Maintenance Manual

SB-210+
SB-130, SB-230
and SB-330
Additional text information
to be placed here
TK 54909-2-MM (Rev. 4, 05/18)
TK 5XXXX-X-PL
Ingersoll Rand’s Climate Solutions sector delivers energy-efficient HVACR solutions for
customers globally. Its world class brands include 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 54909-2-MM

©2013 Ingersoll Rand Company

Printed in U.S.A.
 SB-130, SB-230
and SB-330
TK 54909-2-MM (Rev. 4, 05/18)

Copyright© 2011 Thermo King Corp., Minneapolis, MN, U.S.A. Printed in

U.S.A.
The maintenance information in this manual covers unit models:
System SB-130 30 (901703) SB-130 30 (069094)
System SB-230 30 (901704) SB-230 30 (069095)
System SB-230 50 (901705) SB-230 50 (069096)
System SB-330 30 (901706) SB-330 30 (069097)

For further information, refer to:

SB-130/SB-230/SB-330 Operator’s Manual TK 54731
SB-130 Parts Manual TK 54898
SB-230 Parts Manual TK 54899
SB-330 Parts Manual TK 54900
SR-3 Microprocessor Control System Diagnostic Manual TK 54842
SB-130, SB-230 and SB-330 Single Temperature Systems Installation Manual TK 54748
OptiSet Plus User’s Guide TK 54045
Radio Expansion Board (REB) Diagnostic Manual TK 55065
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.

Revision History
Rev. 3 – TK 54909-2-MM (Rev. 3, 04/14) Update for compressor pressurized seal cavity,
internal oil filter, and other general updates.
Rev. 4 – TK 54909-2-MM (Rev. 4, 05/18) Update engine oil viscosity specifications.

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.”

2
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.

Recover Refrigerant
At Thermo King, we recognize the need to preserve the environment
and limit the potential harm to the ozone layer that can result from
allowing refrigerant to escape into the atmosphere.

We strictly adhere to a policy that promotes the recovery and limits

the loss of refrigerant into the atmosphere.

In addition, service personnel must be aware of Federal regulations

concerning the use of refrigerants and the certification of technicians.
For additional information on regulations and technician certification
programs, contact your local Thermo King dealer.

3
 CHANGES, COMMENTS and SUGGESTIONS
You are invited to comment on this manual so it can be updated and improved to better meet you
needs. Any corrections, comments or suggestions are welcome. Please complete the following
information:

Manual Form Number _____________________________________________________

Section and Page # _______________________________________________________

Your Name ______________________________________________________________

Company Name __________________________________________________________

Phone Number ___________________________________________________________

Corrections, Comments and Suggestions _____________________________________

________________________________________________________________________

________________________________________________________________________

________________________________________________________________________

________________________________________________________________________

________________________________________________________________________

________________________________________________________________________

________________________________________________________________________

________________________________________________________________________

________________________________________________________________________

Return to:

NORTH AMERICA EUROPEAN SERVED AREA

THERMO KING CORPORATION THERMO KING CORPORATION

314 West 90th Street Ingersoll Rand Climate Control Technologies
Mail Stop 38 Monivea Road
Minneapolis, MN 55420 Mervue, Galway, Ireland
Attn: Service Department Attn: Service Department

4
Table of Contents
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
General Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Battery Installation and Cable Routing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Battery Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Refrigerant Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Refrigerant Oil Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Electrical Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
High Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Low Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Microprocessor Service Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Welding Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
First Aid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
First Aid, Refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
First Aid, Refrigerant Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
First Aid, Engine Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
First Aid, Electrical Shock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Belt Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Refrigeration System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Electrical Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Electrical Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Electrical Standby (Model 50 Units Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Electric Motor and Overload Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Electric Heater Strips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Standby Power Cord Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Electric Fuel Heater (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Maintenance Inspection Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Unit Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Unit Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Design Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Diesel Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Thermo King X426L and X430L Reciprocating Compressors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Electronic Throttling Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
SMART REEFER 3 (SR-3) Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
CYCLE-SENTRY Start-Stop Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Data Logging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
CargoLink™ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
OptiSet Plus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
FreshSet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Sequence of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Operating Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Opening the Front Doors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Opening the Secondary Door Latch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Closing the Front Doors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Engine Compartment Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Unit Protection Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Serial Number Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
SMART REEFER 3 (SR-3) Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Microprocessor On/Off Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
HMI Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Unit Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Manual Pretrip Inspection (Before Starting Unit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Turning Unit On . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Turning Unit Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

5
Table of Contents

Standard Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Standard Display Variations when OptiSet Plus is in Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Temperature Watch Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Alarm Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Starting the Diesel Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
After Start Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Electric Standby Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Starting the Unit on Electric Standby Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Switching from Diesel to Electric . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Switching from Electric to Diesel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Changing the Setpoint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Selection of Operating Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Selecting CYCLE-SENTRY or Continuous Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Initiating a Manual Defrost Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Terminating a Defrost Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Viewing Gauge Readings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Viewing Sensor Readings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Navigating the Main Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Language Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Return to English at Any Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Alarms Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Datalogger Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Hourmeters Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Mode Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Pretrip Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Electric Standby/Diesel Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Adjust Brightness Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Time Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
OptiSet Plus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Loading Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Post Load Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Post Trip Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Electrical Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Alternator Charging System Diagnostic Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Alternator Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Base Controller Fuse F4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Test Equipment for Checking Voltage and Current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Alternator Load Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
General Diagnostic and Warranty Evaluation Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Field Current Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Battery Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Base Controller LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Smart FETs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
SMART REEFER 3 (SR-3) Microprocessor Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
REB (Radio Expansion Board) Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Fuse Link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Air Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Unit Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Wire Harness Routing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
AC Components (Model 50 Units Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Electrical Contactors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Evaporator Heaters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Auto Phase System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Ultrasonic Fuel Level Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Important USFLS Replacement Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Resistive Fuel Level Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92

6
 Table of Contents

Electric Fuel Heater (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Engine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
EMI 3000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Engine Lubrication System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Engine Oil Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Oil Filter Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Low Oil Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Engine Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
ELC (Extended Life Coolant) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Antifreeze Maintenance Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Bleeding Air from the Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Engine Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Coolant Level Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Engine Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Fuel Line Routing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Fuel Return Line Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Bleeding the Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Draining Water from Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Fuel Pre-Strainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Fuel Filter/Water Separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Fuel Filter/Water Separator Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Engine Speed Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Injection Pump Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Injection Pump Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Injection Pump Reinstallation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
Fuel Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
Trochoid Feed Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
Cold Start Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Electric Fuel Heater (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
Engine Valve Clearance Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Crankcase Breather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
EMI 3000 Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
Air Restriction Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
Belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
Model 30 Belt Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
Model 30 Fan Belt Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
Model 50 Belt Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
Model 50 Compressor Belt Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
Model 50 Fan Belt Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
Clutch (Model 50) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
Drive Bushing Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
Dowel Pin Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
Refrigeration Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
Refrigerant Charge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
Testing The Refrigerant Charge With An Empty Trailer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
Testing the Refrigerant Charge with a Loaded Trailer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
Testing for an Overcharge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
Moisture Indicating Sight Glass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
Refrigerant Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
Oil Collection Container . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
Checking Compressor Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
High Pressure Cutout Switch (HPCO) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
Three-Way Valve Condenser Pressure Bypass Check Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
Electronic Throttling Valve (ETV) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140

7
Table of Contents

Pressure Transducers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141

Hot Gas Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
Refrigeration Service Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
Compressor Coupling Removal (Model 30) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
Compressor Coupling Installation (Model 30) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
Compressors with Pressurized Seal Cavity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
Hex Drive Compressor Seal Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
Condenser Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
Discharge Vibrasorber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
In-Line Condenser Check Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
Condenser Check Valve Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
Bypass Check Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
Receiver Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
Filter Drier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
Expansion Valve Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
Heat Exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
Evaporator Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
Accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
Three-Way Valve Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
Removal/Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
End Cap Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
Assembly/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
Three-Way Valve Condenser Pressure Bypass Check Valve Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
Pilot Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
Suction Vibrasorber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
High Pressure Cutout Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
High Pressure Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
Discharge Pressure Transducer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
Suction Pressure Transducer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
Electronic Throttling Valve (ETV) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
Mechanical Throttling Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
Hot Gas Solenoid Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
Compressor Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
Compressors with Internal Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
Internal Oil Filter Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
Checking Compressor Oil Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
Priming New Compressor Installations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
Structural Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
Unit and Engine Mounting Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
Unit Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
Condenser, Evaporator, and Radiator Coils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
Micro-Channel Coil Cleaning Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
Defrost Drains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
Unit Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
Defrost Damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
Condenser and Evaporator Fan Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
Condenser Fan Blower Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
Evaporator Fan Blower Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
Evaporator Fan Blower Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
Fan Shaft Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
Fan Shaft Assembly Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
Idler Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
Idler Assembly Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175

8
 Table of Contents

Mechanical Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178

Electric Standby Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
Refrigeration Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
Refrigeration Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
Cool Cycle With Mechanical Throttling Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
Heat/Defrost Cycle With Mechanical Throttling Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
Cool Cycle With Electronic Throttling Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
Heat/Defrost Cycle With Electronic Throttling Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
Diagram Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192

9
Safety Precautions
Thermo King recommends that all service be
DANGER: Avoid engine operation in
performed by a Thermo King dealer. However,
confined spaces and areas or
you should be aware of several general safety
circumstances where fumes from the
practices:
engine could become trapped and cause
serious injury or death.
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. Never let them come in
serious injury or death. contact with moving belts, fans, pulleys or
hot surfaces. Defective gauge equipment
WARNING: Denotes the possibility of can damage components or cause serious
serious equipment damage or serious injury.
personal injury.
WARNING: Always wear goggles or safety
CAUTION: Denotes the possibility of glasses when working on a unit.
minor to severe equipment damage or Refrigerant liquid, oil and battery acid can
personal injury. permanently damage your eyes. See “First
Aid” on page 13.
General Practices
WARNING: Use extreme caution when
DANGER: Do not operate the compressor drilling holes in a unit. Holes might
with the discharge service valve closed. weaken structural components. Holes
This condition increases internal pressure, drilled into electrical wiring can cause a
which can cause an explosion. fire or explosion.

DANGER: Never apply heat to a sealed WARNING: Exposed coil fins can cause
refrigeration system or container. Heat lacerations. Service work on the
increases internal pressure, which might evaporator or condenser coils is best left to
cause an explosion. a certified Thermo King technician.

DANGER: Refrigerant in the presence of WARNING: Do not apply heat to a closed

an open flame, spark or electrical short cooling system. Before applying heat to a
produces toxic gases that are severe cooling system, drain it. Then flush it with
respiratory irritants. water and drain the water. Antifreeze
contains water and ethylene glycol. The
DANGER: Keep your hands, 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. Loose clothing might boil off the water.
entangle moving pulleys or belts, causing
serious injury or possible death. WARNING: Be careful when using
ladders or scaffolding to install or service
DANGER: Do not inhale refrigerant. Use a unit. Observe the manufacture’s safety
caution when working with refrigerant or labels and warnings.
a refrigeration system in any confined
area with a limited air supply, such as a CAUTION: Make sure all mounting bolts
cargo area or garage. Refrigerant are tight and are the correct length for
displaces air and can cause oxygen their applications. Improper torque and
depletion, resulting in suffocation and incorrect bolt lengths can damage
possible death. equipment.

10
 Safety Precautions

NOTE: In the USA, EPA Section 608

CAUTION: Always cover battery
Certification is required to work on refrigeration
terminals to prevent them from making
systems.
contact with metal components during
battery installation. Battery terminals
Battery Installation and Cable grounding against metal could cause the
Routing battery to explode.
WARNING: Improperly installed battery
could result in a fire or explosion! A Battery Removal
Thermo King approved battery must be DANGER: Disconnect the negative
installed and properly secured to the battery terminal (-) first when removing a
battery tray. battery. Connect the positive terminal (+)
first when installing a battery.
WARNING: Improperly installed battery
cables could result in fire or explosion! This order is important because the frame is
Battery cables must be installed, routed grounded to the negative battery terminal. If the
and secured properly to prevent them from negative terminal is still connected, a complete
rubbing, chaffing or making contact with circuit exists from the positive terminal of the
hot, sharp or rotating components. battery to the frame. Metal objects contacting the
positive side and the frame simultaneously will
WARNING: Do not attach fuel lines or cause sparks or arcing. If there are sufficient
any additional wiring harnesses to the hydrogen gases emitted from the battery, an
battery cables as this could cause an explosion might occur, causing equipment
electrical fire! damage, serious injury, even death.

CAUTION: Do not connect other

manufacturer’s equipment or accessories
Refrigerant Hazards
to the Thermo King unit. This could result DANGER: Do not use a Halide torch.
in severe damage to equipment and void When a flame comes in contact with
the warranty! refrigerant, toxic gases are produced.
These gases can cause suffocation, even
CAUTION: Set all unit electrical controls death.
to the OFF position before connecting
battery cables to the battery to prevent unit DANGER: Store refrigerant in proper
from starting unexpectedly and causing containers, out of direct sunlight and away
personal injury. from intense heat. Heat increases pressure
inside storage containers, which can cause
CAUTION: Always wear protective them to burst.
clothing, gloves and eye wear when
handling and installing batteries. Battery DANGER: Do not use oxygen (O2 ) or
acid can cause serious burns when compressed air for leak testing. Oxygen
exposed to eyes or skin. If battery acid mixed with refrigerant is combustible.
contacts skin or clothing, wash
immediately with soap and water. If acid WARNING: Wear butyl lined gloves when
enters your eye, immediately flood it with handling refrigerant to help prevent
running cold water for at least twenty frostbite.
minutes and get medical attention
immediately.

11
Safety Precautions

CAUTION: Refrigerant in a liquid state Electrical Hazards

evaporates rapidly when exposed to the
atmosphere, freezing anything it contacts. High Voltage
Be careful when handling refrigerant to DANGER: Lethal amounts of voltage are
protect your skin from frostbite. present in some electrical circuits. Use
extreme care when working on an
CAUTION: When being transferred, operating refrigeration unit.
refrigerant must be in liquid state to avoid
possible equipment damage. WARNING: Do not make rapid moves
when working on high voltage circuits in
CAUTION: When transferring
refrigeration units. Do not grab for falling
refrigerant, use a process that prevents or
tools because you might accidentally touch
greatly restricts refrigerant from escaping
a high voltage source.
into the atmosphere. Refrigerant damages
the earth’s upper ozone layer. WARNING: Use tools with well insulated
handles. Never hold uninsulated metal
Refrigerant Oil Hazards tools near exposed, energized conductors.
WARNING: Protect your eyes from WARNING: Treat all wires and
contact with refrigerant oil. The oil can connections as if they were high voltage
cause serious eye injuries. Avoid until a meter and wiring diagram indicate
prolonged or repeated contact with otherwise.
refrigerant oil. To prevent irritation, wash
your hands and clothing thoroughly after WARNING: Never work alone on high
handling the oil. voltage circuits in the refrigeration unit.
Another person should be nearby to shut
CAUTION: Use the correct oil in Thermo off the unit and provide aid in the event of
King systems to avoid damaging an accident.
equipment and invalidating its warranty.
WARNING: Safety glasses, rubber-
CAUTION: Do not mix refrigerant oils insulated gloves and cable cutters should
because that can cause system damage. be near your work area, in the event of an
electrical accident.
CAUTION: Use dedicated equipment to
prevent contaminating systems with the WARNING: Use caution when working
wrong type of oil. with electrical circuits that contain
capacitors. Some capacitors hold a
CAUTION: Store refrigerant oil in an significant charge that might cause burns
approved sealed container to avoid or shocks if accidentally discharged. Make
moisture contamination. sure capacitors are discharged before
working on electrical circuits.
CAUTION: Do not expose the refrigerant
oil to the air any longer than necessary. Low Voltage
The oil will absorb moisture, which results
in much longer evacuation times and WARNING: Control circuits used in
possible system contamination. refrigeration units are low voltage (12 to
24 volts dc). This voltage is not dangerous,
CAUTION: Wipe up spills immediately. but the large amount of amperage
Refrigerant oil can damage paints and available from the alternator can cause
rubber materials. severe burns if accidentally shorted to
ground with metal objects, such as tools.

12
 Safety Precautions

WARNING: Do not wear jewelry, watches Welding Precautions

or rings because they increase the risk of Take precautions before electrically welding any
shorting out electrical circuits and portion of the unit or the vehicle to which it is
damaging equipment or causing severe attached. Ensure that welding currents are not
burns. allowed to flow through the unit’s electronic
circuits.
Microprocessor Service Observe the following precautions when welding
Precautions to avoid damaging electronic components.
Take precautions to prevent electrostatic
• If the microprocessor has a power switch, turn
discharge when servicing the microprocessor and
it OFF before connecting or disconnecting the
its related components. Even tiny amounts of
battery.
current can severely damage or destroy electronic
components. • Disconnect power to the unit.
Observe the following precautions when servicing • Disconnect all wire harnesses from the
a microprocessor control system to avoid microprocessor.
damaging electronic components. Refer to the
• If there are any electrical circuit breakers in
appropriate microprocessor diagnosis manual and
the control box, switch them OFF.
the Electrostatic Discharge Training Guide (TK
40282) for more information. • Close the control box.
• If the microprocessor has a power switch, turn • Components that could be damaged by
it OFF before connecting or disconnecting the welding sparks should be removed from the
battery. unit.
• Disconnect power to the unit. • Use normal welding procedures, but keep the
ground return electrode as close to the area
• Avoid wearing clothing that generates static
being welded as practical. This will reduce the
electricity (wool, nylon, polyester, etc.).
likelihood of stray welding currents passing
• Wear a wrist strap (P/N 204-622 or its through any electronic circuits.
equivalent) with the lead end connected to the
microprocessor’s ground terminal. These First Aid
straps are available from most electronic
equipment distributors. DO NOT wear these First Aid, Refrigerant
straps with power applied to the unit.
In the event of frostbite, protect the frozen area
• Avoid unnecessary contact with the electronic from further injury, warm the area rapidly and
components. maintain respiration.
• Store and ship electronic components in EYES : For contact with liquid, immediately flush
antistatic bags and protective packaging. eyes with large amounts of water. CALL A
• Leave electronic components in their antistatic PHYSICIAN.
packing materials until you’re ready to use SKIN: Flush area with large amounts of warm
them. water. Do not apply heat. Remove contaminated
clothing and shoes. Wrap burns with dry, sterile,
• After servicing any electronic components,
bulky dressing to protect from infection. CALL A
check the wiring for possible errors before
PHYSICIAN. Wash contaminated clothing before
restoring power to the unit.
reuse.
• Never use a battery and a light bulb to test
circuits on any microprocessor-based
equipment.

13
Safety Precautions

INHALATION: Move victim to fresh air and use

CPR (cardio pulmonary resuscitation) or
mouth-to-mouth resuscitation to restore breathing,
if necessary. Stay with victim until emergency
personnel arrive.

First Aid, Refrigerant Oil

EYES : Immediately flush with water for at least
15 minutes. CALL A PHYSICIAN. Wash skin
with soap and water.
INGESTION: Do not induce vomiting.
Immediately contact local poison control center or
physician.

First Aid, Engine Coolant

EYES : Immediately flush with water for at least
15 minutes. CALL A PHYSICIAN. Wash skin
with soap and water.
INGESTION: Do not induce vomiting.
Immediately contact local poison control center or
physician.

First Aid, Electrical Shock

Take IMMEDIATE action after a person has
received an electrical shock. Get quick medical
assistance, if possible.
The source of the shock must be quickly stopped,
by either shutting off the power or removing the
victim. If the power cannot be shut off, the wire
should be cut with an non-conductive tool, such as
a wood-handle axe or thickly insulated cable
cutters. Rescuers should wear insulated gloves
and safety glasses, and avoid looking at wires
being cut. The ensuing flash can cause burns and
blindness.
If the victim must be removed from a live circuit,
pull the victim away with a non-conductive
material. Use wood, rope, a belt or coat to pull or
push the victim away from the current. DO NOT
TOUCH the victim. You will receive a shock from
current flowing through the victim’s body. After
separating the victim from power source,
immediately check for signs of a pulse and
respiration. If no pulse is present, start CPR
(cardio pulmonary resuscitation). If a pulse is
present, respiration might be restored by using
mouth-to-mouth resuscitation. Call for emergency
medical assistance.

14
Specifications

Engine
Model: SB-130 and SB-230 TK486V (Interim Tier 4)
SB-330 TK486VH (Interim Tier 4)
Number of Cylinders 4
Cylinder Arrangement In-line vertical, number 1 on flywheel end
Firing Order 1-3-4-2
Direction of Rotation Counterclockwise viewed from flywheel end
Fuel Type No. 2 diesel fuel under normal conditions
No. 1 diesel fuel is acceptable cold weather fuel
Oil Capacity 13 quarts (12.3 liters) crankcase and oil filter
Fill to full mark on dipstick
Oil Type API Classification CI-4 or better
(ACEA Rating E3 or better for Europe)
Oil Viscosity 14 F to 122 F (-10 C to 50 C): SAE 15W-40 (Synthetic)
5 to 104 F (-15 to 40 C): SAE 15W-40
5 to 104 F (-15 to 40 C): SAE 10W-30 (Synthetic or
Synthetic Blend)
-13 to 104 F (-25 to 40 C): SAE 10W-40
-13 to 86 F (-25 to 30 C): SAE 10W-30
-22 to 122 F (-30 to 50 C): SAE 5W-40 (Synthetic)
Below -22 F (-30 C): SAE 0W-30 (Synthetic)
Engine rpm:
SB-130 and SB-230 Low Speed Operation 1450 ± 25 rpm
SB-130 and SB-230 High Speed Operation 2200 ± 25 rpm
SB-330 Low Speed Operation 1450 ± 25 rpm
(1720 ± 25 rpm with High Capacity Fresh Option)
SB-330 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 0.006 to 0.010 in. (0.15 to 0.25 mm)
Exhaust Valve Clearance 0.006 to 0.010 in. (0.15 to 0.25 mm)
Valve Setting Temperature 70 F (21 C)
Fuel Injection Timing: See “Injection Pump Timing” on page 111.
Fuel Injection Nozzle Opening Pressure: 2,800-3,000 psi (19,300 to 20,700 kPa)
Low Oil Pressure Switch (Normally Closed) 17 ± 3 psi (117 ± 21 kPa)
Engine Coolant Thermostat 160 F (71 C)

15
Specifications

Engine
Engine Coolant Type ELC (Extended Life Coolant), 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, except in an emergency. If
conventional coolant is added to Extended Life
Coolant, the coolant must be changed after 2 years
instead of 5 years.
Coolant System Capacity 7.5 quarts (7.1 liters)
Radiator Cap Pressure 7 psi (48 kPa)
Drive: Model 30 Direct to compressor; belts to fans, alternator, and water
pump
Model 50 Centrifugal clutch to compressor; belts to electric standby
motor, fans, alternator, and water pump

Belt Tension
Tension No. on TK Gauge P/N 204-427
Model 30 New Belt Field Reset
Alternator Belt:
SB-130 and SB-230 with 37 Amp Alternator 74 71
SB-130 and SB-230 with 65 Amp Alternator 75 72
SB-330 with 37 Amp Alternator 73 70
SB-330 with 65 Amp Alternator 74 71
Lower Fan Belt (Engine to Idler):
SB-130 and SB-230 88 84
SB-330 87 84
Upper Fan Belt (Fan to Idler) 88 85
Model 50 (SB-230 Only)
Alternator Belt:
14 HP Electric Motor and 37 Amp Alternator 76 73
14 HP Electric Motor and 65 Amp Alternator 77 74
24 HP Electric Motor and 37 Amp Alternator 74 71
24 HP Electric Motor and 65 Amp Alternator 75 72
Compressor Drive Belts 94 91
Fan Belt: 14 HP Electric Motor 91 88
24 HP Electric Motor 90 86
Water Pump Belt 74 71

16
 Specifications

Refrigeration System
Compressor: SB-130 Thermo King X426LSC5
SB-230 and SB-330 Thermo King X430LSC5
Refrigerant Charge—Type: SB-130 and SB-230 13 lb (5.9 kg)—R404A
SB-130 and SB-230 with Micro-Channel
Condenser Coil (starting 12/11) 11.5 lb (5.2 kg)—R404A
SB-330 16 lb (7.3 kg)—R404A
SB-330 with Micro-Channel Condenser
Coil (starting 05/12) 12.5 lb (5.7 kg)—R404A
Compressor Oil Charge 4.3 qt (4.1 liters)*
Compressor Oil Type Polyol Ester type P/N 203-513
Mechanical Throttling Valve Setting
(Units without ETV):
SB-130 and SB-230 Model 30 27 to 29 psi (186 to 200 kPa)
SB-230 Model 50 23 to 25 psi (159 to 172 kPa)
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, 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 12.5 Vdc
One, group C31, 12 volt, (950 CCA recommended for
Battery
operation below -15 F [-26 C])
Fuses See “Fuses” on page 84.
Battery Charging 12 volt, 37 amp, brush type, Thermo King Alternator
(65 amp alternator optional)
Voltage Regulator Setting 13.95 to 14.35 volts @ 77 F (25 C)
NOTE: Fuse F4 (Bypass resistor for Prestolite Alternator) must be removed for the Thermo King
Alternator. Thermo King Alternators are painted black (see Figure 90 on page 80).

17
Specifications

Electrical Components
NOTE: Disconnect components from unit circuit to check resistance.
Component Current Draw (Amps) Resistance—Cold
at 12.5 Vdc (Ohms)
Fuel Solenoid: Pull-in Coil 35 to 45 0.2 to 0.3
Hold-in Coil 0.5 24 to 29
Damper Solenoid 5.7 2.2
High Speed (Throttle) Solenoid 2.9 4.3
Air Heater 89 0.14
Pilot Solenoid 0.7 17.0
Electronic Throttling Valve (if used):
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 (if used) 1.1 11.1
Starter Motor 350-475*
* On-the-engine cranking check. Bench test is approximately 140 amps.

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 14.0 10.4 1755 37.8 38
460/3/60 14.0 10.4 1755 18.9 20
460/3/60 24.0 17.9 3500 29 31

Electric Heater Strips

Number 3
Watts 1000 watts (each)
Resistance 48 ohms (each)

Standby Power Cord Requirements

Supply Circuit Breaker: 14 HP Motor 230/3/60 70 amps
14 HP Motor 460/3/60 40 amps
24 HP Motor 460/3/60 60 amps
Extension Cord Size: 14 HP Motor 230/3/60 8 AWG Power Cable, 25 to 50-foot length
14 HP Motor 230/3/60 6 AWG Power Cable, 75-foot length
14 HP Motor 460/3/60 10 AWG Power Cable, up to 75-foot length
24 HP Motor 460/3/60 8 AWG, 4-Conductor, 2000V, Type W Power Cable, up to
75-foot length

18
 Specifications

Electric Fuel Heater (Optional)

Electric Fuel Heater: Resistance 0.9 to 1.1 ohms
Current Draw at 12.5 Vdc 11.4 to 13.9 amps
Internal Thermostat Minimum Closing Temp. 30 F (-1 C)
Internal Thermostat Maximum Opening Temp. 75 F (24 C)
W Fuse 3 amps
Diesel Power Fuse 3 amps
2A/2FH Circuit Breaker 20 amps, manual reset

19
Maintenance Inspection Schedule

Pretrip Every Every Annual/ Inspect/Service These Items

1,500 3,000 4,500
Hours Hours* Hours
Microprocessor
• Run Pretrip Test (see “Pretrip Tests” on page 66).
Engine
• Check fuel supply.
• Check engine oil level.
• • • • Inspect/clean fuel pre-strainer.
• • • • Inspect belts for condition and proper tension (belt tension tool
No. 204-427).
• • • • Check engine oil pressure hot, on high speed (should display “OK”).
• • • • Listen for unusual noises, vibrations, etc.
• • • • Check engine coolant level and antifreeze protection (-30 F [-40 C]).
• Check air cleaner restriction indicator if so equipped (change filter when
indicator reaches 25 in.). Replace EMI 3000 air cleaner element (see
“EMI 3000 Air Cleaner” on page 123) at 3,000 hours or two years
(whichever occurs first) if indicator has not reached 25 in.
• • • Drain water from fuel tank and check vent.
• • • Inspect/clean fuel transfer pump inlet strainer.
• • • Check and adjust engine speeds (high and low speed).
• • • Check condition of drive coupling bushings per Service Bulletin T&T 171.
• Check engine mounts for wear.
• Replace fuel filter/water separator.
• Change engine oil and oil filter (hot). Requires oil with API Rating CI-4 or
better (ACEA Rating E3 for Europe).
— Change ELC (red) engine coolant every 5 years or 12,000 hours. Units
equipped with ELC have an ELC nameplate on the expansion tank (see
page 100).
• Test fuel injection nozzles at least every 3,000 hours. **
— Replace fuel return lines between fuel injection nozzles every 10,000
hours.
Electrical
• • • Inspect battery terminals and electrolyte level.
• • • Inspect wire harness for damaged wires or connections.
• • • • Check operation of damper door (closes on defrost initiation and opens
on defrost termination).
• Inspect alternator wire connections for tightness.
• Inspect electric motor, replace bearings yearly or every 6,000 hours.
*3,000 hours or two years, whichever occurs first.
** Based on EPA 40 CFR Part 89.

20
 Maintenance Inspection Schedule

Pretrip Every Every Annual/ Inspect/Service These Items

1,500 3,000 4,500
Hours Hours* Hours
Refrigeration
• • • • Check refrigerant level.
• • • Check for proper suction pressure.
• • • Check compressor oil level and condition.
• • • Check throttling valve regulating pressure (units with mechanical throttling
valve only).
• Check compressor efficiency and pump down refrigeration system.
• Empty oil collection container mounted on compressor.
— Replace dehydrator and check discharge and suction pressure every two
(2) years.
Structural
• • • • Visually inspect unit for fluid leaks.
• • • • Visually inspect unit for damaged, loose or broken parts (includes air
ducts and bulkheads).
• • • Inspect tapered roller bearing fanshaft and idlers for leakage and bearing
wear (noise).
• • • Clean entire unit including condenser and evaporator coils and defrost
drains.
• • • Check all unit and fuel tank mounting bolts, brackets, lines, hoses, etc.
• • • Check evaporator damper door adjustment and operation.
*3,000 hours or two years, whichever occurs first.
** Based on EPA 40 CFR Part 89.

21
Unit Description

Unit Overview
The Thermo King SB-130, SB-230, and SB-330
are one piece, self-contained, diesel powered, air
cooling/heating units operating under the control
of the SMART REEFER 3 (SR-3) programmable
microprocessor controller. The unit mounts on the
front of the trailer with the evaporator extending
through an opening in the front wall.
The units feature cooling and heating using a quiet
running engine from the Thermo King TK486
engine family.
The units are available in the following models:
• SB-130 30: Cooling and heating on diesel
engine operation.
• SB-230 30: Cooling and heating on diesel
engine operation.
• SB-230 50: Cooling and heating on diesel
Figure 1: Front View
engine operations and electric standby
operation.
• SB-330 30: High capacity cooling and heating
on diesel engine operation. Designed for
engine operation at a high speed of 2600 rpm.

22
 Unit Description

Design Features ˆ Standard Features

The following chart lists key design features and ❍ Option/Factory Installed
options. ❑ Option/Dealer Installed
SB-130 SB-230 SB-230 SB-330
Key Features & Options
Model 30 Model 30 Model 50 Model 30
SMART REEFER SR-3 Controller ˆ ˆ ˆ ˆ
OptiSet Plus™ ˆ ˆ ˆ ˆ
ETV (Electronic Throttling Valve) ❍ ❍ ❍ ˆ
ServiceWatch™ Data Logger ˆ ˆ ˆ ˆ
FreshSet™ Programmable Modes (requires ETV) ❍ ❍ ❍ ˆ
CargoWatch™ Data Logger ˆ ˆ ˆ ˆ
CargoWatch™ Accessories:
• Door Switches ❍/❑ ❍/❑ ❍/❑ ❍/❑
• Temperature Sensor Kits ❍/❑ ❍/❑ ❍/❑ ❍/❑
CargoLink™ Wireless Sensors ❍/❑ ❍/❑ ?❍ / ❑ ❍/❑
EMI-3000 ˆ ˆ ˆ ˆ
High-Capacity Condenser Coil ˆ ˆ ˆ ˆ
Whisper Quiet Technology ❍ ❍ ❍ ❍
Easy-access door design ˆ ˆ ˆ ˆ
Composite Exterior Panels ˆ ˆ ˆ ˆ
Long-Life Coolant/Silicone Hoses ˆ ˆ ˆ ˆ
Remote Status Display ❍/❑ ❍/❑ ❍/❑ ❍/❑
Remote Status Display with Fuel Level ❑ ❑ ❑ ❑
Remote Status Display with Fuel Level and Temperature ❑ ❑ ❑ ❑
Standard Unit Color White ˆ ˆ ˆ ˆ
Standard Grille Color Black ˆ ˆ ˆ ˆ
Directional Air Delivery ˆ ˆ ˆ ˆ
Vibration Isolation System ˆ ˆ ˆ ˆ
Aluminum Undermount Fuel Tank 50 Gal. (186 Liter) ˆ ˆ ˆ ˆ
Fuel Level Sensor ❍ ❍ ❍ ❍
Electric Fuel Heater ❍ ❍ ❍ ❍
Frost Plug Heater ❍ ❍ ❍ ❍
Alternator, 65 Amp, 12V dc ❍ ❍ ❍ ❍
Special Color Grills ❍ ❍ ❍ ❍
Fresh Air Exchange ❍ ❍ ❍ ❍
REB Wireless Communication Platform ❍ ❍ ❑ ❑
iBox™ Interface ❍/❑ ❍/❑ ?❍ / ❑ ❍/❑
PrimAir™ bulkhead and duct system ❑ ❑ ❑ ❑
Rear Remote Control ❑ ❑ ❑ ❑
Humidity Sensor ❑ ❑ ❑ ❑
Megatech Battery, 12 Volt, Wet Cell ❑ ❑ ❑ ❑
EON Battery, 12 Volt, Dry Cell ❑ ❑ ❑ ❑
24 HP Electric Motor — — ❍ —
Remote Electric Power Receptacle — — ❑ —

23
Unit Description

Diesel Engine 1 2
The Thermo King TK486 family of engines are
4-cylinder, water cooled, direct injection diesel
engines.The engine is coupled directly to the
compressor on the Model 30. A centrifugal clutch
transfers power from the engine to the compressor
on the Model 50. Belts transmit power to the unit
fans, alternator, and water pump.
The SB-130 and SB-230 use a TK486V (Interim
Tier 4), which is designed to run with a high speed
of 2200 rpm.
The SB-330 uses a TK486VH (Interim Tier 4),
which is designed to run with a high speed of
2600 rpm. 1. Suction Valve Adapter (Has ETV)
2. Mechanical Throttling Valve (No ETV)
Figure 3: Compressors
The Electronic Throttling Valve (ETV) is a
variable position valve operated by a stepper
motor. The ETV is located in the suction line
between the evaporator and the heat exchanger.
Discharge and suction pressure transducers supply
pressure information to the microprocessor
control system. The microprocessor controls the
electronic throttling valve directly. The ETV
replaces both the throttling valve and the
modulation valve used in other units. The ETV
system also uses a hot gas bypass valve like the
AMA1324
one used with the modulation valve in other units.
Figure 2: TK486V (TK486VH is Similar) The ETV system provides enhanced control of the
refrigeration system as follows:
Thermo King X426L and X430L
Reciprocating Compressors Suction Pressure Control: The suction pressure
control algorithm is the primary control used to
The SB-130 is equipped with a Thermo King obtain maximum capacity. This allows the
X426L reciprocating compressor with 25.9 cu. in. refrigeration system to fully utilize the power
(424 cm3) displacement.The SB-230 and SB-330 capabilities of the engine under varying
are equipped with a Thermo King X430L conditions.
reciprocating compressor with 30.0 cu. in.
Discharge Pressure Protection: This protection
(492 cm3) displacement.
algorithm provides an additional measure of
protection against high discharge pressures and
Electronic Throttling Valve
possible compressor damage. It will prevent
The Electronic Throttling Valve (ETV) is optional shutdowns in high ambient temperatures by
on the SB-130 and SB-230. It is standard on the allowing continued operation of the unit at a
SB-330. temporarily reduced refrigeration capacity.
You can tell if the unit has an ETV by looking at
the compressor. Units with an ETV have a suction
valve adapter. Units without an ETV have a
mechanical throttling valve.

24
 Unit Description

Engine Coolant Temperature Protection: This

WARNING: The unit can start at any time
protection algorithm protects the engine from high
without warning. Press the OFF key on the
coolant temperature shutdowns and possible
HMI control panel and place the
engine damage. It will reduce the load on the
microprocessor On/Off switch in the Off
engine by temporarily reducing refrigeration
position before inspecting or servicing any
capacity. This lowers the engine temperature
part of the unit.
while still allowing continued unit operation.
Modulation Control: The ETV system replaces the The CYCLE-SENTRY system automatically
modulation valve. The modulation control starts the unit on microprocessor demand, and
algorithm operates much the same as modulation shuts down the unit after those conditions are
on other units. satisfied.
NOTE: The SR-3 controller provides a wide
SMART REEFER 3 (SR-3) Control range of control and programming flexibility.
System However, pre-programming of the unit
WARNING: Do not operate the unit until controller may prohibit operation in certain
you are completely familiar with the temperature ranges within some modes and may
location and function of each control. also prohibit certain modes of operation. Refer
to TK 54842 the SR-3 Microprocessor Control
The SR-3 is a microprocessor control system System Diagnostic Manual for information
designed for a transport refrigeration system. The about controller programming.
SR-3 integrates the following functions:
The system automatically monitors and maintains
• Changing setpoint and operating mode the compartment temperature, engine block
temperature, and battery charge levels at a
• Viewing gauge, sensor and hourmeter
condition where quick, easy starts are possible.
readings
If the block temperature falls below 30 F (-1 C),
• Initiating Defrost cycles
the engine will start and run until the block
• Viewing and clearing alarms. temperature is above 90 F (32 C). If the battery
voltage falls to the programmed limit selected by
The microprocessor components are located
CYCLE-SENTRY Battery Voltage (typically 12.2
inside the control box, which is located inside the
volts) and Diesel CYCLE-SENTRY mode is
lower roadside service door. The microprocessor
selected, the engine will start and run until the
is connected to an HMI (Human Machine
charge rate falls below that programmed by
Interface) Control Panel. It is used to operate the
CYCLE-SENTRY Amps (typically 5 amperes).
unit. The HMI control panel is mounted on the
face of the control box. It is clearly visible Features of the CYCLE-SENTRY system are:
through an opening in the lower roadside service
• Offers either CYCLE-SENTRY or
door.
Continuous Run operation.
See the Operating Instructions Chapter for more
• Controller regulated all season temperature
information about the SR-3 controller.
control.
CYCLE-SENTRY Start-Stop Controls • Maintains minimum engine temperature in
low ambient conditions.
The CYCLE-SENTRY Start-Stop fuel saving
system provides optimum operating economy. • Battery Sentry keeps batteries fully charged
during unit operation.
• Variable preheat time.
• Preheat indicator buzzer.

25
Unit Description

Data Logging CargoWatch™: CargoWatch™ data logging

requires the installation of optional sensors. Up to
There are two separate data loggers. The data is six temperature sensor/probes and four door
downloaded through the data ports on the front of switches can be installed. CargoWatch also logs
the control box using an IBM® PC compatible the setpoint. Use the CargoWatch Port to
laptop or desktop computer and Thermo King downloaded the CargoWatch data. If optional
WinTrac 5.1 (or higher) software. temperature sensors are installed, their readings
2 are displayed as Datalogger Sensor (1-6)
1 3 Temperature in the sensor readings. See “Viewing
Sensor Readings” on page 50.
A printer can also be used to print a report of the
optional sensor readings. See “Printing a Trip
Report” on page 58.
USB Port: Standard USB drives that have been
programmed with Wintrac can be used. Use of a
USB drive eliminates the need for an on-site
computer and does not require cables.
The USB port can be used to:
AMA1322 • Upload and download OptiSet™ Plus files.
1. CargoWatch Port • Download the CargoWatch and ServiceWatch
2. USB Port Data Loggers.
3. ServiceWatch Port • Flashload the Base Controller and HMI
Figure 4: HMI Controller and Data Ports Control Panel.

ServiceWatch™: ServiceWatch™ is standard Refer to TK 54842 the SR-3 Microprocessor

equipment. It records operating events, alarm Control System Diagnostic Manual and for
codes and compartment temperatures as they information about using the USB port.
occur and at preset intervals. This information is
typically used to analyze unit performance. Use CargoLink™
the ServiceWatch Port to downloaded the CargoLink™ is a wireless sensor system. The
ServiceWatch data. main components are the coordinator module,
IMPORTANT: A ServiceWatch download can be interconnect harness, antenna, and wireless
helpful when diagnosing a problem in a unit sensors. The coordinator module receives
with an SR-3 Controller. Therefore, it is information from the wireless sensors through the
recommended that a ServiceWatch download be antenna, and communicates with the controller
preformed to help diagnose a problem. A through the interconnect harness. Currently, only
ServiceWatch download must be preformed wireless door switches are available. Other
before contacting the Thermo King Service wireless sensors will be available in the future.
Department for assistance in diagnosing a Refer to TK 55151 the Truck and Trailer Edition
problem. Refer to the SR-3 Microprocessor CargoLink Installation Manual for information
Control System Diagnostic Manual TK 54842 about installing the CargoLink system and
for information about downloading the sensors, and troubleshooting problems with the
ServiceWatch Data Logger and viewing the data. system.

26
 Unit Description

OptiSet Plus In electric operation (Model 50 units only) the

drive motor operates at a single speed. It does not
OptiSet Plus™ is a group of programmable
run in Null. Electric evaporator heaters are also
functions that control how the unit will operate
used to increase the Heat and Defrost capacities
with specific setpoints or named products. This
during electric operation.
assures that when a particular setpoint named
product is selected, the unit will always operate
Diesel Operation
the same way. This allows an entire fleet to be
configured to match customers’ needs. Refer to In diesel operation the microprocessor will select
TK 54842 the SR-3 Microprocessor Control the operating mode from the following:
System Diagnostic Manual and TK 54045 the
• High Speed Cool
OptiSet Plus User’s Guide for configuration
instructions. • Low Speed Cool
• Low Speed Modulated Cool (ETV units only)
FreshSet
• Null (CYCLE-SENTRY operation only)
FreshSet™ is included in OptiSet Plus. FreshSet
is a demand base temperature control for fresh • Low Speed Modulated Heat (ETV units only)
products. FreshSet modifies and adjusts unit
• Low Speed Heat
airflow operation to control temperature and to
maximize protection of cargo, while keeping • High Speed Heat
operating costs to a minimum. TK 54842 the SR-3
• Defrost
Microprocessor Control System Diagnostic
Manual for configuration instructions.
Electric Operation

Sequence of Operation In electric operation the microprocessor will

select the operating mode from the following:
When the Microprocessor On/Off switch is turned
on and Controller ON key is pressed, the LCD • Cool
display is illuminated and shows the setpoint and • Modulated Cool
the return air temperature. If the
CYCLE-SENTRY mode has been selected, the • Null (CYCLE-SENTRY operation only)
unit will start and stop automatically. If the • Modulated Heat (Hot Gas only)
Continuous mode has been selected, the unit will
start and run automatically. • Hot Gas Heat
• Full Heat (Hot Gas and Electric Heat)
Operating Modes
• Defrost (Hot Gas and Electric Heat)
The microprocessor uses a complex program to
determine which operating mode the unit should Defrost
be in. Therefore, it is difficult to predict which
operating mode the unit should be in by Frost gradually builds-up on evaporator coils as a
comparing the setpoint to the box temperature. result of normal operation. The unit uses hot
refrigerant to defrost the evaporator coils. Hot
In diesel operation the diesel engine operates at refrigerant gas passes through the evaporator coil
either low speed or high speed as determined by and melts the frost. The water flows through
the microprocessor. The unit will Cool or Heat in collection drain tubes onto the ground. The
either high or low speed. The unit will Defrost in methods of Defrost initiation are Automatic, and
low speed only. Heat and Defrost consists of hot Manual.
gas delivered to the evaporator coil distributor.
Automatic Defrost: The controller is programmed
to automatically initiate timed or demand defrost
cycles. The controller can be programmed to
initiate timed defrost cycles at intervals of 2, 4, 6,

27
Unit Description

8, or 12 hours. Demand defrost cycles occur if the Opening the Front Doors
differences between the return air temperature,
discharge air temperature, and coil temperature Pull the door latch handle to open the doors and
exceed certain limits. The unit can enter defrost access the engine compartment. Slam the door to
cycles as often as every 30 minutes if required. close it. Do not push the door closed while
holding the door latch handle open or the door
Manual Defrost: In Manual Defrost Mode, the will not close properly.
operator initiates a defrost cycle. See “Initiating a
Manual Defrost Cycle” on page 47.
NOTE: The unit will not perform a Manual
Defrost cycle unless the unit has been turned on
with the ON key, the unit is running in
Continuous or CYCLE-SENTRY mode (or shut
down in CYCLE-SENTRY Null mode), and the
coil temperature is below 45 F (7 C). 1

The evaporator coil temperature must be below 2

45 F (7 C) to allow defrost.
The following four defrost timers are used. These
timers can be set for intervals of 2, 4, 6, 8 or 12
hours.
1. Door Latch
• Defrost Interval In Range with Fresh Setpoint 2. Secondary Door Latch Nameplate
(standard setting 6 hours)
Figure 5: Door Latch Location
• Defrost Interval Not In Range with Fresh
Setpoint (standard setting 4 hours) Opening the Secondary Door Latch
• Defrost Interval In Range with Frozen Later model units are equipped with a secondary
Setpoint (standard setting 6 hours) door latch. These units also have a secondary door
latch nameplate located below the front doors.
• Defrost Interval Not In Range with Frozen
After opening the door latch, reach between the
Setpoint (standard setting is 6 hours)
front doors and lift the spring latch over the spring
This feature allows a shorter Defrost interval to be catch while opening the door.
used when the unit is out of range during a
pull-down and more frequent Defrost cycles may 1
be beneficial.
Normally, longer defrost timer intervals are used
for colder loads. The defrost interval may need to
be changed if the unit will not hold the
compartment temperature at setpoint.
Use a longer defrost interval if defrost is not being
initiated on demand. 2

Use a shorter defrost interval if defrost is

frequently being initiated on demand. 1. Spring Latch
If the unit is in CYCLE-SENTRY Null mode, the 2. Spring Catch
engine will start when defrost is initiated. The unit Figure 6: Opening Secondary Door Latch
will stay in defrost until the evaporator coil
temperature rises to 58 F (14 C).

28
 Unit Description

Closing the Front Doors 25, service the air filter. Press the button on the
bottom of the restriction indicator to reset after
Slam the door to close it. Do not push the door servicing the air cleaner.
closed while holding the door latch handle open
or the door will not close properly. Compressor Oil Sight Glass: Use this sight glass
to check the compressor oil level. See the
Refrigeration Maintenance Chapter for the correct
Engine Compartment procedure.
Components
Engine Oil Dipstick: Use the engine oil dipstick to
The following maintenance items can be checked check the engine oil level.
visually.
CAUTION: Make sure the engine is
WARNING: The unit can start at any time turned off before attempting to check the
without warning. Press the Off key on the engine oil.
HMI control panel and place the
Receiver Tank Sight Glass: Use this sight glass to
microprocessor On/Off switch in the Off
check the level of refrigerant in the receiver tank.
position before inspecting any part of the
See the Refrigeration Maintenance Chapter for the
unit.
correct procedure.
Air Filter Restriction Indicator: The air filter
restriction indicator is attached to the engine
intake manifold. When the diaphragm indicates

1 10
2
3 11
4
12

5
13
6
7
14
8
15

9
AMA1330 16

1. Air Filter Restriction Indicator 9. Engine Oil Filter

2. Suction Service Valve 10. Three-Way Valve
3. Discharge Service Valve 11. Throttle Solenoid
4. Suction Valve Adapter 12. Receiver Tank Sight Glass
5. Engine Starter Motor 13. Low Engine Oil Pressure Switch
6. Engine RPM Sensor 14. Battery
7. Compressor Sight Glass 15. Hand Primer Pump
8. Compressor Oil Filter 16. Engine Oil Dipstick
Figure 7: Engine Compartment Components

29
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. If it stays closed for a specified
closes if the coolant level drops below an time, the microprocessor shuts the unit down and
acceptable level. If it stays closed for a specified records alarm code 19.
time, the microprocessor records alarm code 37.
Preheat Buzzer: The preheat buzzer sounds when
Engine Coolant Temperature Sensor: The
the controller energizes the preheat relay. 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.
temperature. If the engine coolant temperature
rises above an acceptable level, the Overload Relay—Automatic Reset (Model 50): An
microprocessor records alarm code 41 and overload relay protects the standby electric motor.
possibly 18. The the microprocessor might also The overload relay opens the circuit to the electric
shut the unit down. motor if the motor overloads for any reason (e.g.,
low line voltage or improper power supply) while
Fuse Link (Current Limiter): The fuse link is
the unit is on electric standby operation. The
located in the positive battery cable. The fuse link
microprocessor will record Alarm Code 90.
protects the electric system from a short. If the
fuse link burns out, replace it by replacing the
positive battery cable.
Fuses: Various fuses are located on the base
controller to protect circuits and components. See
“Fuses” on page 84 for more information.
Smart FETs: Smart FETs in the base controller
protect circuits and components. See “Smart
FETs” on page 85 for more information.
High Pressure Cutout Switch: The high pressure
cutout switch is located on the compressor
discharge manifold. If the compressor discharge
pressure becomes excessive, the switch opens the
circuit to the run relay to stop the unit. The
microprocessor will record Alarm Code 10.
High Pressure Relief Valve: This valve is designed
to relieve excessive pressure in the refrigeration
system. It is located on the receiver tank. The
valve is a spring-loaded piston that lifts off its seat
when refrigerant pressure exceeds 500 psi (3447
kPa). The valve will reseat when the pressure
drops to 400 psi (2758 kPa). The valve could
possibly leak refrigerant after it has relieved
excess pressure. Tapping the valve lightly may
help the valve reseat and seal properly. The valve
is non-repairable and requires no adjustment. If
the valve fails to reseat properly, recover the
refrigerant charge and replace the valve.
Low Oil Level Switch: The low oil level switch
closes if the oil drops below an acceptable level. If
it stays closed for a specified time, the
microprocessor shuts the unit down and records
alarm code 66.

30
 Unit Description

Serial Number Locations

Unit: Nameplates on the bulkhead above the
compressor inside the curbside door, and on the 1
roadside of the evaporator.
Engine: See the engine identification plate located
on the engine valve cover.
Compressor: Stamped between the cylinders on
the front end above the oil pump.

1 1

1. Serial Number Location

Figure 10: Unit Serial Number Locations

1 2

4
1. Serial Number Location
Figure 8: Compressor Serial Number Location

1
ARA793

1. Unit Serial Number

2. Bill of Material Number
3. Unit Model
4. Unit ID
Figure 11: Laminated Serial Number Plate
(Located Where Shown Above)

1. Serial Number Location

Figure 9: Engine Serial Number Location

31
Unit Description

3 2

1. Defrost Damper
2. Compressor
3. TK486V/VH Engine
Figure 12: Back View

32
 Unit Description

1 2 3

ARA1749

1. Overload Relay
2. Heaters Contactor
3. Phase Selection Module
4. On/Off Switch (With Optional Remote Power Receptacle Only)
5. Drive Motor Contactors
Figure 13: High Voltage Tray (Model 50 Only)

33
Operating Instructions

SMART REEFER 3 (SR-3) HMI Control Panel

Control System Use the HMI control panel to operate the unit.
The microprocessor components are located Refer to the SB-130/SB-230/SB-330 Operator’s
inside the control box, which is located inside the Manual TK 54731 and the SR-3 Microprocessor
lower roadside service door. The microprocessor Control System Diagnostic Manual TK 54842 for
is connected to an HMI (Human Machine more information.
Interface) Control Panel. It is used to operate the The HMI control panel has a display and eight
unit. The CargoWatch, USB, and ServiceWatch touch sensitive keys. The display is capable of
ports are used to retrieve data from the data showing both text and graphics. The four keys on
logging system. the left and right sides of the display are dedicated
1
keys. The four keys under the display are “soft”
keys. The function of “soft” keys change
depending on the operation being performed. If a
2 soft key is active, its function will be shown in the
display directly above the key.

5
3
6

AMA1326

1. Control Box 4. HMI Control Panel

2. Microprocessor 5. USB Port
On/Off Switch
3. CargoWatch Port 6. ServiceWatch Port AMA1321

Figure 14: Control Box With Service Door Open Figure 15: SR-3 HMI Control Panel

Microprocessor On/Off Switch

This switch supplies or removes electrical power
to the microprocessor. It is located on the left side
of the control box.
CAUTION: The unit can start at any time
without warning. 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.

34
 Operating Instructions

Control Panel Display Off Key: This key is used to turn the
unit off. First the display will briefly
The display is used to supply unit information to show “System is Powering Down -
the operator. This information includes setpoint, Please Wait. Press On to Resume” and
current box temperature operating information, then “Off” will appear momentarily.
unit gauge readings, system temperatures and When the power-down sequence is
other information as selected by the operator. complete the display will be blank.
The default display is called the Standard Display. Defrost Key: Press this key to initiate a
It is shown in Figure 16 and is described in detail Manual Defrost cycle.
later in this chapter.
3
CYCLE-SENTRY/Continuous Mode
Key: Press this key to switch back and
2 4
forth between the CYCLE-SENTRY
1 5 mode and the Continuous Run mode. If
OptiSet Plus is in use, it may not be
possible to change the Mode.
The four “soft” keys under the display
are multi-purpose keys (see Figure 16).
6 Their function changes depending on
the operation being performed. If a soft
1. Off Key (Dedicated Key) key is active, it’s function will be
2. On Key (Dedicated Key) shown in the display directly above the
3. Display key.
4. Defrost Key (Dedicated Key)
Typical soft key applications:
5. CYCLE-SENTRY/Continuous Mode Key
(Dedicated Key) • Setpoint
6. Soft Keys • Gauges
Figure 16: Dedicated and Soft Keys
• Sensors
Control Panel Keys • Menu
The four keys on the left and right sides of the • Next/Back
display screen are “dedicated keys” (see Figure
16). Their functions are listed below. • Yes/No

On Key: This key is used to turn the • +/–

unit on. First the display will briefly • Select/Exit
show the Thermo King Logo and then
the statement “Configuring System - • Clear/Help
Please Wait”. When the power-up • Hourmeters
sequence is complete the display
shows the Standard Display of box
temperature and setpoint.

35
Operating Instructions

Unit Operation Turning Unit On

Complete the following steps to turn on the unit:
Manual Pretrip Inspection (Before
Starting Unit) 1. Press the ON key.
The following Manual Pretrip Inspection should 2
be completed before starting the unit and loading 1
the trailer. While the pretrip inspection is not a
substitute for regularly scheduled maintenance
inspections, it is an important part of the
preventive maintenance program designed to head
off operating problems and breakdowns before
they happen.
Fuel: The diesel fuel supply must be adequate to 1. On Key
guarantee engine operation to the next check 2. Display
point. Figure 17: Press On Key
Engine Oil: The engine oil level should be at the
FULL mark with the dipstick turned (threaded) 2. The display briefly shows a Thermo King
into oil pan. Never overfill. Logo.
Coolant: The engine coolant must have antifreeze IMPORTANT: The ON key must be held down
protection to -30 F (-34 C). Alarm Code 37 until the Thermo King Logo appears. If the ON
indicates low coolant. Add coolant in the key is not held down long enough
expansion tank. (approximately 1/2 second), the display may
flicker but the unit will not start up. If this
CAUTION: Do not remove expansion occurs, hold the ON key down until the Thermo
tank cap while coolant is hot. King logo appears.
NOTE: With extremely cold ambient
CAUTION: Do not add “GREEN” or temperatures it may take up to 15 seconds for the
“BLUE-GREEN” conventional coolant to first display to appear.
cooling systems using “RED” Extended
Life Coolant, except in an emergency. If
conventional coolant is added to Extended
Life Coolant, the coolant must be changed
after 2 years instead of 5 years.
Battery: The terminals must be clean and tight.
Belts: The belts must be in good condition and
adjusted to the proper tensions.
Electrical: The electrical connections should be
securely fastened. The wires and terminals should
be free of corrosion, cracks or moisture.
Structural: Visually inspect the unit for leaks,
loose or broken parts and other damage. The
condenser and evaporator coils should be clean
and free of debris. Check the defrost drain hoses
and fittings to make sure they are open. Make sure
all the doors are latched securely.

36
 Operating Instructions

More Than One Language Enabled

If more than one language has been enabled, a
prompt will appear to allow the desired language
to be chosen. Only languages enabled from the
Guarded Access Menu are available. Press YES to
select the language displayed. If a different
language is desired, press the NO key as shown in
Figure 19.
IMPORTANT: The engine start is not delayed by
the language prompt as shown in Figure 19. The
prompt will appear for 10 seconds and then the
engine will start. After the engine is started the
display will return to the prompt shown in
Figure 19.

Figure 19: NO Key

The Language menu will appear as shown in

Figure 18: Turning Unit On Screen Sequence, Figure 20. Press the + or - keys to select the
One Language Enabled
desired language. When the desired language is
3. The “Configuring System” Screen briefly shown press the YES key to confirm the choice.
appears while communications are established
and the unit prepares for operation. See Figure
18.
NOTE: If more than one language has been
enabled, a prompt will appear at this point to
allow the desired language to be chosen. If
this occurs, go to “More Than One
Language Enabled” on page 37. If this does
Figure 20: Language Menu
not occur, only one language is enabled and
you can continue with the unit start up Step 4 The display will briefly show PROGRAMMING
below. LANGUAGE - PLEASE WAIT in the new
4. The Standard Display showing box language as shown in Figure 21.
temperature and setpoint briefly appears. See
“Figure 18: Turning Unit On Screen
Sequence, One Language Enabled”.
5. The “Diesel Engine Starting” Screen briefly
appears as the engine preheats and starts.
6. The Standard Display showing box
temperature and setpoint reappears when the
unit is running. (See Figure 18.) Figure 21: New Language

37
Operating Instructions

The new language is confirmed, and then the Turning Unit Off
Standard Display will appear in the new language
Complete the following steps to turn unit off:
as shown in Figure 22. The unit is now ready to
run. 1. Press the OFF key.

Figure 22: Standard Display

The “Diesel Engine Starting” Screen will briefly 1. Off Key

appear as the engine preheats and starts. 2. Display
The Standard Display showing box temperature Figure 23: Press Off Key
and setpoint will reappear (as shown in Figure 22)
when the unit is running. 2. The engine will immediately shut off.
3. The “System is Powering Down” Screen will
briefly appear.

Figure 24: Turning Unit Off Screen Sequence

4. The Off Screen will briefly appear.

5. The screen goes blank when the unit power is
off. To start the unit again, press the ON Key.

38
 Operating Instructions

Standard Display Standard Display Variations when

The Standard Display is the default display. It OptiSet Plus is in Use
appears if no other display function is selected. The Standard Display has variations. A display
The Standard Display shows the box temperature showing any of the following variations is still
and setpoint. The box temperature is measured by considered a Standard Display (see Figure 26).
the controlling sensor. The return air sensor is the
The top of the display may show a named product
controlling sensor except when the controller is
if the controller has been programmed with
programmed to use the discharge air sensor as the
OptiSet Plus temperature profiles. The far left soft
controlling sensor during modulation. The box
key may display PRODUCT or PRODUCT/SETPOINT if
temperature shown below in Figure 25 is 35.5 F.
the controller has been programmed with OptiSet
The setpoint shown is 35 F. The CYCLE-
Plus temperature profiles. See “OptiSet Plus” on
SENTRY Icon in the upper right corner shows the
page 72 for information about selecting or
unit is operating in the CYCLE-SENTRY mode.
changing the named product or the setpoint if the
The arrow pointing down indicates the unit is
controller has been programmed with OptiSet
cooling.
Plus temperature profiles. Refer to TK 54045 the
NOTE: The CYCLE-SENTRY Icon will appears OptiSet Plus User’s Guide and TK 54842 the
when the unit is operating in CYCLE-SENTRY SR-3 Microprocessor Control System Diagnostic
mode as shown below. If the CYCLE-SENTRY Manual for information about programming the
Icon is not present the unit is operating in controller with OptiSet Plus temperature profiles.
Continuous mode.
The temperature can be displayed in degrees
1 3
Fahrenheit (F) or degrees Celsius (C). An arrow
pointing upwards indicates the unit is heating. An
4 arrow pointing downwards indicates the unit is
2 cooling.
1 4
2

1. Box Temperature 3. CYCLE-SENTRY 3

Icon
2. Cooling 4. Setpoint
5 6
Figure 25: Standard Display

1. Named Product
2. Heating
3. PRODUCT or PRODUCT/SETPOINT Soft Key
4. Degrees Celsius
5. Cooling
6. Degrees Fahrenheit
Figure 26: Standard Display Variations

39
Operating Instructions

Temperature Watch Display Alarm Display

The Standard Display defaults to the Temperature If a unit alarm condition occurs the large Alarm
Watch Display after about 2-1/2 minutes of Icon will appear on the Standard Display as
non-use (when no keys are pressed) and no check, shown below in Figure 28.
prevent or shutdown alarms are present. The
NOTE: A shutdown alarm will also cause the
Temperature Watch Display shows the same box
display and backlight to flash on and off, and the
temperature and setpoint but in larger fonts. This
display will switch from normal video to reverse
creates easy operator viewing from a distance. To
video and back to normal video (light areas
return to the Standard Display press the MENU soft
become dark and dark areas become light).
key (or any of the other three soft keys that are not
assigned). See “Alarms Menu” on page 55 for information
about displaying and clearing alarms.
NOTE: A named product may appear above the
temperature reading if the controller has been 1 2
programmed with OptiSet Plus temperature
profiles and a named product has been selected.
NOTE: The CYCLE-SENTRY Icon will appear
in the Temperature Watch display when the unit
is operating in CYCLE-SENTRY mode as shown
below. If the CYCLE-SENTRY Icon is not
present the unit is operating in Continuous
mode. 1. Alarm Icon
2 2. Named Product (If Selected)
1
Figure 28: Alarm Display

1. Named Product (If Selected)

2. CYCLE-SENTRY Icon
3. Menu Soft Key
Figure 27: Temperature Watch Display

40
 Operating Instructions

Starting the Diesel Engine After Start Inspection

Diesel engine preheats and starts automatically in After the unit is running, check the following
both Continuous Mode and CYCLE-SENTRY items to confirm that the unit is running properly.
mode. The engine will preheat and start if Oil Pressure: Check the engine oil pressure by
necessary when the unit is turned on. The engine pressing the GAUGES soft key. See “Viewing Gauge
preheat and start will be delayed in Readings” on page 48. The Engine Oil Pressure
CYCLE-SENTRY mode if there is no current Display should indicate OK not LOW.
need for the engine to run. If a key or sequence of
keys are pressed on the HMI Control Panel before Ammeter: Check the ammeter reading by pressing
the engine starts, the engine will preheat and start the GAUGES soft key. See “Viewing Gauge
approximately 10 seconds after pressing the last Readings” on page 48. The Amps Display should
key. indicate a positive charge amperage rate to the
battery. A negative (-) number indicates a
See “Turning Unit On” on page 36. discharge condition.
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. minutes of operation. If not, check the compressor
oil level using the procedure in the Refrigeration
WARNING: Never use starting fluid. Maintenance Chapter.
Pre-Cooling: Make sure that the setpoint is at the
NOTE: Run a pretrip test if the unit has not been desired temperature. See “Changing the Setpoint”
used recently. See “Pretrip Tests” on page 66. on page 44. Allow the unit to run for a minimum
of 30 minutes (longer if possible) before loading
Unit Fails To Start the trailer.

If the engine does not start and the Alarm Icon This provides a good test of the refrigeration
appears on the display, take the following steps. system while removing residual heat and the
moisture from the trailer interior to prepare it for a
1. Check for and correct any alarm conditions. refrigerated load.
See “Viewing and Clearing Alarms Screen Defrost: When the unit has finished pre-cooling
Sequence” on page 56. the trailer interior, manually initiate a Defrost
2. Clear all alarms. See “Viewing and Clearing cycle. See “Initiating a Manual Defrost Cycle” on
Alarms Screen Sequence” on page 56. page 47. This will remove the frost that builds up
while running the unit to pre-cool the trailer.
3. Press the OFF key to turn the unit off.
4. Press the ON key to turn the unit on.
5. The controller will go through the start up
screens and then after a 10 second delay the
unit will start automatically.
6. If the engine will still not start, turn the unit
off. Determine and correct the cause for not
starting.
7. Repeat the procedure.

41
Operating Instructions

Electric Standby Operation Starting the Unit on Electric Standby

Model 50 units are equipped with Electric Operation
Standby. This feature allows the unit to operate on Units equipped with the Electric Standby option
electric power as well as be powered by the only.
standard diesel engine.
Electric motor starting is automatic in both
During Electric Standby operation, power to the Continuous Mode and Cycle Sentry Mode. The
unit is supplied by an electric motor connected to motor will start as required when the unit is turned
a high voltage power source. The required voltage on. If any keys are being pressed on the HMI
is shown on a decal on the unit’s electric power control panel prior to the motor start, the motor
receptacle. start will be delayed until 10 seconds after the last
key is pressed. Start the unit on Electric Standby
WARNING: Units equipped with electric operation as follows:
standby may start at any time when the
unit is connected to live electric power and 1. Press the controller OFF key to make sure the
the controller is turned on. unit is turned off.
2. Connect the unit electric power receptacle to
CAUTION: Always turn the electric an appropriate electric power supply.
power supply off when handling,
connecting, or disconnecting high voltage 3. Press the controller ON key.
power cords.
CAUTION: The motor may start
CAUTION: Do not start the electric drive automatically any time the unit is turned
motor unless the diesel engine is on.
completely stopped. 4. If a screen asking if you wish to switch to
Electric Power Receptacle: The electric power Electric Standby appears, press the YES soft
receptacle is used to connect the unit to an key. This screen does not appear if the
appropriate electric power source for electric controller is programmed to automatically
standby operation. The electric power receptacle switch from Diesel to Electric Standby, or if
is located next to the HMI Control Panel. Make the unit was in Electric Standby when it was
sure the unit and the power supply are turned off turned off.
before connecting or disconnecting a power cord.

Figure 30: Electric Standby Detected Screen

5. If the microprocessor determines that the unit

should cool or heat, the motor start screen
appears as shown below. The preheat buzzer
sounds for 20 seconds before the electric
motor starts. It may not start if the return air
sensor temperature is within a few degrees of
setpoint. The electric motor cycles on and off
in CYCLE-SENTRY Mode and runs
Figure 29: Electric Power Receptacle continuously in Continuous Mode.

42
 Operating Instructions

If NO is selected, then the unit will continue to

operate in Diesel Mode. If YES is selected then
ELECTRIC MOTOR STARTING the display will briefly show the screen below.

ARA909

Figure 31: Electric Motor Starting Screen

6. Complete an After Start Inspection (see

page 41) for Compressor Oil, Pre-Cooling and
Figure 33: Programming Electric Standby Screen
Defrost.
Electric Mode operation will briefly be
Unit Fails to Start confirmed. If unit operation is required the
If the electric motor does not start and the Alarm electric motor will start as shown in “Starting the
Icon appears on the display, take the following Unit on Electric Standby Operation” on page 42.
steps. If the Diesel to Electric Autoswitch Enabled
1. Check for and correct any alarm conditions. feature in Guarded Access is set NO then the unit
See “Viewing and Clearing Alarms Screen can also be switched from Diesel mode to Electric
Sequence” on page 56. mode operation using the Electric Standby
Selection as shown in “Electric Standby/Diesel
2. Clear all alarms. See “Viewing and Clearing Mode” on page 69.
Alarms Screen Sequence” on page 56.
3. Press the Controller OFF key. Switching from Electric to Diesel
4. Press the Controller ON key. Units equipped with the Electric Standby option
only.
5. If the unit still does not start, repeat the above
steps. If the Electric to Diesel Autoswitch Enabled
feature in Guarded Access is set YES then the unit
will automatically switch to Diesel Mode
Switching from Diesel to Electric operation when standby power is turned off or is
Units equipped with the Electric Standby option no longer available.
only
If the Electric to Diesel Autoswitch Enabled
If the Diesel to Electric Autoswitch Enabled feature in Guarded Access is set NO and standby
feature in Guarded Access is set YES then the unit power is disconnected or fails, the unit will not
will automatically switch to Electric Mode automatically switch to Diesel mode. This is
operation when standby power is connected and primarily designed to prevent unauthorized diesel
available. engine starts when the truck is indoors or on a
If the Diesel to Electric Autoswitch Enabled ferry where engine operation is strictly prohibited.
feature in Guarded Access is set NO, then the If the Electric to Diesel Autoswitch Enabled
prompt screen shown below will appear when feature in Guarded Access is set NO then the
standby power is connected and available. prompt screen shown below will appear when
standby power is turned off or is no longer
available.

ELECTRIC STANDBY UNDETECTED

DO YOU WISH TO SWITCH TO

DIESEL?

Figure 32: Electric Standby Detected Screen YES NO

ARA910

Figure 34: Electric Standby Undetected Screen

43
Operating Instructions

If YES is selected then the display will briefly 1

show the screen below.

PROGRAMMING DIESEL MODE

2
PLEASE WAIT

ARA911

1. Standard Display
Figure 35: Programming Diesel Mode Screen
2. Setpoint Soft Key
Diesel Mode operation will briefly be confirmed.
Figure 36: Changing Setpoint
If unit operation is required the diesel engine will
start as shown in “Starting the Diesel Engine” on 3. Press the + or - soft keys to change the setpoint
page 41. reading. See Figure 37.
If the Electric to Diesel Autoswitch Enabled NOTE: If the setpoint is changed using the
feature in Guarded Access is set NO then the unit “+” or “-” keys, the change must be
can also be switched from Diesel mode to Electric confirmed or rejected by pressing the YES or
mode operation using the Diesel Selection as NO soft key within 10 seconds of changing
shown in “Electric Standby/Diesel Mode” on the setpoint. A warning beep will sound for 5
page 69. seconds as a reminder.

Changing the Setpoint 4. Press the YES OR NO soft key accordingly as

described below. See Figure 37.
To change the setpoint complete the following
steps. • If the NO key is pressed the setpoint change
made with the “+” or “-” soft keys will not be
NOTE: If the SETPOINT soft key (far left) displays accepted, the setpoint will not be changed and
PRODUCT or PRODUCT/SETPOINT, the controller has the display will return to the Standard Display.
been programmed with OptiSet Plus temperature
profiles. See “OptiSet Plus” on page 72 for • If the YES soft key is pressed, the setpoint
information about selecting or changing the change made with the “+” or “-” soft keys will
named product or the setpoint. be accepted, and the display screens will
appear as shown in Figure 37.
1. Begin at the Standard Display.
If the Temperature Watch Display is showing, • If the YES or NO key is not pressed within 10
press the MENU soft key once to return to the seconds of making a change with the “+” or
Standard Display. “-” key, the setpoint is not changed and the
display returns to the Setpoint Display. The
2. Press the SETPOINT soft key on the Standard display briefly shows [SETPOINT NOT
Display. See Figure 36. The “Setpoint” Screen CHANGED] and Alarm Code 127 Setpoint
briefly appears, then the “Current Setpoint” Not Entered is set, to indicate that the setpoint
Screen appears. See Figure 37. change was started but not completed.
5. The “Programming New Setpoint” Screen will
appear. See Figure 37.
6. The “New Setpoint Is XX” Screen briefly
appears. See Figure 37.
7. The Standard Display appears with setpoint
changed to the new setpoint. See Figure 37.

44
 Operating Instructions

If YES Key was pressed If NO Key was pressed

SETPOINT Key

+ or – Key

YES or NO Key

Figure 37: Changing the Setpoint Screen Sequence

Selection of Operating Modes Examples of products normally requiring

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

45
Operating Instructions

Selecting CYCLE-SENTRY or 5. Press the CYCLE-SENTRY/CONTINUOUS MODE

Continuous Mode key again to change the unit back to the
previous mode.
When CYCLE-SENTRY Mode is selected the
unit will start and stop automatically to maintain IMPORTANT: If the unit is in CYCLE-SENTRY
the setpoint, keep the engine warm, and the Null and the mode is switched to Continuous
battery charged. When Continuous mode is Mode, the unit will start automatically.
selected, the unit will start automatically and run
NOTE: CYCLE-SENTRY or Continuous Mode
continuously to maintain setpoint and provide
may be disabled by OptiSet Plus.
constant airflow.
If the unit is operating in CYCLE-SENTRY
Mode, the CYCLE-SENTRY Icon will be present
in the upper right corner of the display as shown
in Figure 38. If the CYCLE-SENTRY Icon is not
present the unit is operating in Continuous Mode.
IMPORTANT: If OptiSet Plus is in use, it may
not be possible to change the Mode.
Complete the following steps to change modes:
NOTE: The mode can also be changed using the
Mode Menu Screen in the Main Menu. See
“Turning CYCLE-SENTRY On or Off” on page
62.
1. Press the CYCLE-SENTRY/CONTINUOUS MODE
key. See Figure 38.
1
Figure 39: Screen Sequence for Changing from
2 CYCLE-SENTRY Mode to Continuous Mode

1. CYCLE-SENTRY Icon Shows Mode Selected

Displayed for CYCLE-SENTRY Mode
Not Displayed for Continuous Mode
2. CYCLE-SENTRY/Continuous Mode Key
Figure 38: Changing Mode

2. The “Programming Continuous Mode” or

“Programming CYCLE-SENTRY Mode”
Screen briefly appears. See Figure 39 and
Figure 40.
3. The “New System Mode is Continuous”
Screen or the “New System Mode
CYCLE-SENTRY” Screen briefly appears.
See Figure 39 and Figure 40.
4. The Standard Display appears showing the Figure 40: Screen Sequence for Changing from
new mode. See Figure 39 and Figure 40. Continuous Mode to CYCLE-SENTRY Mode

46
 Operating Instructions

Initiating a Manual Defrost Cycle The unit may be prevented from going into a
Manual Defrost. For example, this can occur if
Defrost cycles are usually initiated automatically
the coil temperature is more than 45 F (7 C). If
based on time or temperature. Manual Defrost is
defrost is not available, the “Defrost
also available if the unit is running and the coil
Unavailable” message will briefly appear and
temperature is less than 45 F (7 C).
the display will return to the Standard Display.
Other features such as door switch settings may See Figure 42.
not allow Manual Defrost to be initiated.
Use the following steps to initiate a Manual
Defrost:
1. Press the DEFROST key. See Figure 41.

1
2

or

1. Standard Display
2. Defrost Key
Figure 41: Initiating a Manual Defrost Cycle

2. The “Defrost” Screen briefly appears. See

Figure 42. Figure 42: Initiating Manual Defrost Screen
Sequence
3. The “Programming Defrost” Screen briefly
appears. See Figure 42. Terminating a Defrost Cycle
4. The “Defrost Started” Screen briefly appears. The Defrost cycle will terminate automatically
See Figure 42. when the coil temperature reaches 58 F (14 C) or
when the defrost timer expires. The defrost timer
5. A modified Standard Display appears. The bar is normally set for 45 minutes, but can be set for
indicator will fill in showing time remaining 30 minutes. Defrost can also be terminated by
to complete the Defrost cycle. The bar turning the unit off.
indicator in the figure shows that the Defrost
cycle is 50% complete. When the Defrost NOTE: If the defrost timer consistently
cycle is complete the display returns to the terminates Defrost because the evaporator coil
Standard Display. See Figure 42. temperature fails to reach 58 F (14 C), check the
unit to see if it is working properly.

47
Operating Instructions

Viewing Gauge Readings Suction Pressure: Displays the unit suction

pressure (ETV units only).
Use the following steps to view the gauge
readings: ETV Position: Displays
the current position of
the ETV valve (ETV units only).
1. Begin at the Standard Display.
I/O (Input/Output State): Displays the current
If the Temperature Watch Display is showing,
press the MENU soft key once to return to the state of the input/output devices listed below.
Standard Display. • High Speed Relay/Electric Heat as On
2. Press the GAUGES soft key to enter the Gauges or Off
Menu. See Figure 43. • Run Relay

1 • Run Relay Feedback

• Alternator Excite Output
• Defrost Damper
• Heat Output
• Alternator Frequency
2 • Diesel/Electric Relay (Model 50 units
only)
1. Standard Display Screen
2. Gauges Soft Key • Electric Ready Input (Model 50 units
only)
Figure 43: Viewing Gauges
• Electric Overload (Model 50 units
3. Press BACK or NEXT soft keys to scroll through only)
available gauges:
• Hot Gas Bypass (ETV units only)
Gauges Available Selecting I/O enters a group of screens that
Coolant Temperature: Displays the show the status (On or Off if applicable) of the
temperature of the engine coolant. devices listed above. See Figure 44. If no keys
Coolant Level: Displays the coolant level in
are pressed within 30 seconds, the screen will
the overflow tank. return to the standard display.

Oil Pressure: Displays the engine oil pressure NOTE: Units without an Electronic
as OK or LOW. Throttling Valve (ETV) will not display the
Discharge Pressure, Suction Pressure, and
Oil Level: Displays the engine oil level as OK ETV Position. See “Electronic Throttling
or LOW. Valve” on page 24 for more information
Amps: Displays the current flow in amps about the ETV and how to tell if the unit has
flowing to or from the unit battery. an ETV.
Battery Voltage: Displays the voltage of the 4. Press the LOCK soft key to display any Gauge
unit battery. Screen for an indefinite period. Press the key
Engine RPM: Displays the engine speed in again to unlock the screen.
RPMs. 5. Press the EXIT soft key to return to the Standard
Fuel Level Sensor: Displays the fuel level if a Display.
fuel level sensor is installed.
Discharge Pressure: Displays the unit
discharge pressure (ETV units only).

48
 Operating Instructions

BACK Key BACK 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

(Device Screens Not Shown)

Figure 44: Viewing Gauges Screen Sequence

49
Operating Instructions

Viewing Sensor Readings Ambient Air Temperature - Displays the

temperature of the ambient air sensor.
Use the following steps to view the sensor
readings. Spare 1 Temperature - Displays the
temperature of the spare 1 temperature sensor.
1. Begin at the Standard Display.
If the Temperature Watch Display is showing, Optional Datalogger Sensor 1-6 Temperatures
press the MENU soft key once to return to the - Display the temperatures of the CargoWatch
Standard Display. Data Logger temperature sensors. The
Datalogger Sensor Temperature screens
2. Press the SENSOR soft key to enter the Sensor
display dashes (– – –) unless optional sensors
Menu. See Figure 45.
are installed.
1 Board Temperature Sensor - Displays the
internal temperature of the HMI Control Panel
PC board. The controller will turn the HMI
display heater on if this temperature goes
below a certain point in extremely cold
ambient temperatures.
See Figure 46 and Figure 47. If no keys are
2
pressed within 30 seconds, the screen will
1. Standard Display return to the Standard Display.
2. Sensors Soft Key
Figure 45: Viewing Sensors

3. Press the BACK or NEXT soft keys to scroll

through the sensor screens. Pressing the
LOCK key will lock the current sensor on the
display (Figure 46).
Sensors Available 1 2 3 4
Control Return Air Temperature - Displays the 1. Exit Soft Key 3. Back Soft Key
temperature of the control return air sensor. 2. Lock Soft Key 4. Next Soft Key
Display Return Air Temperature - Displays Figure 46: Soft Keys
the temperature of the display return air
sensor. 4. Press the LOCK soft key to display any sensor
screen for an indefinite period. Press the key
Control Discharge Air Temperature - Displays again to unlock the screen.
the temperature of the control discharge air
sensor. 5. Press the EXIT soft key to return to the Standard
Display.
Display Discharge Air Temperature - Displays
the temperature of the display discharge air
sensor.
Temperature Differential - Displays the
calculated difference between the Control
Return Air Temperature and the Control
Discharge Air Temperature.
Evaporator Coil Temperature - Displays the
temperature of the evaporator coil sensor.

50
 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 47: Viewing Sensors Screen Sequence

51
Operating Instructions

Navigating the Main Menu Does not appear unless more than
LANGUAGE
one language activated.
The Main Menu contains several additional
submenus that allow the operator to view ALARMS

information and modify unit operation. Use the

following steps to access these menu areas: DATALOGGER

1. Begin at the Standard Display. HOURMETERS

If the Temperature Watch Display is showing,
press the MENU soft key once to return to the MODE
Standard Display.
PRETRIP
2. Press the MENU soft key. See Figure 48.
3. Press NEXT and BACK soft keys to scroll up or ELECTRIC STANDBY/DIESEL Does not appear on Model 30 units.

down through the main menu areas. See

Figure 48 and Figure 49. ADJUST BRIGHTNESS

4. Press the SELECT soft key to access a specific TIME

menu area when shown on the display screen.
See Figure 48. Figure 49: Main Menu Choices

5. Press the EXIT soft key. To return to the Main Menu Choices
Standard Display. The Main Menu choices are
1. Language Menu: This menu only appears if the
shown in Figure 49. For detailed information
controller is programmed to activate more than
on each menu area, see the individual
one language. It allows the operator to select
explanations of each menu item on the
which language is used. All other subsequent
following pages of this manual.
displays are shown in the selected language.
English is the default language. See page 53.
2. Alarms Menu: Shows any active alarms and
allows alarms to be cleared. See page 55.
3. Datalogger Menu: Allows the operator to view
1 the datalogger displays. See page 57.
4. Hourmeters Menu: If enabled, allows the
operator to view the hourmeter displays. See
page 60.
5. Mode Menu: Allows the operator to change unit
operating modes between CYCLE-SENTRY
mode and Continuous Run mode, select Keypad
Lockout, and start Sleep mode. See page 61.
6. Pretrip: Allows the operator to run a Pretrip.
See page 66.
5 4 3 2 7. Electric Standby/Diesel Mode (Model 50 Only):
This menu only appears on Model 50 units. It
1. Menu Soft Key 4. Select Soft Key
allows the operator to manually select Electric
2. Next Soft Key 5. Exit Soft Key Standby or Diesel operation. See page 69.
3. Back Soft Key 8. Adjust Brightness: Allows the operator to
Figure 48: Accessing Main Menu adjust the display intensity as required by
conditions. See page 70.
9. Time: Allows the operator to view the Time and
Date. The Time is displayed in 24 hour military
time. See page 71.

52
 Operating Instructions

Language Menu To select an alternate language:

If the Language feature is enabled in the controller 1. Begin at the Standard Display.
programming, an alternate language can be If the Temperature Watch Display is showing,
selected from the Language Menu. After a new press the MENU soft key once to return to the
language is chosen all displays will appear in that Standard Display.
language. If the language feature is not enabled
2. Press the MENU soft key on the Standard
this menu does not appear.
Display.
The default language is English. Only languages
that have been enabled in the controller
programming will appear on this menu. Refer to
the SR-3 Microprocessor Control System
Diagnostic Manual TK 54842 for information 1
about programming the controller.
NOTE: Exercise care when changing
languages, as once changed all HMI Control 1. Menu Soft Key
panel displays will be in the new language. If the
Figure 50: Standard Display
user is not familiar with the new language,
problems may be experienced returning to the 3. If more than one language is enabled, the
default language. Language Menu is the first Main Menu item
The languages available are dependant on the to appear. Press the SELECT soft key to choose
HMI control panel software revision. the Language Menu Screen. See Figure 51.
• Software revision 65xx/75xx supports 4. The “NEW LANGUAGE WILL BE” Screen
English, Spanish, French, German, Italian, will appear. See Figure 51.
Dutch, Portuguese, Greek, Turkish, Arabic 5. Press the + or - soft keys to select the desired
and Hebrew. language. Only languages enabled from the
• Software revision 66xx/76xx supports Guarded Access Menu are available. German
English, Danish, Russian, Norwegian, is shown in Figure 51.
Swedish, Finnish, Polish, Hungarian, 6. When the desired language is shown, press the
Romanian, Bulgarian, and Czech. YES soft key to confirm the choice.
• Software revision 67xx/77xx supports 7. The “PROGRAMMING LANGUAGE
English, Japanese and Chinese. PLEASE WAIT” Screen briefly appears.
• Software Revision 68xx/78xx supports 8. The “LANGUAGE SELECTED IS XXX”
English and Spanish, or allows any 5 Screen briefly appears.
languages from Software Revision 65xx and
Software Revision 66xx to be selected. Note 9. The display will then return to the Language
that Japanese and Chinese are not available for Menu, but will show the new language.
use with this feature. German is shown in Figure 51.
Other than languages supported, software NOTE: Exercise care when changing
revisions 65xx/75xx, 66xx/76xx, 67xx/77xx, and languages, as once changed all HMI Control
68xx/78xx are identical except that 75xx, 76xx, panel displays will be in the new language. If
77xx, and 78xx are not backwards compatible the user is not familiar with the new
with HMI-1 or HMI-2 Control Panels with only 4 language, problems may be experienced
MB memory. returning to the default language.

53
Operating Instructions

10. Repeat the process to select a different

language. Press the NEXT soft key to select a
different main menu item. Press the EXIT soft
key to return to the Standard Display.

SELECT Key

HAUPTMENU

SPRACHE

BEENDEN AUSWHAL WEITER

ARA820

+ or - Key

NEW LANGUAGE WILL BE

DEUTSCH
YES Key
USE +/- TO CHANGE OK?
- + YES NO
ARA819

Figure 51: Change Language Screen Sequence

Return to English at Any Time After 5 seconds the Language Menu will appear in
the current language as shown in Figure 53. Press
IMPORTANT: If necessary, English and all
the + or - Keys to select the desired language.
other languages in the software version may be
When the desired language is shown press the
accessed from the Standard Display.
YES Key to confirm the choice.
When the Standard Display is shown press and
hold the first and last soft key for 5 seconds as
shown below in Figure 52. This example is
Deutsch (German).

1 2

1. + or - Keys 2. YES Key

Figure 53: + or - Keys, YES Key
1

1. Press These Soft Keys

NOTE: All languages in the installed software
can be selected using this method.
Figure 52: Standard Display

54
 Operating Instructions

Alarms Menu IMPORTANT: Always record any Alarm Codes

that occur - in the order that they occur - as well
If an alarm condition occurs the large Alarm Icon
as any other pertinent information. This
will appear on the Standard Display. See “Alarm
information is extremely valuable to service
Display” on page 40.
personnel.
Alarms are viewed and cleared using the Alarm
7. After the alarm situation is resolved press the
Menu as follows:
CLEAR key to clear the alarm. To display the
1. Begin at the Standard Display. next alarm, press the NEXT key (see Figure 55).
If the Temperature Watch Display is showing,
NOTE: For additional information
press the MENU soft key once to return to the
regarding the alarm shown on the display
Standard Display.
press the HELP soft key. A help message will
2. Press the MENU soft key on the Standard appear.
Display.
Important Alarm Notes
• If an alarm will not clear, it may still exist. If
the alarm is not corrected, it will not clear.
1 • If an alarm cannot be cleared from the Main
menu, the CLEAR key will not appear. These
alarms must be cleared from the Guarded
Access Menus.
1. Menu Soft Key
• All alarms must be viewed before any of the
Figure 54: Standard Display
alarms can be cleared.
3. The Language Menu or Alarm Menu will • If the optional Fuel Level Sensor is installed,
appear. If the Language Menu appears, press Check Alarm Code 96 (Low Fuel Level) is set
the NEXT soft key until the Alarm Menu when the fuel level falls below 15% of tank
appears. capacity. The controller can be programmed to
4. Press the SELECT soft key. The Alarm Display set a shutdown Alarm Code 44 (Check Fuel
will appear. See Figure 55. System) when the fuel level falls to 5%.
Shutdown Alarm Code 44 can be manually
5. If no alarms are present, the “No Alarm” cleared with the CLEAR key. In that case it
Screen is shown. Press the EXIT soft key to becomes a check alarm and the unit will
return to the Standard Display. continue to run until it runs out of fuel (if it is
6. If alarms are present, the quantity of alarms (if not refilled). Alarm Code 96 and Alarm Code
more than one), the alarm code number and 44 are both automatically reset when the fuel
alarm description will be shown on the tank is refilled above 25%.
display. In the example below (see Figure 55), NOTE: Shutdown Alarm Code 44 reappears
there are two alarms present. The most recent when it is manually cleared from the Alarms
is Alarm Code 6. This alarm code indicates a Menu. However, it changes to a check alarm
problem with the coolant temperature sensor. so the unit will now start after you exit the
NOTE: If a serious alarm occurs, the unit Alarms Menu.
will be shut down to prevent damage to the Refer to the SR-3 Microprocessor Control System
unit or the load. If this occurs, the display Diagnostic Manual TK 54842 for more
will show that the unit is shut down and information about alarm codes and their
display the alarm code that caused the diagnosis.
shutdown.

55
Operating Instructions

ALARM 6

2 OF 2 ALARMS
COOLANT TEMP SENSOR

EXIT CLEAR HELP NEXT

ARA823
MENU Key NEXT Key

ALARM 5

1 OF 2 ALARMS
SELECT Key AMBIENT TEMP SENSOR

EXIT CLEAR HELP NEXT

ARA824

SELECT Key CLEAR Key

Figure 55: Viewing and Clearing Alarms Screen Sequence

56
 Operating Instructions

Datalogger Menu
Initiating a Start of Trip
A “Start Of Trip” places a marker in the
1
datalogger memory. It is typically initiated when
the cargo is being loaded. The Start Of Trip
marker then shows when the trip started in the
data that is downloaded or printed from the 1. Menu Soft Key
datalogger. A Start Of Trip can be initiated Figure 56: Standard Display
through the use of WinTrac datalogging software,
or manually in the field. The following procedure 3. Press the NEXT soft key until the Datalogger
covers manual initiation. For more information on Menu appears. See Figure 57.
datalogging, see the WinTrac User Manual
included with the WinTrac software. 4. Press the SELECT soft key on the Datalogger
Menu. The “Start Trip” Screen will appear.
1. Begin at the Standard Display.
If the Temperature Watch Display is showing, 5. Press the SELECT soft key. The “Start Of Trip”
press the MENU soft key once to return to the Screen will appear.
Standard Display. See Figure 56. 6. Press the SELECT soft key to initiate a start of
2. Press the MENU soft key on the Standard trip.
Display. 7. A Start Of Trip Marker has been inserted into
the datalogger memory.
NOTE: The start of trip marker is sent to both
the CargoWatch and ServiceWatch data loggers.

SELECT Key SELECT Key

SELECT Key

Figure 57: Start of Trip Screen Sequence

57
Operating Instructions

Printing a Trip Report 4. Press the NEXT soft key until the Datalogger
Menu appears. See Figure 60.
This procedure prints the CargoWatch datalogger
record directly to a handheld printer. The printed 5. Press the SELECT soft key on the Datalogger
record shows things such as the unit and Base Menu. The “Start Trip” Screen will appear.
Controller identification numbers, dates and
6. Press the NEXT soft key. The “Print/View”
times, the setpoint, and data from the optional
Screen will appear.
sensors connected to the CargoWatch data logger.
If no sensors are connected, the printed record 7. Press the SELECT soft key. The “Delivery
shows the same things without the sensor data. Ticket” Screen will appear. Press the SELECT
soft key to print a Delivery Ticket. The
1 Delivery Ticket is a short ticket that shows
delivery specific details including the current
temperature. See Figure 61.
8. Press the NEXT soft key to go to the “Trip
Ticket” Screen. Press the SELECT soft key to
print a Trip Ticket. The Trip Ticket is a long
ticket that shows details for the current trip
including a temperature history. The Trip
Ticket is also called a Journey Ticket. See
Figure 62.
AMA1320 9. Pressing the EXIT key returns the display to
2 the Main Menu.
1. CargoWatch Port For additional information concerning the
2. Printer Port CargoWatch Data Logger see Service Procedure
Figure 58: Printer Port Location
A49A in the SR-3 Microprocessor Control
System Diagnostic Manual TK 54842.
1. Connect the printer to the 6-pin printer port
located inside the control box.
NOTE: The printer port can be mounted so it
is accessible without opening the control box.
2. Begin at the Standard Display.
If the Temperature Watch Display is showing,
press the MENU soft key once to return to the
Standard Display. See Figure 59.

1. Menu Soft Key

Figure 59: Standard Display

3. Press the MENU soft key on the Standard

Display.

58
 Operating Instructions

SELECT Key SELECT Key

SELECT Key

NEXT Key

NEXT Key SELECT Key

Figure 60: Print Report Screen Sequence

UNIT SERIAL NUMBER: xxxxxxxxxx

CONTROLLER SERIAL NUMBER: A00021506190T3
TRAILER ID: xxxxxxxxxx
CONTROLLER VERSION NUMBER: B007
CONTROLLER TYPE: SR2
DATALOGGER VERSION NUMBER: 6512
TEMPERATURE UNITS: FAHRENHEIT
START: 05/30/08 09:50:08
FINISH: 05/30/08 13:07:33
SENSORS: 1
SETPOINT: 32.0

30 - MAY - 2008
1305 35.0
1250 35.2
1235 35.1
1220 35.2
1205 35.1
30 - MAY - 2008
AMA1299 1150 35.0
Figure 61: Sample Delivery Ticket 1135 35.0
1120 35.0
1105 34.9
1050 35.0
1035 35.0
1020 35.0
1005 35.1
0950 35.1

SENSOR #1: LOG SENSOR 1

SENSOR #2: LOG SENSOR 2

AMA1301

Figure 62: Sample Trip Ticket

59
Operating Instructions

Hourmeters Menu 2. Press the MENU soft key on the Standard

Display.
The Hourmeters are programmable to be visible
or hidden in Guarded Access. Hourmeters that are
visible are displayed. Hourmeters that are hidden
are not displayed, but they do count hours. The
default setting for Model 30 units is to display
only the Engine Hours. The default setting for 1
Model 50 units is to display Total Run Time
Hours, Engine Hours, and Electric Run Hours.
The Hourmeters Menu will not appear if all 1. Menu Soft Key
hourmeters are hidden. Refer to the SR-3
Figure 63: Standard Display
Microprocessor Control System Diagnostic
Manual TK 54842 for information about 3. Press the NEXT soft key until the Hourmeters
programming the controller. Menu appears. See Figure 64.
Hourmeters can be viewed in the Hourmeters 4. Press the SELECT soft key to enter the
Menu as follows: Hourmeters Menu.
1. Begin at the Standard Display. 5. Press the NEXT and BACK soft keys to view the
If the Temperature Watch Display is showing, hourmeter displays. Press the EXIT soft key to
press the MENU soft key once to return to the return to the Standard Display.
Standard Display.

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 64: Viewing Hourmeters Screen Sequence

60
 Operating Instructions

Mode Menu Start Sleep Mode

Various operating modes can be selected using the If this feature is enabled in Guarded Access /
Mode menu. Not all modes may be available, Main Menu Configuration, the operator can select
depending on OptiSet Plus usage and settings of and set Sleep Mode from the Mode Menu. Sleep
other programmable features. The following Mode is used to keep the engine warm and the
modes may be available. battery charged when the unit is not in use. When
the unit is in Sleep Mode the display will show
Turn CYCLE-SENTRY On or Off “SLEEP” and the current time. See “Selecting
Sleep Mode” on page 64.
The CYCLE-SENTRY Mode can be turned On or
Off. If CYCLE-SENTRY is turned off the unit • Program Wakeup Time: This feature allows a
runs in Continuous mode. See “Turning wakeup time to be specified. When the
CYCLE-SENTRY On or Off” on page 62. selected time is reached the unit will start and
resume normal operation.
NOTE: OptiSet Plus may prevent selecting
CYCLE-SENTRY or Continuous. If this If Wakeup Time is selected:
happens, the display will advise that the selection
• Day to Wake Up: The day the unit is to
is not available.
wake up can be specified.
Select Temperature Units • Hour to Wake Up: The hour the unit is to
If this feature enabled in Guarded Access / Main wake up can be specified.
Menu Configuration, the operator can select • Minute to Wake Up: The minute the unit is
temperature units to be displayed as either degrees to wake up can be specified.
Fahrenheit or degrees Celsius.
• Run Pretrip on Wake Up: A Pretrip Test
Keypad Lockout can be automatically run when the unit
wakes up.
If enabled in Guarded Access, the keypad can be
locked to prevent unauthorized use. If the keypad
is locked only the On and Off keys function. The
keypad will remain locked even if the unit is
turned off and back on. If Keypad Lockout is
active, press and hold any soft key for 5 seconds
to deactivate the feature. See “Selecting Keypad
Lockout” on page 63.

61
Operating Instructions

Turning CYCLE-SENTRY On or Off 2. Press the MENU soft key on the Standard
Display.
The easiest way to switch between
CYCLE-SENTRY and Continuous Run is to press 3. Press the NEXT soft key until the Mode Menu
the Mode key (see page 46). But, you can also appears.
switch modes in the Mode Menu as follows:
4. Press SELECT soft key to enter the Mode Menu.
1. Begin at the Standard Display. See Figure 66.
If the Temperature Watch Display is showing,
5. Press the SELECT soft key, to switch between
press the MENU soft key once to return to the
modes.
Standard Display.
6. The new mode is then confirmed for 10
1 seconds.

2 7. The display then returns to the Mode Menu.

Press the SELECT soft key again to change the
3 mode again.
CAUTION: If the unit is in
CYCLE-SENTRY null and the mode is
1. CYCLE-SENTRY Icon Shows Current Mode switched to Continuous mode, the unit will
Displayed for CYCLE-SENTRY Mode start automatically.
Not Displayed for Continuous Mode
2. Mode Key IMPORTANT: If OptiSet Plus is in use, it may
3. Menu Soft Key not be possible to change the Mode.
Figure 65: Standard Display

SELECT Key

SELECT Key SELECT Key

Figure 66: Selecting Mode Screen Sequence

62
 Operating Instructions

Selecting Keypad Lockout 5. Press the NEXT soft key until the Keypad
Lockout Display appears.
This feature must be enabled in Guarded Access
to be available. See “Keypad Lockout” on page 61 6. Press the SELECT soft key to select Keypad
for more information about Keypad Lockout. Use Lockout.
the following steps to select Keypad Lockout:
1. Begin at the Standard Display. ON
CHANGE MODE

KEYPAD LOCKOUT
If the Temperature Watch Display is showing,
press any soft key to return to the Standard OFF

EXIT SELECT BACK NEXT

Display. 1

2. Press the MENU soft key on the Standard

ARA834
Display.

1. Press Select Soft Key

Figure 69: Keypad Lockout Display

7. The new mode is then confirmed for 10

1 seconds.
8. The display then returns to the Mode Menu.
9. Press the Exit soft key to return to the
1. Press Menu Soft Key
Standard Display. If no keys are pressed
Figure 67: Standard Display within 30 seconds, the screen will return to the
Standard Display.
3. Press the NEXT soft key until the Mode Menu
appears. NOTE: If Keypad Lockout is active, press and
hold any soft key for 5 seconds to deactivate the
4. Press the SELECT soft key to enter the Mode
feature.
Menu. The Turn CYCLE-SENTRY On/Off
Screen will appear.

MAIN MENU
ON

MODE

OFF

EXIT SELECT BACK NEXT

1

ARA832

1. Press Select Soft Key

Figure 68: Mode Menu Display

63
Operating Instructions

Selecting Sleep Mode 2. Press the MENU soft key on the Standard
Display.
This feature must be enabled in Guarded Access
to be available. Sleep mode starts and stops the
unit as required to keep the unit battery in a
charged condition and keep the unit engine warm
in cold ambient conditions. Sleep mode does not
maintain setpoint, it keeps the compartment 1
temperature near the ambient temperature when
the unit is running. This is useful in extremely
cold weather or when the unit is to be out of 1. Menu Soft Key
service for an extended time.
Figure 70: Standard Display
The following features are available in Sleep
Mode. 3. Press the NEXT soft key until the Mode Menu
appears. See Figure 71.
Program Wakeup Time: This feature allows a
wakeup time to be specified. When the selected 4. Press SELECT soft key to enter the Mode Menu.
time is reached the unit will start and resume
5. Press the NEXT soft key as required to display
normal operation.
the Sleep Mode Screen.
If a Wakeup Time is selected the following
6. Press the SELECT soft key to start the Sleep
features are available:
mode.
Day to Wake Up: The day the unit is to wake up
can be specified. 7. You now choose to program a Sleep mode
Wake-up Time or simply enter Sleep mode
Hour to Wake Up: The hour the unit is to wake up immediately. Press the NO soft key to
can be specified. immediately enter Sleep mode.
Minute to Wake Up: The minute the unit is to wake
a. The display will show “SLEEP” and the
up can be specified.
unit will start and stop as required to keep
Run Pretrip on Wakeup: A Pretrip Test can be engine warm and/or the battery charged.
automatically run when the unit wakes up. Sleep mode does not maintain the
Sleep mode operates in both Diesel mode and compartment temperature.
Electric mode. In Diesel mode the unit will start b. Press the EXIT soft key to exit Sleep mode
and stop as required to maintain engine or turn the unit off and back on. The unit
temperature and battery charge. In Electric mode will resume normal operation and control
the unit starts and stops as necessary to maintain to setpoint.
battery charge only.
8. To enter a Wake-up Time verify that the unit
When Sleep mode is entered, the operator can clock is set properly (see “Time Display” on
program an automatic Wake-up Time up to a week page 71). Then press the YES soft key at the
away. Using this feature, the unit will “Program A Wake-Up Time?” Screen.
automatically restart and run normally at the
determined time. If a Wake-up Time is 9. Press the + or - soft keys to select the day the
programmed, the operator can also program an unit is to restart in normal operation. In this
automatic Pretrip Test when the unit restarts. example Monday has been chosen. Press the
YES soft key to confirm the day.
Select Sleep Mode as follows:
10. The display will now prompt you for the hour
1. Begin at the Standard Display. the unit is to restart in normal operation. In
If the Temperature Watch Display is showing, this example 18:00 hours has been chosen.
press the MENU soft key once to return to the Note that 24 hour “military time” is used.
Standard Display. Press the YES soft key to confirm the hour.

64
 Operating Instructions

11. The display will now prompt you for the 14. The unit will restart at the programmed time
minute the unit is to restart in normal (in this example 18:37 hours) and perform a
operation. In this example 18:37 hours has Pretrip (if selected). After the Pretrip is
been chosen. Press the YES soft key to confirm complete the test results will be displayed and
the minute. the unit will resume normal operation and
control to setpoint.
12. The display will now prompt you to “Run A
Pretrip On Wake-Up?” Press YES soft key or 15. To exit Sleep mode before the selected
the NO soft key accordingly and the display Wake-up time press the EXIT soft key or turn
will show the unit is programming the Sleep the unit off and back on. The unit will resume
mode. normal operation and control to setpoint.
13. The display will show “SLEEP” and the unit
will start and stop as required to keep the
engine warm and/or the battery charged. Sleep
mode does not maintain setpoint.

SELECT Key then NEXT Key YES Key

SELECT Key YES Key

YES Key YES Key or NO Key

YES Key

Figure 71: Selecting Sleep Mode Screen Sequence

65
Operating Instructions

Pretrip Tests • Engine or Electric Motor Start – The engine or

electric motor will start automatically.
A Pretrip test verifies unit operation. This display
allows a Pretrip Test to be selected and initiated • Defrost – If the coil temperature is below 45 F
by the operator. If the Pretrip Test is entered with (7 C), a Defrost cycle is initiated.
the unit shut down a Full Pretrip Test with device
• Cool Check – The ability of the unit to cool in
amp checks will be performed. If the Pretrip Test
low speed is checked.
is entered with the unit running in either diesel or
electric mode a Running Pretrip Test is • RPM Check (Diesel Mode only) – If the unit
performed. Test results are reported as PASS, is running in the Diesel Mode, the engine
CHECK or FAIL when the Pretrip Test is RPM in high and low speed is checked during
completed. the Cool Check.
• Heat Check - The ability of the unit to heat in
Pretrip Test Conditions
low speed is checked.
• Current unit settings are saved and restored at
• Report Test Results – The test results are
the end of the Pretrip Test or if the unit is
reported as “PASS”, “CHECK” or “FAILED”
turned off and back on.
when the Pretrip is completed. If test results
• Pretrip Test can be run in either Diesel or are Check or Failed, alarm codes will exist to
Electric Mode. direct the technician to the source of the
problem.
• The unit will auto switch from Diesel Mode to
Electric Mode or from Electric Mode to Diesel
Running Pretrip
Mode during a Pretrip Test if these features
are enabled and the auto switch conditions A Running Pretrip occurs when Pretrip is initiated
occur. after the engine or electric motor is running. The
Running Pretrip test proceeds in the order shown
Conditions where Pretrip Tests are not below:
allowed
• Defrost – If the coil temperature is below 45 F
• If any shutdown alarms are present. Pretrip (7 C), a Defrost cycle is initiated.
tests are allowed with some Check and Log
• Cool Check – The ability of the unit to cool in
alarms.
low speed is checked.
• The unit is in Sleep mode.
• RPM Check (Diesel Mode only) – If the unit
• Unit is in Service Test Mode, Interface Board is running in the Diesel Mode, the engine
Test Mode, or Evacuation Mode. RPM in high and low speed is checked during
the Cool Check.
CAUTION: Monitor the return air
temperature when performing a Pretrip • Heat Check - The ability of the unit to heat in
Test on a loaded trailer. The controller low speed is checked.
may not maintain setpoint during the • Report Test Results – The test results are
Pretrip Test. reported as “PASS”, “CHECK” or “FAILED”
when the Pretrip is completed. If test results
Full Pretrip are Check or Failed, alarm codes will exist to
A Full Pretrip occurs when Pretrip is initiated direct the technician to the source of the
before the engine or electric motor starts running. problem.
The Full Pretrip test proceeds in the order shown
below:
• Amp Checks – Each electrical control
component is energized and the current drawn
is confirmed to be within specification.

66
 Operating Instructions

Pretrip Test Issues

When performing a Pretrip Test, the following
issues should be considered.
• Whenever possible, run pretrip tests on empty, 1
dry trailers with the doors closed.
• If running a Pretrip Test on a trailer loaded
with dry cargo, insure that proper airflow can 1. Menu Soft Key
occur around the load. If the load restricts Figure 72: Standard Display
airflow, false test results may occur. Also,
SR-3 units have high refrigeration capacity 4. Press the NEXT soft key until the Pretrip Screen
which results in rapid temperature changes. appears. See Figure 74.
Sensitive dry cargo may be damaged as a
result. 5. Press the SELECT soft key to start a Pretrip.

• If running a Pretrip Test on a trailer that has NOTE: If all alarms were not cleared, a
just been washed down, the extremely high prompt appears as shown below. Press the
EXIT key to exit the Pretrip Test, clear all
humidity inside the trailer may result in false
test results. alarms and repeat the Pretrip Test.

• If running a Pretrip Test on a trailer loaded

with sensitive cargo, monitor the load ON
NO PRETRIP -- ALARM ACTIVE

temperature during the test as normal OFF

temperature control is suspended during 1

EXIT

pre-trip operation.
• Always perform Pretrip Tests with the trailer ARA835

cargo doors closed to prevent false test 1. Press Exit Soft Key
failures.
Figure 73: No Pretrip Alarm Active Display

Initiating a Pretrip Test 6. The Pretrip display appears. See Figure 74.
Before initiating a Pretrip Test, clear all alarm • The top line of the display indicates which
codes. test the unit is performing.
To stop a Pretrip Test at any time, turn the unit off. • The second line shows Test 1 of 49 is
Use the following procedure to initiate a Full being performed. Note that the tests may
Pretrip or a Running Pretrip. A Running Pretrip not be performed in numerical order.
can also be initiated by starting at step 3 with the • The soft keys may be used during the
unit running. Pretrip Test to select the Hourmeter,
1. If the unit is running, press the OFF key to stop Gauge or Sensor menus.
the unit. In a Full Pretrip, when the non-running tests
2. Press the ON key to turn the unit on. are complete the unit will start automatically
and continue with the running tests.
3. To initiate a Full Pretrip press the MENU soft
key as soon as the Standard Display appears 7. When all tests are complete, the results are
and before the unit starts. reported as “PASS”, “CHECK” or “FAILED”.
To initiate a Running Pretrip let the unit start If “FAILED” appears, the unit will shut down.
before pressing the MENU soft key on the If the results are Check or Failed, the
Standard Display. accompanying alarm codes will direct the
technician to the cause of the problem.

67
Operating Instructions

8. If the Pretrip Test results are Check or Failed, Stopping a Pretrip Test
the problem should be diagnosed and
Turn the unit off to stop a Pretrip Test at any time.
corrected and the Pretrip Test repeated and
This will generate Alarm Code 28–Pretrip Abort.
passed before the unit is released for service.
Other alarm codes may also be generated. This is
The Pretrip Test result screen will exit to the
normal when the Pretrip test is stopped before
Main Menu Alarm Submenu for convenient
completion.
access to any alarms generated during the
Pretrip Test.

SELECT Key

Figure 74: Pretrip Test Screen Sequence

68
 Operating Instructions

Electric Standby/Diesel Mode 3. Press the NEXT soft key until the Electric
Standby/Diesel Mode Screen appears. See
The Electric Standby/Diesel Mode display allows
Figure 76 and Figure 77.
the operator to manually select Electric Standby
or Diesel Mode operation. The unit can also be NOTE: The Electric Standby Screen will not
programmed to automatically select Electric appear if diesel to electric switchover is
Standby operation when standby power is enabled. The Diesel Mode Screen will not
available and Diesel Mode operation if standby appear if electric to diesel switchover is
power fails or is removed. Refer to the SR-3 enabled.
Microprocessor Control System Diagnostic
4. Press the SELECT soft key to select the mode
Manual TK 54842 for information about
shown on the display.
programming the controller.
NOTE: Manual selection is the default setting
for both Electric Standby and Diesel Mode.
A screen asking if you wish to switch to Electric
Standby will appear if the unit is connected to SELECT Key
standby power when in the Diesel Mode.
A screen asking if you wish to switch to Diesel
Mode will appear if standby power is
disconnected when in Electric Standby. Pressing
the YES soft key will switch unit operation to the
Diesel Mode. Pressing the NO soft key will force
the unit to remain in Electric Standby even though
standby power is not available. The unit will not
run and Alarm Code 91 Check Electric Ready
Input will be set as a prevent alarm.
Select Electric Standby or Diesel Mode as Figure 76: Programming Diesel Mode
follows:
1. Begin at the Standard Display.
If the Temperature Watch Display is showing,
press the MENU soft key once to return to the
Standard Display.
2. Press the MENU soft key on the Standard
SELECT Key
Display.

1. Menu Soft Key

Figure 75: Standard Display
Figure 77: Programming Electric Standby Mode

69
Operating Instructions

Adjust Brightness Menu 10. Press the Exit soft key to return to the
Standard Display. If no keys are pressed
The brightness of the HMI Control Panel display
within 30 seconds, the screen will return to the
backlight can be adjusted to allow for changing
Standard Display.
ambient light conditions. The choices available to
the operator are HIGH, MEDIUM, LOW, and
OFF. OFF actually results in a very dim backlight
suitable for low light conditions.
IMPORTANT: Before replacing an HMI
Control Panel with no backlight, check the
SELECT Key
Adjust Backlight feature to be sure the backlight
is turned on.
Adjust the display brightness as follows:
1. Begin at the Standard Display.
If the Temperature Watch Display is showing,
press the MENU soft key once to return to the + Key

Standard Display.
2. Press the MENU soft key on the Standard
Display.

YES Key

1. Menu Soft Key

Figure 78: Standard Display

3. Press the NEXT soft key until the Adjust

Brightness Menu appears. See Figure 79.
4. Press the SELECT soft key to enter the Adjust
Brightness Menu. See Figure 79.
5. Press the + or - soft keys to select the desired
brightness. See Figure 79. This example
shows changing screen brightness from low to
medium.
6. Press the YES soft key to enter the new
Figure 79: Adjusting Display Brightness
brightness level. Screen Sequence
7. The “ADJUSTING BRIGHTNESS - PLEASE
WAIT” Screen briefly appears.
8. The selected level appears on the screen.
9. The Adjust Brightness Main Menu Screen
reappears and if no keys are pressed the
Standard Display appears.

70
 Operating Instructions

Time Display
The time and date held by the HMI Control Panel
real time clock can be checked. Time and Date
cannot be changed from the Main Menu. The time
and date are changed by programming the HMI
Control Panel. Refer to the SR-3 Microprocessor
Control System Diagnostic Manual TK 54842 for
information about programming the HMI Control
Panel.
View the time and date as follows:
1. Begin at the Standard Display.
If the Temperature Watch Display is showing,
press the MENU soft key once to return to the
Standard Display.
2. Press the MENU soft key on the Standard
Display.
3. Press the NEXT soft key until the Time Display
appears.
4. Press the SELECT soft key to view the time and
date.

MENU Key then NEXT Key

SELECT Key

1. Standard Display
2. Menu Soft Key
Figure 80: Time and Date Screens

71
Operating Instructions

OptiSet Plus
The controller can be programmed with OptiSet
Plus temperature profiles that allow the user to
select named products. Refer to TK 54045 the 1
OptiSet Plus User’s Guide and TK 54842 the
SR-3 Microprocessor Control System Diagnostic
Manual for information about programming the
controller with OptiSet Plus temperature profiles. 1. Product Soft Key
Figure 81: Standard Display with Product Soft Key
• Named products can have a single setpoint, or
they can have a setpoint range that allows the
user to select a setpoint within that range.
• The controller can be programmed to allow
only named products to be selected. In which
1
case the far left soft key will display PRODUCT.
See Figure 81.
• The controller can be programmed to allow
1. Product/Setpoint Soft Key
named products or numeric setpoints to be
selected. In which case the far left soft key Figure 82: Standard Display with
Product/Setpoint Soft Key
will display PRODUCT/SETPOINT. See Figure 82.
NOTE: In OptiSet Plus the terms “numeric
setpoint” and “setpoint” mean the same
thing and are displayed as numbers. The
terms “named product” and “product” mean
the same thing and are displayed as words.
See “Selecting a Named Product” on page 73 for
information about selecting or changing the
named product.
See “Changing the Setpoint for a Named Product”
on page 76 for information about changing the
setpoint for a named product.
See “Selecting a Setpoint” on page 78 for
information about selecting or changing the
setpoint.

72
 Operating Instructions

Selecting a Named Product 7. Press the YES or NO soft key accordingly as

described below. See Figure 84.
To select or change a named product complete the
following steps. This example shows the Standard • If the NO key is pressed the named product
Display with the PRODUCT/SETPOINT soft key. Using change made with the “+” or “-” soft keys will
the Standard Display with the PRODUCT soft key is not be accepted, the named product will not be
basically the same but some of the screens differ changed and the display will return to the
slightly. Standard Display.
1. Begin at the Standard Display. • If the YES soft key is pressed, the named
If the Temperature Watch Display is showing, product change made with the “+” or “-” soft
press the MENU soft key once to return to the keys will be accepted, and the following
Standard Display. screens will appear.
2. Press the PRODUCT/SETPOINT (or PRODUCT) soft NOTE: Alarm Code 127 may be generated if
key on the Standard Display. See Figure 83. the + or - soft keys are used to change the
named product, but the YES or NO soft keys
1
are not used to accept or decline the new
named product.
8. The “Programming Named Product” Screen
2 will briefly appear. See Figure 84.
NOTE: If the “Change Setpoint for
XXXXX” Screen appears, the named product
1. Standard Display has been programmed with a setpoint range.
2. Product/Setpoint Soft Key See “Selecting the Setpoint for a Named
Product” on page 75.
Figure 83: Selecting Named Product
9. The “New Named Product Is XXXXX”
3. The “Named Product / Numeric Setpoint?” (or Screen briefly appears. See Figure 84.
Named Product) Screen briefly appears, then
the “Named Product or Numeric Setpoint?” 10. The Standard Display appears with the new
(or Named Product) Screen will appear. See named product. See Figure 84.
Figure 84. NOTE: Pressing the EXIT soft key at any point
4. Press the NAMED soft key. See Figure 84. will return to the Standard Display.

5. The “Product” Screen briefly appears, then the NOTE: If no keys are pressed for 30 seconds
“Current Product Is” Screen will appear. See while in the Named Product Changer Screens,
Figure 84. the HMI Control Panel will return to the
Standard Display.
6. Press the + or - soft keys to change the named
product. See Figure 84.

73
Operating Instructions

NOTE: If “Change Setpoint

PRODUCT/SETPOINT Key for XXXXX” Screen appears
instead, see “Selecting the
Setpoint for a Named
Product” on page 75

+ or – Key

NAMED Key YES Key

Figure 84: Selecting or Changing Named Product Screen Sequence

74
 Operating Instructions

Selecting the Setpoint for a Named Product 3. If the + or - soft keys were pressed to change
the current setpoint for the named product, the
If the “Change Setpoint for XXXXX” Screen
“New Setpoint for XXXXX Will Be” Screen
appears after pressing the YES soft key to select a
will appear. See Figure 85.
named product, the named product has been
programmed with a setpoint range. Complete the 4. Press the YES soft key to accept the new
following steps to select a setpoint for the named setpoint for the named product.
product.
NOTE: If the NO key is pressed, the setpoint
1. The “Change Setpoint for XXXXX” Screen will not be changed and the display will
briefly appears, then the “Current Setpoint of return to the Standard Display.
XXXXX & Setpoint Range Is XX to XX”
5. The “Programming New Setpoint for
Screen will appear. See Figure 85.
XXXXX” Screen will briefly appear. See
2. Press the + /- or EXIT soft keys accordingly as Figure 85.
described below. See Figure 85.
6. The “New Setpoint Is XX” Screen briefly
• Press the + or - soft keys to change the current appears. See Figure 85.
setpoint for the named product and then go to
7. The Standard Display appears with the named
step 3.
product and new setpoint. See Figure 85.
• Press the EXIT soft key to accept the current
NOTE: Pressing the EXIT soft key at any point
setpoint for the named product. The Standard
will return to the Standard Display.
Display will appear with the named product
and setpoint. See Figure 85. NOTE: If no keys are pressed for 30 seconds
while in the Named Product Changer Screens,
the HMI Control Panel will return to the
Standard Display.

+ or – Key EXIT Key

YES Key

Figure 85: Selecting Setpoint for Named Product Screen Sequence

75
Operating Instructions

Changing the Setpoint for a Named 7. Press the YES or NO soft keys accordingly as
Product described below. See Figure 87.
If the named product has been programmed with a • If the NO key is pressed the named product
setpoint range, the setpoint for the named product setpoint change made with the “+” or “-” soft
can be changed. Complete the following steps to keys will not be accepted, the named product
change the setpoint for a named product. This setpoint will not be changed and the display
example shows the Standard Display with the will return to the Standard Display.
PRODUCT/SETPOINT soft key. Using the Standard
• If the YES soft key is pressed, the named
Display with the PRODUCT soft key is basically the
product setpoint change made with the “+” or
same but some of the screens differ slightly.
“-” soft keys will be accepted, and the
1. Begin at the Standard Display. following screens will appear.
If the Temperature Watch Display is showing,
8. The “Programming New Setpoint for
press the MENU soft key once to return to the
XXXXX” Screen will briefly appear. See
Standard Display.
Figure 87.
2. Press the PRODUCT/SETPOINT (or PRODUCT) soft
9. The “New Setpoint Is XX” Screen briefly
key on the Standard Display. See Figure 86.
appears. See Figure 87.
1
10. The Standard Display appears with the new
setpoint. See Figure 85.
NOTE: Pressing the EXIT soft key at any point
2 will return to the Standard Display.
NOTE: If no keys are pressed for 30 seconds
while in the Named Product Changer Screens,
1. Standard Display the HMI Control Panel will return to the
2. Product/Setpoint Soft Key Standard Display.
Figure 86: Changing Setpoint for Named Product

3. The “Named Product, Numeric Setpoint or

Change Setpoint?” (or Named Product or
Change Setpoint?) Screen will appear. See
Figure 87.
4. Press the CHANGE SP soft key. See Figure 87.
5. The “Change Setpoint for XXXXX” Screen
briefly appears, then the “Current Setpoint for
XXXXX & Setpoint Range Is XX to XX”
Screen will appear. See Figure 87.
6. Press the + or - soft keys to change the setpoint
reading. See Figure 87.

76
 Operating Instructions

PRODUCT/SETPOINT Key + or – Key

CHANGE SP Key YES Key

Figure 87: Changing Setpoint for Named Product Screen Sequence

77
Operating Instructions

Selecting a Setpoint 6. Press the + or - soft keys to change the

setpoint. See Figure 89.
To select or change a setpoint complete the
following steps. 7. Press the YES or NO soft key accordingly as
described below. See Figure 89.
1. Begin at the Standard Display.
If the Temperature Watch Display is showing, • 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. accepted, the setpoint will not be changed and
the display will return to the Standard Display.
2. Press the PRODUCT/SETPOINT soft key on the
Standard Display. See Figure 88. • If the YES soft key is pressed, the setpoint
change made with the “+” or “-” soft keys will
1
be accepted, and the following screens will
appear.
8. The “Programming New Setpoint” Screen will
2 appear. See Figure 89.
9. The “New Setpoint Is XX” Screen briefly
appears. See Figure 89.
1. Standard Display
10. The Standard Display appears with setpoint
2. Product/Setpoint Soft Key changed to the new setpoint. See Figure 89.
Figure 88: Selecting or Changing Setpoint
NOTE: Pressing the EXIT soft key at any point
3. The “Named Product / Numeric Setpoint?” will return to the Standard Display.
Screen briefly appears, then the “Named NOTE: If no keys are pressed for 30 seconds
Product or Numeric Setpoint?” Screen will while in the Named Product Changer Screens,
appear. See Figure 89. the HMI Control Panel will return to the
4. Press the NUMERIC soft key. See Figure 89. Standard Display.

5. The “Setpoint” Screen briefly appears, then

the “Current Setpoint Is” Screen will appear.
See Figure 89.

PRODUCT/SETPOINT Key

+ or – Key

NUMERIC Key YES Key

Figure 89: Selecting or Changing Numeric Setpoint Screen Sequence

78
 Operating Instructions

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.)
2. Spot check and record load temperature while
loading. Especially note any off-temperature
product.
3. Load the product so that there is adequate
space for air circulation completely around the
load. DO NOT block the evaporator inlet or
outlet.
4. Products should be pre-cooled before loading.
Thermo King transport refrigeration units are
designed to maintain loads at the temperature
at which they were loaded. Transport
refrigeration units are not designed to pull hot
loads down to temperature.

Post Load Procedure

1. Make sure all the doors are closed and locked.
2. Start the unit if it was shut off to load (see
“Turning Unit On”).
3. Make sure the setpoint is at the desired setting.
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
Defrost. The microprocessor will terminate
Defrost automatically when the evaporator
coil temperature reaches 58 F (14 C) or the
unit has been in the Defrost mode for 30 or 45
minutes (depending on setting).

Post Trip Checks

1. Wash the unit.
2. Check for leaks.
3. Check for loose or missing hardware.
4. Check for physical damage to the unit.

79
Electrical Maintenance

Alternator Charging System • The alternator charging output will be low if

Diagnostic Procedures the alternator belt or pulleys are defective or
the belt is not properly adjusted. Be sure the
General Information belt is not loose or cracked and the pulleys are
the correct size and in good condition.
Poor charging performance may not be caused by
a bad alternator. The following conditions can • The excitation circuit (EXC circuit) must
cause improper battery charging, even with a supply voltage to the excite terminal of the
good alternator. (See Service Bulletin T&T 388 alternator.
for more information.) • The sense circuit (2 circuit) must supply
• A problem may exist in the 2A output circuit voltage to the sense terminal of the alternator.
from the alternator to the battery. Check for an • The alternator must be properly grounded.
open 2A circuit, loose connections, defective
battery cables or dirty battery terminals. • The unit control circuits or installed
accessories may be drawing excessive current.
• The battery must be in good condition and
capable of accepting a charge. Check for a • An overcharged battery is usually caused by a
damaged battery, correct electrolyte level, and defective voltage regulator.
loose or corroded connections.
Alternator Identification
• These units use Thermo King Alternators (see
Figure 90), which are painted black.

1 2

3
4
5

7 6

1. B+ Terminal (Positive Output - 2A Wire) 5. F2 Terminal (Do Not Ground)

2. B- Terminal (Negative Ground - CH Wire) 6. Voltage Regulator and Brush Assembly
3. S Terminal (Regulator Sense - 2 Wire) 7. W Terminal (AC Output)
4. L Terminal (Regulator Excite - 7K Wire)

Figure 90: Thermo King Alternator Terminal and Component Locations

80
 Electrical Maintenance

Base Controller Fuse F4 under full unit load conditions. For example, on
multi-temp units, all remote evaporators should be
The base controller has a 300 ohm resistor and a
turned on.
resistor bypass fuse (F4) in the alternator
excitation circuit. The fuse and resistor are
connected in parallel and are located on the base General Diagnostic and Warranty
controller. Removing the resistor bypass fuse Evaluation Procedure
places the 300 ohm resistor in the excitation Complete the following diagnostic procedures
circuit as required for Thermo King alternators before replacing an alternator or the voltage
(and Australian Bosch alternators). Installing the regulator.
resistor bypass fuse removes the 300 ohm resistor
1. When testing an alternator, use accurate
from the excitation circuit as required for
equipment such as a Thermo King P/N
Prestolite alternators. See the specific unit wiring
204-1079 digital multimeter and a Thermo
diagram for exact details.
King P/N 204-947 amp clamp or an
NOTE: The F4 fuse must be removed from the equivalent.
base controller on units equipped with Thermo
2. Make sure the drive belts and pulleys of the
King alternators. The voltage regulator on the
charging system are in good condition and are
Thermo King alternators will be damaged if the
adjusted properly before testing the alternator.
unit is turned On with the F4 fuse in place on
Be sure the pulleys are the correct size. Worn
the base controller.
belts, loose belts and worn or improperly sized
pulleys will lower the output of the alternator.
Test Equipment for Checking
Voltage and Current 3. The battery must be charged and in good
condition, the battery cable connections must
Always use accurate test equipment such as the
be clean and tight, and the 2A, 2 (sense), and
Fluke 23 Digital Multi-Meter and the Fluke
EXC (excitation) circuits must be connected
Clamp-On Ammeter accessory when checking
properly. All charging circuit connections
alternator circuit voltage and amperage. See the
must be clean and secure. If the unit battery is
table below for Thermo King service parts
questionable, a known good jumper battery
numbers. Be sure voltages are measured from the
should be substituted for alternator testing.
designated terminal to the alternator chassis
ground. All voltages are DC voltages unless NOTE: If the unit battery is questionable, a
otherwise noted. known good jumper battery should be
substituted for alternator testing.
Service
Meter Part NOTE: Do not perform this test with a
Number battery charger connected to the unit battery.
Fluke 23 Digital Multi-Meter 204-1079 NOTE: All voltage readings should be taken
Clamp-On Ammeter for above Meter 204-947 between the chassis ground on the alternator
and the terminals indicated, unless stated
Alternator Load Test otherwise.
Thermo King no longer recommends a full field 4. Check that the resistor bypass fuse (F4) has
test for determining the alternator current output. been removed. Units with Thermo King
Full fielding an alternator can cause increases in alternators must have the resistor bypass fuse
alternator output voltage that may damage internal (F4) removed.
alternator or unit components. This damage may
CAUTION: Energizing the circuit with
not be readily apparent.
the resistor bypass fuse installed will
To test the alternator under load, Thermo King damage Thermo King alternators. Be sure
recommends the use of a clamp-on ammeter to the resistor bypass fuse is removed for
monitor output current, both on initial startup and Thermo King alternators.

81
Electrical Maintenance

5. Check and note the battery voltage at the should fall to normal unit load plus charge
battery with the unit turned off. current to the unit battery (typically 5-10
amps).
6. With the unit off, check the voltage at the B+
terminal on the alternator. Battery voltage A reading on the clamp-on ammeter at or near
must be present. If not, check the 2A circuit. 0 amps indicates the alternator is not charging.
Checking the unit ammeter will show a
7. Disconnect the alternator harness from the
discharge condition. The alternator is
voltage regulator. On Thermo King
defective if there are no problems in the
alternators, carefully push on the spring clip to
wiring. Recheck the wiring before assuming
release the plug lock.
the alternator is defective.
8. Turn the unit on, enter the Interface Board
15. Check the voltage at the B+ terminal. The
Test Mode, and energize the Alternator Excite
voltage should increase until it reaches the
Output. Refer to the appropriate Diagnostic
anticipated voltage regulator setting as shown
Manual for information about the Interface
in the table below. Record the voltage.
Board Test Mode.
The voltage regulator setting varies inversely
9. Check the voltage at the sense circuit (2
with the temperature as shown below.
circuit). Battery voltage should be present. If
Regulator voltage can vary from
not, check the sense circuit (2 circuit) in the
approximately 15.2 Vdc at -40 F (-40 C) to
alternator harness and in the main wire
approximately 13.2 Vdc at 176 F (80 C).
harness.
10. Check the voltage at the excitation circuit Temperature Anticipated Regulator Voltage
(EXC circuit). 10 Vdc or more should be -40 F (-40 C) From 15.2 Vdc to 14.0 Vdc
present. If not, check the excitation circuit 77 F (25 C) From 14.4 Vdc to 13.6 Vdc
(EXC circuit) in the alternator harness and in
176 F (80 C) From 14.2 Vdc to 13.2 Vdc
the main wire harness.
NOTE: LED 18 lights up when the EXC If the voltage does not increase to the
circuit is energized. The EXC circuit is anticipated voltage regulator setting, the
operated by a Smart FET so during normal alternator is defective if there are no problems
operation the unit must be running for the in the wiring. Recheck the wiring before
EXC circuit to be energized. replacing the alternator.
11. Turn the unit off and reconnect the alternator 16. If the voltage does increase until it reaches the
harness. anticipated voltage regulator setting, compare
12. Attach a clamp-on ammeter around the 2A the voltage at the B+ terminal to the voltage
wire connected to the B+ terminal on the between the battery terminals. The voltage at
alternator. All wires connected to the B+ the B+ terminal should be no more than 1.0
terminal must pass through the clamp-on Vdc higher than the voltage between the
ammeter. battery terminals.

13. Connect a digital multi-meter between the B+ If the voltage at the B+ terminal is no more
terminal at the alternator and chassis ground. than 1.0 Vdc higher than the voltage between
the battery terminals, continue with Step 17.
14. Turn the unit on and allow it to start. Using the
clamp-on ammeter, check the current flow in If the voltage at the B+ (POS) terminal is
the 2A wire. more than 1.0 Vdc higher than the voltage
between the battery terminals, clean and check
A positive reading indicates the alternator is the wires and connections in the 2A and 2
charging. On unit startup, the current flow circuits and repeat this check.
should momentarily increase to allow for
battery current used during preheat and
cranking. Within a short time the current

82
 Electrical Maintenance

17. Increase the charging system load as much as • High field current indicates a short in the
possible by running the unit in high speed or field circuit. Replace the rotor or the
defrost. alternator.
18. Monitor the alternator output voltage.
Battery
With the increased load, the alternator output
voltage should decrease no more than 0.5 Vdc. Inspect/clean the battery terminals and check the
The voltage may increase as much as 1.0 Vdc. electrolyte level during scheduled maintenance
If the alternator output voltage decreases no inspections. A dead or low battery can be the
more than 0.5 Vdc the alternator is good. cause of an ammeter indicating discharge due to
lack of initial excitation of the alternator even
If the alternator output voltage decreases more after the unit has been boosted for starting. The
than 0.5 Vdc, the alternator is defective if minimum specific gravity should be 1.235. Add
there are no problems in the wiring. Recheck distilled water as necessary to maintain the proper
the wiring before replacing the alternator. water level.
Alternator Diode Quick Check:

This check confirms proper diode function. Battery Cables

19. With the unit still running, set the digital Units with Interim Tier 4 engines use 0-gauge
multi-meter connected from the alternator B+ battery cables to ensure reliable starting in
output to chassis ground for AC volts. No extremely cold weather. Make sure to use the
more than 1.0 Vac should be present. A 0-gauge battery cables when replacing the battery
reading of more than 1.0 Vac indicates cables for a Interim Tier 4 engine. Refer to the
damaged alternator diodes. unit Parts Manual for the correct part numbers.

20. Turn the unit off.

Field Current Test

Use this test to determine if the alternator can be
repaired. Perform this test with the unit turned off.
1. Attach a clamp-on ammeter to the 2A wire
near the B+ terminal on the alternator.
2. Energize the field on the Thermo King
alternator by connecting a jumper wire
between the F2 terminal and the B+ terminal.
Do not connect the F2 terminal to ground or
the alternator will be damaged.
3. Note the ammeter reading. The ammeter
reading indicates the field current, which
should be 2.0 to 6.0 amps at 12 volts.
• No field current or a low field current
indicates an open circuit or excessive
resistance in the field circuit. Remove the
voltage regulator and brush assembly and
inspect the slip rings. If the slip rings and
are acceptable, install a new voltage
regulator and brush assembly and repeat
the test. If the brushes are not the problem,
replace the alternator.

83
Electrical Maintenance

Fuses Fuses (Continued)

A number of fuses, located on the base controller, F10 There are three in-line fuse clips that allow for
two configurations of the F10 fuse. The right position
protect various circuits and components. The base is the normal position. This position has a white bar
controller is located inside the control box. Refer below it on the circuit board. When fuse F10 is
to the SR-3 Microprocessor Control System installed in the right position, control power is routed
Diagnostic Manual TK 54842 for a complete list to the K9 On/Off Relay contacts. The On/Off keys on
of the size and function of the fuses. the HMI Control Panel energize and de-energize the
K9 On/Off Relay. When the K9 On/Off Relay is
Fuses energized power is supplied through the normally
open K9 contacts to turn the unit on.
Fuse Size Function
When fuse F10 is installed in the left position, power
F2 15A Power to On/Off Switch
bypasses the K9 On/Off relay contacts and the unit
F3 40A Fuel Sol Pull-In/Starter Circuit will start and run without the HMI Control Panel
None No Fuse - All Bosch and Thermo connected. Do not operate the unit with the F10 fuse
F4 King Alternators installed in the left position unless absolutely
2A 2A Fuse - All Prestolite Alternators necessary.
F5 60A Preheat Circuit IMPORTANT: If fuse F10 is installed in the left
position the unit may start and run. If the HMI Control
F6 15A Damper and High Speed Circuits
Panel is connected the On and Off keys will still
8XP Circuit - Controller On Feedback function. The Off key will turn the unit off if Fuse F10
F7 2A
to HMI is in the left position, but the Base Controller will
F8 5A 2A Power to CAN Connector J12 remain powered up.
F9 5A 2A Power to CAN Connector J14 F15 The device identified as F15 is a poly switch.
These over-current devices reset automatically and
8X Power (Install fuse in right
F10 10A are not replaceable.
position)
F11 10A Fresh Air Exchange Solenoid Circuit
F12 5A 2A Power to CAN Connector J13
8FC Circuit (Remote Status
F13 2A
Light/Optional Power)
F15 P/S On/Off Relay
F20 2A Alternator Sense
F25 7.5A HPCO Switch Circuit
F26 5A Power to CAN Connector J98
F4 Fuse F4 must be removed for Bosch and Thermo
King alternators. Fuse F4 fuse must be in place for
Prestolite alternators to charge.
F5 The F5 preheat fuse is a “slow blow” type fuse. It
is designed for use with the Yanmar trailer engine air
pre-heater. Always replace the fuse with the TK
specified fuse.

Figure 91: Base Controller

84
 Electrical Maintenance

Base Controller LEDs Smart FETs

The base controller has LEDs that indicate which A Smart FET (Field Effect Transistor) is a self
outputs are energized. The LED is illuminated protecting output device used for the functions
when the associated circuit output is energized. shown in the table below. If an over-current
condition occurs, the Smart FET will turn off until
Base Controller LED Functions the over-current condition no longer exists. It will
LED # Function then resume normal operation. A fuse is not
LED 3 K2 Preheat Circuit required. Smart FETs are not field repairable.
LED 4 K4 Damper Circuit Refer to the SR-3 Microprocessor Control System
LED 5 K3 High Speed Circuit Diagnostic Manual TK 54842 for more
information about the Smart FETs.
LED 6 K1 Run Relay Circuit
LED 7 K5 Diesel/Electric Relay Not all Smart FETs shown below are used on
LED 8 Pilot Solenoid Circuit single temperature trailer units.
LED 9 Liquid Line Solenoid Circuit (Not Used)
Base Controller Outputs With Smart FETs
LED 10 Hot Gas Bypass Valve Circuit
Output Function
LED 11 Purge Valve Solenoid Circuit (Not Used)
EVA, EVB, EVC, EVD ETV Outputs
LED 17 Loader Valve 1 (Not Used)
HG Hot Gas Bypass Solenoid
LED 18 Alternator Excite
LV1 Not Currently Used
LED 19 Liquid Injection Valve Circuit (Not Used)
EXC Alternator Excite
LED 20 Loader Valve 3 (Not Used)
LV3 Not Currently Used
Status – Flashes once per second when
LQIP Liquid Injection Valve
the base controller is powered and
operating normally. Flashes several times LLSP Liquid Line Solenoid
per second when flash loading. Is on 26 Pilot Solenoid
LED 21
without flashing during reboot and when
PV Purge Valve
Base Controller under test. Flashes twice
within 1 second followed by 1 second off if
a CAN communication error is present. SMART REEFER 3 (SR-3)
LED 22 K8 Fresh Air Exchange Solenoid Circuit Microprocessor Controller
LED 23 K9 On/Off Circuit
Refer to the SR-3 Microprocessor Control System
LED 24 K6 Fuel Solenoid Pull-In Circuit Diagnostic Manual TK 54842 for complete
LED 25 K7 Starter Circuit service information about the Microprocessor
LED 27 ETV – D* Controller and the related components.
LED 28 ETV – B* IMPORTANT: A ServiceWatch download can be
LED 29 ETV – A* helpful when diagnosing a problem in a unit
LED 30 ETV – C* with an SR-3 Controller. Therefore, it is
* Illuminated when the respective ETV output is recommended that a ServiceWatch download be
energized. On applications without an ETV the ETV preformed to help diagnose a problem. A
LED's may be illuminated even though there is no ServiceWatch download must be preformed
ETV present. before contacting the Thermo King Service
Department for assistance in diagnosing a
problem. Refer to the SR-3 Microprocessor
Control System Diagnostic Manual TK 54842
for information about downloading the
ServiceWatch Data Logger and viewing the data.

85
Electrical Maintenance

REB (Radio Expansion Board) 1 2

Option
The REB (Radio Expansion Board) option is a
wireless communication platform that offers fleet
owners the ability to monitor their refrigerated
trailers. Cellular, GPS, and Wi-Fi capabilities
communicate with Thermo King’s web-based
TracKing application. A third party interface
(using iBox protocol) offers a gateway for
telematics providers to communicate with the
Thermo King unit.
Currently, REBs with the following capabilities
are available. Some combinations of these
capabilities are also available.
• REB with Cellular and GPS capabilities for
use with the TracKing application.
• REB with Wi-Fi and GPS capabilities for use
with the TracKing application.
• REB with iBox protocol for use with third
party telematics systems.
NOTE: REBs that have iBox and Cellular
capabilities can be configured to either use the 1. REB Fuse (3 Amp)
iBox protocol, or communicate with TracKing. 2. REB (Radio Expansion Board)
They cannot be configured to do both.
Figure 92: REB Mounted on Base Controller
The REB is a “daughter board” that mounts on the
upper right corner of the base controller as shown Fuse Link
below. The REB communicates with the base
controller through the CAN connector J98 on the The fuse link is located in the positive battery
base controller. Refer to the Radio Expansion cable. The fuse link protects the electric system
Board (REB) Diagnostic Manual TK 55065 for from a short in the 2 circuit. If the fuse link burns
complete service information about the REB. out, check for a grounded 2 wire before replacing
Refer to the iBox Diagnostic Manual TK 53242 the fuse link. Replace the fuse link by replacing
for complete service information about the REB the positive battery cable.
iBox II.
REBs with cellular capabilities also have a battery
Air Heater
mounted on the bottom of the frame panel above The air heater is mounted on the open end of the
the control box. The REB battery is used to intake manifold. It heats the intake air to help the
provide back-up power for at least 24 hours if the engine start in cold weather. The air heater is
main battery power is lost or interrupted. The energized by the microprocessor during preheat,
REB only transmits its location during this just before the engine is started.
back-up mode. The REB contains an intelligent
The heater is probably defective if the resistance
battery charger that keeps the REB battery
is more than 0.2 ohms and the current draw is less
charged during normal unit operation.
than 60 amps, or if the current draw is more than
100 amps.

86
 Electrical Maintenance

Check the resistance of the air intake heater with

1 2
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). The resistance
should be 0.14 ± 0.02 ohms.
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. During preheat
the current draw should be approximately 70
amps.

1. Wire Harness In Front Of Starter

2. Harness Routing Bracket
Figure 94: Wire Harness Routing

AC Components (Model 50
1 Units Only)
AEA693
CAUTION: Model 50 units use high
1. M6 Terminal voltage ac for electric standby operation.
Figure 93: Air Heater Lethal voltage potentials can exist on
connections in the high voltage box. Take
appropriate precautions and use extreme
Unit Wiring care when testing the unit.
Inspect the unit wiring and the wire harnesses
during scheduled maintenance inspections for Electrical Contactors
loose, chaffed or broken wires to protect against
unit malfunctions due to open or short circuits. Periodically inspect all contactor points for pitting
or corrosion and repair or replace as necessary.
Test the contact points by checking the voltage
Wire Harness Routing drop across each set of points when the contactor
The wire harness is routed in front of the starter is energized and the system is operating. If the
on the TK486V/VH (Interim Tier 4) engine. The voltage drop across a set of points is more than 15
wire harness is attached to a harness routing Vac, replace the contact points as a set.
bracket, which is attached to the starter. Test the contactor coil by checking the voltage
across the coil. The contactor coil should be
energized by a minimum of 10 Vdc.

Evaporator Heaters
Test the resistance of each evaporator heater by
disconnecting it from the circuit and checking it
with an ohmmeter. The resistance of each host
evaporator heater should be approximately
122 ohms.

87
Electrical Maintenance

Auto Phase System h. Wires Black, Blue (or Gray), and Brown
for the 14 HP motor (or Red, White, and
The Auto Phase system automatically adjusts the
Black for the 24 HP motor) should be
phase sequence of the power supply to correspond
connected respectively to terminals Z, Y,
with the wiring of the electric motor. The main
and X in the power receptacle.
components of the system are the phase selection
module (PSM), and the two motor contactors i. Wires Brown, Blue (or Gray), and Black
(MC1 and MC2). Contactor MC1 is wired to for the 14 HP motor (or Black, White, and
retain the phase sequence. Contactor MC2 is Red for the 24 HP motor) should be
wired to change the phase sequence. The PSM connected respectively to terminals L1,
senses the phase sequence at the heater contactor L2, and L3 on MC1.
and energizes the appropriate motor contactor. NOTE: If the unit is equipped with the
optional remote power receptacle, these
Troubleshooting the Auto Phase System wires may be different colors and should
If the electric motor runs backwards (unit airflow be connected respectively to terminals
incorrect): 2T1, 4T2, and 6T3 on the On/Off Switch.
1. Turn the electric power supply Off and check Wires L1A, L2A, and L3A should be
the unit wiring. See the appropriate wiring connected respectively to terminals 1L1,
diagrams, schematics, and Figure 95. 3L2, and 5L3 on the On/Off Switch and
terminals L1, L2, and L3 on MC1.
a. The three wires from the PSM should be
connected to the heater contactor terminals j. The 9-pin wire connector between the
as follows: Brown wire to terminal L1, PSM and the wire harness should be clean
Blue (or Gray) wire to terminal L2, and and tight.
Black wire to terminal L3. k. The electric motor must be wired
b. Wires L1B, L2B, and L3B should be correctly.
connected respectively to terminals L1, 2. Check MC1 and MC2 to make sure that one of
L2, and L3 on the heater contactor and them is not faulty (contacts stuck closed).
MC2.
3. If all of the wiring is correct, and the relays
c. Wires L1, L2, and L3 should be connected and contactors are acceptable, but the electric
respectively to terminals L1, L2, and L3 motor still runs backwards, switch the Brown
on the heater contactor and both motor wire and the Black wire from the PSM at the
contactors. heater contactor: Black to L1, Blue (or Gray)
d. Wires T1, T2, and T3 should be connected to L2, and Brown to L3. If the electric motor
respectively to terminals T1, T2, and T3 now runs correctly, it is probably wired
on MC1. incorrectly.
If the electric motor does not run at all:
e. Wires T1, T2, and T3 should be connected
respectively to terminals T3, T2, and T1 1. Make sure that the unit is turned On, that
on MC2. Electric Standby has been selected in the
Operator Menu, and that the power supply is
f. Wires T1A, T2A, and T3A should be
connected and turned On.
connected respectively to terminals L1,
L2, and L3 on the overload relay. 2. Check the CH wire to the PSM for continuity
to the CH circuit (chassis ground). If there is
g. Wires T2 & T8, T1 & T7, and T3 & T9 for
no continuity to the CH circuit, check the CH
the 14 HP motor (or T2, T1, and T3 for the
wire for continuity.
24 HP motor) should be connected
respectively to terminals T1, T2, and T3
on the overload relay.

88
 Electrical Maintenance

3. Check for battery voltage (12 volts) at the 1 2 3

7E/7EA wire to the PSM. Battery voltage
should be present. If not, check the 7E circuit,
the diesel/electric relay (K5), the run relay
(K1), the HPCO circuit, the HPCO switch, the
PHPC circuit, the F25 fuse, the 8 circuit, the
Microprocessor On/Off switch, the 2AB
circuit, the F2 fuse, the 2 circuit, the fuse link,
and the battery. Also make sure that the
microprocessor display is on and that the
microprocessor is calling for Heat or Cool.
4. Check for battery voltage at the 7EB and 7EC
wires at the PSM. Battery voltage should be 4
present on one of these wires when the correct
AC voltage is present on L1, L2, and L3. If
battery voltage is not present, the PSM is
faulty.
5. Check for battery voltage at the 7EB terminal
on MC1 and at the 7EC terminal on MC2.
Battery voltage should be present at one of
these terminals. If not, check the continuity of
the 7EB and 7EC wires. 5
6. Check the continuity of the RED wires on the
6
motor contactors. The RED wires must have
continuity. ARA1749

7. Check the CH circuit at MC1 and MC2 for

continuity to a chassis ground. If the CH 1. Overload Relay
circuits do not have continuity to a chassis
2. HC—Heaters Contactor
ground, check the CH wires.
3. PSM—Phase Selection Module
8. Check the continuity of the BLK wires on the 4. On/Off Switch (With Optional Remote
motor contactors. The BLK wires must have Power Receptacle Only)
continuity. 5. MC1—Motor Contactor
9. If the CH circuits and BLK wires do have 6. MC2—Motor Contactor
continuity to CH, the contactor that has Figure 95: High Voltage Tray
battery voltage present at 7EB (MC1) or at
7EC (MC2) is faulty.

89
Electrical Maintenance

Ultrasonic Fuel Level Sensor agree closely is at 50% or 1/2 full. The readings at
other fuel levels may not agree as closely. If you
The ultrasonic fuel level sensor (if used) is think the ultrasonic fuel level sensor is not
mounted to a flange on top of the fuel tank. The working correctly, the best thing to do is to check
ultrasonic fuel level sensor consists of a sensor, a the output voltage as shown in step 4 below. The
sensor tube (or focus tube), and two gaskets. The output voltage should be between approximately
sensor is a transducer that emits ultrasonic sound 1.0 Vdc for an empty tank to 4.0 Vdc for a full
waves. The sound waves reflect off the fuel in the tank.
sensor tube and return to the transducer. The
transducer senses the reflected sound waves and Check the operation of the fuel level sensor as
determines the fuel level in the sensor tube. follows:
Ultrasonic fuel level sensors are calibrated for use 1. Use the GAUGES soft key to display the Fuel
with fuel tanks of particular size and shape. Refer Level Sensor reading and compare it to the
to the appropriate unit Parts Manual for the reading of the fuel gauge on the end of the fuel
correct part numbers. tank. The Fuel Level Sensor reading should be
approximately 50% when the fuel gauge reads
1 1/2 full.
4 2. Check to make sure that the Fuel Sensor Type
2
is set to Solid State in Unit Configuration in
the Guarded Access Menu.
3
3. Turn the unit on and check the for battery
voltage (12 Vdc) between the 2PL (J3-12 pin)
and FUELN (J3-35 pin) wires in the sensor
harness at the J3 connector on the base
controller. This is the input voltage. If battery
voltage is not present, check the
microprocessor.
4. If battery voltage is present, check the output
voltage between the FLL (J3-23 pin) and
FUELN (J3-35 pin) wires in the sensor
harness at the J3 connector on the base
controller. The voltage should be between 1
and 4 Vdc depending on the fuel level as
shown the following table.

Fuel Level Output Voltage

1. Ultrasonic Fuel Level Sensor Empty Approximately 1.0 Vdc
2. Gaskets 1/2 Full Approximately 2.5 Vdc
3. Sensor Tube Full Approximately 4.0 Vdc
4. Sensor Cable
NOTE: The output voltages listed above are
Figure 96: Fuel Level Sensor
for the ultrasonic fuel level sensor designed
The ultrasonic fuel level sensor and the fuel gauge to be used with the SR-2 and SR-3
on the end of the fuel tank measure the fuel level Controllers. Other systems such as third
differently. The ultrasonic fuel level sensor party telematics systems may use sensors
measures the actual volume of fuel in the tank. with slightly different output voltages. Refer
The fuel gauge measures the height of the fuel in to the sensor specifications for those sensors.
the tank. Therefore, the fuel level at which fuel
level sensor reading and the fuel gauge reading

90
 Electrical Maintenance

5. If the output voltage is incorrect, check the 1. Remove and discard the sensor and its gasket.
continuity of the wires that go from the J3 DO NOT reuse the gasket.
connector on the base controller to the sensor
2. Check the gasket between the sensor tube and
as shown in the following table and make sure
the tank to make sure it is in good condition.
the connections are clean and tight.
Replace it if necessary.
NOTE: The sensor cable (or interconnect
3. Confirm the gasket surface areas on the tank
harness) wires are connected to the sensor
flange and the sensor tube are clean.
wires with solder connections and heat
shrink tubing during installation. See the
Pre-Assembly
SB-130, SB-230 and SB-330 Installation
Manual TK 54748 for more information. The mounting holes of the sensor, sensor tube,
gaskets, and the fuel tank flange are not
J3 Con- Sensor Sensor Sensor symmetrical. The holes align only in one position.
Sensor
nector Harness Cable Con- Cable
Pin Wire nector Pin Wire
Wire The distance between the two mounting holes
next to the notch (see Figure 97) are further apart
12 2PL A Green Red
than the others. These two holes will be used as a
23 FLL C White Yellow reference point to correctly align the components.
35 FUELN B Black Black

6. If the wires have good continuity and the

connections are clean and tight, replace the
sensor.

Important USFLS Replacement

Information 1

NOTE: This procedure covers replacing the

sensor. For information about installing the
USFLS Kit on a unit that does not already have
a USFLS, see the SB-130, SB-230 and SB-330
Installation Manual TK 54748 for more
information.
• DO NOT connect power to the UFLS until it 2
has been installed into the fuel tank.
• DO NOT use thread locking compounds as
they can cause stress cracking of the plastic 4
3
sensor.
• DO NOT apply any type of gasket sealer.
• USE ONLY new gaskets. Make sure to order
new gaskets when ordering the replacement 2
sensor.
1. Sensor
• DO NOT use power tools to tighten the
2. Pin Holes
mounting hardware or damage to the plastic
sensor will result. 3. Mounting Hole Reference
4. Notch
• DO NOT overtighten the mounting hardware
Figure 97: USFLS Components
or damage to the plastic sensor will result.

91
Electrical Maintenance

4. The UFLS assembly should be pre-assembled IMPORTANT: DO NOT burn the heat
before installing it into the fuel tank. shrink. If the heat shrink is burnt, charred,
or has bubbles from overheating, the wire
a. Slide a gasket up the sensor tube to the
connections must be removed and redone
flange, making sure the pin hole in the
correctly.
gasket is centered between the two
mounting holes next to the notch as shown
in Figure 97. Resistive Fuel Level Sensor
b. While holding the lower gasket in place, The resistive (float) fuel level sensor (if used) is
place the upper gasket onto the sensor tube mounted in the end of the fuel tank.
flange, again making sure the pin hole in Check the operation of the fuel level sensor as
the gasket is positioned between the two follows:
mounting holes next to the notch as shown
in Figure 97. 1. Disconnect the three pin connector that
connects the harness from the fuel level sensor
c. Place the sensor on top of the upper gasket to the sensor harness from the J3 connector on
with the harness pointing towards the the base controller. This three pin connector is
notch on the sensor tube flange. All holes located either in the control box or under the
should now be aligned. unit near the control box.
d. Install the 10-32 screws, lock washers and
flat washers onto the sensor and through 1
the gasket holes to hold the assembly
together.

Installation In Tank
5. Insert assembly into fuel tank making sure the
notch on the sensor tube is aligned with the
notch on the tank flange. When installed
correctly, the sensor harness will be pointed
towards the fuel fill on the end of the tank.
Hand tighten the five mounting screws in a
criss-cross pattern and torque them to 10-15
in-lbs (1.1-1.7 N•m).
DO NOT overtighten the mounting hardware
or damage to the plastic sensor will result.
The fuel tank is now ready to be reinstalled.

Wire Connections 2
6. Cut the sensor cable wires (or old sensor
wires) to the appropriate length and splice 1. Float in Full Position
them to the new sensor wires using solder 2. Float in Empty Position
connectors (P/N 41-5210) and heat shrink Figure 98: Fuel Level Sensor
tubing (P/N 92-846) as follows:
2. Check the resistance between the two wires
Sensor Cable Wire Sensor Wire that go to the fuel level sensor. The resistance
Green Red should be approximately 30 ohms with the
White Yellow float in the full position. The resistance should
Black Black
be approximately 240 ohms with the float in
the empty position.

92
 Electrical Maintenance

NOTE: If the resistance of the fuel level NOTE: The electric fuel heater does not
sensor is incorrect, check the continuity of function when the unit is in the Electric Mode
the wires between the three pin connector (electric standby operation), the Null Mode, or
and the fuel level sensor before assuming the during the non-running portion of the Pretrip
fuel level sensor is bad. Test.
3. If the resistance of the fuel level sensor is
acceptable, turn the unit on and check the
voltage between the FLL and FUELN wires in
the sensor harness going to the base controller.
The voltage between the FLL and FUELN
wires should be approximately 7.4 Vdc with
the fuel level sensor disconnected.
4. If the voltage is incorrect, check the continuity
of the FLL and FUELN wires in the sensor
harness going to the base controller. The FLL
wire goes to the J3-23 pin. The FUELN wire Figure 99: Electric Fuel Heater Schematic
goes to J3-35 pin.
Components
5. If the FLL and FUELN wires have good
continuity, check the microprocessor. The main components of the electric fuel heater
option are listed below.

Electric Fuel Heater (Optional) • Electric Fuel Heater

An electric fuel heater is optional equipment on • Mounting Bracket and Hardware
these units. • Fuel Heater Harness (includes the following)

Operation • W Fuse (3 amp)

The electric fuel heater has an internal thermostat • Electric (Power) Filter
that closes at 30 F (-1 C) minimum, and opens at • Unit Run Relay
75 F (24 C) maximum.
• Diesel Power Fuse (3 amp)
When the unit is turned On (and Model 50 units
are in Diesel Mode) the 8DF circuit is energized. • Diesel Run Relay
This energizes the Diesel Run Relay and closed its • 2A/2FH Circuit Breaker (20 amp manual
contacts. reset)
After the engine starts running, the alternator will The electric fuel heater is mounted on the
output AC power to the W/WF circuit. The bulkhead below and to the left of the fuel filter as
electric (power) filter converts this to DC power, shown in Figure 100. The inlet line to the fuel
which energizes the Unit Run Relay and closes its filter is moved to the electric fuel heater inlet. A
contacts. short fuel line is added between the electric fuel
With the relay contacts closed, the 2A circuit heater outlet and the fuel filter inlet.
provides power to the fuel heater, which will heat
up if its internal thermostat is closed. The current
through the fuel heater is 11.4 to 13.9 amps at 12.5
Vdc.

93
Electrical Maintenance

1 1 2

ARA1752
1. Diesel Run Relay
3 2 2. Unit Run Relay
1. Fuel Filter Inlet 3. Electric (Power) Filter

2. Electric Fuel Heater Inlet 4. 2A/2FH Circuit Breaker

3. Electric Fuel Heater Outlet Figure 102: Electrical Components In Control Box
Figure 100: Electric Fuel Heater The wires in the fuel heater harness are connected
to the unit as follows.
The relays, fuses, electric (power) filter, and
circuit breaker are mounted inside the control box • The WF wire is attached to the W terminal
as shown in Figure 101 and Figure 102. (AC output) on the alternator.
NOTE: The end of the WF wire that is
attached to the W terminal is a red wire about
8 in. (203 mm) long with yellow fuse holder
in the middle. This red wire with the fuse
1 holder is connected with a splice to the WF
wire.
• The 7R1 wire is plugged into the 8DF socket
in the J-15 (8-pin) connector on the base
controller.
NOTE: The end of the 7R1 wire that is
plugged into the 8DF socket in the J-15
(8-pin) connector is a red wire about 8 in.
2 (203 mm) long with yellow fuse holder in the
middle. This red wire with the fuse holder is
connected with a splice to the 7R1 wire.
ARA1753
• The 2A wire is attached to the 2A screw
1. Electrical Connections to Base Controller terminal on the base controller.
2. Electrical Components In Control Box
• The CH wires are connected to the CH ground
Figure 101: Control Box plate behind the battery.

94
 Electrical Maintenance

indicates an open circuit, the electric fuel

1 heater is probably defective and should be
replaced.
• If the resistance is significantly less than
0.9 ohms, the heating element is probably
defective and the electric fuel heater
should be replaced.
NOTE: The unit must be turned on and running
in Diesel Mode for the rest of the procedure.

2
3. If the resistance of the electric fuel heater is
acceptable, turn the unit on and let the engine
start. Check the voltage between the 2HP and
CH wires in the fuel heater harness at the
ARA1754 2-pin connector that was disconnected from
the electric fuel heater in Step 1. Battery
voltage should be present between the 2HP
Red End of 7R1 Wire Plugged into 8DF
1. and CH wires.
Socket in the J15 Connector
2A Wire Attached to 2A Screw Terminal, 4. If battery voltage is not present, check for AC
2.
which is also marked J25 voltage at the W terminal on the alternator. At
Figure 103: Wire Connections to Base Controller least 8 Vac should be present at the W
terminal on the alternator. If not, check the
Diagnosis alternator.
Use the following procedure to diagnose the 5. If the AC voltage at the W terminal is
electric fuel heater. acceptable, check for AC voltage at the WF
wire where it connects to the screw (8)
1. Disconnect the electric fuel heater from the terminal on the electric (power) filter in the
fuel heater harness at the 2-pin connector control box. At least 8 Vac should be present
located near the electric fuel heater. on the WF wire at electric (power) filter. If
2. Check the resistance of the electric fuel heater not, check the W fuse and the continuity of the
by checking the resistance between the two WF wire. The W fuse holder is located in the
terminals in the 2-pin connector on the wires Red wire that is spliced to the end of the WF
to the electric fuel heater. The resistance wire and attached to the W terminal on the
should be 0.9 to 1.1 ohms. alternator.
NOTE: The temperature of the electric fuel NOTE: The fuel heater harness has two WF
heater must be below 30 F (-1 C) to verify the wires connected to the screw (8) terminal on
internal thermostat closes. the electric (power) filter as shown in Figure
104 and Figure 105. The opposite end of one
• If the resistance is acceptable, go to Step 3. of these WF wires is connected to the
• If the resistance is very high, indicating an alternator. Which WF wire is connected to
open circuit, check the temperature of the the alternator is determined by the type of
electric fuel heater using a non-contact unit. Model 30 units use one and Model 50
thermometer. The temperature of the units use the other. The end of the WF wire
electric fuel heater must be below 30 F that is not connected to the alternator is tied
(-1 C) to close the internal thermostat. If off.
the temperature of the electric fuel heater
is below 30 F (-1 C) and high resistance

95
Electrical Maintenance

1 2 3
2

1
3
1. Red Wire
2. Fuse Holder
3. WF Wire (or 7R1 Wire)
Figure 106: Fuse Holder
(WF Wire Shown, 7R1 Wire Similar)
6. If the AC voltage on the WF wire at electric
(power) filter is acceptable, check for DC
voltage on the 7R2 wire (pin 85) at the Unit
Run Relay in the control box. At least 8 Vdc
WF Wires Connected to Screw Terminal
1. should be present on the 7R2 wire (pin 85) at
(Marked 8 on Side)
the Unit Run Relay. If not, check the
2. Black Wire Spliced to CH Wire
continuity between the 7R2 wire (pin 85) at
3. Red Wire Spliced to 7R2 Wire the Unit Run Relay and the Red wire at the
Figure 104: Electric (Power) Filter Top View electric (power) filter. Also check the
continuity between the Black wire at the
electric (power) filter and the CH wire where
it attaches to the CH ground plate. If these
wires have good continuity, replace electric
(power) filter.
7. If the voltage on the 7R2 wire (pin 85) at the
Unit Run Relay is acceptable, check for
1 continuity on the CH wire between the Unit
Run Relay (pin 86) and the CH ground plate.
3
8. Check for battery voltage on the Red (7R1)
wire where it is plugged into the 8DF socket
2 in the J-15 (8-pin) connector on the base
controller. Make sure that the unit is turned on
and running in Diesel Mode, and the Red
(7R1) wire is correctly plugged into the 8DF
WF Wires Connected to Screw Terminal socket in the J-15 (8-pin) connector.
1.
(Marked 8 on Side)
2. Black Wire Spliced to CH Wire 9. If battery voltage is present on the Red (7R1)
3. Red Wire Spliced to 7R2 Wire
wire, check for battery voltage on the 7R1
wire (pin 85) at the Diesel Run Relay. If
Figure 105: Electric (Power) Filter Side View battery voltage is not present, check the Diesel
Power fuse and the continuity of the 7R1 wire.
The Diesel Power fuse holder is located in the
Red wire that is spliced to the end of the 7R1
wire and plugged into the J-15 connector.
10. If battery voltage is present on the 7R1 wire
(pin 85) at the Diesel Run Relay, check for
continuity on the CH wire between the Diesel
Run Relay (pin 86) and the CH ground plate.

96
 Electrical Maintenance

11. Check for battery voltage on the 2A wire

where it is attached to the 2A screw terminal
on the base controller. If battery voltage is not
present, check to make sure the 2A wire
connection is clean and tight.
12. If battery voltage is present on the 2A wire at
the 2A terminal, check for battery voltage on
the 2FH wire (pin 30) at the Diesel Run Relay.
If battery voltage is not present, press the reset
button on the side of the 2A/2FH circuit
breaker and check the continuity of the 2A and
2FH wires.

1. Reset Button, Press to Reset

Figure 107: 2A/2FH Circuit Breaker
13. If battery voltage is present on the 2FH wire
(pin 30) at the Diesel Run Relay, check for
battery voltage on the 2H wire (pin 30) at the
Unit Run Relay. If battery voltage is not
present, check the continuity of the 2H wire
and check for a defective Diesel Run Relay.
14. If battery voltage is present on the 2H wire
(pin 30) at the Unit Run Relay, check for
battery voltage on the 2HP wire at the 2-pin
connector that was disconnected from the
electric fuel heater in Step 1. If battery voltage
is not present, check the continuity of the 2HP
wire and check for a defective Unit Run
Relay.
15. If battery voltage is present on the 2HP wire at
the 2-pin connector, check for continuity on
the CH wire between the 2-pin connector and
the CH ground plate.

97
Engine Maintenance

EMI 3000 Engine Oil Change

EMI 3000 is an extended maintenance interval The engine oil should be changed according to the
package. The EMI 3000 package consists of the Maintenance Inspection Schedule. Drain the oil
following key components: only when the engine is hot to ensure that all the
oil drains out. When changing oil, keep unit and
• EMI 3000-Hour Cyclonic Air Cleaner trailer level so all the oil can flow from the oil
Assembly and Air Cleaner Element pan. It is important to get as much of the oil out as
• EMI 5-Micron 3000-Hour Fuel Filter (green possible because most of the dirt particles are
with black lettering) contained in the last few quarts of oil that drain
out of the pan. Refill the pan with 13 quarts
• EMI 3000-Hour Dual Element Oil Filter (12.3 liters) and check the dipstick level. Run the
(black with gold lettering) unit, and then recheck the oil level. The engine oil
• API Rating CI-4 Mineral Oil (ACEA Rating level should be at the FULL mark with the
E3 for Europe) dipstick turned (threaded) into the oil pan. Never
overfill. See Specifications Chapter for correct
• Five Year or 12,000 Hour ELC (Extended Life type of oil.
Coolant).
The EMI package allows standard maintenance Oil Filter Change
intervals to be extended to 3,000 hours, or 2 years, The oil filter should be changed along with the
whichever occurs first. engine oil. Use a genuine Thermo King extended
NOTE: Units equipped with the EMI 3000 maintenance oil filter.
package do require regular inspection in
1. Remove the filter.
accordance with Thermo King's maintenance
recommendations. 2. Apply oil to the rubber ring of the new filter
and install the filter.
NOTE: The new EMI 3000 oil filters and new
EMI 3000 air cleaners are NOT interchangeable 3. Tighten the filter until the rubber ring makes
with the oil filters and air cleaners previously contact, then tighten 1/2 turn more.
used in trailer units.
4. Start the unit and check for leaks.

Engine Lubrication System Low Oil Pressure

The TK486 family of engines use a pressure Oil pressure is affected by oil temperature, oil
lubrication system. Refer to the TK482 and viscosity, and engine speed. Low oil pressure can
TK486 Engine Overhaul Manual TK 50136 for a usually be traced to the lack of oil, a faulty oil
detailed description of the engine lubrication pressure regulating valve, or worn bearings. Low
system. oil pressure is not normally caused by a faulty oil
pump. Use the “Low Oil Pressure Flow Chart” on
the following page to help diagnose low oil
pressure.

98
 Engine Maintenance

Low Oil Pressure Flow Chart

Low Oil Pressure

Check for oil dilution. Add oil until full.

Is it just thin or does it Full Check Oil Level Low Re-check oil pressure in
smell like fuel? low and high speed.

Verify the unit switch,

Repair and
sensor, or gauge Not
Thin OK re-check oil pressure in
accuracy using a test Accurate
low and high speed.
gauge.

Diluted
Accurate
with Fuel

See
Check for excessive
EDP08
radial end play at the
Fuel in Oil
flywheel with a dial Excessive
indicator. Maximum;
0.007 in. 4-cylinder.

OK

Drain oil through a

clean coffee filter and Wear Metal Repair or
check for wear metal Present replace engine.
contamination.

No Wear
Metal
Check oil pressure regulator
or oil pressure control valve
and repair or replace as
Change oil and filter.
necessary. Re-check oil
Re-check oil pressure Low
pressure in
in low and high speed.
low and high speed. If oil
pressure is still low, repair or
replace engine.
ARA1368
OK

99
Engine Maintenance

Engine Cooling System

The engine employs a closed, circulating type,
pressurized cooling system. Correct engine
temperatures are controlled and maintained by a
radiator, fan and thermostat. The coolant is
circulated through the system by a belt driven
centrifugal pump. The pump draws the coolant
from the side of the radiator, circulates it through
the cylinder block and head and returns it to the
radiator. A thermostat mounted in the coolant
outlet line from the cylinder head to the radiator
automatically maintains coolant temperature
within the specified temperature range.
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. Figure 108: ELC Nameplate
Located Above Expansion Tank
This provides the following:
The following are the Extended Life Coolants
1. Prevents freezing down to -30 F (-34 C). currently approved by Thermo King for use in
2. Retards rust and mineral scale that can cause ELC units for five years or 12,000 hours:
engine overheating. • Chevron Dex-Cool
3. Retards corrosion (acid) that can attack • Texaco ELC (nitrite free)
accumulator tanks, water tubes, radiators and
core plugs. • Havoline Dex-Cool (with nitrates)

4. Provides lubrication for the water pump seal. • 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. A nameplate above the coolant expansion • Saturn/General Motors Dex-Cool
tank identifies units with ELC.
• Caterpillar ELC
NOTE: The new engine coolant, Texaco
Extended Life Coolant, is RED in color instead • Detroit Diesel POWERCOOL Plus.
of the current GREEN or BLUE-GREEN
CAUTION: Do not add “GREEN” or
colored coolants.
“BLUE-GREEN” conventional coolant to
cooling systems using “RED” Extended
Life Coolant, except in an emergency. If
conventional coolant is added to Extended
Life Coolant, the coolant must be changed
after 2 years instead of 5 years.

100
 Engine Maintenance

NOTE: The use of 50/50 percent pre-mixed changing the antifreeze. Change ELC (red) engine
Extended Life Coolant (ELC) is recommended to coolant every five years or 12,000 hours
assure that de-ionized water is being used. If 100 (whichever occurs first).
percent full strength concentrate is used,
Do not mix green or blue-green engine coolant
de-ionized or distilled water is recommended
with ELC (red) engine coolant. See “ELC
over tap water to insure the integrity of the
(Extended Life Coolant)” on page 100 for more
cooling system is maintained.
information about ELC.
Antifreeze Maintenance Procedure The factory recommends the use of a 50/50
antifreeze mixture in all units even if they are not
As with all equipment containing antifreeze,
exposed to freezing temperatures. This antifreeze
periodic inspection on a regular basis is required
mixture will provide the required corrosion
to verify the condition of the antifreeze. Inhibitors
protection and lubrication for the water pump.
become worn out and must be replaced by
1 2

4
3

6 7

1. Expansion Tank 5. Water Pump

2. Expansion Tank Cap 6. Coolant Hoses to Cold Start Device on Injection Pump
3. Coolant Level Switch 7. Thermostat
4. Radiator 8. Thermostat Housing
Figure 109: Engine Cooling System

101
Engine Maintenance

Checking the Antifreeze 7. If using ELC concentrate, mix one gallon of

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. (Do not add antifreeze and
or a refractometer (P/N 204-754) designed for
then add water to the unit. This procedure may
testing antifreeze. Maintain a minimum of
not give a true 50/50 mixture because the
50 percent permanent type antifreeze concentrate
exact cooling system capacity may not always
and 50 percent water solution to provide
be known.)
protection to -30 F (-34 C). Do not mix antifreeze
stronger than 68 percent permanent type coolant 8. Refill the radiator with the 50/50 antifreeze
concentrate and 32 percent water for use in mixture and make sure to bleed the air from
extreme temperatures. the cooling system as needed.

Changing the Antifreeze Bleeding Air from the Cooling

1. Run the engine until it is up to its normal System
operating temperature. Stop the unit. Jiggle pin thermostats are original equipment on
units that have engines from the TK486 engine
2. Open the engine block drain (located behind
family. Jiggle pin thermostats make it unnecessary
the starter) and completely drain the coolant.
to bleed the air out of the engine block because
Observe the coolant color. If the coolant is
they keep air from being trapped in the engine
dirty, proceed with a, b, and c. Otherwise go
block. Normally, all but about 1.5 qt (1.4 liters) of
to 3.
coolant drain out of the cooling system when it is
CAUTION: Avoid direct contact with hot drained. If approximately half of the Cooling
coolant. System Capacity (see Specifications Chapter)
seems to fill the cooling system after it has been
a. Run clear water into the radiator and allow drained, air has been trapped in the block. Bleed
it to drain out of the block until it is clear. the air out of the block using the following
procedure:
b. Close the block drain and install a
commercially available radiator and block CAUTION: Do not start the engine
flushing agent, and operate the unit in without bleeding the air out of the block.
accordance with instructions of the
flushing agent manufacturer. NOTE: If an engine runs with air trapped in the
block, the engine may be damaged. The high
c. Open the engine block drain to drain the water temperature switch may not protect an
water and flushing solution. engine that has air trapped in the block, because
CAUTION: Avoid direct contact with hot the high water temperature switch is designed to
coolant. protect an engine from overheating due to
failures in the cooling system.
3. Run clear water into the radiator, and allow it 1. Remove the plug from the front end of the
to drain out of the block until it is clear. water pump below the thermostat housing as
4. Inspect all hoses for deterioration and hose shown in Figure 110.
clamp tightness. Replace if necessary. 2. Slowly pour the coolant into the system until
5. Loosen the water pump belt. Check the water you see coolant at the plug fitting.
pump bearing for looseness. 3. Reinstall the plug.
6. Inspect the radiator cap. Replace the cap if the
gasket shows any signs of deterioration.

102
 Engine Maintenance

Coolant Level Switch

1
The plastic expansion tank uses a reed type
coolant level switch. The coolant level switch
senses the position of the magnetic float inside the
expansion tank. When the coolant level is above
the switch, the float is in the upper position and
the switch is closed. When the coolant level is
below the switch, the float is in the lower position
and the switch is open.

1. Plug
Figure 110: Remove Plug from Water Pump
4. Pour coolant into the system until it appears to
be full.
5. Make sure that the amount of coolant that
1 2
goes back into the system is approximately
equal to the amount of coolant that came out
of the system.
6. Start the engine. Monitor the coolant
temperature with the unit engine coolant
temperature gauge, or by using a non-contact
thermometer pointed at the thermostat housing
in the location of the high water temperature
switch or sensor. When the temperature
reaches 150 F (66 C), shut the engine off for 2
minutes. This allows time for the thermostat to 1. Coolant Level Switch
heat soak and open fully, ensuring that any 2. Float
remaining air will be purged out of the engine
Figure 111: Plastic Expansion Tank
block when the engine is restarted.
NOTE: Figure 111 shows the expansion tank in
7. Restart the engine and run it in low speed. two pieces. The two pieces are bonded together
Remove the cap from the expansion tank and when the tank is assembled, so it cannot be
slowly pour coolant into expansion tank until disassembled, but the coolant level switch can be
it is full, then reinstall the expansion tank cap. replaced.
8. Repeat steps 6 and 7 until the coolant level
stabilizes. Testing the Coolant Level Switch
You can test the switch in the unit by adjusting the
Engine Thermostat coolant level. You can also remove the expansion
For the best engine operation, use a 160 F (71 C) tank from the unit and test the switch by flipping
thermostat year-round. the expansion tank upside down and right side up.
1. Remove the wire harness connector from the
coolant level switch.

103
Engine Maintenance

2. Use an ohmmeter to check the continuity of 2. Use a wide, flat screwdriver to pry the switch
the switch at the connection pins. out of the expansion tank.
3. Make sure the coolant level is above the
switch and check the continuity of the switch.
The switch should be closed. If you removed 1
the tank from the unit, do this check with the
tank upside down.
4. Drain coolant from the expansion tank until
the coolant level is well below the switch and
check continuity of the switch. The switch
should be open. If you removed the tank from
the unit, do this check with the tank right side 2
up.
5. Replace the switch if it is does not closed in
step 3 and does not open in step 4. 1. Warm Here
2. Pry Here
Checking the Float Figure 112: Removing Coolant Level Switch
The float is made of polypropylene foam. It is 3. Look at the new coolant level switch. Notice
unlikely that the float would fail unless it sticks that the switch has a raised ring around it. This
inside the tank so it cannot move. ring snaps into a grove in the expansion tank.
Also, notice that there is a slot in the top of the
1. Make sure the coolant level is above the float.
switch. This slot fits around a tab in the
2. Slowly drain coolant from the expansion tank expansion tank.
and watch the float. The float should drop
with the coolant level.
1 2
3. If the float did not drop with the coolant level,
remove the expansion tank from the unit.
4. Flip the expansion tank upside down and right
side up to see if the float moves inside the
expansion tank. Replace the expansion tank
with a new one if the float is stuck or does not
move with the coolant level.

Replacing the Coolant Level Switch

1. Raised Ring
It makes it easier to remove and install the switch
2. Slot
if you use a blow drier or heat gun to warm the
expansion tank in the area around the switch. Do Figure 113: Coolant Level Switch
not overheat the expansion tank. Warm it to about
the temperature of hot bath water.
1. Warm the area around the coolant level
switch, but do not overheat it.

104
 Engine Maintenance

4. Look at the hole in the expansion tank from 7. Press the coolant level switch into the
which the coolant level switch was removed. expansion tank. It should click when it snaps
Notice that there is a tab in the top of the hole. into place. It may be helpful to use a wide
The slot in the switch must fit around this tab bladed screwdriver to press on the switch
when the switch is installed. where shown in the following photograph.

1. Tab 1. Tab
Figure 114: Expansion Tank Figure 115: Expansion Tank

5. Warm the expansion tank in the area around 8. Refill the expansion tank with coolant (after
the hole for the coolant level switch, but do installing the expansion tank if it was
not overheat it. removed).
6. Place the coolant level switch in the expansion 9. Connect the wire harness connector to the
tank. Make sure that the slot in the switch is coolant level switch.
aligned with the tab in the expansion tank.

105
Engine Maintenance

Engine Fuel System Fuel Line Routing

TK486V/VH engines use a mono-plunger and The fuel lines inside the unit are installed and
distributor injection pump. routed at the factory. The fuel lines from the fuel
tank connect to the fittings on the bottom of the
The components of the fuel system are: unit frame. Do not change the factory routing of
• Fuel tank the fuel lines inside the unit. See the fuel line
routing diagrams in the Diagrams Chapter.
• Fuel pre-strainer
• Inlet strainer (in fuel transfer pump) Maintenance
• Priming pump The injection pump and fuel transfer pump are
relatively trouble-free and if properly maintained
• Fuel transfer pump will usually not require major service repairs
• Fuel filter/water separator between engine overhauls.
• Injection pump Contamination is the most common cause of fuel
system problems. Therefore, to ensure best
• Trochoid feed pump operating results, the fuel must be clean and fuel
• Injection nozzles tanks must be free of contaminants. Change the
fuel filter/water separator regularly, inspect/clean
The priming pump is used to manually draw fuel the fuel pre-strainer, and clean the inlet strainer on
from the tank up to the fuel pump if the unit the inlet side of the fuel transfer pump.
should run out of fuel.
NOTE: The injection nozzles must be tested (and
Operation repaired if necessary) at least every 3,000 hours
in accordance with EPA 40 CFR Part 89.
Fuel is drawn from the fuel tank and through the Normal conditions are considered to be the use
fuel pre-strainer and inlet strainer by the fuel of clean high quality fuel, no used oil blending,
transfer pump. The fuel transfer pump delivers and regular maintenance of the fuel system
fuel to the fuel filter/water separator. Two orifices according to the Maintenance Inspection
in the filter head control the pressure in the fuel Schedule. Refer to the TK482 and TK486
system by allowing a certain amount of fuel to Overhaul Manual TK 50136 for injection nozzle
return to the tank. One orifice is located in the testing and repair procedures.
center of the filter head. It bleeds off water. The
other orifice is located off-center on the filter Whenever the fuel system is opened, take the
head. It bleeds off air. Filtered fuel passes through following precautions to prevent dirt from
a line from the outlet fitting on the filter base to entering the system:
the injection pump. 1. Cap all fuel lines.
The injection pump forces the fuel, at a very high 2. Work in a relatively clean area whenever
pressure, through the injection nozzles. The possible.
injection nozzles atomize the fuel as it is injected
directly into the combustion chambers. 3. Complete the work in the shortest possible
time.
Injection pump leakage, injection nozzle overflow
and excess fuel from the fuel filter orifice are then
all sent back to the fuel tank in the return line.

106
 Engine Maintenance

Any major injection pump or nozzle repairs 4. Fuel transfer pump replacement or repair.
should be done by a quality diesel injection
5. Injection line replacement.
service shop. The necessary service equipment
and facilities are not found in most engine rebuild 6. Engine speed adjustments.
shops because of the large investment required.
7. Injection pump timing.
The following procedures can be done under field
8. Nozzle spray pattern testing and adjustment.
conditions:
9. Injection nozzle testing, adjustment, and
1. Bleeding air from the fuel system.
minor repair.
2. Fuel tank and filter system maintenance.
10. Trochoid feed pump replacement.
3. Priming pump (hand) replacement or repair.

1 2

ARA1755
9 8

1. Fuel Pre-Strainer 6. Priming Pump

2. Filter Head 7. Fuel Filter/Water Separator
3. Bleed Screw 8. Inlet Line (From Fuel Tank)
4. Mono-plunger and Distributor Injection Pump 9. Return Line (To Fuel Tank)
5. Fuel Transfer Pump
Figure 116: Fuel System

107
Engine Maintenance

Fuel Return Line Replacement 2. Discard the old clamps, end cap, and fuel
return lines.
The fuel return lines (hoses) and end cap on the
fuel injection nozzles should be changed every 3. Install the end cap and clamp. Note that the
10,000 engine operating hours. The return line kit end cap has a larger OD than the other hoses
(P/N 10-373) contains new return lines, clamps, and requires the larger clamp.
an end cap, and a decal like the one shown below.
4. Install the fuel return lines and clamps. It may
The decal is located near the unit serial plate. The
be necessary to adjust the banjo fitting slightly
date and engine hours must be entered on the
to obtain the straightest routing for the long
decal when the fuel return lines are changed.
return line.
5. Be sure all the fittings are tight and check for
leaks.
6. Write the date and engine hours on the decal.

Bleeding the Fuel System

Figure 117: Fuel Return Line Replacement Decal
If the engine runs out of fuel, repairs are made to
Use the following procedure to replace the fuel the fuel system, or if air gets into the system for
return lines and end cap. any other reason, the air must be bled out of the
fuel system.
1. Remove the clamps, the end cap, the short fuel
return lines between the injection nozzles, and NOTE: MAKE SURE the fuel tank vent is kept
the long fuel return line from the injection open. If the vent becomes clogged, a partial
nozzle to the banjo fitting on the injection vacuum develops in the tank, and this increases
pump. the tendency for air to enter the system.

1
1 2
2 3

3 5

4
4

aea751 3
3
1. Stand Pipes 4. Drain Plug
5 2. Anti-Siphon Screen (Optional) 5. Vent
3. Fuel Gauge

3 Figure 119: Fuel Tank

To bleed air from the fuel system:
1. End Cap 4. Short Fuel Return Lines
1. Loosen the bleed screw about one turn.
2. Larger Clamp 5. Long Fuel Return Lines
3. Smaller Clamps
Figure 118: Fuel Return Line Replacement

108
 Engine Maintenance

1
2. Remove the drain plug from the bottom of the
fuel tank.
NOTE: Some fuel tanks have a check valve in
the drain plug fitting. Push the check valve open
with a small screw driver to drain the tank.
3. Let the water and fuel drain into the container
until no water is visible in the fuel draining
from the tank. If the water and fuel do not
drain freely, the vent may be plugged. If so,
clean or replace the vent.
4. Install the drain plug.

2
Fuel Pre-Strainer
The fuel pre-strainer removes the larger
1. Bleed Screw 2. Priming Pump contaminant particles from the fuel before it goes
Figure 120: Injection Pump through the fuel transfer pump and the fuel
filter/water separator. Inspect the fuel pre-strainer
2. Unscrew the priming pump handle and during pretrip inspections and scheduled
manually prime the fuel system until air maintenance inspections. Remove the bowl and
bubbles are no longer visible in the fuel clean the screen if it looks dirty. Fill the bowl with
coming out of the bleed screw. clean fuel when reinstalling the screen and bowl.
3. Tighten the bleed screw and screw the priming
pump handle back in.
4. Loosen the injection lines at the injection
1
nozzles.
5. Crank the engine until fuel appears at the
nozzles.
6. Tighten the injection lines.
2
7. Start the engine and observe the engine run for
a few minutes. If the engine fails to start, or
3
starts but stops in a few minutes, repeat the
procedure.

Draining Water from Fuel Tank 4

Water run through the system may damage the

injection pump or nozzles. Damage to the fuel
system will subsequently cause more expensive
damage to the engine. A large accumulation of
water in the bottom of the fuel tank will stop a
ARA1756
diesel engine. Water should be drained off during
scheduled maintenance inspections to prevent
breakdowns. Drain the water off after the fuel 1. Head
tank and unit have remained idle for an hour. 2. Screen
3. Seal
1. Place a container under the fuel tank to catch 4. Bowl
the draining water and fuel.
Figure 121: Fuel Pre-Strainer Components

109
Engine Maintenance

NOTE: You must lubricate the seal with diesel

fuel and reseat the seal fully into the groove in 1 2
the bowl when reinstalling the screen and bowl.
Proper lubrication of the seal is necessary to
insure an air tight seal between the pre-strainer
head and the plastic bowl.

ARA160

1. Fill Through Small Openings

2. Do Not Fill Through Center Hole
Figure 123: Filling Fuel Filter/Water Separator
5. Screw the new canister on hand-tight. Using a
ARA1897
strap wrench, tighten another 1/4 turn.

1. Lubricate seal with diesel fuel and reseat seal Engine Speed Adjustments
fully into groove in bowl.
When the diesel engine fails to maintain the
Figure 122: Reseat Seal Fully in Groove in Bowl
correct engine speed, check the following before
adjusting the speed:
Fuel Filter/Water Separator
The fuel filter/water separator removes water 1. Check the fuel inlet strainer. Check the speed.
from the fuel and returns it to the fuel tank. 2. Bleed the air out of the fuel system. Check the
speed.
Fuel Filter/Water Separator
3. Bleed the air out of the nozzles. Check the
Replacement
speed.
Replace the fuel filter/water separator at intervals
according to the Maintenance Inspection Make the engine speed adjustments with the
Schedule. engine fully warmed up.

1. Unscrew the fuel filter/water separator High Speed

canister with a strap wrench. Drain, and
dispose of properly. 1. Use the Service Test Mode to run the unit in
high speed and check the high speed rpm. It
2. Clean the filter head seal surface. should be 2200 ± 25 rpm for the SB-130 and
3. Lubricate the canister seal with clean fuel. SB-230, and 2600 ± 25 rpm for the SB-330.

4. Through one of the small openings in the top 2. Shut the unit off.
of the canister, fill the new fuel filter/water 3. Remove the ball joint from the eye bolt in the
separator canister with clean fuel. This will high speed solenoid (see Figure 124).
purge the air from the canister. Do not fill
canister through the center hole. 4. Remove the boot from the high speed
solenoid.

110
 Engine Maintenance

5. Pull the plunger out of the solenoid enough to Injection Pump Timing
loosen the jam nut. An Allen wrench placed in
Use this timing procedure when installing a new
the hex opening in the face of the plunger will
injection pump. It is not necessary to use this
keep the plunger from turning. Turn the
timing procedure when removing and reinstalling
plunger eye bolt clockwise to increase the
the original injection pump. In that case, align the
speed and counterclockwise to decrease the
index marks on the injection pump and the gear
speed.
case as they were before removing the injection
6. Replace the ball joint, start the unit and check pump.
the speed. When the speed is correct, tighten
1. Before removing the old injection pump, note
the jam nut and replace the solenoid boot.
the alignment of the index marks on the
NOTE: If the correct speed cannot be set close injection pump and the gear case. The index
enough with half turns of the eye bolt, use the mark on the injection pump is usually aligned
Allen wrench to turn the plunger in smaller with the index mark on the gear case. If not,
increments. make a mark on gear case in line with the
index mark on the injection pump (see Figure
Low Speed 127).
1. Loosen the jam nut on the low speed
adjustment screw (see Figure 124).
2. Use the Service Test Mode to run the unit in
low speed. Adjust the screw to obtain the
correct speed. It should be 1450 ± 25 rpm
(1720 ± 25 rpm for SB-330 units with High
Capacity Fresh).
3. Tighten the jam nut and recheck the speed.

1 2 3 4 5

1. Index Marks
Figure 125: Index Mark Location

1. High Speed Solenoid

2. Boot
3. Ball Joint
4. Speed Control Rod
5. Low Speed Adjustment Screw
1 2
Figure 124: Engine Speed Adjustments
1. Index Mark on Injection Pump
2. Index Mark on Gear Case
Figure 126: Index Mark Alignment

111
Engine Maintenance

3. Remove the old injection pump. Use the

2 injection pump gear tool P/N 204-1011 to
1 remove the injection pump gear without
removing the timing gear cover (see “Injection
3
Pump Removal” on page 114).
NOTE: Remove the injection pump gear by
removing the nut and lock washer that
1. Index Mark on Injection Pump secure the injection pump gear assembly to
2. Existing Index Mark on Gear Case the injection pump shaft. The injection pump
3. Make New Mark on Gear Case If Needed gear assembly is made of three pieces; the
flange, the gear, and the transfer pump cam.
Figure 127: Marking Gear Case
Do not loosen or remove the four bolts that
2. Clean the area with brake cleaner or fasten the gear to the flange because that
something similar. Place an injection angle changes the factory-set timing. The EPA
sticker on the gear case so the center line on certification is based on the factory-set
the sticker is aligned with the index mark on timing. If the factory-set timing is changed,
the injection pump. An injection angle sticker the EPA certification is void.
is provided with the new injection pump. 1

1
2

1
1

1 2
1. Do Not Loosen or Remove These Four Bolts
1. Index Mark on Injection Pump
2. Remove Nut and Lock Washer
2. Injection Angle Sticker
Figure 130: Removing Injection Pump Gear
Figure 128: Place Injection
Angle Sticker on Gear Case 4. Record the injection angle marked on the old
injection pump (see the following
photographs). The injection angle mark is
located on the side of the pump facing the
0.5 Degrees engine. The injection angle mark on the pump
1 does not use a decimal point. Add a decimal
2 point before the last digit of the injection
angle mark to get the injection angle. The
3 injection angle mark in the following
photographs is 67. That equals an injection
angle of 6.7 degrees.

Examples
1. –1.0 Degrees Mark Injection Angle Mark Injection Angle
2. Center Line (0 Degrees Mark) 67 6.7 Degrees
3. +1.0 Degrees Mark 85 8.5 Degrees
Figure 129: Injection Angle Sticker

112
 Engine Maintenance

5. Record the injection angle marked on the side

1
of the new injection pump.
6. Calculate the injection angle difference by
subtracting the injection angle of the old
injection pump from the injection angle of the
new injection pump.

Examples
Injection Angle of New
8.5 6.1
Injection Pump (Degrees)
– Injection Angle of Old
– 6.7 – 6.7
Injection Pump (Degrees)
= Injection Angle Difference
= +1.8 = –0.6
1. Injection Angle Mark (Degrees)

Figure 131: Injection Angle Mark Location 7. 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). Tighten the injection pump
mounting nuts when the index mark is aligned
as necessary with the injection angle sticker.

1
1
1. Injection Angle Mark
Figure 132: Injection Angle Mark

NOTE: If you cannot read the injection angle

mark, contact the Thermo King Service
Department with the injection pump serial
number or the engine serial number and they 2
will provide the injection angle. The injection
pump serial number is located on the bottom of 1. Injection Pump Index Mark at –0.6 Degrees
the sticker on the injection pump.
2. Injection Pump Index Mark at +1.8 Degrees
Figure 134: Examples of Injection Pump Index
Mark Alignment with Injection Angle Sticker
1
8. Install the injection pump gear, lock washer,
and nut. Torque the nut to 58 to 65 ft-lb (78 to
88 N•m).
NOTE: If the timing gear cover was removed to
remove the injection pump gear, make sure the
timing marks on the timing gears are aligned as
1. Injection Pump Serial Number
shown below. It helps to install the idler gear last
Figure 133: Injection Pump Serial Number Location when aligning the timing marks.

113
Engine Maintenance

3
Injection Pump Removal
1
2 The injection pump drive gear will not fit through
the gear housing when removing the pump, the
gear must be separated from the pump. Using tool
P/N 204-1011, it will not be necessary to remove
the belts, fuel pump, crankshaft pulley, crankshaft
seal or front plate. See Figure 139 “Injection
Pump Gear Tool” on page 115.
1. Note the alignment of the index marks on the
injection pump and the gear case. The index
4
mark on the injection pump is usually aligned
with the single index mark on the gear case. If
1. Fuel Injection Pump Gear not, mark it so the injection pump can be
2. Idler Gear returned to the same position when it is
3. Camshaft Gear reinstalled.
4. Crankshaft Gear
Figure 135: Timing Mark Alignment

NOTE: The oil pump is located in the timing

gear cover on TK486V/VH engines. The inner
rotor of the oil pump fits around the crankshaft
gear. 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.

1
2
5 1
3
4 1. Index Marks
Figure 137: Index Mark Location
7

1. Crankshaft Gear
2. Oil Pump Cover
3. Outer Rotor
4. Inner Rotor
5. Timing Gear Cover 1 2
6. Flat Sides on Inner Rotor
1. Index Mark on Injection Pump
7. Flat Side on Crankshaft Gear
2. Index Mark on Gear Case
Figure 136: Align Flat Sides of Crankshaft Gear
with Flat Sides of Inner Rotor in Timing Gear Cover Figure 138: Index Mark Alignment

114
 Engine Maintenance

2. Remove the starter for clearance, remove 5. Align the threaded holes in the injection pump
throttle linkage, fuel lines, harness and gear with the two holes in the tool plate by
mounting hardware from injection pump. rotating the engine crankshaft. Attach the gear
to the tool plate with the screws provided with
3. Remove the cover plate from the gear case.
the tool plate.
Remove the nut and lock washer which secure
the gear to the injection pump shaft. Use a 6. Thread the long screw supplied with the tool
shop rag to prevent the lock washer or nut plate into the small end of the adapter, also
from falling into the gear case. supplied with the tool plate. Insert the adapter
into the tool plate and rotate to provide a solid
NOTE: The injection pump gear assembly is
made of three pieces; the flange, the gear, position to force the injection pump shaft from
the gear. Caution should be made to align the
and the transfer pump cam. Do not loosen or
remove the four bolts that fasten the gear to screw over the center of the injection pump
shaft.
the flange because that changes the timing.
7. Remove the screw and adapter leaving the tool
4. Use the hardware from the cover plate to
attach the tool plate (with the marked side plate in place. This holds the gear in proper
pointing up and out) to the gear case. tooth alignment until the injection pump is
re-installed.

8 7 6

1. Injection Pump 5. Adapter (Tool)

2. Gear Case 6. Tool Long Screw (Tool)
3. Cover Plate 7. Tool Short Screw (Tool)
4. Cover Plate Bolt 8. Tool Plate (Tool)
Figure 139: Injection Pump Gear Tool

115
Engine Maintenance

Injection Pump Reinstallation

1. Position injection pump shaft into gear,
rotating shaft to mate key with keyway in
gear. Take care to make sure the key mates
with the keyway.
2. Secure injection pump to gear case with
previously removed hardware. Make sure to
align the index marks on the injection pump
and the gear case like they were in step 1 of
“Injection Pump Removal”.
NOTE: If a different injection pump is being 1
installed, see “Injection Pump Timing” on
page 111 to set the timing. 1. Fuel Solenoid

Figure 140: Fuel Solenoid Location

3. Remove hardware holding gear to tool plate,
then remove tool plate.
Testing the Fuel Solenoid
4. Secure the gear to the injection pump shaft
NOTE: The fuel solenoid pull-in coil will
with the lock washer and nut. Use a shop rag,
require 35 to 45 amps to turn on the fuel. The
as before, to prevent the lock washer or nut
unit’s battery must be in good condition. If the
from falling into the gear case. Torque the nut
battery has enough power to crank the engine
to 58 to 65 ft-lb (78 to 88 N•m).
over, it has enough power to energize the fuel
5. Fasten cover plate to gear case and reinstall all solenoid pull-in coil.
components removed previously to facilitate
If you suspect that the engine does not run
injection pump removal.
because the fuel solenoid is not operating
correctly, use the following procedure:
Fuel Solenoid
1. Use the microprocessor keypad to enter the
The fuel solenoid is located on the end of the
Interface Board Test Mode. Refer to the
injection pump. It contains two coils: the pull-in
appropriate Microprocessor Diagnostic
coil, and the hold-in coil. The pull-in coil draws
Manual for specific information about the
approximately 35 to 45 amps at 12 volts. The
Interface Board Test Mode.
hold-in coil draws approximately 0.5 amps at
12 volts. 2. Energize the run relay with the Interface
Board Test Mode. The fuel solenoid relay is
The pull-in coil must be energized to move the
momentarily energized when the run relay is
injection pump governor linkage to the fuel on
energized with the Interface Board Test Mode.
position. Once the injection pump governor
This energizes the fuel solenoid, which makes
linkage has been moved to the fuel on position,
a definite click when energized.
the hold-in coil will keep it in fuel on position
until the 8D circuit is de-energized. The pull-in 3. De-energize the run relay with the Interface
coil must be de-energized after a few seconds to Board Test Mode. This de-energizes the fuel
keep it from being damaged. The pull-in coil is solenoid, which makes a definite click when
controlled by the microprocessor through the fuel de-energized.
solenoid pull in relay (K6).
4. Repeat steps 2 and 3 a few times to check the
operation of the fuel solenoid.

116
 Engine Maintenance

NOTE: The fuel solenoid may be removed resistance of the pull-in coil should be 0.2
from the injection pump to visually check its to 0.3 ohms. If the resistance of the pull-in
operation. The fuel solenoid must be coil is not in this range, replace the fuel
energized when it is re-installed in the solenoid.
injection pump. If it is not, the plunger and
b. If the pull-in coil does energize, go to
the linkage may not line up correctly and the
step 9.
fuel solenoid will not function properly.
9. Test the hold-in coil.
5. If the fuel solenoid is not operating properly,
check the run relay (K1), the fuel solenoid pull a. Energize the hold-in coil by placing a
in relay (K6), their fuses, and the associated jumper between the red wire (8D—pin A)
circuits. If the relays, fuses and circuits are in the fuel solenoid connector and the
acceptable, use steps 6 through 9 to isolate and positive battery terminal.
check the fuel solenoid.
b. Momentarily energize the pull-in coil by
6. Disconnect the fuel solenoid wire connector placing a jumper between the white wire
from the main wire harness. (8DP—pin B) in the fuel solenoid
connector and the positive battery
terminal. The fuel solenoid should make a
definite click when the pull-in coil is
energized, but should not click when the
pull-in coil is de-energized.
c. De-energize the hold-in coil by removing
the jumper from the red wire (8D—pin A)
AEA633
and the positive battery terminal. The fuel
1. Red (8D) solenoid should make a definite click
2. White (8DP) when the hold-in coil is de-energized.
3. Black (CH) d. If the hold-in coil does not function
Figure 141: Fuel Solenoid properly, check the resistance of the
Connector Pin Identification hold-in coil by placing an ohmmeter
between the red wire (8D—pin A) and the
7. Place a jumper wire between the black wire black wire (CH—pin C) in the fuel
(CH—pin C) in the fuel solenoid connector solenoid connector. The resistance of the
and a good chassis ground. hold-in coil should be 24 to 29 ohms. If
8. Test the pull-in coil by momentarily placing a the resistance of the hold-in coil is not in
jumper between the white wire (8DP—pin B) this range, replace the fuel solenoid.
in the fuel solenoid connector and the positive
battery terminal. The fuel solenoid should Fuel Solenoid Replacement
make a definite click when the pull-in coil is 1. Disconnect the fuel solenoid wire connector
energized and should click again when the from the main wire harness and remove the
pull-in coil is de-energized. old fuel solenoid.
NOTE: The pull-in coil will draw 35 to 45 2. Connect the new fuel solenoid wire connector
amps so do not leave the jumper connected to to the main wire harness.
the white wire (8DP—pin B) for more than a
few seconds. 3. Press the ON key to turn the unit on.

a. If the pull-in coil does not energize, check 4. Use the microprocessor keypad to enter the
the resistance of the pull-in coil by placing Interface Board Test Mode. Refer to the
an ohmmeter between the white wire appropriate Microprocessor Diagnostic
(8DP—pin B) and the black wire (CH— Manual for specific information about the
pin C) in the fuel solenoid connector. The Relay Test Mode.

117
Engine Maintenance

5. Energize the fuel solenoid by energizing the

run relay with the Interface Board Test Mode. 1
NOTE: The fuel solenoid must be energized
when it is installed. If not, the plunger and
the linkage may not line up correctly and the
fuel solenoid will not function properly.
2
6. Place the O-ring in the groove in the end of
the fuel injection pump. Make sure that the
O-ring is positioned correctly during
installation to avoid damage and leaks.
1. Trochoid Feed Pump Outlet Pressure Port
2. Trochoid Feed Pump
Figure 143: Trochoid Feed Pump Location

Trochoid Feed Pump Leaks

Internal – If the seal in the trochoid feed pump
fails, it could allow some fuel to leak into the
engine oil. A faulty injection nozzle or fuel
AEA635 transfer pump can also dilute the engine oil with
fuel. Replace the trochoid feed pump if the engine
1. Fuel Solenoid oil is being diluted with fuel and a faulty injection
2. O-ring nozzle or fuel transfer pump is not the cause.
3. Groove in Fuel Injection Pump External – Replace the O-ring seal between the
trochoid feed pump and the injection pump if oil
Figure 142: Fuel Solenoid Components
is leaking. Torque the bolts to prevent leaks (6 to 7
7. Install the new fuel solenoid. ft-lb [8 to 10 N•m]).
8. Press the OFF key to turn the unit off after Replace all O-rings if fuel is leaking. Torque the
installing the fuel solenoid. Allen head screws and Hex head bolts to prevent
leaks (6 to 7 ft-lb [8 to 10 N•m]).
Trochoid Feed Pump
Trochoid Feed Pump Replacement
The TK486V/VH engine has a trochoid feed
pump on the fuel injection pump. The trochoid Use the following procedure to replace the
feed pump supplies fuel to the injection pump at a trochoid feed pump.
pressure of 65 to 87 psi (450 to 600 kPa). Check 1. Remove the four hex head screws that attach
the outlet pressure of the trochoid feed pump by the trochoid feed pump to the injection pump
removing the plug and attaching a pressure gauge (see Figure 144). Do not remove the two Allen
to the port shown below. The plug has M12x1.25 head screws.
threads. You will have to make an adaptor to
attach a pressure gauge. Replace the trochoid feed
pump if the outlet pressure is below the pressure
specifications in the following table.

Trochoid Feed Pump Outlet Pressure

Cranking 15-30 psi (103-206 kPa)
Low Speed 30-50 psi (206-345 kPa)
High Speed 65-87 psi (450-600 kPa)

118
 Engine Maintenance

5. Place the new trochoid feed pump on the

injection pump.
6. Install and tighten four hex head screws that
attach the trochoid feed pump to the injection
pump. Torque the hex head screws to 6 to
7 ft-lb (8 to 10 N•m).

Cold Start Device

The TK486V/VH Interim Tier 4 engine has a cold
start device located on the fuel injection pump.
The cold start device has a plunger that retracts at
engine coolant temperatures below 41 F (5 C) to
1 2 1 advance the injection timing approximately 2
1. Allen Head Screws (Do Not Remove) degrees. The plunger controls the position of a
2. Hex Head Screws
piston in the injection pump to change the timing.
The plunger is extended and the injection timing
Figure 144: Trochoid Feed Pump Removal is normal at engine coolant temperatures above
2. Remove the trochoid feed pump from the 41 F (5 C). Check the operation of the cold start
injection pump. device if it is difficult to start the engine in cold
weather.
NOTE: The gear on the trochoid feed pump
is lubricated with engine oil. Some engine oil NOTE: Do not pull the plunger out of a cold
might leak out of the injection pump when start device because that will damage it.
the trochoid feed pump is removed. The
trochoid feed pump does not need to be timed
when it is installed. Clean the area on the
injection pump from which the trochoid feed
pump was removed.
3. Clean the area on the injection pump from
which the trochoid feed pump was removed.
4. Place new O-rings on the new trochoid feed
pump and make sure it is clean.
1

1. Plunger (Extended)
Figure 146: Cold Start Device

Checking Cold Start Device Operation

Use the following procedure to check the
operation of the cold start device. The engine
coolant temperature must be below 32 F (0 C) to
start the procedure.
1 1. Press the ON key to turn the unit on.
1 2. Press the GAUGES key before the engine starts
(to enter the Gauges Menu) and check the
1. O-Rings coolant temperature to make sure it is below
Figure 145: Trochoid Feed Pump 32 F (0 C).

119
Engine Maintenance

3. Let the engine start, then check the engine rpm

in the Gauges Menu. The engine rpm should
be approximately 100 rpm higher than normal
(see Specifications). 1

4. Let the engine run to warm up and use the

Gauges Menu to check the coolant
temperature and engine rpm. When the 2
coolant temperature rises above 41 F (5 C),
the engine rpm should drop back to normal.
Replace the cold start device if the engine rpm
does not drop approximately 100 rpm when
the engine warms up.

Cold Start Device Replacement 1. Cold Start Device

2. Injection Pump Fitting
1. Drain the engine coolant.
Figure 148: Remove Cold Start Device
2. Remove the banjo bolt that fastens the engine
coolant fitting to the cold start device. Use a 4. Make sure the piston inside the injection
backup wrench on the cold start device if pump fitting is clean.
necessary.

1
1
2

1. Piston
Figure 149: Clean Piston
1. Banjo Bolt 5. Install the new cold start device with a new
2. Engine Coolant Fitting O-ring in the injection pump fitting. Torque
3. Coolant Hoses to Cold Start Device the cold start device to 22 to 26 ft-lb (30 to 35
N•m).
Figure 147: Remove Engine Coolant Fitting
6. Install the coolant fitting and banjo bolt on the
3. Remove the cold start device from the
cold start device. Torque the banjo bolt to 16
injection pump fitting. Use a backup wrench
to 18 ft-lb (22 to 25 N•m).
on the injection pump fitting if necessary.
7. Refill the engine cooling system and make
sure to bleed the air from the cooling system.

Electric Fuel Heater (Optional)

See “Electric Fuel Heater (Optional)” on page 93
for information about the electric fuel heater.

120
 Engine Maintenance

Engine Valve Clearance 4. Use a feeler gauge to check the valve

Adjustment clearance on both valves for the number one
cylinder, the intake valve for the number two
1. Remove the rocker arm cover. cylinder, and the exhaust valve for the number
2. Remove the round cover (plug) from the three cylinder. The valve clearance for both
timing mark access hole on the front of the the intake valve and the exhaust valve should
bell housing. be 0.006 to 0.010 in. (0.15 to 0.25 mm).
NOTE: Check to make sure that the valve
CAUTION: Loosen all of the injection
stem cap is in good condition and is
lines at the injection nozzles to prevent the
positioned squarely on the top of the valve
possibility of the engine firing while it is
stem. Replace the valve stem cap if it shows
being rotated.
significant wear.
3. Place the engine at top dead center of the
5. Adjust the valves if necessary by loosening
compression stroke for the number one
the locknut and turning the adjustment screw
cylinder. See steps a through d. until the valve clearance is correct.
6. Hold the adjustment screw in place and
1 2 tighten the locknut.

AEA701

1. Index Mark
2. Top Dead Center Mark for 1 and 4
Figure 150: Top Dead Center One and Four AEA705

a. Rotate the engine in the normal direction Figure 151: Adjusting the Valve Clearance
of rotation (clockwise viewed from the 7. Recheck the valve clearance.
water pump end) until the 1-4 timing mark
on the flywheel lines up with the index 8. Rotate the engine one full turn (360 degrees)
mark in the timing mark access hole. in the normal direction of rotation (clockwise
viewed from the water pump end), and align
b. Check the rocker arms on the number one the 1-4 timing mark on the flywheel with the
cylinder to see if they are loose. index mark in the timing mark access hole.
c. If the rocker arms are loose, the engine is This is top dead center of the compression
at top dead center of the compression stroke for the number four cylinder.
stroke for the number one cylinder. 9. Check and adjust the exhaust valve for the
d. If the rocker arms are tight, the engine is at number two cylinder, the intake valve for the
top dead center of the exhaust stroke for number three cylinder, and both valves for the
the number one cylinder. Rotate the engine number four cylinder.
360 degrees to place the engine at top dead 10. Replace the rocker arm cover, the cover for
center of the compression stroke for the the timing mark access hole, and tighten the
number one cylinder. fuel injection lines when finished.

121
Engine Maintenance

Valve Adjustments and Cylinder Configurations

Rear Front
Flywheel End Pulley End
Cylinder Number 1 2 3 4
Valve arrangement E I E I E I E I

Piston in No. 1 cylinder is at

TDC on compression stroke

Piston in No. 4 cylinder is at

TDC on compression stroke

Crankcase Breather Normal crankcase pressures with a new air

cleaner are 0 to 12 in. (0 to 300 mm) H2O of
Gases formed in the crankcase are directed to the
vacuum. The vacuum will increase as the air
intake manifold. Harmful vapors that would
cleaner gets dirty and becomes more restrictive.
otherwise collect in the crankcase and
Check the air restriction indicator before checking
contaminate the oil, or escape to the outside, are
the crankcase pressure. Replace the air cleaner if
drawn back into the engine and burned.
the reading on the air restriction indicator exceeds
The crankcase breather is located in the valve 20 in. (508 mm) H2O of vacuum. A dirty air
cover. A restrictor is cast into the fitting for the cleaner may cause excessive vacuum, leading to
breather hose on the intake manifold. The oil carry over and high oil consumption.
restrictor limits the flow of gases from the
The crankcase breather and the breather hose
crankcase to the intake manifold and keeps the
should be inspected when the air cleaner element
crankcase pressure from getting too low in
is replaced to make sure they are not plugged or
vacuum. A breather hose connects the crankcase
damaged. Inspect the insulation to make sure it is
breather to the intake manifold.
in place and undamaged. The insulation is used to
3 prevent freezing in cold weather.

1 2 The following items can effect the crankcase

4 pressure readings.

Crankcase
Pressure Typical Cause
8 Effect
Increase Piston Rings Stuck or Worn
Breather Hose or Restrictor
Increase
Plugged with Dirt or Ice
Decrease Air Cleaner Dirty or Plugged
7
6 5

1. Breather Hose 5. Baffle Breather

2. Insulation 6. Baffle Plate
3. Breather Cover 7. Intake Manifold
4. O-Ring 8. Restrictor Location
Figure 152: Crankcase Breather

122
 Engine Maintenance

EMI 3000 Air Cleaner

The EMI 3000 air cleaner is a dry element air
cleaner. Replace the EMI 3000 air cleaner element
when the air restriction indicator reads 25 in. of
vacuum, or at 3,000 hours or 2 years, whichever
occurs first. The EMI 3000 air cleaner element
has a nameplate that reads “EMI 3000.” It cannot
be interchanged with air cleaners used on previous
units, however it can be retrofit on previous units
by using the EMI 3000 Air Cleaner Assembly and 1
the related components. 2

1. EMI 3000 Air Cleaner Assembly

2. EMI 3000 Air Filter Element
ARA189
3. Air Restriction Indicator
Figure 155: EMI 3000 Air Cleaner System
Figure 153: EMI 3000 Air Cleaner Assembly Model 30 Shown Model 50 Similar

ARA190

1. Dust Ejector Must Point Down When Installed

Figure 154: EMI 3000 Air Filter Element

123
Engine Maintenance

Air Restriction Indicator Belts

Excessive restriction of the air intake system Belts should be regularly inspected during unit
reduces the flow of air to the engine affecting pretrip inspections for wear, scuffing or cracking.
horsepower output, fuel consumption and engine Belt tension should also be checked during
life. scheduled maintenance inspections. Belts that are
too loose will whip and belts that are too tight put
An air restriction indicator is installed on the air
too much strain on the belt fibers and bearings.
intake manifold. Visually inspect the restriction
indicator periodically to assure the air filter is not Using belt tension gauge, P/N 204-427, is the best
restricted. Service the air filter when the yellow method of checking belts for tightness. Install the
diaphragm indicates 25 in. of vacuum. Press the belt gauge in the center of the longest belt span.
reset button on the top of the air restriction Press the plunger so the hook will engage the belt.
indicator after servicing the air filter. Make sure the hook is on the face of the belt, not
in a notch. Release the plunger with a quick
motion and without pulling on the belt. Then read
the dial. Use an average of three readings.
NOTE: Do not attempt to remove or install belts
without loosening adjustments. Belts that are
installed by prying over pulleys will fail
prematurely due to internal cord damage.
CAUTION: Do not attempt to adjust belts
with the unit running.

AEA710
CAUTION: Turn the unit off before
performing maintenance or repair
Figure 156: Air Restriction Indicator procedures. When the unit is turned on, it
can start at any time without warning.

124
 Engine Maintenance

Model 30 Belt Adjustments Upper and Lower Fan Belt Adjustment

See “Belt Tension” on page 16 in the
Alternator Belt Adjustment
“Specifications” chapter for the correct upper and
See “Belt Tension” on page 16 in the lower fan belt tension settings.
“Specifications” chapter for the correct alternator NOTE: Both the upper and lower fan belts are
belt tension settings.
adjusted at the same time in one procedure.
1. Loosen the alternator pivot bolt and the NOTE: If a fan belt is loose or damaged, replace
adjusting arm bolt. the belt (see “Model 30 Fan Belt Replacement”
2. Move the alternator on the adjusting arm slots on page 126).
to adjust the belt to the correct belt tension 1. Loosen the idler assembly pivot bolts and the
setting. idler adjusting arm bolts.
3. Tighten the adjusting arm bolt and alternator 2. Push in or pull out on the idler adjusting arm
pivot bolt. to “center” the idler assembly between the
belts and balance the tension between the
upper and lower belts to the correct belt
tension settings.

2
3
4

13

7
12

8
9
11 9
10

1. Upper Fan Belt 8. Lower Fan Belt

2. Condenser Fan Pulley 9. Engine Pulley
3. Condenser Fan 10. Idler Adjusting Arm Bolt
4. Condenser Inlet Ring 11. Idler Adjusting Arm
5. Idler Assembly Pivot Bolt 12. Alternator Belt
6. Idler Assembly 13 Idler Adjusting Arm Pivot Bolt
7. Belt Guide
Figure 157: Model 30 Belt Arrangement

125
Engine Maintenance

3. Tighten both idler adjusting arm bolts and 3. Pull the idler adjusting arm OUT. The upper
both idler assembly pivot bolts. fan belt should slip off the idler pulley as the
NOTE: If the idler assembly binds when idler pulley hub clears the curbside idler
moving for belt adjustment, loosen the upper mounting bracket.
idler support bracket mounting bolts to free 4. Loosen the two condenser fan hub to the shaft
up the assembly. Check the main idler clamping bolts.
retainer nut assembly for proper alignment
between the nut and the support bracket 5. Tap the blower wheel with a soft hammer to
slots. drive the blower wheel up the fan shaft to
provide 1/2 in. (13 mm) clearance between the
blower wheel and the inlet ring.
Model 30 Fan Belt Replacement
NOTE: If the condenser fan does not slide
NOTE: Do not attempt to remove or install the
on the fan shaft with light tapping, remove
belts without loosening the adjustments. Belts
the small access panel located on the
that are installed by prying over pulleys will fail
condenser coil header above the radiator
prematurely due to internal cord damage.
tank. Thread a 1/4-20 x 1 in. diameter bolt
into the end of the fan shaft. Tighten the bolt
Lower Fan Belt
and washer down on the condenser fan hub
Removal to loosen the blower wheel. Drive the blower
1. Loosen both idler adjusting arm bolts and both wheel back to provide 1/2 in. (13 mm)
idler pulley assembly bolts. clearance between the blower wheel and
condenser fan inlet ring.
2. Push the idler adjusting arm IN. The lower fan
belt will come off the engine pulley. Move the 6. Lift the belt up over the condenser blower
arm OUT far enough to clear the roadside wheel and remove it from the unit.
idler mounting bracket. Installation
Installation 1. Slip the belt over the condenser blower wheel
1. Slip the belt into the groove of the idler pulley. and place it in the condenser fan pulley.

2. Push the idler adjusting arm back in toward 2. Drive the condenser blower wheel out toward
the unit. the condenser fan inlet ring using a soft
hammer.
3. Slip the belt onto the pulley groove on the
engine. 3. Position the blower wheel so the edge of the
inlet ring lines up with the alignment mark on
4. Pull the idler adjusting arm back OUT and the blower wheel.
adjust the belts to the proper tension.
4. Check the radial clearance between the blower
5. Tighten the idler assembly pivot bolts and the wheel and inlet ring with a gauge wire. Check
idler adjusting arm bolts. around the entire circumference to the inlet
ring and blower wheel (see “Condenser and
Upper Fan Belt Evaporator Fan Location” on page 171).
Removal 5. Torque the blower hub clamping bolts to
1. Loosen the idler adjusting arm bolts and 18 ft-lb (24 N•m).
remove the lower fan belt (see “Lower Fan 6. Seat the upper belt in the blower wheel pulley
Belt” above). groove.
2. Push the idler adjusting arm in and the idler 7. Push inward on the idler adjusting arm and
assembly up. The upper belt should become slip the belt into the idler pulley groove.
slack and slip down out of the idler pulley
groove.

126
 Engine Maintenance

8. Pull the idler adjusting arm forward and install Compressor Belt Adjustment
the lower fan belt.
See “Belt Tension” on page 16 in the
1 2
“Specifications” chapter for the correct
compressor belt tension settings.
1. Loosen the back-up hex nut on the belt
3 tensioner compression spring adjustment
screw.
2. Move the hex nuts on the compression spring
adjustment screw to adjust the belt tension to
the correct belt tension setting.
4
3. With the proper belt tension adjustment,
tighten the back-up hex nut to the adjustment
hex nut on the compression spring adjustment
screw.

Water Pump Belt Adjustment

See “Belt Tension” on page 16 in the
AEA749 “Specifications” chapter for the correct water
pump belt tension settings.
1. Blower Wheel
1. Remove the bolts from the water pump pulley.
2. Inlet Ring
3. Alignment Mark
2. Remove the pulley sliding section and add or
remove shims to adjust the belt tension.
4. Edge of Inlet Ring
Figure 158: Condenser Blower Alignment 3. Reinstall the belt on the pulley and replace the
sliding pulley section on the pulley.
Model 50 Belt Adjustments 4. Tighten the mounting belts on the water pump
pulley.
Alternator Belt Adjustment
5. Check the belt tension setting and readjust if
See “Belt Tension” on page 16 in the necessary.
“Specifications” chapter for the correct alternator
belt tension settings. Fan Belt Adjustment
1. Loosen the alternator pivot bolt and the See “Belt Tension” on page 16 in the
adjusting arm bolt. “Specifications” chapter for the correct fan belt
2. Move the alternator on the adjusting arm slot tension settings.
to adjust the belt to the correct belt tension 1. Loosen the idler pulley mounting bolts.
setting.
2. Move the idler pulley assembly to adjust the
3. Tighten the adjusting arm bolt and alternator belt tension to the correct belt tension setting.
pivot bolt.
3. Tighten the idler pulley mounting bolt.

127
Engine Maintenance

1 2
3

12

11

10

6
8
AGA223

1. Condenser Fan Pulley 7. Electric Motor

2. Condenser Fan 8. Compressor Pulley
3. Condenser Inlet Ring 9. Compressor Belts
4. Idler Pulley 10. Belt Tension Adjustment Idler
5. Fan Belt 11. Alternator Belt
6. Water Pump Belt 12. Alternator
NOTE: Units with the optional 24 HP electric motor have some pulleys and
belts that are different from those in units with the standard 14 HP electric
motor. See the appropriate Parts Manual for the correct part numbers.
Figure 159: Model 50 Belt Arrangement

Model 50 Compressor Belt 5. Remove the belts through the gap between the
Replacement clutch and the flywheel.

Removal Installation
1. Loosen the back-up hex on the belt tensioner 1. Install the belts on the clutch pulley through
compression spring adjustment screw. the gap between the clutch and the flywheel.
2. Move the hex nuts on the compression spring 2. Place the compressor in position and install
adjustment screw to relieve belt tension. the mounting bolts.
3. Support the compressor and unbolt the 3. Adjust the hex nuts on the compression spring
compressor form the flywheel housing (leave adjustment to tighten the belts to the correct
the refrigeration lines connected). belt tension setting.
4. Swing the compressor assembly away from 4. Tighten the back-up hex nut on the belt
the flywheel housing. tension compression spring adjustment screw.

128
 Engine Maintenance

Model 50 Fan Belt Replacement 4. Check the radial clearance between the blower
wheel and inlet ring with a gauge wire. Check
NOTE: Do not attempt to remove or install the
around the entire circumference to the inlet
belts without loosening the adjustments. Belts
that are installed by prying over pulleys will fail ring and blower wheel (see “Condenser and
Evaporator Fan Location” on page 171).
prematurely due to internal cord damage.
5. Torque the blower hub clamping bolts to
Removal 24 N•m (18 ft-lb).
1. Loosen the idler pulley mounting bolts. 6. Seat the upper belt in the blower wheel pulley
groove.
2. Move the idler pulley assembly to obtain
enough slack to remove the belt from the idler 7. Place the belt in the idler and electric motor
and the electric motor. pulleys.
3. Loosen the two condenser fan hub to the shaft 8. Move the idler pulley assembly to adjust the
clamping bolts. belt tension to the correct belt tension setting.
4. Tap the blower wheel with a soft hammer to 9. Tighten the idler pulley mounting bolt.
drive the blower wheel up the fan shaft to
provide 13 mm (1/2 in.) clearance between the Clutch (Model 50)
blower wheel and the inlet ring.
Periodically inspect the clutch for worn bearings,
NOTE: If the condenser fan does not slide worn friction shoes and for broken springs. To
on the fan shaft with light tapping, remove inspect the clutch:
the small access panel located on the
condenser coil header above the radiator 1. Loosen the back-up hex nut and move the hex
tank. Thread a 1/4-20 x 1 in. diameter bolt nuts on the compression spring adjustment
into the end of the fan shaft. Tighten the bolt screw to relieve the tension on the compressor
and washer down on the condenser fan hub belts.
to loosen the blower wheel. Drive the blower 2. Support the compressor and unbolt the
wheel back to provide 1/2 in. (13 mm) compressor from the bell housing studs.
clearance between the blower wheel and
condenser fan inlet ring. 3. Remove the compressor from the bell housing
and turn the compressor to provide better
5. Lift the belt up over the condenser blower access to the clutch.
wheel and remove it from the unit.
NOTE: The refrigeration lines may be
Installation removed from the compressor to allow more
movement of the compressor for better access
1. Slip the belt over the condenser blower wheel to the clutch.
and place it in the condenser fan pulley.
4. Remove the compressor belts.
2. Drive the condenser blower wheel out toward
the condenser fan inlet ring using a soft 5. Remove the clutch mounting bolt and special
hammer. washer.
3. Position the blower wheel so the edge of the 6. Remove the clutch with a clutch puller.
inlet ring lines up with the alignment mark on 7. Remove the key from the compressor
the blower wheel (see Figure 158 on page crankshaft and inspect the key and the
127). crankshaft for wear, burrs, or damage.

129
Engine Maintenance

8. To disassemble the clutch, press the pulley out c. Use a soft hammer to tap the friction shoe
of the bearing. mounting bolts out of the hub and remove
them from the friction shoes.
9. Inspect the friction shoes and springs.
d. Attach the new friction shoes to the hub
a. Replace the friction shoes if the linings are
with the mounting bolt plate, the mounting
worn to a thickness of less than 1/16 to
bolts, and the lock nuts. Torque the lock
3/32 in. (1.6 to 2.4 mm).
nuts to 30 to 35 ft-lb (41 to 47 N•m).
b. Replace the springs if they are worn or
11. To replace the bearing:
broken.
a. Remove the snap ring and press the
10. To replace the friction shoes:
bearing out of the hub.
a. Remove the springs from the friction
b. Press the new bearing into the hub and
shoes.
install the snap ring.
b. Remove the lock nuts from the friction
12. To assemble the clutch, press the pulley into
shoe mounting bolts.
the bearing.

11

10

8
7

AGA338
6

5
4
3
2
1

1. Clutch Mounting Bolt 7. Spring

2. Special Washer 8. Friction Shoe
3. Snap Ring 9. Mounting Bolt Plate
4. Bearing 10. Friction Shoe Mounting Bolt
5. Lock Nut 11. Pulley
6. Hub
Figure 160: Clutch

130
 Engine Maintenance

13. Place the clutch on the compressor crankshaft,

align the keyways (use Keyway Tool 1
204-972), and insert the key to be flush with
the end of the crankshaft.
CAUTION: Do not place the key on the 2
compressor crankshaft before installing
the clutch because the key might be
pushed out of place behind the clutch
when the clutch is installed.
1. Elastomer
14. Install the special washer and the clutch
mounting bolt. Torque the clutch mounting 2. Outer Steel Sleeve
bolt to 90 ft-lb (122 N•m). Figure 162: Old Style Drive Bushing
15. Reinstall the compressor drive belts. The new style drive bushings and dowel pins
16. Reinstall the compressor on the bell housing should be used to replace the old style drive
studs. bushings and dowel pins. Use 8-Pin and Bushing
Replacement Kit 70-208.
17. Install and tighten the flatwashers, lock
washers and nuts on the studs. NOTE: The new bushing must be mated with a
newly designed, heat-treated dowel pin. It is
18. Readjust the compressor drive belts. imperative the old style dowel pins are replaced
with the new heat-treated dowel pins. See
Drive Bushing Replacement “Dowel Pin Replacement” on page 134.
A new style, bonded drive bushing was The design of the new style drive bushing requires
introduced in July 2004 in model 50 trailer units that the following procedure be used to replace the
with 8-pin clutches. drive bushings.
1. Loosen the compressor drive belt(s).
1
2. Remove the compressor, or pull the
compressor away from the bell housing and
turn the compressor to access the clutch.
2 Support the compressor so it is not hanging
from the vibrasorbers if you are not removing
it.
3. Remove the clutch mounting bolt and special
1. Elastomer washer, and remove the clutch.
2. Inner Fiber Sleeve 4. Remove the clutch pulley by pressing it out of
the bearing. It is not necessary to remove the
Figure 161: New Style, Bonded Drive Bushing
bearing to replace the drive bushings.
5. Remove the friction shoes.
a. Remove the springs from the friction
shoes.
b. Remove the lock nuts from the friction
shoe mounting bolts.
c. Use a soft hammer to tap the friction shoe
mounting bolts out of the hub, and remove
the mounting bolts and the friction shoes.

131
Engine Maintenance

6. Use the Clutch Bushing Removal Tool 9. Put a thick ring of Loctite adhesive 203-535
204-1154 to press the old bushings out of the around the bottom of the new bushing before
clutch hub (see Figure 163). pressing it into place. The adhesive will
squeegee up the entire length of bushing as it
7. Clean the holes from which the bushings were
is pressed into the hole.
removed.
8. “Start fit” the bushing in the clutch WARNING: If a thin coating of adhesive
hub/coupling about 1/8 in. (3 mm) to make is applied all over the bushing before it is
sure it fits in the hole and does not hang up on started in the hole, the adhesive will begin
something. “Start fit” the bushing in the side to cure before the bushing can be pressed
of the hub/coupling that faces the flywheel. completely into place.

NOTE: The Loctite adhesive has a working 10. Use the cupped end of the Clutch Bushing
time of 2 minutes so the bushing must be Installation Tool 204-1155 to press the new
installed within 2 minutes of when the bushing into the hub until the cup contacts the
adhesive was applied. Apply the adhesive and hub. Press the new bushing into the hub from
install the bushings one at a time to avoid side of the hub that faces the flywheel (see
exceeding the time limit. Figure 164).
NOTE: Let the Loctite adhesive cure for at
least 1 hour at 70 F (21 C) before running
the unit. The components can be
reassembled immediately.

1. Straight Pin End

Figure 163: Press Old Bushings Out Of Hub With Removal Tool 204-1154

132
 Engine Maintenance

1 2

1. Clean Holes
2. Cupped End

Figure 164: Press New Bushing Into Hub With Installation Tool 204-1155

11. Inspect the clutch components before 17. Install the special washer and the clutch
reassembling the clutch and replace them if mounting bolt. Torque the clutch mounting
necessary. bolt to 90 ft-lb (122 N•m).
12. Install the friction shoes, mounting bolt plate, 18. If the clutch had old style drive bushings,
and friction shoe mounting bolts. replace the dowel pins in the flywheel with
new, hardened (black) dowel pins. See
13. Torque the lock nuts on the friction shoe
“Dowel Pin Replacement” on page 134.
mounting bolts to 35 ft-lb (47 N•m).
19. Install the compressor drive belts.
14. Install the springs on the friction shoes.
20. Install the compressor on the bell housing
15. Press the clutch pulley into the bearing.
studs.
16. Place the clutch on the compressor crankshaft,
NOTE: Do not place any kind of lubricant
align the keyways (use Keyway Tool
on the outside of the dowel pins or on the
204-972), and insert the key to be flush with
inside of the drive bushings. Lubricant
the end of the crankshaft.
between the dowel pins and drive bushings
CAUTION: Do not place the key on the will cause premature wear.
compressor crankshaft before installing 21. Install and tighten the flatwashers,
the clutch because the key might be lockwashers, and nuts on the studs.
pushed out of place behind the clutch
when the clutch is installed. 22. Adjust the compressor drive belts.

133
Engine Maintenance

Dowel Pin Replacement

1. Remove the flywheel.
2. Press the old dowel pins out of the flywheel.
3. Use the Manual Pin Tool 204-1117 or the
Impact Pin Tool 204-1118 to press or drive the
new dowel pins into the flywheel. The end of
each dowel pin should be 1.15 in. (29.2 mm)
from the outer face of the flywheel. The
proper dimension is critical and is set by using
either of the tools.

1 2
2

3 3
1.15 in. (29.2 mm) 1

1. Press Dowel Pin In Until Flush With 1. Drive Dowel Pin In Until Tool
Tool 204-1117 204-1118 Hits Flywheel

2. Dowel Pin 2. Dowel Pin

3. Outer Face Of Flywheel 3. Outer Face Of Flywheel

Figure 165: Pressing New Dowel Pin Into Flywheel Figure 166: Driving New Dowel Pin Into Flywheel
Using Manual Pin Tool 204-1117 With Impact Pin Tool 204-1118

4. Install the flywheel and align it with the dowel

pin in the end of the crankshaft.
5. Install the flywheel mounting bolts. Torque
the flywheel mounting bolts to 65 ft-lb (88
N•m).
6. Install the compressor and adjust the drive
belts.

134
Refrigeration Maintenance
NOTE: The following procedures involve 8. Under these conditions, refrigerant should be
servicing the refrigeration system. Some of these visible in the receiver tank sight glass. If
service procedures are regulated by Federal, and refrigerant is not visible in the receiver tank
in some cases, by State and Local laws. sight glass, the unit is low on refrigerant.
In the USA all regulated refrigeration service
procedures must be performed by an EPA Testing the Refrigerant Charge with
certified technician, using approved equipment a Loaded Trailer
and complying with all Federal, State and Local 1. Install a gauge manifold.
laws.
2. Use the Service Test Mode to run the unit in
high speed cool. Refer to the appropriate
Refrigerant Charge Diagnostic Manual for specific information
about the Service Test Mode.
Testing The Refrigerant Charge With
An Empty Trailer 3. Build up and maintain 275 psi (1896 kPa) of
head pressure. If the pressure is below this, it
If the unit has an insufficient charge of refrigerant, 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. The suction pressure will drop as the
refrigerant charge decreases. If the unit has an 4. Cool the compartment to the lowest
overcharge of refrigerant, the unit may not cool temperature required.
properly and the suction and discharge pressure 5. Check suction pressure. It should be 13 to 25
may be high. The charge may be determined by psi (90 to 165 kPa).
inspection of the refrigerant through the receiver
tank sight glasses with the following conditions 6. Under these conditions, refrigerant should be
established: visible in the receiver tank sight glass. If
refrigerant is not visible in the receiver tank
1. Place a test box over the evaporator. sight glass, the unit is low on refrigerant.
2. Install a gauge manifold.
Testing for an Overcharge
3. Use the Service Test Mode to run the unit in
high speed cool. Refer to the appropriate Use the following procedure to identify a Thermo
Diagnostic Manual for specific information King unit with an excessive refrigerant charge:
about the Service Test Mode. 1. Install a calibrated gauge manifold on the
4. Use the microprocessor thermometer to compressor.
monitor the return air temperature. 2. Use the Service Test Mode to run the unit in
5. Run the unit on high speed cool until the air in high speed cool. Refer to the appropriate
the box is at 0 F (-18 C). By allowing the box Diagnostic Manual for specific information
to leak a small amount, you will be able to about the Service Test Mode.
maintain 0 F (-18 C). 3. Operate the unit in high speed cool long
6. The suction pressure should be 13 to 18 psi enough to stabilize system pressures and
(90 to 124 kPa). reduce the box temperature to approximately
60 F (16 C) or colder.
7. The discharge pressure should be at least 275
sag (1896 kPa). If the pressure is below this, it 4. Observe discharge pressure and cover the
can be raised by covering a portion of the condenser to increase the discharge pressure
condenser grille with a piece of cardboard to approximately 75 to 100 psi (500 to 690 kPa)
block condenser airflow. above observed pressure.

135
Refrigeration Maintenance

NOTE: If the liquid level in the receiver sight h. Close the hand valve on the refrigerant
glass drops during step 4, the unit is not tank when the liquid level approaches the
overcharged and it is not necessary to top of the receiver sight glass.
complete the procedure.
4. Repeat the overcharge test.
5. Remove the condenser cover to rapidly reduce
discharge pressure. Moisture Indicating Sight Glass
6. Observe the receiver tank sight glass and the The receiver tank is equipped with a moisture
unit discharge pressure. indicating sight glass. The outer edge of the sight
7. By the time the discharge pressure drops glass has a colored ring approximately 0.1 in.
approximately 50 psi (345 kPa), the liquid (2.5 mm) thick. The color of the ring indicates the
level in the receiver tank should drop. moisture content of the refrigerant, but it is not
completely reliable.
a. When the discharge pressure stabilizes,
the liquid level will rise. • Green = Dry
b. If the liquid level will not drop, the unit • Chartreuse = Caution
most likely has an overcharge of • Yellow = Wet
refrigerant. The refrigerant level should be
adjusted.
1
To adjust the refrigerant level:
1. Stop the unit and remove some refrigerant
with an approved refrigerant recovery device.
2
2. Perform a refrigerant level check and repeat AEA672

the overcharge test.

1. Floating Ball
3. If the liquid level is low, add refrigerant as 2. Colored Ring
follows:
Figure 167: Moisture Indicating Sight Glass
a. Connect a refrigerant tank to the gauge
manifold service line and purge the line. A system has to run for at least 15 minutes to
change the color of the indicator ring after the
b. Mid seat the compressor suction service
moisture content of the system has been changed.
valve.
For example, evacuating a system to remove the
c. Set the refrigerant tank for liquid removal moisture will not change the color of the indicator
and open the hand valve. ring until the system has been recharged and then
operated for at least 15 minutes.
d. Operate the unit in high speed cool.
e. 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.
valve. Inspect for signs of oil leakage, which is the first
sign of a leak in the refrigeration system.
f. Control the liquid flow so the suction
pressure increases approximately 20 psi NOTE: It is normal for compressor shaft seals to
(138 kPa). have a slightly oily film.

g. Maintain a discharge pressure of at least

275 psi (1896 kPa) while adding
refrigerant.

136
 Refrigeration Maintenance

Oil Collection Container NOTE: Compressors with the Pressurized Seal

Cavity do not use the check valve in the oil
The oil collection container collects the collection container. See “Compressors with
compressor shaft seal seepage to keep the unit Pressurized Seal Cavity” on page 145 for more
clean. This seepage is normal and is necessary for information about the Pressurized Seal Cavity.
shaft seal durability.
1
The oil collection container is mounted on the
body of the compressor. A tube connects the oil
collection container to the compressor shaft seal
cover. The oil that seeps from the seal will travel
through the tube and collect in the container.
Empty the container once per year during oil
changes, or during annual services. The container
has a drain spout with a cap. Remove cap and
drain the oil into a cup (not provided) and discard
the oil properly. Retighten the cap snugly by hand.
2
3
4
5

1. Seal Cover Drain Barb

2. Tube from Seal Cover to Oil Collection
Container
3. Grommet
4. Check Valve (Starting in Second Quarter
1 of 2013)
2
5. Oil Collection Container
3 Figure 169: Oil Collection Container
Showing Check Valve
4
If maintenance in the area requires removal of the
1. Tube to Compressor Shaft Seal Cover
oil collection container or the tube, caution should
2. Compressor Mounting Flange be observed to prevent damage to the check valve.
(Sectioned to Show Detail) Although the check valve was glued to the tube at
3. Oil Collection Container production, pulling the check valve back through
4. Cap (Remove to Drain Oil) the grommet may cause the Valve to fall off or be
damaged.
Figure 168: Oil Collection Container Components
Several options are available:
The check valve was added in the second quarter
1. If possible, disconnect the tube at the seal
of 2013 to improve the shaft seal reliability by
cover drain barb and leave the tube in the oil
ensuring oil stays on the shaft seal when the
collection container.
suction pressure is in a vacuum. It is made of
silicone rubber, a material that can be damaged 2. The grommet can be pried off the bottle with
easily. The check valve is located on the end of the tube still inserted, allowing the tube and
the tube inside the container. It is a very tight fit check valve to be easily removed from the
between the check valve and the grommet in the container.
oil collection container.

137
Refrigeration Maintenance

3. If option 1 or 2 are not feasible and it is NOTE: Use refrigeration compressor oil ONLY.
necessary to pull the check valve back through Polyol Ester P/N 203-513 is required for
the grommet, gently twist as pulling back. R-404A.
If the check valve does come off the tube, install a To add compressor oil pump down the compressor
new check valve from stock. and equalize the pressure to slightly positive.
Disconnect the compressor oil filter return line
Checking Compressor Oil from the top of the compressor and add the oil.
Reattach the oil filter return line to the
The compressor oil should be checked when there compressor. Evacuate the compressor before
is evidence of oil loss (oil leaks) or when opening the service valves.
components in the refrigeration system have been
removed for service or replacement.
High Pressure Cutout Switch
(HPCO)
The HPCO is located on the compressor discharge
manifold. If the discharge pressure rises above
470 psi (3241 kPa), the HPCO opens the HPCO
circuit to the run relay and stops the unit. To test
1
the HPCO, rework a gauge manifold as shown in
Figure 171 “High Pressure Cutout Manifold” and
use the following procedure.

1. Sight Glass

Figure 170: Checking Compressor Oil

To check compressor oil level with an

ambient air temperature above 50 F (10 C):
Install a gauge manifold on the compressor.
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.
After the unit has maintained the above conditions
for 15 minutes, observe the oil level. The oil
should be 1/4 to 1/2 up in the sight glass.

To check compressor oil level with an

ambient air temperature below 50 F (10 C):
Run the unit through a complete defrost cycle.
After completing the defrost cycle, run the unit on 1. Relief Valve (66-6543)
cool for ten minutes. Observe the oil level. The oil
should be 1/4 to 1/2 up in the sight glass. 2. O-Ring (33-1015)
3. Adapter Tee Weather Head No. 552X3
If the box is empty, you can run the unit on the
heat cycle instead of the defrost cycle. Figure 171: High Pressure Cutout Manifold

138
 Refrigeration Maintenance

1. Connect the gauge manifold to the compressor end cap should be checked. See “End Cap
discharge service valve with a heavy duty, Checks” in the Refrigeration Service Operations
black jacketed thick wall #HCA 144 hose with Chapter.
a 900 psi (6204 kPa) working pressure rating.
To check the operation of the condenser pressure
2. Use the Service Test Mode to run the unit in bypass check valve:
high speed cool.
1. Remove the condenser pressure bypass check
3. Raise the discharge pressure of the valve cap from the three-way valve.
compressor first by blocking the condenser
2. Using a screwdriver, gently turn the check
coil air flow by covering the condenser grille
valve stem in until the valve is front seated.
with a piece of cardboard. If this does not raise
the discharge pressure to the cutout level of 3. Install a gauge manifold set on the
the HPCO, increase the engine speed by compressor.
overriding the throttle solenoid. This should
4. Close (front seat) the receiver tank outlet
increase the discharge pressure enough to
valve.
cause the HPCO to cut out.
CAUTION: If the discharge pressure
reaches 477 psi (3289 kPa), shut the unit
off immediately. Do not allow the
discharge pressure to exceed 477 psi (3289
kPa).
4. If the HPCO does not open to de-energize the
run relay and stop the unit, it must be
replaced.

Three-Way Valve Condenser

Pressure Bypass Check Valve
A three-way valve condenser pressure bypass
check valve is used in this unit. This check valve
controls the bypass flow of refrigerant gas
between the condenser inlet line and the
compressor discharge line.
The check valve is closed when the unit is running
on cool, or whenever the discharge pressure is
higher than the condenser pressure.
1. Check Valve
When the unit is running on defrost or heat, if the
2. Heating/Defrost Position
condenser pressure is higher than the discharge
3. Cooling Position
pressure, the check valve opens and the condenser
pressure is bled off until it drops to the level of the Figure 172: Three-way Valve Condenser
discharge pressure. The purpose of the valve is to Pressure Bypass Check Valve
improve the three-way valve response time when
5. Operate the unit on cool and pump down the
shifting from heat to cool.
low side to 20 in. Hg (-68 kPa) of vacuum.
If a three-way valve does not shift back to cool
6. Stop the unit. The condenser and suction
immediately after the pilot solenoid closes, and
pressures should remain stable, indicating no
finally shifts to cool when the temperature rise
leaks.
puts the unit into high speed, the three-way valve

139
Refrigeration Maintenance

7. Shift the three-way valve to the heat position. frozen expansion valve, or a restriction in suction
The low side gauge will raise slightly. The line. The microprocessor ignores the test results if
high side gauge will drop to approximately the box temperature or the ambient temperature is
zero. The gauges will equalize. below 10 F (-12 C). The ETV test can also be
performed using the Service Test Mode.
8. The gauges will remain in this position,
approximately zero, if the three-way valve The GAUGES key allows observation of the ETV
seals properly toward the condenser and the position during the ETV test. The expected ETV
condenser pressure bypass check valve seals position observation is a decrease followed by an
properly. increase. The suction pressure should decrease
when the valve position decreases and increase
9. Back seat condenser pressure bypass check
when the valve position increases.
valve stem against the snap ring. Both gauges
should rise indicating the condenser pressure Refer to the SR-3 Microprocessor Control System
bypass check valve is properly releasing Diagnostic Manual TK 54842 for complete
condenser pressure into the discharge tube and information about the testing and operation of the
evaporator. ETV.
10. Replace the cap on the condenser pressure See “Electronic Throttling Valve” in the
bypass check valve. Refrigeration Service Operations chapter of this
manual for removal and installation procedures.
NOTE: Valve stem MUST be back seated
during normal unit operation.
11. Open the receiver tank return outlet valve,
3
remove the gauges and return the unit to
normal operation.
2
Electronic Throttling Valve 1
(ETV)
The Electronic Throttling Valve (ETV) is optional
on the SB-130 and SB-230. It is standard on the
SB-330.
4
The Electronic Throttling Valve (ETV) is a
variable position valve operated by a stepper 1. Inlet
motor. The ETV is located in the suction line
2. Valve Body
between the evaporator and the heat exchanger.
The ETV system also uses discharge and suction 3. Stepper Motor
pressure transducers, and a hot gas bypass valve. 4. Outlet

The ETV has two internal coils. The Figure 173: Electronic Throttling Valve
microprocessor operates the valve by energizing
the coils with a variable frequency ac signal. The
valve position can be monitored with the
GAUGES key. Zero (0) indicates the valve is fully
closed and 800 indicates the valve is fully open.
The microprocessor tests the ETV if required
when the unit is started. Alarm Code 89 indicates
the refrigeration system pressures did not respond
as expected during the test. This may be caused by
a malfunction of the ETV or by a refrigeration
system problem such as low refrigerant level, a

140
 Refrigeration Maintenance

Pressure Transducers
The discharge pressure transducer and the suction
pressure transducer supply pressure information
to the microprocessor. These pressures can be
monitored with the GAUGES key. Check the
readings by comparing them to the readings on a
gauge manifold set attached to the compressor.
Refer to the SR-3 Microprocessor Control System
Diagnostic Manual TK 54842 for more
information about the testing and operation of the
pressure transducers.

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. 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 energized (opened) at full modulation.
The hot gas solenoid is de-energized (closed)
when modulation is discontinued.
Refer to the SR-3 Microprocessor Control System
Diagnostic Manual TK 54842 for information
about testing the hot gas solenoid. See the
Refrigeration Service Operations chapter of this
manual for removal and installation procedures.

141
Refrigeration Service Operations
NOTE: The following procedures involve Installation
servicing the refrigeration system. Some of these
1. Slide the compressor into the unit.
service procedures are regulated by Federal, and
in some cases, by State and Local laws. 2. Place the compressor in position, install the
compressor belts on Model 50 units, and
In the USA all regulated refrigeration service
install the mounting bolts.
procedures must be performed by an EPA
certified technician, using approved equipment NOTE: The compressor drive coupling or
and complying with all Federal, State and Local clutch will only slide onto the coupling pins
laws. in either of two positions, which are 180
degrees apart.
Compressor 3. Install the service valves using new gaskets
soaked in compressor oil. Connect the high
Removal pressure cutout switch, the pilot solenoid
1. Pump down the low side and equalize the valve line, and install the compressor oil filter.
pressure to slightly positive. 4. Pressurize the compressor and test for
2. Loosen the compressor belts on Model 50 refrigerant leaks.
units. 5. If no leaks are found, evacuate the
3. Front seat the discharge and suction service compressor.
valves. 6. Back seat the suction and discharge service
4. Recover the refrigerant remaining in the valves.
compressor. 7. Tighten the compressor belts on Model 50
5. Unbolt the discharge and suction service units.
valves from the compressor. 8. Operate the unit at least 30 minutes and then
6. Disconnect the high pressure cutout switch, inspect the oil level in the compressor. Add or
the pilot solenoid line, and remove the remove oil if necessary.
compressor oil filter. 9. Check the refrigerant charge and add
7. Support the compressor and remove the refrigerant if needed.
compressor mounting bolts from the flywheel
housing. Compressor Coupling Removal
(Model 30)
8. Lift the service valves out of the way.
1. After the compressor has been removed from
9. Slide the compressor to the left until the the unit, use the appropriate Allen tool
coupling pins are clear, and remove the provided with removal tool P/N 204-991 to
compressor belts from Model 50 units. loosen the center bolt which holds the
10. Remove the compressor from the front of the coupling to the compressor shaft.
unit. Keep the compressor ports covered to 2. Attach the tool to the coupling with the
prevent dust, dirt, etc., from falling into the provided socket head screws and spacers. Two
compressor. sets of spacers are provided with the tool, use
NOTE: When the compressor is removed the short spacers with shallow compressor
from the unit, the oil level should be noted, mounting flanges and the longer set for deeper
or the oil removed from the compressor flanges. The side with the countersunk holes
should be measured so that the same amount should be toward the coupling.
of oil can be added before placing the
replacement compressor in the unit.

142
 Refrigeration Service Operations

3. To prevent the tool and crankshaft from needed. In fact, if the key is not installed correctly
rotating, 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. not fit easily into the keyway, it will push the
If a nut is used to prevent the bolt from falling tapered components apart and the reduced friction
out, the nut should not be tightened. could lead to slippage and premature failure.
4. Use the appropriate Allen tool to loosen the The following procedure requires the key to be
coupling mounting screw. fitted after the tapers are pulled together with
20 ft-lb (27 N•m) torque. This insures that the key
5. Once the center screw has been loosened,
cannot hold the tapers apart when the final bolt
back the head against the tool and it should
torque is applied.
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. Using this tool compressor coupling on the compressor
will prevent the coupling from popping off crankshaft.
because the center bolt and flatwasher will
1. Clean the compressor shaft taper and coupling
hold it in place.
bore taper with a solvent that leaves no oily
residue (such as naphtha, lacquer thinner,
Compressor Coupling Installation brake cleaner or the like).
(Model 30)
2. Inspect both mating surfaces for burrs,
In a tapered fit joint the entire twisting load
oxidation and other surface imperfections.
should be handled by the friction fit between the
Dress with crocus cloth if necessary and
two tapered parts. The key is only a backup and is
re-clean as required.
used to index the parts correctly. When a taper fit
is machined and assembled properly a key is not
1
2

3
8

7
6

AGA1059

1. Coupling 5. 10 mm Allen Tool (for large shaft compressor)

2. Long Spacers (supplied with tool) 6. 5/16 Allen Tool (for small shaft compressors)
3. Short Spacers (supplied with tool) 7. Coupling Removal Tool (P/N 204-991)
4. Socket Head Bolts (supplied with tool) 8. Engine Mounting Flange
Figure 174: Compressor Coupling Removal Tool

143
Refrigeration Service Operations

3. Using no lubricants, set the coupling on the 8. Install the key in the keyway. As above, it
crankshaft and align the keyways using the should fit with a light press fit requiring only a
Keyway Tool (P/N 204-972). Insert the minimum of light tapping. Do not install the
tapered end of the tool into the keyway and key into the keyway beyond the front face
gently move the coupling on the shaft while of the coupling. If tapped in farther it may
pressing the tool into the keyway. This will cause the coupling to move off center on the
align the keyway in the crankshaft with the shaft.
keyway in the coupler.
1
2
3

AGA333

Figure 175: Keyway Tool P/N 204-972

CAUTION: If you are assembling a used

coupler or crankshaft and the tool does 5 4
AGA1254
not fit easily there is a problem with one of
the keyways! Do not remove the coupler
and place the key in the crankshaft 1. Compressor Coupling or Clutch
keyway and then drop the coupler on. If 2. Key tapped flush with outside face of coupling.
the tool does not fit, the key will not fit, Do not tap key any farther into keyway.
and it will hold the taper in the coupler off 3. Torque bolt to 90 ft-lb (122 N•m)
the taper on the shaft. Check both keyways
4. Washer
for burrs or corrosion. A key can be
coated with fine lapping compound and 5. Spray this area with corrosion inhibitor after
assembling.
used as a lapping tool to clean the
keyways. Figure 176: Compressor Coupling Installation

4. Remove the Keyway Tool and check the fit of 9. Re-install the bolt and heavy flat washer and
the key (P/N 55-9024). It should fit into the snug the bolt down by hand. Torque the bolt to
keyway with a light press fit requiring only a 90 ft-lb (122 N•m).
minimum of light tapping. If the key does not
fit properly, remove the coupler and inspect 10. Spray a corrosion inhibitor (such as spray
the keyways and key for burrs or other paint) on the exposed part of the shaft and the
problems. Recheck the fit as shown above. joint between the shaft and the coupling. This
prevents moisture from wicking into the joint
5. When the key fits properly, remove the and causing corrosion.
coupling and key from the shaft.
6. Re-install the coupling and align the keyways
with the Keyway Tool.
7. Do not install the key at this time. Install the
flat washer and bolt and pre-torque to 20 ft-lb
(27 N•m). Remove the bolt and washer.

144
 Refrigeration Service Operations

Compressors with Pressurized Hex Drive Compressor Seal

Seal Cavity Replacement
Starting in the first quarter of 2014 the pressurized 1. Remove the compressor from the unit.
seal cavity was phased into use on large shaft four
2. Remove the six mounting flange bolts and
cylinder compressors. Compressors with a
remove the mounting flange.
pressurized seal cavity can be identified by the
“P” on the seal cover as shown in Figure 177. The 3. Remove the three seal plate bolts and use a
model number of the compressor has been slide hammer to remove the seal plate.
changed to X430P to signify the Pressurized Seal
NOTE: Use slide hammer P/N 204-638 and
Cavity as shown in Figure 178. The pressurized
adapter P/N 204-640 to obtain the 5/16-18
seal cavity uses a new compressor seal with a hex
male thread needed to fit the seal plate.
drive and a new crankshaft with a hex drive collar.
See “Hex Drive Compressor Seal Replacement” 4. Place the seal plate gasket side down on a
below for the replacement procedure. work bench and push the hard ring out of the
seal plate.

1 NOTE: Provide a clean soft surface for hard

ring to fall onto when pushed out of the seal
plate.
5. Remove the small lip seal from the seal plate,
but do not remove the larger, internal lip seal
unless it is damaged.
6. Remove the bellows assembly from the shaft
by prying evenly on each side with small pry
bar.
7. Save all old seal parts for warranty return if
required.
8. Clean all parts thoroughly to remove all oil
ARA2163
and gaskets.
1. “P” Indicates Pressurized Seal Cavity 9. Polish the crankshaft with crocus cloth if it is
Figure 177: Seal Cover for Compressor with rusted or dirty. Do not allow abrasives to
Pressurized Seal Cavity contaminate the compressor.
1 10. Install the new lip seal in the seal plate with
the lip side facing out and the flat side facing
toward the compressor.

2 ARC010

1. “X430P” Indicates Pressurized Seal Cavity

1. Lip Side Facing Out
Figure 178: Model Number for Compressor with 2. Flat Side Toward Compressor
Pressurized Seal Cavity
Figure 179: Lip Seal Installation

145
Refrigeration Service Operations

NOTE: Do not replace the internal lip seal 1 2

unless it is damaged. To replace it, pry the old
one out and press the new one into place with
the lip facing into the seal plate. Make sure
the lip seal is pressed all the way down into
the seal plate. Oil the lip seal with supplied
compressor oil.

1. This Side Toward Seal Plate

2. This Side Toward Compressor
Figure 181: Hard Ring Positions

CAUTION: DO NOT touch or damage the

polished seal face surfaces on the hard
ring. Keep the protective cap in position
on the bellows until final assembly.

1 2
3
4

ARA2172

1. Lip Facing Into Seal Plate

Figure 180: Internal Lip Seal Installation 1. Seal Plate
2. O-ring
11. Apply clean compressor oil to the new O-ring
and install it in the seal plate. Apply clean 3. Hard Ring—Install with Polished Surface
Toward Compressor
compressor oil to the new hard ring. Ensure
that the hard ring installation tool (P/N 4. Hard Ring Installation Tool P/N 204-953
204-953) is clean. Use the hard ring 5. Internal Lip Seal
installation tool to push the hard ring (with the Figure 182: Hard Ring Installation
polished surface toward the installation tool)
12. Apply clean compressor oil to the O-ring
fully into the seal plate. Do not pinch the
inside the bellows. Slide the bellows on the
O-ring.
crankshaft, align the hex drive on the bellows
NOTE: If the installation tool is not with the hex drive collar, and then push the
available, use the pad in the new seal bellows firmly against the hex drive collar.
packaging to protect the polished surface of Leave the protective cap in place during
the hard ring during assembly. installation. If the hex drive does not slide on
easily, rotate the assembly 30 degrees.

146
 Refrigeration Service Operations

1 CAUTION: Oil applied to the seal faces

must be absolutely clean.
2
14. Install the seal plate and gasket to the
compressor body. Do not bump the seal hard
ring on the end of the crankshaft during
assembly.
15. Install the seal plate mounting bolts and
washers. Torque the seal plate bolts to 28 ft-lb
(38 N•m) in two steps using a criss-cross
pattern.
16. Install the mounting flange and torque the
1. Hex Drive Collar bolts to 28 ft-lb (38 N•m) in two steps using a
2. Hex Drive criss-cross pattern.
Figure 183: Hex Drive Bellows Installation 17. Install the compressor in the unit.
(Shown Without Protective Cap)

1 2
Condenser Coil
Removal
3
1. Recover the refrigerant charge.
4
5 2. Open the roadside condenser fan grille.
3. Drain engine coolant from the expansion tank.
Unbolt and remove the expansion tank from
the condenser coil frame.
6 4. Remove the condenser coil mounting bolts.
Remove the mounting clamps from the
ARA2166
condenser inlet line.
5. Unsolder the inlet line and liquid line
1. O-ring (Inside Bellows) connections. On units with micro-channel
2. Hex Drive coils make sure to use a heat sink on the
3. Seal Faces copper stub tubes. Lift the coil from the unit.
4. Hard Ring IMPORTANT: Micro-channel condenser
5. O-ring (In Seal Plate) coils are being phased into these units
6. Bellows starting in the fourth quarter of 2011.
Figure 184: Hex Drive Type Bellows Seal Micro-channel coils are made of aluminum
but have copper stub tubes at the inlet and
13. Remove the yellow protective cap. Clean the outlet connections. Make sure to use a heat
hard ring and the primary ring (bronze ring) sink on the copper stub tubes to prevent
with the alcohol wipes found in package damage to the heat shrink tubing and brazed
labeled “1”. Then clean the polished mating connections (and the aluminum) that attach
surfaces of both rings with the lint free dry the copper stub tubes to the aluminum
wipes from package number “2”. Apply clean micro-channel coil. The heat shrink tubing is
compressor oil to the polished surfaces of the used to prevent corrosion between the copper
seal, the lip seals, and the seal plate gasket and aluminum.
from the package number “3” before
assembling.

147
Refrigeration Service Operations

1 Discharge Vibrasorber
3 Removal
2
1. Recover the refrigerant charge.
2. Heat the connections on the vibrasorber until
ARA1972 the vibrasorber can be removed.

1. Copper Stub Tube CAUTION: Use a heat sink, P/N 204-584

or wrap the vibrasorber with wet rags to
2. Heat Shrink Tubing (Protects Brazed
Connection between Copper Stub Tube and prevent damaging the vibrasorber.
Aluminum Micro-Channel Condenser Coil)
3. Aluminum Micro-Channel Condenser Coil
Installation

Figure 185: Top View of 1. Prepare the vibrasorber and tubing fittings by
Micro-Channel Condenser Coil cleaning thoroughly.
2. Solder the vibrasorber connections.
Installation
1. Clean the fittings for soldering. CAUTION: Use a heat sink, P/N 204-584
or wrap the vibrasorber with wet rags to
2. Place the coil in the unit and install the prevent damaging the vibrasorber.
mounting bolts.
3. Pressurize the system and test for leaks. If no
3. Solder the inlet line and liquid line leaks are found, evacuate the system.
connections. On units with micro-channel
coils make sure to use a heat sink on the 4. Charge the unit with the proper refrigerant and
copper stub tubes. check the compressor oil level.

IMPORTANT: Micro-channel condenser

coils are being phased into these units
In-Line Condenser Check Valve
starting in the fourth quarter of 2011. This unit uses an in-line condenser check valve.
Micro-channel coils are made of aluminum The in-line check valve is not repairable and must
but have copper stub tubes at the inlet and be replaced if it fails. A heat sink must be used on
outlet connections. Make sure to use a heat the in-line check valve when it is being soldered
sink on the copper stub tubes to prevent in place to prevent damage to the neoprene seal.
damage to the heat shrink tubing and brazed
connections (and the aluminum) that
attached the copper stub tubes to the
aluminum micro-channel coil. The heat
shrink tubing is used to prevent corrosion
between the copper and aluminum.
4. Pressurize the refrigeration system and test for
leaks. If no leaks are found, evacuate the AEA648

system.
5. Install the clamps on the condenser inlet line.
6. Install the engine coolant expansion tank and 1. Valve
refill half way with engine coolant. 2. Neoprene Seal
3. Valve Seat
7. Close the roadside condenser fan grille.
4. Spring
8. Recharge the unit with proper refrigerant and
Figure 186: Cross Section of In-line
check the compressor oil. Condenser Check Valve

148
 Refrigeration Service Operations

Condenser Check Valve 2. Solder the bypass check valve line to the
Replacement bypass check valve. Use a heat sink on the
bypass check valve.
Removal 3. Pressurize the low side and test for leaks. If no
1. Recover the refrigerant charge. leaks are found, evacuate the system.

2. Place a heat sink on the check valve. 4. Open the bypass service valve and place the
unit in operation.
3. Unsolder the lines and remove the check
valve.
Receiver Tank
Installation
Removal
NOTE: A heat sink must be used on the in-line
1. Recover the refrigerant charge.
check valve when it is being soldered in place to
prevent damage to the neoprene seal. 2. Unsolder the inlet, outlet, and bypass check
valve lines from the receiver tank. Use a heat
1. Clean the tubes for soldering.
sink on the bypass check valve.
2. Place the check valve in position. The arrow
3. Unsolder and remove the bypass check valve
on the valve body indicates the direction of
from the receiver tank. Use a heat sink on the
refrigerant flow through the valve.
bypass check valve.
3. Place a heat sink on the check valve.
4. Remove the high pressure relief valve from
4. Solder the inlet and outlet connections. the receiver tank.
5. Pressurize the refrigeration system and test for 5. Unbolt the mounting brackets and remove the
leaks. receiver tank from the unit.
6. If no leaks are found, evacuate the system.
Installation
7. Recharge the unit with proper refrigerant and
1. Install the high pressure relief valve in the
check the compressor oil.
receiver tank.

Bypass Check Valve 2. Solder the bypass check valve onto the
receiver tank. Use a heat sink on the bypass
Removal check valve.

1. Pump down the low side and equalize the 3. Place the receiver tank in the unit and install
pressure to slightly positive. the mounting bolts and nuts loosely. Position
the receiver tank so that the sight glass is
2. Close the bypass service valve. clearly visible through the viewing hole in the
3. Unsolder the bypass check valve line from the mounting bracket.
bypass check valve. Use a heat sink on the 4. Solder the inlet, outlet, and bypass check
bypass check valve. valve lines to the receiver tank. Use a heat
4. Unsolder and remove the bypass check valve sink on the bypass check valve.
from the receiver tank. Use a heat sink on the 5. Tighten the receiver tank mounting hardware
bypass check valve. securely.

Installation 6. Pressurize the refrigeration system and check

for leaks. If no leaks are found, evacuate the
1. Solder the bypass check valve onto the system.
receiver tank. Use a heat sink on the bypass
check valve. 7. Recharge the unit with proper refrigerant.

149
Refrigeration Service Operations

Filter Drier 3. Connect the equalizer line to the suction line.

4. Clean the suction line to a bright polished
Removal condition. Install the feeler bulb clamps and
1. Pump down the low side and equalize the the feeler bulb on the side of the suction line
pressure to slightly positive. in its former position. The feeler bulb must
make good contact with the suction line or
2. Disconnect the nuts at the ends of the drier. operation will be faulty. Wrap with insulating
3. Loosen the mounting hardware and remove tape.
the drier.

Installation
1. Place the new O-rings in the ORS fittings on
the ends of the drier.
2. Install the new drier and tighten the mounting
hardware.
3. Install and tighten the ORS nuts. Hold the
drier with a back-up wrench on the hex behind
the ORS fitting.
4. Pressurize the low side and inspect for leaks. AEA713
If no leaks are found, evacuate the low side.
1. End View
5. Open the refrigeration valves and place the
2. Side View
unit in operation.
Figure 187: Location of Expansion Valve Bulb

Expansion Valve Assembly 5. Pressurize the low side and test for leaks. If no
leaks are found, evacuate the low side.
Removal
6. Replace the access panels.
1. Pump down the low side and equalize the
pressure to slightly positive. 7. Open the refrigeration valves and place the
unit in operation.
2. Remove the evaporator access panels.
8. Test the unit to see that the expansion valve is
3. Remove the feeler bulb from the clamp. Note properly installed.
the position of the feeler bulb on the suction
line.
Heat Exchanger
4. Disconnect the equalizer line from the suction
line. Removal
5. Disconnect the inlet liquid line and unsolder 1. Pump down the low side and equalize the
the distributor from the expansion valve. pressure to slightly positive.
6. Remove the expansion valve mounting bolt 2. Remove the upper and lower evaporator
and remove the expansion valve from the unit. access panels.
3. Remove the mounting bolts that hold the heat
Installation
exchanger on the bulkhead.
1. Install and bolt the expansion valve assembly
4. Disconnect the equalizer line from the suction
in the unit.
line.
2. Connect the inlet liquid line and solder the
distributor to the expansion valve.

150
 Refrigeration Service Operations

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

151
Refrigeration Service Operations

9. Open the refrigeration valves and place the

unit in operation. Check the refrigerant charge
and the compressor oil. Add as required.

Accumulator
Removal
1. Pump down the low side and equalize the
pressure to slightly positive.
2. Unsolder the inlet and outlet suction lines
from the accumulator.
CAUTION: Use a heat sink or wrap
vibrasorber with wet rags to prevent
damaging the vibrasorber.
3. Disconnect the tee fitting from the
accumulator tank.
4. Unbolt and remove the accumulator from the
unit.

Installation
1. Place the accumulator in the unit and tighten
the mounting bolts and nuts.
2. Solder the inlet and outlet suction lines to the
accumulator.
CAUTION: Use a heat sink or wrap
vibrasorber with wet rags to prevent AEA714
damaging the vibrasorber.
1. Cap 7. Clip
3. Connect the tee fitting and lines to the
2. End Cap 8. Seat
accumulator.
3. Check Valve 9. Gaskets
4. Pressurize the low side and test for refrigerant 4. Spring 10. Stem Assembly
leaks. If no leaks are found, evacuate the low
5. Piston 11. Screen
side.
6. Seal 12. Bottom Cap
5. Open the refrigeration valves and place the Figure 188: Three-Way Valve
unit in operation. Check the refrigerant charge
and the compressor oil. Add as required. Removal/Disassembly
1. Recover the refrigerant charge.
Three-Way Valve Repair
2. Clean the exterior surface of the valve.
NOTE: The three-way valve can be repaired in
the unit if leakage or damage to the PTFE seals 3. Remove the line from the three-way valve to
should occur. There is usually enough give in the pilot solenoid.
the copper tubing to separate the three sections
of the valve without unsoldering any tubes.

152
 Refrigeration Service Operations

4. Loosen the four 1/4 in. Allen head screws (DO

NOT REMOVE OR CAP MAY POP OFF);
use tool P/N 204-424 to break the gasket at 1
each side of the center section.
CAUTION: Do not force the tool into the
brass or against the bolts.

5 2

AGA1069

Figure 189: Gasket Tool P/N 204-424

5. Remove the four bolts from the valve. 1. Seal Groove in Piston
2. Connecting Notch in Piston
6. Remove the end cap and spring.
3. Internal Spring in Seal
7. Remove the spring clip which secures the 4. Connecting Groove in Stem
stem to the piston. Use Clip Tool P/N
5. Retaining Clip
204-1983 if available. Slide piston off the
stem. Figure 190: Piston and Stem Parts

8. Remove the seat and stem assembly. End Cap Checks

9. Inspect the following parts for wear or All end caps, even new ones, should be checked
damage: as follows. See Service Bulletin T&T 260 for
a. Bottom cap, sealing and support area. more information.

b. Seat, sealing surface. Check Valve Bleed Hole Diameter

c. End cap, sealing and support surface. 1. Remove the condenser pressure bypass check
The following parts will be discarded: valve snap ring, stem, spring, and piston from
the end cap.
a. Stem assembly.
2. Use a number 43 (0.089 in. [2.26 mm]) drill
b. All gaskets. bit to check the size of the hole from the end
c. Piston seal. cap gasket face to the check valve piston bore
as shown.
10. Remove the screen. If any particles drop from
the screen into the discharge line, the 3. If the drill does not go all the way into the
discharge line must be removed at the bore, drill the hole completely through.
compressor. 4. Deburr the hole in the check valve piston bore.
NOTE: The valve body cannot be A used drill bit can be modified to use as a
reconditioned. Seat positions change and deburring tool.
improper sealing will result.

153
Refrigeration Service Operations

3. With the piston pushed all the way back in its

bore, use a strong light to look down the
1
0.089 in. (2.26 mm) hole towards the back of
the piston and determine how much of the end
of the hole is covered by the piston. If the
piston covers more than three-quarters of the
hole replace the end cap.
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.
1. Number 43 Drill
Seat (Center Section) Orifice Check
Figure 191: Check Bleed Hole Diameter
There are three 0.033 in. (0.84 mm) holes located
Piston Bleed Orifice Check in the three-way valve seat (center section). Only
one is used depending on how the valve is config-
1. Use a number 66 (0.033 in. [0.84 mm]) drill
bit to check the orifice in the bleed hole from ured. 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. pressure is higher than discharge pressure because
gas will flow to the discharge line instead of
2. Carefully check to see that the drill projects
behind the piston. 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. Do
not enlarge this hole. charge pressure is higher than condenser pressure
because the flow is restricted. Do not enlarge this
1 hole larger than 0.033 in. (0.84 mm)! Whenever
2 you disassemble a three-way valve you should
check that all three of the holes are drilled cleanly.

1. Number 66 Drill
1
2. Check for Burr Here
Figure 192: Check Piston Bleed Orifice
1. Number 66 Drill
Check Valve Piston Check
Figure 193: Check Seat Orifice
1. Reassemble the end cap using a new check
valve piston, spring, stem, and snap ring (Kit Assembly/Installation
P/N 60-163).
After cleaning and inspecting all parts, reassemble
2. Leave the stem back seated against the snap the valve.
ring. Use a paper clip bent into a 90 degree
1. Install the screen in the bottom cap.
angle to push the check valve piston back in
its bore. Make sure you can feel the piston 2. Install the new stem in the bottom cap.
working against the spring.

154
 Refrigeration Service Operations

3. Install new gaskets on both sides of the seat. 5. Install the piston on the stem. In SB trailer
Oil the gaskets in compressor oil before units the three-way valve is mounted
installing. horizontally. In these units the best practices
recommendation is to install the piston on the
4. Use the three-way valve seal installation tool
stem with the slot in the piston facing up (12
P/N 204-1008 to install a new seal on the
O'clock) as shown below in Figure 195 and
piston. This prevents the seal from being
Figure 197. The clip must also be installed on
stretched and damaged.
the piston with the closed end of the clip
a. Place the tapered tool over the piston. facing up (12 O'clock). Use Clip Tool P/N
204-1983 if available. Do not install the
b. Lubricate the seal with refrigeration oil.
piston on the stem with the slot in the piston
c. Slide the seal onto the tapered tool with facing down (6 O'clock).
the spring side facing away from the
1
piston.
d. Use the pipe to hand press the seal onto
the piston.
1

3
1. Closed End of Clip Must Face Up
Figure 195: Slot In Piston Must Face Up
4

ARA166

1. Press by Hand 4. Tapered Tool

2. Pipe 5. Piston
3. Seal Figure 196: Do Not Install Piston
With Slot Facing Down
Figure 194: Seal Installation with Tool P/N 204-1008

1. Slot in Piston Must Face Up

Figure 197: Horizontal Three-Way Valve Reassembly

155
Refrigeration Service Operations

6. Install the spring and end cap. 5. Remove the spring and piston.
7. Line up the passageways in the cap and body. 6. Inspect the check valve seat in the three-way
Failure to line up the holes will result in valve.
improper operation of the valve.
7. If replacement parts are needed, a kit
8. Install the bolts and tighten in rotating P/N 60-163 must be used which includes the
sequence. Torque to 160 in-lb (18 N•m). piston, spring, O-ring, valve stem, and snap
ring.
9. Install the pilot solenoid line and pressurize
the system with refrigerant to check for leaks.
Installation
10. If there are no leaks, evacuate the system and
1. Coat the O-ring with compressor oil and
recharge with the proper refrigerant.
install it on the check valve stem.
11. Run the unit to check for proper three-way
2. Insert the spring into the hole in the check
valve operation.
valve stem and then install the piston on the
other end of the spring with the hole in the
Three-Way Valve Condenser piston towards the spring.
Pressure Bypass Check Valve 3. Coat the entire assembly with compressor oil
Repair and install the assembly into the check valve
seat in the three-way valve.
Removal
1. Recover the refrigerant charge. CAUTION: The piston must be inserted
with the flat side against the valve seat to
2. Unscrew the condenser pressure bypass check ensure proper sealing.
valve cap from the three-way valve.
4. Screw the check valve stem into the three-way
3. Remove the snap ring. valve until the snap ring can be installed.
5. Install the snap ring.
6. Unscrew (back seat) the check valve stem
against the snap ring.
NOTE: The valve stem must be back seated
during normal unit operation.
7. Coat the sealing area in the cap with
compressor oil, install and tighten the cap on
the three-way valve.
AEA715
8. Pressurize the refrigeration system and test for
1. Piston 4. Stem leaks. If no leaks are found, evacuate the
2. Snap Ring 5. O-ring system.
3. Cap 6. Spring 9. Recharge the unit with the proper refrigerant.
Figure 198: Check Valve Assembly
Pilot Solenoid
4. Unscrew the check valve stem by using a
screwdriver in the slot provided. Removal
NOTE: The spring and piston are held in by 1. Recover the refrigerant charge.
the stem. While removing the stem, use care
so the spring and piston are not lost. 2. Disconnect the wires and remove the coil from
the valve.

156
 Refrigeration Service Operations

3. Unsolder the refrigeration lines. 5. Open the refrigeration valves and place the
unit in operation.
4. Remove the mounting bolts and remove the
valve.
High Pressure Cutout Switch
Installation
Removal
1. Remove the coil from the valve.
1. Pump down the low side and equalize the
2. Place the valve in the unit and install the pressure to slightly positive.
mounting bolts. The arrow on the valve
indicates the direction of flow through the 2. Front seat the discharge and suction service
valve. Make sure that the arrow points in the valves. Recover the refrigerant remaining in
proper direction. the compressor.
3. Solder the refrigeration lines to the valve. 3. Disconnect the wires and remove the high
pressure cutout switch from the compressor
4. Install the coil and connect the wires. discharge manifold.
5. Pressurize the refrigeration system and test for
leaks. If no leaks are found, evacuate the Installation
system. 1. A new high pressure cutout switch does not
6. Recharge the unit with the proper refrigerant have a connector installed. Use the old
and check the compressor oil. connector and just install new wire terminals,
or install a new connector and wire terminals.
See the appropriate Parts Manual for the
Suction Vibrasorber correct connector and terminal part numbers.
Removal 2. Place a new copper sealing washer on the high
pressure cutout switch.
1. Pump down the low side and equalize pressure
to slightly positive. 3. Install the high pressure cutout switch and
torque it to 20 ± 2 ft-lb (27 ± 3 N•m).
2. Unsolder the suction vibrasorber from the
suction service valve. Unsolder the connection 4. Connect the wires.
to the accumulator and remove the vibrasorber
5. Pressurize the compressor and test for leaks.
from the unit.
6. If no leaks are found, open the refrigeration
Installation service valves and place the unit in operation.
1. Prepare the suction vibrasorber and tube
fittings for soldering by cleaning the High Pressure Relief Valve
thoroughly.
Removal
2. Solder the vibrasorber to the suction service
valve. 1. Recover the refrigerant charge.

CAUTION: Use a heat sink or wrap 2. Unscrew and remove the high pressure relief
vibrasorber with wet rags to prevent valve.
damaging the vibrasorber.
Installation
3. Solder the suction vibrasorber connection to
1. Apply a refrigerant oil to the O-ring of the
the accumulator.
high pressure relief valve.
4. Pressurize the low side and check for leaks. If
2. Install and tighten the high pressure relief
no leaks are found, evacuate the system.
valve.

157
Refrigeration Service Operations

3. Pressurize the refrigeration system and test for Electronic Throttling Valve
leaks. If no leaks are found, evacuate the (ETV)
system.
4. Recharge the unit with the proper refrigerant Removal
and check the compressor oil. 1. Pump down the low side and equalize the
pressure to slightly positive.
Discharge Pressure Transducer 2. The ETV must be open to remove the stepper
motor and piston assembly. Open the ETV by
Removal
placing the unit in the Evacuation Mode/Test,
1. Recover the refrigerant charge. and then turning the unit off. Refer to the
appropriate Microprocessor Diagnostic
2. Disconnect the wires and remove the
Manual for information about the Evacuation
discharge pressure transducer.
Mode/Test.
Installation 3. Remove the evaporator access panels.
1. Apply a refrigerant Loctite to the threads of 4. Disconnect the ETV harness from the four-pin
the discharge pressure transducer. connector on the main wire harness.
2. Install and tighten the discharge pressure 5. Unscrew the large nut that attaches the stepper
transducer and reconnect the wires. motor and piston assembly to the valve body.
The torque on the nut is approximately 118
3. Pressurize the refrigeration system and test for
ft-lb (160 N•m). Hold the valve body with
leaks. If no leaks are found, evacuate the
backup wrench to prevent damage to the
system.
refrigeration tubing.
4. Recharge the unit with the proper refrigerant
and check the compressor oil. CAUTION: Unscrew the large nut. Do not
unscrew the small hex on the stepper
motor.
Suction Pressure Transducer
WARNING: If the ETV is stuck in the
Removal closed position, much of the refrigerant
1. Pump down the low side and equalize pressure charge may be trapped in the evaporator.
to slightly positive. If you hear refrigerant begin to flow
through the valve when the stepper motor
2. Disconnect the wires and remove the suction and piston assembly are loosened,
pressure transducer. unscrew the stepper motor and piston
assembly no more than four turns and
Installation check the suction (low side) pressure on
3. Apply a refrigerant Loctite to the threads of the gauge manifold. If the suction
the suction pressure transducer. pressure has increased from the pressure
to which it was equalized after the low side
4. Install and tighten the suction pressure pump down, refrigerant is trapped and
transducer and reconnect the wires. must be recovered. Screw the stepper
5. Pressurize the low side and check for leaks. If motor and piston assembly back into the
no leaks are found, evacuate the low side. valve body. Attach a refrigerant recovery
device to the service port on the receiver
6. Open the refrigeration valves and place the tank outlet valve. Midseat the receiver tank
unit in operation. outlet valve, and recover the refrigerant
charge. The stepper motor and piston
assembly may then be removed.

158
 Refrigeration Service Operations

Installation of Service Kit

NOTE: Do not connect the ETV harness to main
wire harness and turn the unit on before the
1 stepper motor and piston assembly is installed in
2 the valve body. The controller is programmed to
3 close the ETV when the unit is turned on. If the
unit is turned on with the ETV harness
connected to main wire harness, the controller
will attempt to close the ETV. This will cause the
piston to be turned (screwed) off the threaded
shaft of the stepper motor because the valve body
is not present to stop it. Further disassembly is
1. Small Hex on Stepper Motor
required to reassemble the piston and stepper
2. Large Nut motor. See “Reassembly of Piston and Stepper
3. Valve Body Motor”.
Figure 199: Electronic Throttling Valve 1. The new stepper motor and piston assembly is
supplied with the piston in the open position.
In the open position the bottom edge of the
piston is 0.3 to 0.7 in. (8 to 18 mm) from the
bottom edge of the brass nut. The piston
retracts to open and extends to close.

1 2

1. Unscrew Large Nut

2. Backup Wrench 0.3 in.
Figure 200: Removing Electronic Throttling Valve (8 mm)

6. If the complete ETV assembly is being 1

replaced, unsolder and remove the valve body.
It may be necessary to unsolder the tubes 2
above or below the valve body to obtain
enough clearance to remove the valve body. 1. Bottom Edge of Brass Nut
Note the position of the valve body so the new 2. Bottom Edge of Piston
one will be placed in the same position. The
Figure 201: Stepper Motor and Piston Assembly
new ETV could interfere with the evaporator with Piston in Fully Open Position
access panel if it is not placed in the same
position as the old one.

159
Refrigeration Service Operations

2. Lubricate the piston and threads on the new 2. Insert the piston into the piston nut. You must
stepper motor and piston assembly with align the rectangular shaft on the piston with
refrigeration oil. the rectangular hole in the piston nut to allow
the piston to be inserted into the piston nut.
3. Screw the new stepper motor and piston
assembly into the valve body.
4. Torque the nut to approximately 118 ft-lb 1
(160 N•m). Hold the valve body with backup
wrench to prevent damage to the refrigeration
tubing.
5. Connect the ETV harness to the main wire
harness at the four-pin connector.
6. Pressurize the low side and test for leaks. 1. Align Rectangular Shaft on Piston
with Rectangular Hole in Piston Nut
7. If no leaks are found, evacuate the low side.
Figure 203: Insert Piston into Piston Nut
8. Install the evaporator access panels.
3. Push the piston into the piston nut until the
9. Open the refrigeration valves and place the
end of the rectangular shaft is about even with
unit in operation.
the top of the piston nut.
Reassembly of Piston and Stepper Motor
1
Use the following procedure to reassemble the
piston and stepper motor if the piston has
accidentally been turned off of the threaded shaft
of the stepper motor.
1. Disassemble the stepper motor and piston
assembly by unscrewing the stepper motor
(small hex) from the piston nut (large nut).
1 2 3 4 5 6

1. Position End of Rectangular Shaft

about Even with Top of Piston Nut
Figure 204: Push Piston into Piston Nut
1. Piston 4. Make sure the copper washer is in place in the
2. Rectangular Shaft on Piston top of the piston nut.
3. Piston Nut
5. Place the threaded shaft of the stepper motor
4. Copper Washer
into the rectangular shaft of the piston and
5. Threaded Shaft of Stepper Motor turn the piston and piston nut onto the
6. Stepper Motor threaded shaft of the stepper motor.
Figure 202: Stepper Motor and 6. When the threads in the top of piston nut reach
Piston Assembly Components
the threads on the bottom of the stepper motor,
carefully continue to turn the piston and piston
nut onto the stepper motor. Make sure that the
copper washer is in place and take care to
avoid cross threading the fine threads on the
stepper motor and in the top of the piston nut.

160
 Refrigeration Service Operations

7. Continue to turn the piston and piston nut onto

the stepper motor until they are tight. Torque
the piston nut and stepper motor to 37 ft-lb (50
N•m).

Installation of Complete ETV Assembly

1. Clean the tubes for soldering.
2. Place the new complete ETV assembly (and
any tubes that were removed) in the same
position from which the old one was removed.
The new ETV could interfere with other
components if it is not placed in the same
position as the old one. The ETV assembly
must be installed as shown below relative to
the direction of refrigerant flow from the
evaporator to the heat exchanger.
NOTE: Do not disassemble the new ETV to
solder it in place.

1. Use Heat Sink

2. Direction of Refrigerant Flow
Figure 205: Installing Complete ETV Assembly

3. Use a heat sink or wrap the valve body with a

wet rag to prevent damage and solder the
tubing connections with 95-5 soft solder.
4. Connect the ETV harness to the main wire
harness at the four-pin connector.
5. Pressurize the low side and test for leaks.
6. If no leaks are found, evacuate the low side.
7. Install the components that were removed to
access the ETV.
8. Open the refrigeration valves and place the
unit in operation.

161
Refrigeration Service Operations

Mechanical Throttling Valve 2. Front seat the discharge and suction service
valves. Recover the refrigerant remaining in
See Figure 206 for an illustration of the the compressor.
mechanical throttling valve assembly.
3. Remove the suction service valve.
Removal 4. Unbolt and remove the throttling valve from
1. Pump down the low side and equalize the the unit.
pressure to slightly positive.

AEA717

1. Screw - Mtg Plate 10. Gasket - Piston Housing

2. Flatwasher 11. Piston
3. Plate - Bellows End 12. Spring - Piston
4. Gasket - End Plate 13. Nut - Adjusting
5. Shim - Adjusting 14. Pin - Cotter
6. Spring - Bellows 15. Housing - Piston
7. Bellows & Shaft - Assy 16. O-ring - Valve to Compressor
8. O-ring 17. Cap - Rubber
9. Housing

Figure 206: Mechanical Throttling Valve Assembly

162
 Refrigeration Service Operations

Disassembly
1. Remove the piston end cap (round end).
2. Remove the cotter pin from the castle nut and
remove the nut.
3. Remove the spring and piston.
4. Loosen all the bolts on the bellows end cap.
CAUTION: This end cap is under slight
spring pressure.
1. Inspect for Wear
5. Break the gasket free and remove the end cap.
Figure 208: Inspect for Wear
6. Note the number of shims next to the cap.
These can be reused.

1. Inspect Cap 1. Inspect for Damage

2. Inspect Spring Figure 209: Inspect for Damage
3. Shims
9. Clean the parts that will be reused.
Figure 207: Inspect Parts

7. Remove the bellows. Reassembly

1. Install the bellows with the O-ring in the
8. Inspect all the parts.
housing.
a. Piston and cap for wear (scuff marks).
2. Center the spring on the bellows shoulder.
b. Body for stripped threads.
3. Oil the gasket, install it on the housing, and
c. Bellows end cap for damage in the pilot place the shims in the end cap (use same
hole. number as removed). Tighten the end cap in
place with the vent hole closest to the outlet
NOTE: The bellows is normally replaced.
opening of the valve housing.
4. Install the piston, spring and tighten the castle
nut until it is firmly seated against the bottom
of the piston.

163
Refrigeration Service Operations

5. Back off the castle nut, one full turn only. Hot Gas Solenoid Valve
6. Insert the cotter pin.
Removal
1. Recover the refrigerant charge.
2. Disconnect the wires and remove the coil for
the valve.
3. Unsolder the lines and remove the valve.

Installation
1. Clean the tubes for soldering.
2. Remove the coil and place the valve in
AEA716
position.
3. Solder the inlet and outlet connections. After
the valve cools, install the coil.

1. Tighten castle nut to bottom, then back 4. Pressurize the refrigeration system and test for
off 1 turn only. Insert cotter pin leaks.
Figure 210: Throttling Valve Reassembly 5. If no leaks are found, evacuate the system.

7. Oil the gasket and install the end cap. 6. Recharge the unit with proper refrigerant and
check the compressor oil.
8. The throttling valve will have to be
recalibrated on operating unit. (See the
Specifications Chapter for the setting.)
9. Adjust the setting by adding or removing
shims under the spring.

Installation
1. Install the throttling valve using a new O-ring
soaked in compressor oil. Bolt the throttling
valve to the compressor.
2. Install the suction valve.
3. Pressurize the compressor and check for leaks.
If no leaks are found, evacuate the
compressor.
4. Open the refrigeration valves and place the
unit in operation.

164
 Refrigeration Service Operations

Compressor Oil Filter 2. Front seat the discharge and suction service
valves. Recover the remaining refrigerant
This unit is equipped with a compressor oil filter. from the compressor.
The compressor oil filter should be changed when
the drier is replaced. 3. Disconnect the oil lines from the compressor
oil filter. Hold the oil filter with back-up
The outlet fitting is larger than the inlet fitting, so wrench on the hex behind the ORS fitting.
the compressor oil filter cannot be put on
backwards. There are two fittings on the inlet end 4. Remove the clamp and the compressor oil
of the compressor oil filter. The inlet fitting filter.
contains a check valve that prevents reverse flow 5. Coat the new O-rings with clean compressor
through the compressor oil filter. The capped oil and place them in the ORS fittings on the
fitting is called the oil pressure access port and is ends of the new compressor oil filter.
used to check the compressor oil pressure (see
“Checking Compressor Oil Pressure”). 6. Fasten the new compressor oil filter in place
with the clamp.
7. Attach and tighten the oil lines to the
compressor oil filter. Hold the oil filter with a
back-up wrench on the hex behind the ORS
fitting.
8. Evacuate the compressor and filter to a
maximum of 500 microns to remove trapped
air.
9. Open the service valves, operate the system,
and check the compressor oil filter for leaks.

Compressors with Internal Oil

Filter
In the first quarter of 2014 four cylinder
1 compressors with an internal oil filter are being
phased into truck and trailer units that typically
use compressors with external oil filters. The
internal oil filter is located in the compressor
3 sump near the oil pickup tube (see Figure 212).
NOTE: These units use compressors with oil
filters. If the compressor does not have an
2 external oil filter, it has an internal oil filter.
AEA718

1. Oil Pressure Access Port Internal Oil Filter Replacement

2. Inlet Fitting
The internal oil filter should be replaced in the
3. Outlet Fitting same situations in which the external oil filter was
Figure 211: Compressor Oil Filter replaced, such as when the drier is replaced or the
Use the following procedure to change the compressor oil is changed.
compressor oil filter. 1. Remove the compressor from the unit if
1. Pump down the low side and equalize the needed to access the oil sump.
pressure to slightly positive. 2. Remove the oil sump.

165
Refrigeration Service Operations

4. Remove the internal oil filter from the oil

1 discharge tube.
2

1
4

5 6

1. Oil Discharge Tube 1. Internal Oil Filter

2. O-Ring 2. Oil Discharge Tube
3. Internal Oil Filter Figure 214: Remove Internal Oil Filter from Oil
4. Pressure Relief Valve Discharge Tube

5. Oil Pickup Tube 5. Place the new internal oil filter on the oil
6. Stud On Oil Pickup Tube Bracket discharge tube and the stud on the oil pickup
tube bracket. Be careful to avoid damaging the
Figure 212: Internal Oil Filter
O-ring in the oil filter.
3. Remove the nut that fastens the internal oil
filter to the stud on the oil pickup tube bracket. 6. Install and tighten the nut that fastens the
internal oil filter to the stud on the oil pickup
tube bracket.
7. Install the oil sump.
8. Install the compressor in the unit if it was
removed.

Checking Compressor Oil

Pressure
The oil pressure at the oil pressure access port
varies with the suction pressure in the compressor.
Therefore, we need to calculate the “net oil
1 pressure” to determine the actual compressor oil
pressure. The net oil pressure is the pressure at the
1. Stud On Oil Pickup Tube Bracket oil pressure access port minus the suction pressure
below the throttling valve. Use the following
Figure 213: Remove Nut from Stud
procedure to check the compressor oil pressure.
1. Attach a suitable oil pressure gauge to the oil
pressure access port on the compressor oil
filter, or to the oil pressure access port on the
oil pump cover.

166
 Refrigeration Service Operations

2. Attach the low pressure gauge of a gauge NOTE: The microprocessor will probably
manifold to the fitting on the side of the record some alarm codes because the
throttling valve (or suction valve adapter). solenoids are disconnected and the engine
This fitting allows you to monitor the suction does not start. Clear these alarm codes as
pressure in the compressor below the necessary.
throttling valve.
5. Turn the unit on and let the engine crank (or
3. Start the unit and note the pressure at the oil crank the engine) for 30 seconds, but do not
pressure access port and the suction pressure crank the engine for more than 30 seconds.
below the throttling valve.
a. Note the pressure at the oil pressure access
4. Subtract the suction pressure below the port and the suction pressure below the
throttling valve from the pressure at the oil throttling valve while the engine is
pressure access port to get the net oil pressure. cranking. Subtract the suction pressure
below the throttling valve from the
Pressure at Oil Pressure Access Port
pressure at the oil pressure access port to
– Suction Pressure Below Throttling Valve
get the net oil pressure.
= Net Oil Pressure
b. If the compressor does not develop at least
5. The net oil pressure should be at least 20 psi 10 psi (96 kPa) of net oil pressure in the
(138 kPa). If the net oil pressure is low, first first 30 seconds, allow the starter to cool
check the compressor oil level, then check the for a few minutes and the crank the engine
compressor oil pump and relief valve. again for 30 seconds. If 10 psi (96 kPa) of
net oil pressure still does not develop, first
Priming New Compressor check the compressor oil level, then check
the compressor oil pump and relief valve.
Installations
6. As soon as the compressor develops 10 psi
Thermo King remanufactured compressors have
(96 kPa) of net oil pressure, re-connected the
had a special break in process to assure that the oil
fuel solenoid wires, but do not re-connect the
pump is primed, functioning, and broken in. The
high speed solenoid wires.
following procedure is recommended, but not
required for factory-remanufactured compressors. 7. Start unit and run the engine on low speed for
at least five minutes. If the net oil pressure is
This procedure must be followed to prevent
above 20 psi (138 kPa) for this period, stop the
premature pump failure in any compressor that
unit and re-connect the high speed solenoid
has had an oil pump installed, especially a
wires.
compressor that has been stored for any length of
time. 8. Run the engine on high speed for at least five
more minutes. The compressor oil pump is
1. Attach a suitable oil pressure gauge to the oil
now primed and broken in.
pressure access port on the compressor oil
filter.
2. Attach the low pressure gauge of a gauge
manifold to the fitting on the side of the
throttling valve (or suction valve adapter).
This fitting allows you to monitor the suction
pressure in the compressor below the
throttling valve.
3. Disconnect the wires to the fuel solenoid.
4. Disconnect the wires to the high speed
solenoid.

167
Structural Maintenance

Unit and Engine Mounting Bolts Unit Inspection

Check and tighten all unit and engine mounting Inspect the unit during pretrip inspection and
bolts during scheduled maintenance inspections. scheduled maintenance inspections for loose or
Torque the unit mounting bolts to 60 ft-lb broken wires or hardware, compressor oil leaks,
(81 N•m). Torque the engine mounting bolts to or other physical damage which might affect unit
150 ft-lb (203 N•m). performance and require repair or replacement of
parts.

Condenser, Evaporator, and

Radiator Coils
Clean the coils during scheduled maintenance
inspections. Remove any debris (e.g., leaves or
plastic wrap) that reduces the air flow. Clean dirty
coils with compressed air or a pressure washer. Be
careful not to bend the fins when cleaning a coil.
If possible, blow the air or water through the coil
in the direction opposite the normal airflow.
Repair bent fins and any other noticeable damage.

Micro-Channel Coil Cleaning

Recommendations
Cleaning Intervals
• The coils should be cleaned a Minimum of
once a year.
• It is recommended that any time the unit is in
1
for service or maintenance that the coils be
inspected and cleaned if needed.
• The coil should be cleaned if there are visible
accumulations that obstruct the view of the
fins or tubes of the coil.
• The coils should be cleaned if there is debris
imbedded in the tubes and fins
The area and conditions in which the unit operates
will dictate the cleaning intervals and method(s)
needed.

Cleaning Methods (listed in order of

1. Check Bolts for Tightness recommended method)
Figure 215: Unit and Engine Mounting Bolts • Take a cloth or towel and wipe the air side of
the coil going with the fins, across the tubes.
(Results shown in Figure 217.) The coil will
clean in a manner similar to the way lint
cleans from the lint trap of a household
clothes dryer.

168
 Structural Maintenance

• Use a soft bristled brush (DO NOT USE A

WIRE BRUSH) and brush the coil going with
the fins, across the tubes. The coil will clean
in a manner similar to the way lint cleans from
the lint trap of a household clothes dryer.
• A vacuum with a soft attachment can be used
to suck the debris off the face as well as in the
fins and tubes from the air side of the coil.
• Compressed air can be used and will work
best when blown thru the coil from the non-air
side when possible. Blowing thru from the
airside may imbed debris in the coil that was
only on the surface. It is recommended to start
with one of the first three options before using
compressed air if the non-air side is not
accessible. The angle at which the air should
be directed at the coil should not be less than
75 degrees (see Figure 218).
• Power water sprayer may be used in pressures
under 600 psi. Water will work best when
blown thru the coil from the non-air side when
possible. Spraying thru from the airside may
Figure 216: Coil Before Cleaning
imbed debris in the coil that was only on the
surface. It is recommended to start with one of
the first three options before using water if the
non-air side is not accessible. The angle at
which the water should be directed at the coil
should not be less than 75 degrees (see Figure
218).
Chemicals to aid in cleaning WILL VOID
WARRANTY and are NOT RECOMMENDED.
In some instances in may take a combination of
two methods to result in a clean coil. Such as, first
wiping the coil to clean the surface and then using
a vacuum, water or compressed air to clean down
in the fins. This will depend on the type of debris
that needs to be cleaned from the coil.
Be sure not to contact the coil with any hard
vacuum nozzle, air nozzle, or any other tool. This
will damage the tubes of the coil.

Figure 217: Coil after Wiping

Right Hand Side with Cloth

169
Structural Maintenance

Unit Installation
All nuts that hold the unit to the trailer are
accessible using an impact wrench with a 10 in.
extension, ball-type swivel and a deep-well
socket.
NOTE: The nuts for mounting the unit should
be elastic stop nuts (Nylock type).

Defrost Damper
Figure 218: Source Angle for
Cleaning with Air or Water Check the damper during scheduled maintenance
inspections for shaft wear, end play, and the
Defrost Drains ability to stop the air flow.
Clean the defrost drains during scheduled Position the damper so that air flow is stopped on
maintenance inspections to be sure the lines the top and bottom edges with the solenoid
remain open. plunger bottomed out.

1 2

3 6
5

7
9

AEA719
8
1

1. Stop 6. Eye Bolt

2. Mounting Bolts 7. Round Stop
3. Closed Position 8. Distance A 2.75 in. (69.85 mm)
4. Open Position 9. Solenoid
5. Damper Link
Figure 219: Defrost Damper Adjustment

170
 Structural Maintenance

To adjust the damper: Condenser Fan Blower Alignment

1. Remove the damper assembly from the 1. Loosen the condenser inlet ring (spinning) on
evaporator. the condenser coil bulkhead.
2. Disconnect the damper link from the eye bolt. 2. Slide the blower towards the inlet ring until it
contacts the inlet ring. This centers the inlet
3. Check Distance A, the distance from the
ring in the blower orifice.
shoulder on the solenoid to the center of the
hole in the eye bolt. Distance A should be 3. Tighten the inlet ring securely.
2.75 in. (69.85 mm) with the solenoid
4. Slide the blower away from the inlet ring.
de-energized.
1
4. If necessary, adjust Distance A to the proper 2
dimension by loosening the locknut on the end
of the solenoid plunger and turning the eye 3
bolt. Tighten the locknut when Distance A is
correct.
5. Connect the damper link to the eye bolt.
6. Energize the solenoid (apply 12 volts dc) and 4
check the damper blade to make sure that both
edges contact the damper housing. If
necessary, adjust this by loosening the
solenoid mounting bolts and moving the
solenoid. Tighten the solenoid mounting bolts
when both edges of the damper blade contact
the damper housing.
7. Adjust the damper blade stops so they contact AEA749

the edges of the damper blade. This keeps the

damper from sticking closed. 1. Blower Wheel 3. Alignment Mark
2. Inlet Ring 4. Edge of Inlet Ring
8. De-energize and energize the damper several
times to make sure that the damper operates Figure 220: Condenser Blower Alignment
correctly and seals properly. 5. Pass a gauge wire completely around the
9. Make sure the damper blade rests on the round blower orifice to check for uniform clearance.
stops when the damper is open. Adjust the 6. Spin the blower by hand to check for blower
round stops if necessary. distortion.
10. Install the damper assembly in the evaporator. 7. Position the blower so the edge of the inlet
ring lines up with the alignment mark on the
Condenser and Evaporator Fan blower.
Location 8. Torque blower hub bolts to 18 ft-lb (24 N•m).
When mounting the condenser or evaporator fan
and hub assembly on the fanshaft, the blowers and
inlet orifices must be properly aligned for proper
air flow and to prevent damage to the blower.

171
Structural Maintenance

Evaporator Fan Blower Changes

1
The evaporator blower was changed in production
units starting in June of 2011. The new blower is 2
narrower than the old blower and the following
parts are also new; blower hub, inlet rings
(orifices), and housing member (cutoff).
IMPORTANT: Do not mix old evaporator blower
parts with new evaporator blower parts. Both
inlet rings must be replaced with new ones if an
old blower is being replaced with a new blower.
The new evaporator blower supersedes the old
evaporator blower. Refer to the appropriate unit
Parts Manual for the correct part numbers.
3
The new blower is fastened to the new blower hub
with three 5/16-18 in. hex head screws and one
3/8-16 hex head screw. 1. Evaporator Blower Assembly
The old blower is fastened to the old blower hub 2. Inlet Ring (Orifice)
with four 5/16-18 in. hex head screws. 3. Housing Member (Cutoff)
Figure 222: Old Evaporator Blower Components
1 The new evaporator blower has a notch in one of
2 its blades that allows a socket and extension to be
used to access the pinch bolts on the blower hub.
See the following photos.
1

1. Evaporator Blower Assembly

1. Notch in Blade
2. Inlet Ring (Orifice)
Figure 223: New Evaporator Blower
3. Housing Member (Cutoff)
Figure 221: New Evaporator Blower Components

Figure 224: Use Socket and Extension

to Access Pinch Bolts on Blower Hub
in New Evaporator Blower

172
 Structural Maintenance

Evaporator Fan Blower Alignment Fan Shaft Assembly

1. Loosen the inlet rings on the sides of the The unit is equipped with a one-piece fan shaft
blower housing. assembly that contains tapered roller bearings in a
2. Center the blower wheel in the blower housing sealed oil reservoir.
with equal overlap on both inlet rings. The This assembly does not require any maintenance.
overlap on each ring should be approximately There is a level plug and a fill plug, but they are
0.15 in. (3.8 mm) on the old style evaporator not normally used except after removal and repair
blower, or approximately 0.60 in. (15.2 mm) of the fan shaft assembly. The condenser and
on the new style evaporator blower. evaporator end oil seals should be checked during
3. Tighten the hub pinch bolts that hold the the pretrip inspection for oil leakage. If there is
blower wheel on the fanshaft. any sign of leakage, the fan shaft assembly should
be removed and repaired.
4. Center the inlet rings in the blower orifices.
Tighten the inlet rings securely. NOTE: The fan shaft assembly requires a
special lubricant, Thermo King P/N 203-278.
5. Check the radial clearance by passing a wire
completely around the circumference of the Fan Shaft Assembly Overhaul
inlet rings and the blower wheel.
Disassembly
6. Torque the blower hub bolts to 18 ft-lb
(24 N•m). 1. Remove the fan shaft assembly from the unit.
Remove both oil plugs and drain the oil from
the housing.
2. After draining the oil from the housing,
remove the four retaining bolts from the
condenser end of the assembly.
3. To remove the shaft from the assembly, tap the
opposite end of the shaft with a soft hammer.
After the shaft has been removed, clean all
parts in clean solvent.

AEA720
4. Using a punch, remove the oil seal from the
evaporator end of the assembly. With the seal
1. Check Clearance with a Wire removed, clean the housing in clean solvent.
2. Blower Housing Sides
5. Check the condition of the vent. If it is loose
3. Inlet Rings
or damaged, it must be repaired or replaced.
4. Evaporator Blower
5. Radial Clearance
6. After all the parts are cleaned, inspect the
bearings and bearing races for wear or
6. Equalize Blower Inlet Overlap
damage.
Figure 225: Evaporator Fan Location
7. If necessary, remove the bearings by tapping
them off the shaft with a hammer and a punch.
Be careful not to damage the shaft with the
punch.
8. The bearing races can now be driven out with
a punch and replaced in the same manner.

173
Structural Maintenance

AEA721

1. Cap and Shims 6. Oil Seal

2. Oil Plug Screw (Use Oil P/N 203-278) 7. Shaft
3. Breather Vent 8. Sleeve
4. Housing 9. Pin
5. Roller Bearing 10. O-ring
Figure 226: Fan Shaft Assembly

Reassembly should be 0.002 to 0.006 in. (0.051 to 0.152

mm). If end-play is incorrect, use different
1. Tap the new bearings on the shaft with a pipe.
shims to obtain correct end-play.
2. Install new oil seals after replacing the bearing IMPORTANT: The shaft must be rotated
races. back and forth while firmly being pushed
3. Replace the shaft in the housing. Install a new and pulled to get an accurate end-play
seal in the retainer cap. Use the original shims measurement.
and replace the O-ring if needed.
Shims available from the Service Parts
4. Install the retainer cap assembly over the Department
shaft, then install the bolts. 0.020 in. (0.500 mm) Thermo King P/N 99-4231
5. Torque the bolts in a criss-cross pattern in 0.007 in. (0.177 mm) Thermo King P/N 99-2902
equal steps to 80 in-lb (9.04 N•m). 0.005 in. (0.127 mm) Thermo King P/N 99-2901

6. Lock the assembly in a vise and set up a dial

indicator to read end-play. To measure the
end-play, rotate the shaft back and forth while
firmly pushing in one direction (see Figure
227) and set the dial indicator to ‘0’. Now
rotate the shaft back and forth and firmly pull
in the opposite direction (see Figure 228)
while reading the dial indicator. End-play

174
 Structural Maintenance

Idler Assembly
The unit is equipped with a one-piece idler
assembly that contains tapered roller bearings in a
sealed oil reservoir. This assembly does not
require any maintenance. There is a level plug and
a fill plug, but they are not normally used except
Push and Rotate
after removal and repair of the idler assembly. The
roadside end oil seal and the curbside end oil seal
should be checked during the pretrip inspection
for oil leakage. If there is any sign of leakage, the
Figure 227: Measuring End-Play -
Push and Rotate Shaft idler assembly should be removed and repaired.

Idler Assembly Overhaul

Disassembly
1. Remove the idler assembly from the unit.
Remove both oil plugs and drain the oil from
the housing.
Pull and Rotate 2. After draining the oil from the housing,
remove the four retaining bolts from the
curbside end of the assembly.
Figure 228: Measuring End-Play -
Pull and Rotate Shaft 3. To remove the shaft from the assembly, tap the
opposite end of the shaft with a soft hammer.
7. After correct end-play is obtained, add oil for After the shaft has been removed, clean all the
the bearings. parts in clean solvent.
8. Lock the assembly in a vise with the vent 4. Using a punch, remove the oil seal from the
facing up. Pour the oil (P/N 203-278) through curbside end of the assembly. With the seal
the top plug until it runs out of the side hole. removed, clean the housing in solvent.
The assembly holds approximately 2.5 oz
(74 ml). Check the condition of the O-ring 5. Check the condition of the vent. If it is loose
used on the plugs and replace if necessary. or damaged, it must be repaired or replaced.
Install the top and side plugs. Clean up any 6. After all the parts are cleaned, inspect the
spillage. bearings and bearing races for wear or
9. Place the assembly on the workbench with the damage.
vent up. Rotate the shaft by hand. The shaft 7. To replace the bearings, first drive bearing off
should be free enough to rotate without having shaft with a punch at notch in the base of the
to hold the housing. shaft.
CAUTION: When installing the fan shaft
Reassembly
assembly, make sure that the vent is
mounted facing up. 1. Install the new bearings on the shaft with a
pipe. Place the pipe over the shaft and drive
bearing down. Turn the shaft upside down,
and use the pipe to drive the other bearing
down.
2. Install a new oil seal on the curbside end of
the assembly after replacing the bearing race
and splash guard.

175
Structural Maintenance

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 229: Idler Assembly

3. Replace the shaft in the housing. Install a new NOTE: Figures 227 and 228 show the
seal in the retainer cap. Use the original shims fanshaft, but measuring the end-play on the
and replace the O-ring if needed. idler is similar.
4. Install the retainer cap assembly over the IMPORTANT: The shaft must be rotated
shaft, then install the bolts. back and forth while firmly being pushed
and pulled to get an accurate end-play
5. Torque the bolts in a criss-cross pattern in
measurement.
equal steps to 80 in-lb (9.04 N•m).
6. Lock the assembly in a vise and set up a dial Shims available from the Service Parts
Department
indicator to read end-play. To measure the
end-play, rotate the shaft back and forth while 0.020 in. (0.500 mm) Thermo King P/N 99-7980
firmly pushing in one direction (see Figure 0.007 in. (0.177 mm) Thermo King P/N 99-7979
227) and set the dial indicator to ‘0’. Now 0.005 in. (0.127 mm) Thermo King P/N 99-7978
rotate the shaft back and forth and firmly pull
7. After the correct end-play is obtained, add
in the opposite direction (see Figure 228)
approximately 1.1 oz (33 ml) of oil
while reading the dial indicator. End-play
(P/N 203-278) for the bearings.
should be 0.002 to 0.006 in. (0.051 to 0.152
mm). If end-play is incorrect, use different 8. Lock the assembly in a vise with the vent
shims to obtain correct end-play. facing up. Pour the oil through the top plug
until it runs out of the side hole. Check the

176
 Structural Maintenance

condition of the O-ring used on the plugs and

replace if necessary. Install the top and side
plugs. Clean up any spillage.
9. Place the assembly on the workbench with the
vent up. Rotate the shaft by hand. The shaft
should be free enough to rotate without having
to hold the housing.
CAUTION: Reinstall the assembly into
the unit, making sure the vent is mounted
facing up.

177
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

178
 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

179
Mechanical Diagnosis

Condition Possible Cause Remedy

Engine runs hot Dirty radiator Wash radiator

Coolant level is low Add coolant

Cooling system heavily scaled Cleaning cooling system

Cylinder head gasket leaks Replace cylinder head gasket. Use

correct gasket

Faulty thermostat Check or replace thermostat

Loose or worn water pump belt Replace belt

Oil pressure low Insufficient oil in pan Add oil

Faulty oil pressure switch Check oil pressure switch. Replace

if necessary

Oil control valve defective Check oil pressure control valve

Worn oil pump, camshaft, main or Repair engine

connecting rod bearings, loose oil
gallery plug

High oil consumption Oil leakage Check and eliminate possible

causes at rocker arm cover, oil lines,
oil filter, front timing cover or
crankshaft seals

Damaged valve seals Replace seals on valve stem

Worn valve stem Replace valves

Broken piston rings or cylinder bore Have engine repaired and rebored.
worn or scored Replace broken piston rings

Clogged air cleaner system Unclog air cleaner

180
 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

181
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 F25 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, ER, EOL, 7E, 7EB, 7EC,

CH, L1, L2, 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 7E, 26E, L1, L2, L3, BRN,

BLU and BLK circuits

Faulty heaters Check heaters

182
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, 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

183
 •
Rapid cycling between cool and heat

184
•
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
• Faulty ETV Symptom
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

Refrigeration Diagrams

Cool Cycle With Mechanical Throttling Valve

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

AGA282

185
Refrigeration Diagrams

Heat/Defrost Cycle With Mechanical Throttling Valve

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

AGA283

186
 Refrigeration Diagrams

Cool Cycle With Electronic Throttling Valve

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

187
Refrigeration Diagrams

Heat/Defrost Cycle With Electronic Throttling Valve

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

188
Index
A compressor oil sight glass 29
AC components 87 compressor, replacement 142
accumulator, replacement 152 compressors with internal oil filter 165
adjust brightness menu 70 compressors with pressurized seal cavity 145
air cleaner, EMI 3000 123 condenser check valve, replacement 149
air heater 86 condenser coil, replacement 147
air restriction indicator 29, 124 continuous mode
alarms menu 55 selecting 46
alternator 80 control panel 34
field current test 83 display 35
general diagnostic and warranty evaluation keys 35
procedure 81 coolant level switch 30, 103
identification 80 checking the float 104
load test 81 replacing 104
antifreeze testing 103
changing 102 cooling system, engine 100
checking 102 bleeding air from 102
maintenance procedure 101 crankcase breather 122
auto phase system 88 CYCLE-SENTRY
selecting 46
B CYCLE-SENTRY Operation 25
base controller LEDs 85 CYCLE-SENTRY Start-Stop Controls 25
battery 83
battery cables 83 D
belt adjustments, model 30 125 data logging 26, 31
alternator belt 125 datalogger menu 57
upper and lower fan belts 125 defrost 27, 31
belt adjustments, model 50 127 defrost damper, adjustment 170
alternator belt 127 defrost drains 170
compressor belts 127 Defrost key 35
fan belt 127 diagnosis, electric standby 182
water pump belt 127 diagnosis, mechanical 178
belt replacement, model 30 diagnosis, refrigeration 183
lower fan belt 126 diagrams
upper fan belt 126 fuel line routing 192
belt replacement, model 50 refrigeration 185
compressor 128 wiring 192
fan 129 diesel mode, selecting 69
belt tension, specifications 16 discharge pressure transducer, replacement 158
belts 124 discharge vibrasorber, replacement 148
bypass check valve, replacement 149
E
C ELC (Extended Life Coolant) 100
CargoLink 26 electric fuel heater 93
charging system diagnostic procedures 80 electric power receptacle 42
clutch 129 electric standby
dowel pin replacement 134 operation 42
drive bushing replacement 131 selecting 69
cold start device 119 starting unit on 42
compressor electrical components, specifications 18
priming new compressor installations 167 electrical contactors 87
compressor coupling electrical control system, specifications 17
installation 143 electrical standby, specifications 18
removal 142 electronic throttling valve (ETV) 24, 31, 140
compressor oil replacement 158
checking 138 EMI 3000 98
compressor oil filter, replacement 165 engine compartment components 29
compressor oil pressure, checking 166 engine coolant temperature sensor 30

189
Index

engine speed adjustments 110 injection pump

high speed 110 reinstallation 116
low speed 111 removal 114
engine, specifications 15 timing 111
evaporator blower changes 172 in-line condenser check valve 148
evaporator coil, replacement 151 inspection, unit 168
evaporator heaters 87 installation, unit 170
expansion valve assembly, replacement 150
K
F keypad lockout 61
fan alignment selecting 63
condenser blower 171
evaporator blower 173 L
fan shaft assembly 173 language menu 53
overhaul 173 leaks, refrigerant 136
filter drier, replacement 150 loading procedure 79
first aid 13 low oil level switch 30
electrical shock 14 low oil pressure 98
engine coolant 14 low oil pressure switch 30
refrigerant 13 lubrication system, engine 98
refrigerant oil 14
FreshSet 27 M
front doors main menu
closing 29 choices 52
opening 28 maintenance inspection schedule 20
fuel filter/water separator, replacement 110 manual defrost cycle, initiating 47
fuel level sensor, resistive 92 manual pretrip inspection 36
fuel level sensor, ultrasonic 90 mechanical throttling valve 162
fuel line routing 106 disassembly 163
fuel pre-strainer 109 installation 164
fuel return line replacement 108 reassembly 163
fuel solenoid 116 removal 162
replacement 117 microprocessor On/Off switch 34
testing 116 Mode key 35
fuel system 106 mode menu 61
bleeding 108 moisture indicating sight glass 136
maintenance 106 mounting bolts, unit and engine 168
fuel tank, draining water from 109
fuse link 30, 86
O
fuses 30, 84
Off key 35
oil change, engine 98
G oil collection container 137
gauge readings, viewing 48 oil filter change, engine 98
On key 35
H operating modes 27
heat exchanger, replacement 150 operator menu
hex drive seal replacement 145 navigating 52
high pressure cutout switch (HPCO) 30, 138 OptiSet Plus 27, 72
replacement 157 overload relay 30
high pressure relief valve 30
HMI control panel 34 P
hot gas solenoid valve 141 pilot solenoid, replacement 156
hot gas solenoid valve, replacement 164 post trip checks 79
hourmeters menu 60 preheat buzzer 30
pretrip tests 66
I priming new compressor installations 167
idler assembly 175 protection devices 29
overhaul 175

190
 Index

R unit wiring 87
REB (Radio Expansion Board) 0ption 86
receiver tank sight glass 29 V
receiver tank, replacement 149 valve clearance adjustment, engine 121
refrigerant charge
testing for an overcharge 135 W
testing with a loaded trailer 135 wire harness routing 87
testing with an empty trailer 135
refrigerant leaks 136 X
refrigeration system, specifications 17
X426L compressor 24
routing
X430L compressor 24
fuel line 106
wire harness 87

S
safety precautions 10
battery installation and cable routing 11
battery removal 11
electrical hazards 12
general practices 10
microprocessor service precautions 13
refrigerant hazards 11
refrigerant oil hazards 12
welding precautions 13
selection of operating modes 45
sensor readings, viewing 50
serial number locations 31
setpoint, changing 44
sight glass, moisture indicating 136
sleep mode 61
sleep mode, selecting 64
Smart FETs 30, 85
SMART REEFER 3 (SR-3) Control System 34
soft keys 35
specifications
electric fuel heater 19
SR-3 Control System 34
standard display 39
start of trip, initiating 57
suction pressure transducer, replacement 158
suction vibrasorber, replacement 157

T
temperature watch display 40
thermostat, engine 103
three-way valve condenser pressure bypass check
valve 139
three-way valve condenser pressure bypass check
valve, repair 156
three-way valve, repair 152
throttling valve, mechanical See mechanical throttling
valve
time display 71
transducers, pressure 141
trip report, printing 58
trochoid feed pump 118

U
unit description 22

191
Diagram Index

Drawing No. Drawing Title Page

1E64645 Model 30 and 50 Schematic Diagram 193-197

1E64644 Model 30 and 50 Wiring Diagram 198-202

Model 30 with Tier 2/Interim Tier 4 Engine Fuel Line Routing Diagram 203-205

Model 50 with Tier 2/Interim Tier 4 Engine Fuel Line Routing Diagram 206-208

192
Model 30 and 50 Schematic Diagram - Page 1 of 5
RELEASED 08/May/2013

193
Model 30 and 50 Schematic Diagram - Page 2 of 5
RELEASED 08/May/2013

194
Model 30 and 50 Schematic Diagram - Page 3 of 5
RELEASED 08/May/2013

195
Model 30 and 50 Schematic Diagram - Page 4 of 5
RELEASED 08/May/2013

196
Model 30 and 50 Schematic Diagram - Page 5 of 5
RELEASED 08/May/2013

197
Model 30 and 50 Wiring Diagram - Page 1 of 5
RELEASED 08/May/2013

Thermo King

198
Model 30 and 50 Wiring Diagram - Page 2 of 5
RELEASED 08/May/2013

Thermo King

199
Model 30 and 50 Wiring Diagram - Page 3 of 5
RELEASED 08/May/2013

Thermo King

200
Model 30 and 50 Wiring Diagram - Page 4 of 5
RELEASED 08/May/2013

Thermo King

201
Model 30 and 50 Wiring Diagram - Page 5 of 5
RELEASED 08/May/2013

Thermo King

202
Model 30 with Tier 2/Interim Tier 4 Engine Fuel Line Routing Diagram - Page 1 of 3

1. Screw 1/4-20 X 0.75 in. 55-145

2. Flatwasher 1/4 in. (2) 55-411
3. Nylock Nut 1/4 in. 55-4118
4. Clamp 1/2 in. Diameter 55-3065
5. Band Wrap 1.75 Diameter (4) 56-2330
FUEL LINE ROUTING DIAGRAM
6. 3/8 in. Inlet Line from Fuel Tank MODEL 30, TIER 2 YANMAR
7. 1/4 in. Return Line to Fuel Tank 1E65124MAP1 SHEET 1 OF 3

203
Model 30 with Tier 2/Interim Tier 4 Engine Fuel Line Routing Diagram - Page 2 of 3

1. Fuel Pre-Strainer 11. Flatwasher M8 55-7069

2. Outlet to Fuel Transfer Pump 12. Lockwasher M8 55-7727
3. Inlet from Fuel Tank 13. Screw M8 X 25 55-5424
4. Return to Fuel Tank 14. Clamp 5/8 in. Diameter (2) 55-3026
5. Return from Injection Pump 15. Screw 1/4-20 X 0.75 in. (2) 55-145
6. Inlet from Fuel Transfer Pump 16. Flatwasher 1/4 in. (2) 55-411
7. Outlet to Injection Pump 17. Lockwasher 1/4 in. (2) 55-366
8. Fuel Filter 11-9954 18. Band Wrap 1.75 Diameter (4) 56-2330
FUEL LINE ROUTING DIAGRAM
9. Grommet 33-316 19. Clamp 5/8 in. Diameter 55-4203 MODEL 30, TIER 2 YANMAR
10. Clamp 1.0 in. Diameter 55-3644 1E65124MAP2 SHEET 2 OF 3

204
Model 30 with Tier 2/Interim Tier 4 Engine Fuel Line Routing Diagram - Page 3 of 3

1. Fuel Pre-Strainer
2. Fuel Filter 11-9954
3. Outlet from Fuel Filter to Injection Pump
4. Return from Injection Pump to Fuel Filter
5. Injection Pump
6. Fuel Transfer Pump
7. Inlet from Fuel Pre-Strainer to Fuel Transfer Pump
8. Outlet from Fuel Transfer Pump to Fuel Filter
FUEL LINE ROUTING DIAGRAM
9. Return from Fuel Filter to Fuel Tank MODEL 30, TIER 2 YANMAR
10 Inlet from Fuel Tank to Fuel Pre-Strainer 1E65124MAP3 SHEET 3 OF 3

205
Model 50 with Tier 2/Interim Tier 4 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
FUEL LINE ROUTING DIAGRAM
6. 3/8 in. Inlet Line from Fuel Tank MODEL 50, TIER 2 YANMAR
7. 1/4 in. Return Line to Fuel Tank 1E65125MAP1 SHEET 1 OF 3

206
Model 50 with Tier 2/Interim Tier 4 Engine Fuel Line Routing Diagram - Page 2 of 3

1. Fuel Pre-Strainer
2. Outlet to Fuel Transfer Pump
3. Inlet from Fuel Tank
4. Return to Fuel Tank
5. Return from Injection Pump
6. Outlet to Injection Pump
7. Inlet from Fuel Transfer Pump
8. Fuel Filter 11-9954
9. Clamp 1.0 in. Diameter 55-3644
10. Flatwasher M8 55-7069
11. Lockwasher M8 55-7727
12. Screw M8 X 25 55-5424
FUEL LINE ROUTING DIAGRAM
13. Band Wrap 1.75 Diameter (10) 56-2330 MODEL 50, TIER 2 YANMAR
14. Clamp 1-1/4 in. Diameter 55-5274 1E65125MAP2 SHEET 2 OF 3

207
Model 50 with Tier 2/Interim Tier 4 Engine Fuel Line Routing Diagram - Page 3 of 3

1. Fuel Pre-Strainer
2. Fuel Filter 11-9954
3. Outlet from Fuel Filter to Injection Pump
4. Return from Injection Pump to Fuel Filter
5. Injection Pump
6. Fuel Transfer Pump
7. Inlet from Fuel Pre-Strainer to Fuel Transfer Pump
8. Outlet from Fuel Transfer Pump to Fuel Filter
FUEL LINE ROUTING DIAGRAM
9. Return from Fuel Filter to Fuel Tank MODEL 50, TIER 2 YANMAR
10 Inlet from Fuel Tank to Fuel Pre-Strainer 1E65125MAP3 SHEET 3 OF 3

208
 Maintenance Manual

SB-210+
SB-130, SB-230
and SB-330
Additional text information
to be placed here
TK 54909-2-MM (Rev. 4, 05/18)
TK 5XXXX-X-PL
Ingersoll Rand’s Climate Solutions sector delivers energy-efficient HVACR solutions for
customers globally. Its world class brands include 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 54909-2-MM

©2013 Ingersoll Rand Company

Printed in U.S.A.