. Solenoid 5. Closed Position 8. Tighten the locknut when Distance A is ability to stop the air flow.75 the edges of the damper blade. If necessary. solenoid mounting bolts and moving the solenoid. shoulder on the solenoid to the center of the 7. Disconnect the damper link from the eye bolt.85 mm) 4. 1 2 3 6 5 4 7 9 AEA719 8 1 1. adjust this by loosening the evaporator. end play. Round Stop 3. correct. and the bolt. Distance A should be 2.

Slide the blower towards the inlet ring until it 4. Slide the blower away from the inlet ring. 2. Center the blower wheel in the blower housing air flow and to prevent damage to the blower. Torque the blower hub bolts to 18 ft-lb 2 (24 N•m). Check the radial clearance by passing a wire 3. Radial Clearance 2. 1. Inlet Rings 4. Tighten the inlet ring securely. Condenser and Evaporator Fan Location Evaporator Fan Blower When mounting the condenser or evaporator fan 1. with equal overlap on both inlet rings. 5. Make sure the damper blade rests on the round distortion. Edge of Inlet Ring 6. Structural Maintenance 8. Torque blower hub bolts to 18 ft-lb (24 N•m). inlet rings and the blower wheel. Pass a gauge wire completely around the times to make sure that the damper operates blower orifice to check for uniform clearance. ring lines up with the alignment mark on the 10. contacts the inlet ring. stops when the damper is open. blower. Evaporator Blower 1. 3 4 AEA720 1. De-energize and energize the damper several 5.8 mm). This centers the inlet Tighten the inlet rings securely.15 in. ring in the blower orifice. (3. Blower Wheel 3. Alignment Mark 5. Center the inlet rings in the blower orifices. correctly and seals properly. 8. Loosen the inlet rings on the sides of the and hub assembly on the fanshaft. Equalize Blower Inlet Overlap Figure 169: Condenser Blower Alignment Figure 170: Evaporator Fan Location 147 . 1 6. Tighten the hub bolts that hold the blower the condenser coil bulkhead. Install the damper assembly in the evaporator. wheel on the fanshaft. Position the blower so the edge of the inlet round stops if necessary. the blowers and blower housing. 6. inlet orifices must be properly aligned for proper 2. The overlap on each ring should be approximately Condenser Fan Blower 0. Adjust the 7. Loosen the condenser inlet ring (spinning) on 3. Check Clearance with a Wire 2. Blower Housing Sides AEA749 3. Spin the blower by hand to check for blower 9. Inlet Ring 4. completely around the circumference of the 4.

Roller Bearing 10.Structural Maintenance Fan Shaft Assembly 2. remove the four retaining bolts from the The unit is equipped with a one-piece fan shaft condenser end of the assembly. If there is removed. remove the oil seal from the evaporator end oil seals should be checked during evaporator end of the assembly. assembly that contains tapered roller bearings in a sealed oil reservoir. Cap and Shims 6. The bearing races can now be driven out with a punch and replaced in the same manner. punch. This assembly does not require any maintenance. Shaft 3. it must be repaired or replaced. Using a punch. To remove the shaft from the assembly. O-ring Figure 171: Fan Shaft Assembly 148 . 8. Sleeve 4. AEA721 1. If necessary. If it is loose be removed and repaired. NOTE: The fan shaft assembly requires a 6. not normally used except after removal and repair of the fan shaft assembly. Breather Vent 8. Fan Shaft Assembly Overhaul 7. Remove both oil plugs and drain the oil from the housing. bearings and bearing races for wear or damage. Check the condition of the vent. inspect the special lubricant. or damaged. clean the housing in clean solvent. but they are parts in clean solvent. the fan shaft assembly should 5. Housing 9. Thermo King P/N 203-278. tap the opposite end of the shaft with a soft hammer. clean all There is a level plug and a fill plug. 3. After all the parts are cleaned. The condenser and 4. remove the bearings by tapping Disassembly them off the shaft with a hammer and a punch. Oil Plug Screw (Use Oil P/N 203-278) 7. Remove the fan shaft assembly from the unit. any sign of leakage. Oil Seal 2. Pin 5. After draining the oil from the housing. Be careful not to damage the shaft with the 1. After the shaft has been removed. With the seal the pre-trip inspection for oil leakage.

direction while reading the dial indicator. to 0. Install a new oil seal on the curbside end of the assembly after replacing the bearing race and splash guard.005 in. Install the retainer cap assembly over the should be checked during the pre-trip inspection shaft. To remove the shaft from the assembly.025 2. 7. Check the condition of the vent. Replace the shaft in the housing. (74 ml).04 N•m). Turn the shaft upside down. use remove the four retaining bolts from the different shims to obtain correct end-play.500 mm) Thermo King P/N 99-4231 parts in clean solvent. End-play should be 0. it must be repaired or replaced. 5. 5. Install a new a fill plug. Place the pipe over the shaft and drive bearing down. Install new oil seals after replacing the bearing assembly that contains tapered roller bearings in a races.005 in. To measure the Disassembly end-play. Remove the idler assembly from the unit. (0. then install the bolts. Clean up any shaft with a punch at notch in the base of the spillage. Idler Assembly Overhaul 6. The unit is equipped with a one-piece idler 2.007 in. Place the assembly on the workbench with the Reassembly vent up. direction and set the dial indicator to ‘0’. Pour the oil (P/N 203-278) through 6. Structural Maintenance Reassembly Idler Assembly 1. rotate the shaft while pushing in one 1. bearings and bearing races for wear or The assembly holds approximately 2. the idler assembly should be removed and repaired. 9.020 in.001 to 0. After all the parts are cleaned. The and replace the O-ring if needed. After correct end-play is obtained. If it is loose 8. 2. sealed oil reservoir. If there is any sign of leakage.127 mm). remove the oil seal from the curbside end of the assembly. With the seal 7. for oil leakage. Torque the bolts in a criss-cross pattern in equal steps to 80 in-lb (9. (0. tap the Shims available from the Service Parts opposite end of the shaft with a soft hammer.127 mm) Thermo King P/N 99-2901 4. CAUTION: When installing the fan shaft and use the pipe to drive the other bearing assembly. There is a level plug and 3. Department After the shaft has been removed. clean the housing in solvent. but they are not normally used except seal in the retainer cap. (0. This assembly does not require any maintenance. After draining the oil from the housing. Rotate the shaft by hand. If end-play is incorrect. inspect the the top plug until it runs out of the side hole. first drive bearing off Install the top and side plugs. the bearings. 149 . (0. roadside end oil seal and the curbside end oil seal 4. facing up. clean all the 0.5 oz damage. Tap the new bearings on the shaft with a pipe. 3. Now Remove both oil plugs and drain the oil from rotate the shaft and pull in the opposite the housing. Use the original shims after removal and repair of the idler assembly.177 mm) Thermo King P/N 99-2902 0. Check the condition of the O-ring used on the plugs and replace if necessary. Lock the assembly in a vise with the vent or damaged. The shaft should be free enough to rotate without having 1. add oil for removed. shaft. curbside end of the assembly. Install the new bearings on the shaft with a to hold the housing. Using a punch. make sure that the vent is down. To replace the bearings. mounted facing up. Lock the assembly in a vise and set up a dial indicator to read end-play. pipe. 0.

Structural Maintenance

3. Replace the shaft in the housing. Install a new 7. After the correct end-play is obtained, add
seal in the retainer cap. Use the original shims approximately 1.1 oz (33 ml) of oil
and replace the O-ring if needed. (P/N 203-278) for the bearings.
4. Install the retainer cap assembly over the 8. Lock the assembly in a vise with the vent
shaft, then install the bolts. facing up. Pour the oil through the top plug
until it runs out of the side hole. Check the
5. Torque the bolts in a criss-cross pattern in
condition of the O-ring used on the plugs and
equal steps to 80 in-lb (9.04 N•m).
replace if necessary. Install the top and side
6. Lock the assembly in a vise and set up a dial plugs. Clean up any spillage.
indicator to read end-play. To measure the
9. Place the assembly on the workbench with the
end-play, rotate the shaft while pushing in one
vent up. Rotate the shaft by hand. The shaft
direction, and set the dial indicator to ‘0’.
should be free enough to rotate without having
Now rotate the shaft and pull in the opposite
to hold the housing.
direction while reading the dial indicator.
End-play should be 0.001 to 0.005 in. (0.025 CAUTION: Reinstall the assembly into
to 0.127 mm). If end-play is incorrect, use the unit, making sure the vent is mounted
different shims to obtain correct end-play. facing up.
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

1. Oil Seal 6. Shaft
2. Cap and Shims 7. Housing
3. O-ring 8. Breather Vent
4. Roller Bearing 9. Oil Plug Screw (Use Oil P/N 203-278)
5. Splash Guard Tube
Figure 172: Idler Assembly

150

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

Engine cranks but fails to start Fuel solenoid not energized Check 8D and 8DP and CH circuits
and fuel solenoid pull-in relay.
Check that controller is configured
for Yanmar engine. Refer to
appropriate Microprocessor
Diagnostic Manual.

Fuel solenoid defective or stuck Replace

Fuel injection pump defective Replace pump

Air heater defective Replace

No fuel or wrong fuel Fill with proper fuel

Fuel transfer pump defective Replace transfer pump

Air in fuel system Bleed air

Compression low Overhaul engine

Injection nozzles defective Replace nozzles

Incorrect timing Adjust timing

Air cleaner clogged Replace air filter

Exhaust plugged Clean exhaust

Engine stops after starting Air in injection pump Bleed fuel system

Fuel filter obstructed Replace filter element

High head pressure Eliminate cause of high head
pressure

Vent of fuel tank obstructed Unclog vent

Clogged fuel tank or fuel lines Clean fuel tank and fuel lines

151

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

Air cleaner clogged Replace air filter

Delivery of fuel pump insufficient Repair pump

Injection pump timing off Adjusting timing

Injection nozzles defective Repair or replace nozzles

Compression low or unbalanced Overhaul engine

Worn injection pump plungers, Repair or replace pump
delivery valve defective, injection
rate too low, gum formations

Engine speed too high Misadjusted high speed solenoid Adjust high speed solenoid

Defective injection pump Repair injection pump

Engine fails to stop when unit is Fuel solenoid defective Replace
OFF
Injection pump defective Replace pump

Engine knocks heavily Air in system Bleed fuel system

Injection pump not timed Retime injection pump

Wrong fuel Change fuel

Compression too low Overhaul engine

Injection nozzles fouled or opening Clean, repair or replace injection
pressure too low nozzles

Delivery valve spring broken Replace spring or repair injection
pump

Valve out of adjustment Adjust valves

Fuel return line plugged Remove return line restriction

Rod or main bearing worn Replace rod or main bearings

152

front timing cover or crankshaft seals Damaged valve seals Replace seals on valve stem Worn valve stem Replace valves Broken piston rings or cylinder bore Have engine repaired and rebored. oil lines. 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. loose oil gallery plug High oil consumption Oil leakage Check and eliminate possible causes at rocker arm cover. main or Repair engine connecting rod bearings. worn or scored Replace broken piston rings Clogged air cleaner system Unclog air cleaner 153 . Replace if necessary Oil control valve defective Check oil pressure control valve Worn oil pump. oil filter. Use correct gasket Faulty thermostat Check or replace thermostat Loose or worn water pump belt Replace belt Oil pressure low Insufficient oil in pan Add oil Faulty oil pressure switch Check oil pressure switch. camshaft.

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 • Cold engine • Defective valve seals • Poor compression • Excessive load • Faulty injectors • Clogged air intake system • Faulty nozzles • Poor compression • Restricted exhaust • Faulty injection pump 154 .

ER. 7EC. L2. CH. BRN. BLU and BLK circuits Faulty heaters Check heaters 155 . L3. 7EB. and L3 circuits Faulty drive motor Check drive motor Faulty electric standby power Check electric standby power source source Evaporator heaters do not heat Faulty heater contactor Check heater contactor Open circuit Check 7EH. L1. 26E. L2.Electric Standby Diagnosis Condition Possible Cause Remedy Unit turned ON—LCD Blank Battery discharged Charge or replace battery Faulty battery cable connections Clean battery cables Fuse link blown Check for short circuit and replace fuse link Fuse F2 blown Check for short circuits and replace fuse Open circuit Check HMI Harness Unit turned ON and LCD Diesel operation selected Select ELECTRIC backlight ON but motor will not start and run Unit in NULL Check setpoint and box temperature Fuse F1 blown Check for short circuit and replace fuse Faulty HPCO Check HPCO Open or faulty overload relay Determine cause and rest or replace overload relay Faulty PSM Check PSM Faulty motor contactor Check motor contactors Open circuit Check 8. 7E. L1. EOL.

Electric Standby Diagnosis 156 .

dirt or wax • • • Liquid refrigerant entering compressor • • Restricted line on the low side • • • • Restricted line on the high side • • • • Restricted drier • Defrost damper stays open • • • Defrost damper stuck closed • Suction service valve back seated • • • • • • • • Faulty three-way valve • • • • • Faulty pilot solenoid 157 .Refrigeration Diagnosis Rapid cycling between cool and heat Unit cools in heat and defrost cycle Unable to hold vacuum in low side Unable to pull vacuum in low side Unit heats in refrigeration cycle Unable to pump down system Unit not heating or defrosting Receiver sight glass empty Unit operating in a vacuum Suction line frosting back Symptom High suction pressure Low suction pressure Unit not refrigerating No suction pressure High head pressure Low head pressure Noisy compressor Possible Causes • • • • Overcharge of refrigerant • • • • • • Shortage of refrigerant • • • • • No refrigerant • Air through condenser too hot (ambient) • Air flow through condenser restricted • • • Air through condenser too cold (ambient) • • • Air in refrigerant system • Condenser fan blades bent or broken • Air short cycling around evaporator coil • Air through evaporator restricted • • • • Evaporator needs defrosting • • Compressor discharge valves leaking • • Compressor suction valves leaking • Too much compressor oil in system • Faulty oil pump in compressor • Faulty compressor drive coupling • Compressor bearing loose or burned out • • • • • Broken valve plate in compressor • • Expansion valve power element lost its charge • • Expansion valve feeler bulb improperly mounted • • • Expansion valve feeler bulb making poor contact • • Expansion valve open too much • • Expansion valve closed too much • • Expansion valve needle eroded or leaking • • • Expansion valve partially closed by ice.

• Rapid cycling between cool and heat 158 • Unit cools in heat and defrost cycle Unit heats in refrigeration cycle High head pressure • Low head pressure • • • High suction pressure • • • Low suction pressure • • Refrigeration Diagnosis No suction pressure • • • Unit operating in a vacuum Receiver sight glass empty Suction line frosting back • • • Unable to pump down system Unable to pull vacuum in low side Unable to hold vacuum in low side Noisy compressor • • • Unit not refrigerating Unit not heating or defrosting Symptom • Faulty ETV Sensor out of calibration Leaky bypass check valve • Leaky condenser check valve Leaky receiver tank outlet valve • Loose or broken electrical connections Possible Causes • Hot gas bypass valve stuck open or leaking Compound pressure gauge out of calibration • Faulty three-way condenser pressure bypass check valve .

Discharge Vibrasorber 4. Accumulator 23. Sight Glass 12. Drier 15. Discharge Service Valve 3. Heat Exchanger 16. Evaporator Coil 21. Expansion Valve 17. High Pressure Relief Valve 10. Receiver Tank 11. Throttling Valve 26. Defrost Pan Heater 29. Feeler Bulb 18. Suction Vibrasorber 24. Three-Way Valve Bypass Check Valve 7. Condenser Check Valve 9. Compressor 2. Bypass Check Valve 30. Condenser Coil 8. Pilot Solenoid 27. Hot Gas Line 28. Distributor 20.Refrigeration Diagrams Cool Cycle With Mechanical Throttling Valve 1. Receiver Outlet Valve 13. Suction Service Valve 25. Discharge Line 5. Bypass Service Valve AGA282 159 . Three-Way Valve 6. Liquid Line 14. Suction Line 22. Equalizer Line 19.

Drier 15.Refrigeration Diagrams Heat/Defrost Cycle With Mechanical Throttling Valve 1. Suction Vibrasorber 24. Expansion Valve 17. Discharge Line 5. Three-Way Valve Bypass Check Valve 7. Condenser Coil 8. Evaporator Coil 21. Equalizer Line 19. Bypass Check Valve 30. Throttling Valve 26. Distributor 20. Defrost Pan Heater 29. High Pressure Relief Valve 10. Hot Gas Line 28. Receiver Outlet Valve 13. Liquid Line 14. Discharge Service Valve 3. Receiver Tank 11. Feeler Bulb 18. Sight Glass 12. Pilot Solenoid 27. Condenser Check Valve 9. Suction Service Valve 25. Compressor 2. Suction Line 22. Bypass Service Valve AGA283 160 . Accumulator 23. Heat Exchanger 16. Discharge Vibrasorber 4. Three-Way Valve 6.

Electronic Throttling Valve 32. Evaporator Coil 21. Three-way Valve Bypass Check Valve 7. Heat Exchanger 16. Pilot Solenoid 27. Suction Transducer ARA161 33. Three-way Valve 6. Feeler Bulb 18. Bypass Service Valve 31. Discharge Service Valve 3. Compressor 2. Sight Glass 12. Expansion Valve 17. Defrost Pan Heater 29. Condenser Coil 8. Condenser Check Valve 9. Suction Vibrasorber 24. Suction Line 22. Hot Gas Line 28. Refrigeration Diagrams Cool Cycle With Electronic Throttling Valve 1. Equalizer Line 19. Discharge Transducer AEA724 161 . Receiver Tank 11. Suction Service Valve 25. Bypass Check Valve 30. Hot Gas Bypass Valve 26. Liquid Line 14. Drier 15. Receiver Outlet Valve 13. Discharge Line 5. Distributor 20. Accumulator 23. High Pressure Relief Valve 10. Discharge Vibrasorber 4.

Pilot Solenoid 27. Discharge Vibrasorber 4. Expansion Valve 17. Bypass Service Valve 31. Hot Gas Bypass Valve 26. Discharge Transducer 162 . Hot Gas Line 28. Electronic Throttling Valve 32. Sight Glass 12. Three-way Valve Bypass Check Valve 7. Feeler Bulb 18. Suction Transducer ARA162 aea725 33. Distributor 20. Equalizer Line 19. Heat Exchanger 16.Refrigeration Diagrams Heat/Defrost Cycle With Electronic Throttling Valve 1. Discharge Line 5. Suction Vibrasorber 24. Condenser Check Valve 9. Liquid Line 14. High Pressure Relief Valve 10. Three-way Valve 6. Bypass Check Valve 30. Evaporator Coil 21. Suction Service Valve 25. Receiver Outlet Valve 13. Accumulator 23. Suction Line 22. Defrost Pan Heater 29. Compressor 2. Drier 15. Receiver Tank 11. Condenser Coil 8. Discharge Service Valve 3.

replacement 125 evaporator coil. EMI 3000 106 coolant level switch 31 air heater 74 cooling system. specifications 17 compressor. 123 compressor replacement 138 priming new compressor installations 143 EMI 3000 78 compressor coupling engine change 77 installation 126 engine compartment components 30 removal 125 engine coolant temperature sensor 31 compressor oil engine speed adjustments 88 checking 121 high speed 88 compressor oil pressure. Tier 1 engine 104 alternator (Australian Bosch) 67 CYCLE-SENTRY alternator (Prestolite) 71 selecting 48 antifreeze CYCLE-SENTRY Operation 26 changing 81 CYCLE-SENTRY Start-Stop Controls 26 checking 81 maintenance procedure 81 D auto phase system 75 data logging 27. refrigeration 157 model 50 110 diagrams alternator belt 110 fuel line routing 167 compressor belts 110 refrigeration 159 fan belt 110 wiring 167 water pump belt 110 diesel mode. replacement 128 expansion valve assembly. adjustment 146 battery cables 72 defrost drains 145 belt adjustments Defrost key 40 model 30 108 diagnosis. engine 80 air restriction indicator 106 bleeding air from 82 alarms menu 55 crankcase breather. 32 datalogger menu 56 B defrost 28. specifications 19 dowel pin replacement 116 electrical standby. replacement 130 condenser coil. selecting 64 belt replacement discharge pressure transducer. replacement 128 lower fan belt 109 upper fan belt 109 E model 50 ELC (Extended Life Coolant) 80 compressor belt 111 electric power receptacle 45 fan belt 112 electric standby belt tension. mechanical 151 upper and lower fan belts 108 diagnosis. replacement 131 control panel 39 adjust brightness menu 65 display 40 air cleaner restriction indicator 30 keys 40 air cleaner. replacement 131 condenser check valve. replacement 137 model 30 discharge vibrasorber. specifications 18 operation 45 belts 107 selecting 64 bypass check valve. 32 battery 72 defrost damper. checking 143 low speed 89 compressor oil sight glass 30 engine. specifications 20 drive bushing replacement 114 electronic throttling valve 25 cold start device 101 electronic throttling valve (ETV) 32. specifications 20 C electrical contactors 75 clutch 113 electrical control system. electric standby 155 alternator belt 108 diagnosis. replacement 127 163 .Index A continuous mode AC components 75 selecting 48 accumulator. replacement 129 starting unit on 45 electrical components.

replacement 129 manual defrost cycle. replacement 130 P high pressure cutout 31 PCV. unit and engine 145 testing 98 fuel system 83 O bleeding 87 Off key 40 maintenance 85 oil change. Tier 1 engine 89 testing with an empty trailer 119 timing. unit 145 routing fuel line routing 83 L wire harness 73 language menu 54 leaks. Tier 2 engine 92 refrigerant leaks 120 in-line condenser check valve 128 refrigeration system. 74 On key 40 fuses 31. specifications 19 installation. engine 79 general practices 13 164 . Tier 2 engine 105 high pressure relief valve 31 post trip checks 66 HMI control panel 39 preheat buzzer 31 hot gas solenoid 124 pretrip tests 62 hot gas solenoid valve. positive crankcase ventilation 105 high pressure cutout switch (HPCO) 121 pilot solenoid. 73 operating modes 28 operator menu G navigating 53 gauge readings.Index F lubrication system. compressor 142 fuel tank. initiating 49 first aid 16 manual pretrip inspection 41 electrical shock 16 mechanical throttling valve 140 engine coolant 16 disassembly 141 refrigerant 16 installation 142 refrigerant oil 16 reassembly 141 FreshSet 27 removal 140 fuel filter/water separator. replacement 142 priming new compressor installations 143 hourmeters menu 58 protection devices 30 I R idler assembly 149 receiver tank sight glass 30 overhaul 149 receiver tank. replacement 136 replacement 137 positive crankcase ventilation. engine 78 fuse link 31. refrigerant 120 S loading procedure 66 safety precautions 13 low oil level switch 31 battery removal 14 low oil pressure switch 31 electrical hazards 15 low oil pressure. engine 78 fan alignment condenser blower 147 M evaporator blower 147 main menu fan shaft assembly 148 choices 53 overhaul 148 maintenance inspection schedule 21 filter drier. replacement 88 microprocessor On/Off switch 39 fuel line routing 83 Mode key 40 fuel return line replacement 86 mode menu 59 fuel solenoid 98 moisture indicating sight glass 120 replacement 99 mounting bolts. viewing 50 OptiSet 27 overload relay 31 H heat exchanger. engine 78 operation 83 oil filter change. draining water from 88 oil filter change. replacement 129 injection pump refrigerant charge reinstallation 97 testing for an overcharge 119 removal 95 testing with a loaded trailer 119 timing.

printing 57 trochoid feed pump 100 U unit description 23 V valve clearance adjustment. unit 73 X X430L compressor 25 165 . repair 135 three-way valve. initiating 56 starters 106 suction pressure transducer. engine 103 W wire harness routing 73 wiring. replacement 137 suction vibrasorber. pressure 123 trip report. Index microprocessor service precautions 15 refrigerant hazards 14 refrigerant oil hazards 14 welding precautions 16 selection of operating modes 47 sensor readings. replacement 136 T temperature watch display 43 thermostat. moisture indicating 120 sleep mode. mechanical See mechanical throttling valve time display 66 transducers. repair 132 throttling valve. viewing 51 serial number locations 32 setpoint. engine 83 three-way valve condenser pressure bypass check valve 122 three-way valve condenser pressure bypass check valve. changing 46 sight glass. selecting 60 SMART REEFER 2 (SR-2) Control System 39 soft keys 40 SR-2 Control System 39 standard display 43 start of trip.

Index 166 .

Diagram Index Drawing No. Drawing Title Page 1E07692 Model 30 and 50 Schematic Diagram 169-171 1E07693 Model 30 and 50 Wiring Diagram 172-175 Model 30 with Tier 1 Engine Fuel Line Routing Diagram 176-178 Model 30 with Tier 2 Engine Fuel Line Routing Diagram 179-181 Model 50 with Tier 1 Engine Fuel Line Routing Diagram 182-184 Model 50 with Tier 2 Engine Fuel Line Routing Diagram 185-187 167 .

Diagram Index 168 .

Model 30 and 50 Schematic Diagram .Page 1 of 3 169 .

Model 30 and 50 Schematic Diagram .Page 2 of 3 170 .

Page 3 of 3 171 .Model 30 and 50 Schematic Diagram .

Model 30 and 50 Wiring Diagram .Page 1 of 4 172 .

Model 30 and 50 Wiring Diagram .Page 2 of 4 173 .

Page 3 of 4 174 .Model 30 and 50 Wiring Diagram .

Model 30 and 50 Wiring Diagram .Page 4 of 4 175 .

Nylock Nut 1/4 in. Diameter 55-4203 5. 3/8 in. 1/4 in. Clamp 5/8 in. Flatwasher 1/4 in.Model 30 with Tier 1 Engine Fuel Line Routing Diagram . Return Line to Fuel Tank 176 .0 in. (2) 55-411 3. 55-101 2. 55-4118 4. Inlet Line from Fuel Tank 6.Page 1 of 3 1. Screw 1/4-20 X 1.

75 in.Model 30 with Tier 1 Engine Fuel Line Routing Diagram . Fuel Filter 11-9342 2. Diameter (2) 56-2331 7. Diameter 55-4203 8. Flatwasher M8 55-4613 12. Return to Fuel Tank 3. Band Wrap 4. Inlet from Fuel Transfer Pump 5. Diameter (5) 56-2330 9. Diameter 55-3644 10. Clamp 5/8 in. Clamp 1. Clamp 3/4 in.Page 2 of 3 1. Screw M8 X 85 55-7394 11. Band Wrap 1. Outlet to Injection Pump 6. Return from Injection Pump 4.0 in.0 in. Diameter 55-3741 177 . Lockwasher M8 55-4614 13.

Inlet from Fuel Tank to Fuel Transfer Pump 6. Outlet from Fuel Filter to Injection Pump 3.Model 30 with Tier 1 Engine Fuel Line Routing Diagram . Return from Fuel Filter to Fuel Tank 178 . Return from Injection Pump to Fuel Filter 2. Outlet from Fuel Transfer Pump to Fuel Filter 7. Injection Pump 4. Fuel Transfer Pump 5.Page 3 of 3 1.

Screw 1/4-20 X 0.75 in. (2) 55-411 3.75 Diameter (4) 56-2330 6. Diameter 55-3065 5. Inlet Line from Fuel Tank 7. Flatwasher 1/4 in. Band Wrap 1. 1/4 in. 3/8 in. 55-4118 4. Return Line to Fuel Tank 179 . Nylock Nut 1/4 in. Clamp 1/2 in.Model 30 with Tier 2 Engine Fuel Line Routing Diagram .Page 1 of 3 1. 55-145 2.

Fuel Filter 11-9342 9. Clamp 1.Page 2 of 3 1. (2) 55-411 16.75 in.75 Diameter (4) 56-2330 180 . Grommet 33-316 3. Diameter 55-4203 8.0 in. (2) 55-145 15.Model 30 with Tier 2 Engine Fuel Line Routing Diagram . Screw 1/4-20 X 0. Flatwasher M8 55-7069 5. (2) 55-366 2. Clamp 5/8 in. Inlet from Fuel Transfer Pump 12. Diameter 55-3644 4. Outlet to Injection Pump 13. Screw M8 X 110 55-5424 7. Clamp 5/8 in. Diameter (2) 55-3026 14. Return to Fuel Tank 10. Flatwasher 1/4 in. Return from Injection Pump 11. Lockwasher 1/4 in. Lockwasher M8 55-7727 6. Band Wrap 1.

Outlet from Fuel Transfer Pump to Fuel Filter 7. Return from Fuel Filter to Fuel Tank 181 . Return from Injection Pump to Fuel Filter 3. Outlet from Fuel Filter to Injection Pump 2.Model 30 with Tier 2 Engine Fuel Line Routing Diagram . Fuel Transfer Pump 5. Injection Pump 4. Inlet from Fuel Tank to Fuel Transfer Pump 6.Page 3 of 3 1.

Flatwasher 1/4 in. 3/8 in. Screw 1/4-20 X 1. 1/4 in. 55-4118 5.0 in.Page 1 of 3 1. Clamp 5/8 in. (2) 55-411 4.75 Diameter (3) 56-2330 2. Band Wrap 1. Return Line to Fuel Tank 182 . Diameter 55-3026 6. Inlet Line from Fuel Tank 7. Nylock Nut 1/4 in. 55-101 3.Model 50 with Tier 1 Engine Fuel Line Routing Diagram .

Band Wrap 1. Screw M8 X 85 55-7394 12.75 Diameter (9) 56-2330 9.Model 50 with Tier 1 Engine Fuel Line Routing Diagram . Band Wrap 4. Clamp 3/4 in. Clamp 1. Return from Injection Pump 4. Diameter 55-3741 183 . Return to Fuel Tank 3. Inlet from Fuel Transfer Pump 5. Lockwasher M8 55-4614 14.00 Diameter 56-2331 10. Diameter 55-3644 11. Flatwasher M8 55-4613 13. Inlet to Fuel Transfer Pump 2. Clamp 1-1/4 in.0 in.Page 2 of 3 1. Diameter 55-5274 8. Outlet to Injection Pump 6. Fuel Filter 11-9342 7.

Model 50 with Tier 1 Engine Fuel Line Routing Diagram - Page 3 of 3

1. Return from Injection Pump to Fuel Filter
2. Outlet from Fuel Filter to Injection Pump
3. Injection Pump
4. Fuel Transfer Pump
5. Inlet from Fuel Tank to Fuel Transfer Pump
6. Outlet from Fuel Transfer Pump to Fuel Filter
7. Return from Fuel Filter to Fuel Tank

184

Model 50 with Tier 2 Engine Fuel Line Routing Diagram - Page 1 of 3

1. Band Wrap 1.75 Diameter (3) 56-2330
2. Screw 1/4-20 X 0.75 in. 55-145
3. Flatwasher 1/4 in. (2) 55-411
4. Nylock Nut 1/4 in. 55-4118
5. Clamp 1/2 in. Diameter 55-3065
6. 3/8 in. Inlet Line from Fuel Tank
7. 1/4 in. Return Line to Fuel Tank

185

Model 50 with Tier 2 Engine Fuel Line Routing Diagram - Page 2 of 3

1. Inlet to Fuel Transfer Pump
2. Return to Fuel Tank
3. Return from Injection Pump
4. Inlet from Fuel Transfer Pump
5. Outlet to Injection Pump
6. Fuel Filter 11-9342
7. Clamp 1-1/4 in. Diameter 55-5274
8. Band Wrap 1.75 Diameter (10) 56-2330
9. Clamp 3/4 in. Diameter 55-5280
10. Flatwasher M8 55-7069
11. Lockwasher M8 55-7727
12. Screw M8 X 110 55-5424

186

Fuel Transfer Pump 5. Inlet from Fuel Tank to Fuel Transfer Pump 6. Return from Injection Pump to Fuel Filter 3. Return from Fuel Filter to Fuel Tank 187 . Outlet from Fuel Transfer Pump to Fuel Filter 7. Outlet from Fuel Filter to Injection Pump 2.Model 50 with Tier 2 Engine Fuel Line Routing Diagram .Page 3 of 3 1. Injection Pump 4.

. the leader in transport temperature control and Trane. Maintenance Manual SB-210+ SB-210/SB-310 Additional text information to be placed TK 51586-2-MM (Rev. Its world class brands include Hussmann.S. Distributed by: Thermo King Corporate 314 West 90th Street Minneapolis. MN 55420 Direct (952) 887-2200 TK 51586-2-MM ©2011 Ingersoll Rand Company Printed in U. building and contracting services. Thermo King. ventilating and air conditioning systems.A. a manufacturer of refrigeration and food merchandising solutions. 03/05) TK 5XXXX-X-PL Ingersoll Rand’s Climate Solutions sector delivers energy-efficient HVACR solutions for customers globally. a provider of energy efficient heating.here 1. parts support and advanced controls for commercial buildings and homes.