OPERATION AND

SERVICE MANUAL

NOSEMOUNT

TRAILER REFRIGERATION UNITS

WITH STANDARD MICROPROCESSORS
And Tier 4i Engines
 TABLE OF CONTENTS

PARAGRAPH NUMBER Page

SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.1 SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.2 SPECIFIC WARNING AND CAUTION STATEMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.3 SAFETY DECALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

UNIT DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

2.1 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--1
2.2 GENERAL DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--2
2.3 CONDENSING SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--8
2.3.1 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--8
2.3.2 Alternator/Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--9
2.3.3 Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--10
2.3.4 Filter Drier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--11
2.3.5 Receiver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--11
2.3.6 Compressor Transducers and Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--12
2.4 EVAPORATOR SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--12
2.4.1 Thermal Expansion Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--12
2.4.2 Heat Exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--12
2.4.3 Evaporator Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--12
2.5 SYSTEM OPERATING CONTROLS AND COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--12
2.5.1 Special Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--13
2.5.2 Component Description And Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--14
2.6 DATALINK MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--19
2.7 REMOTE MONITORING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--23
2.8 ENGINE DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--23
2.9 ENGINE SCREW THREADS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--24
2.10 ENGINE AIR SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--24
2.11 COMPRESSOR DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--24
2.12 REFRIGERATION SYSTEM DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--24
2.13 SAFETY DEVICES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--25
2.14 COMPONENT RESISTANCE & CURRENT DRAW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--26
2.15 REFRIGERANT CIRCUIT DURING COOLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--27
2.16 REFRIGERANT CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--28

i 62--11352
 TABLE OF CONTENTS (CONTINUED)

PARAGRAPH NUMBER Page

OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3.1 STARTING UNIT -- AUTO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3--1
3.2 MANUAL START . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3--3
3.3 PRETRIP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3--4
3.4 CHANGING SETPOINT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3--5
3.5 START--STOP OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3--6
3.6 CONTINUOUS RUN OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3--7
3.7 MANUAL DEFROST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3--8
3.7.1 Automatic Defrost . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3--9
3.8 FUNCTIONAL PARAMETERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3--10
3.9 UNIT DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3--13
3.10 ALARM DISPLAY AND RESET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3--16
3.11 STOPPING UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3--20

ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.1 AUTO START/STOP OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4--1
4.1.1 Start/Stop -- Continuous . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4--1
4.1.2 Auto Mode Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4--1
4.1.3 Auto Start Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4--1
4.1.4 Auto Start Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4--1
4.1.5 Variable Pre--Heat Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4--2
4.1.6 Minimum On Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4--2
4.1.7 Minimum Off-Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4--2
4.1.8 Battery Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4--2
4.1.9 Oil Pressure Signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4--2
4.1.10 Maximum Off-Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4--2

TEMPERATURE CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

5.1 HEAT/COOL MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5--1
5.1.1 Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5--1
5.1.2 Heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5--1
5.2 ULTRAFRESH 2 TEMPERATURE CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5--6
5.2.1 Heat/Cool/Null Switching Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5--6
5.2.2 Null Band Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5--6
5.3 ULTRA FREEZE TEMPERATURE CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5--7
5.3.1 Ultra Freeze Offset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5--7
5.3.2 Ultra Freeze Start/Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5--7
5.4 CARGO PROTECT MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5--7
5.5 DEFROST CYCLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5--7
5.5.1 Defrost Initiation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5--8
5.5.2 Normal Defrost Mode (Ambient temperatures less than 80_F (26.7_C) . . . . . . . . . . . . . . . . . . . 5--8
5.5.3 Normal Defrost Termination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5--8
5.5.4 High Ambient Defrost (Ambient Air Temperature is Greater Than 80_F (26.7_C) . . . . . . . . . . . 5--9

62--11352 ii
 TABLE OF CONTENTS (CONTINUED)

PARAGRAPH NUMBER Page

TEMPERATURE CONTROL (Continued)
5.6 UNLOADER OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5--9
5.6.1 Unloading in Temperature Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5--9
5.6.2 Suction Pressure Operation of Unloaders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5--10
5.7 SV1 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5--11
5.8 SV2 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5--11
5.8.1 SV2 Operation for Ambient Temperatures Below 50°F (10°C): . . . . . . . . . . . . . . . . . . . . . . . . . . . 5--11
5.9 SPEED SOLENOID OVERRIDES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5--11
UNIT TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
6.1 DIESEL ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6--1
6.1.1 Engine Will Not Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6--1
6.1.2 Engine Starts Then Stops . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6--2
6.1.3 Starter Motor Malfunction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6--2
6.1.4 Malfunction In the Engine Starting Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6--2
6.2 ALTERNATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6--3
6.3 REFRIGERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6--3
6.3.1 Unit Will Not Cool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6--3
6.3.2 Unit Runs But Has Insufficient Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6--4
6.3.3 Unit Operates Long or Continuously in Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6--4
6.3.4 Unit Will Not Heat or Has Insufficient Heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6--4
6.3.5 Defrost Cycle Malfunction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6--5
6.3.6 Abnormal Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6--6
6.3.7 Abnormal Noise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6--7
6.3.8 Control System Malfunction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6--7
6.3.9 No Evaporator Air Flow or Restricted Air Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6--7
6.3.10 Expansion Valve Malfunction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6--8
6.3.11 Solenoid Valve Malfunction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6--8
6.4 Electronic Speed Control Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6--8
6.5 Microprocessor Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6--14
SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
7.1 MAINTENANCE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7--2
7.2 PRETRIP INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7--4
7.3 GRILLE INSERT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7--7
7.4 SURROUND REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7--8
7.5 DOOR LATCH MAINTENANCE AND CABLE REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7--9
7.5.1 Front Door Latch Cable Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7--9
7.5.2 Side Door Latch Cable Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7--9
7.6 PRIMING FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7--10
7.6.1 Mechanical Fuel Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7--10
7.6.2 Electrical Fuel Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7--11
7.6.3 Servicing Fuel Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7--11

iii 62--11352
 TABLE OF CONTENTS (CONTINUED)

PARAGRAPH NUMBER Page

SERVICE (Continued)
7.7 ENGINE SERVICE & COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7--11
7.7.1 Engine Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7--11
7.7.2 Lube Oil Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7--12
7.7.3 Electronic Speed Control (ESC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7--13
7.7.4 Engine Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7--14
7.7.5 Engine Crankcase Breather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7--14
7.7.6 Intake Air Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7--14
7.7.7 Alternator / Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7--15
7.8 SERVICING & ADJUSTING V-BELTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7--15
7.8.1 Belt Tension Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7--15
7.8.2. Water Pump/Alternator/Crankcase V-Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7--17
7.8.3 Gearbox To Fanshaft And Engine To Gearbox V-Belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7--17
7.9 FANSHAFT ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7--19
7.9.1 Clutch Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7--19
7.9.2 Blower Wheel And Fanshaft Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7--20
7.9.3 Fanshaft Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7--20
7.9.4 Blower Wheel Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7--21
7.9.5 Clutch Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7--22
7.10 CHECKING THE REFRIGERATION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7--25
7.10.1 Checking Refrigerant Charge and High Ambient Compressor Operation . . . . . . . . . . . . . . . . . . 7--25
7.10.2 Compressor Unloader Valve Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7--26
7.10.3 SV4 And By--Pass Check Valve Seating Ability During Cool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7--26
7.10.4 Discharge Line Check Valve Leakage, And SV2 Seating & Opening Ability . . . . . . . . . . . . . . . . 7--26
7.10.5 HP2 and SV2 for Cycling During Heat and Defrost . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7--27
7.10.6 SV1 for Seating, Sv4 for Opening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7--28
7.10.7 SV1 Defrost Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7--28
7.11 GENERAL REFRIGERATION SYSTEM PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7--29
7.11.1 Connecting Manifold Gauges To Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7--29
7.11.2 Connecting Manifold Gauges to King Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7--29
7.11.3 Checking The Refrigerant Charge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7--29
7.11.4 Refrigerant System Leak Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7--30
7.11.5 Pumping Down An Operational Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7--30
7.11.6 Refrigerant Removal From An Inoperative Compressor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7--30
7.11.7 Leak Testing, Evacuating and Putting the Compressor Back Into Service . . . . . . . . . . . . . . . . . 7--31
7.11.8 Pumping Down The Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7--31
7.11.9 Removing The Refrigerant Charge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7--32
7.11.10 Evacuation And Dehydration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7--32
7.11.11 Adding A Refrigerant Charge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7--35
7.11.13 Checking Compressor Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7--36
7.11.14 Adding Oil with Compressor in System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7--37
7.11.15 Adding Oil to Service Replacement Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7--37
7.11.16 Removing oil from the compressor: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7--37

62--11352 iv
 TABLE OF CONTENTS (CONTINUED)

PARAGRAPH NUMBER Page

SERVICE (Continued)
7.12 REFRIGERATION SYSTEM COMPONENT REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7--38
7.12.1 Replacing The Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7--38
7.12.2 Compressor Unloader Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7--39
7.12.3 Compressor Discharge Temperature Sensor (CDT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7--41
7.12.4 Suction Pressure Transducer (SPT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7--41
7.12.5 Check Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7--41
7.12.6 Checking And Replacing Filter-Drier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7--42
7.12.7 Thermostatic Expansion Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7--42
7.12.8 High Pressure Cutout Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7--44
7.12.9 Receiver Sight Glass Assembly Or Fusible Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7--44
7.12.10 SV2/SV4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7--45
7.12.11 SV1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7--46
7.13 CHECKING THE REFRIGERATION SYSTEM DURING A DEFROST CYCLE . . . . . . . . . . . . . . . . 7--47
7.13.1 Condenser Pressure Control and Hot Gas Solenoid Valves (SV1 & SV4) . . . . . . . . . . . . . . . . . 7--47
7.13.2 Defrost Air Switch (DA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7--47
7.13.3 Solid State Defrost Timer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7--48
7.14 EVAPORATOR COIL CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7--49
7.15 CONDENSER COIL CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7--49
7.16 MICROPROCESSOR CONTROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7--50
7.16.1 Replacing Keypad, Window or Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7--50
7.16.2 Replacing EEPROM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7--52
7.17 MICROPROCESSOR REPLACEMENT and CONFIGURATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7--53
7.17.1 To Remove and Replace Microprocessor Logic Board: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7--53
7.17.2 To Reach The Configuration List From The Keypad: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7--53
7.17.3 Hour Meters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7--54
7.18 TEMPERATURE SENSOR CHECKOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7--57
7.19 UNIDRIVE TORQUE REQUIREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7--59
7.19.1 Drive Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7--59

WIRING SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

INDEX Index-1

v 62--11352
 LIST OF ILLUSTRATIONS
FIGURE NUMBER Page
Figure 2-1. Front View -- X2 2100 Shown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--3
Figure 2-2. Curbside . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--4
Figure 2-3. Roadside . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--4
Figure 2-4. Ultra XT and Extra XT Splice Pack Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--5
Figure 2-5. X2 Splice Pack Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--6
Figure 2-6. Evaporator Section -- Panels and Grille Removed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--7
Figure 2-7. Frame Mounted Engine Speed Control Unit (ENSCU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--8
Figure 2-8. Alternator and Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--9
Figure 2-9. Compressor Cylinder Head Unloaded . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--10
Figure 2-10. Compressor Cylinder Head Loaded . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--11
Figure 2-11. Display and Keypad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--15
Figure 2-12. Control Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--16
Figure 2-13. Logic Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--17
Figure 2-14. Light Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--18
Figure 2-15. DataLink Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--20
Figure 2-16. DataLink Electrical Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--22
Figure 2-17. R-404A Refrigerant Circuit -- Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--27
Figure 2-18. R-404A Refrigerant Circuit -- Heating and Defrosting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--28
Figure 5-1. UltraFresh II Perishable Setpoint -- Continuous Run Temperature Control . . . . . . . . . . . . . . . . . 5--3
Figure 5-2. UltraFreeze -- Start/Stop And Continuous Run Temperature Control . . . . . . . . . . . . . . . . . . . . . . 5--4
Figure 5-3. Start--Stop -- Perishable Temperature Control Operating Sequence
During Minimum Run Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5--5
Figure 5-4. Start--Stop -- Perishable Temperature Control Operating Sequence After Minimum Run Time 5--5
Figure 5-5 Suction Pressure Unloading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5--11
Figure 6--1. ESC Diagnostic Tree -- 1 Long, 1 Short LED Code (Engine RPM is Over 2530 RPM) . . . . . . . 6--10
Figure 6--2. ESC Diagnostic Tree -- 2 Long, 1 Short LED Code (FSA Electrical Failure) . . . . . . . . . . . . . . . 6--11
Figure 6--3. ESC Diagnostic Tree -- 2 Long, 3 Short LED Code (No Speed Sensor Input To ENSCU) . . . . 6--12
Figure 6--4. ESC Diagnostic Tree -- 2 Long, 7 Short LED Code (ENSCU voltage is over 26 VDC) . . . . . . . 6--13
Figure 6--5. Micro Diagnostic Tree -- Cond. 1 -- SROS In Start/Run Position -- Micro does not power up . 6--15
Figure 6--6. Micro Diagnostic Tree -- Cond. 2 -- SROS In Start/Run Position -- Engine does not operate . . 6--16
Figure 6--7. Micro Diagnostic Tree -- Cond. 2 -- SROS in On position -- Engine does not operate . . . . . . . . 6--17
Figure 6--8. Micro Diagnostic Tree -- Cond. 3 -- SROS in On position -- Engine Operates But Not Properly 6--18
Figure 6--9. Micro Diagnostic Tree -- Cond. 6 -- Unit will not run in low speed . . . . . . . . . . . . . . . . . . . . . . . . . 6--19
Figure 6--10. Micro Diagnostic Tree -- Cond. 7 -- Data Recorder Data Download Problems when using
ReeferManager and download cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6--20

62--11352 vi
 LIST OF ILLUSTRATIONS (CONTINUED)
FIGURE NUMBER Page
Figure 7-1. Door Latch Maintenance And Grille Insert Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7--7
Figure 7-2. Surround Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7--8
Figure 7-3. Side Door Latch Lower Cable Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7--9
Figure 7-4. Priming Fuel Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7--10
Figure 7-5. Mechanical Fuel Pump and Inlet Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7--11
Figure 7-6. Fuel System Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7--13
Figure 7-7. Lube Oil Flow Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7--13
Figure 7-8. Electronic Speed Control Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7--13
Figure 7-9. Frame Mounted Engine Speed Control Unit (ENSCU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7--14
Figure 7-10. Engine Crankcase Breather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7--14
Figure 7-11. Intake Air Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7--14
Figure 7-12. Belt Tension Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7--15
Figure 7-13. Gauge Placement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7--15
Figure 7-14. V-Belt Arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7--16
Figure 7-15. Upper Belt Replacement -- Plastic Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7--18
Figure 7-16. Removing V-Belt from Engine Adapter Drive Sheave . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7--19
Figure 7-17. Evaporator Blower Wheel and Nozzle Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7--21
Figure 7-18. Steel Condenser Fan and Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7--23
Figure 7-19. Plastic Condenser Fan and Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7--24
Figure 7-20. Vacuum Pump Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7--34
Figure 7-21. Oil Level in Sight Glass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7--36
Figure 7-22. Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7--37
Figure 7-23. Pressure Switch and Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7--38
Figure 7-24. Compressor Drive Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7--39
Figure 7-25. Unloader Solenoid Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7--40
Figure 7-26. Discharge Check Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7--42
Figure 7-27. Hot Gas Check Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7--42
Figure 7-28. Thermostatic Expansion Valve Bulb and Thermocouple . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7--43
Figure 7-29. Typical Setup for Testing A High Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7--44
Figure 7-30. SV2/SV4 Marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7--45
Figure 7-31. SV2 and SV4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7--45
Figure 7-32. SV--1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7--47
Figure 7-33. Defrost Air Switch Test Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7--48
Figure 7-34. Display Module Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7--51
Figure 7-35 EEPROM Insertion Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7--52
Figure 7-36. Unidrive Torque Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7--60

vii 62--11352
 LIST OF TABLES
TABLE NUMBER Page
Table 2-1. Model Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--1
Table 2-2. Additional Support Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--1
Table 2-3 DataLink Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--20
Table 2-4. Safety Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--25
Table 2-5. Component Resistance & Current Draw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--26
Table 3-1. Function Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3--11
Table 3-2. Unit Data Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3--14
Table 3-3. Alarm Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3--17
Table 4-1. Pre--Heat Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4--2
Table 4-2. Battery Voltages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4--2
Table 5-1. Stages for High Ambient Defrost (Ambient temperature Greater Than 80°F (26.7°C) . . . . . . 5--9
Table 5-2. Unloading in Temperature Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5--10
Table 6-1. ENSCU LED Fault Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6--8
Table 7-1. Belt Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7--17
Table 7-2. Connection Point Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7--50
Table 7-3. Configuration Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7--55
Table 7-4. Sensor Resistance (RATS, SAS, ATS, DTTs, WTS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7--57
Table 7-5. Sensor Resistance (CDT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7--58
Table 7-6. R-404A Temperature--Pressure Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7--61

62--11352 viii
 9

SECTION 1 -- SAFETY
1.1 SAFETY PRECAUTIONS Engine Coolant
Your Carrier Transicold refrigeration unit has been The engine is equipped with a pressurized cooling
designed with the safety of the operator in mind. During system. Under normal operating conditions, the coolant
normal operation, all moving parts are fully enclosed to in the engine and radiator is under high pressure and is
help prevent injury. During all pre-trip inspections, daily very hot. Contact with hot coolant can cause severe
inspections, and problem troubleshooting, you may be burns. Do not remove the cap from a hot radiator. If the
exposed to moving parts. Please stay clear of all moving cap must be removed, do so very slowly in order to
parts when the unit is in operation and when the unit release the pressure without spray.
main power switch is in the START/RUN position.
Refrigerants
The refrigerant contained in the refrigeration system of
CAUTION your unit can cause frostbite, severe burns, or blindness
when in direct contact with the skin or eyes. For this
Under no circumstances should anyone at- reason, and because of legislation regarding the
tempt to repair the Logic or Display Boards. handling of refrigerants during system service, we
recommend that whenever your unit requires service of
Should a problem develop with these com- the refrigeration system you contact your nearest
ponent, contact your nearest Carrier Tran- Carrier Transicold authorized repair facility for service.
sicold dealer for replacement.
Battery
This unit is equipped with a lead-acid type battery. The
battery normally vents small amounts of flammable
CAUTION hydrogen gas. Do not smoke when checking the battery.
A battery explosion can cause serious physical harm
Under no circumstances should a techni- and/or blindness.
cian electrically probe the processor at any
point, other than the connector terminals 1.2 SPECIFIC WARNING AND CAUTION
where the harness attaches. Microproces- STATEMENTS
sor components operate at different volt- To help identify the label hazards on the unit and explain
age levels and at extremely low current the level of awareness each one carries, an explanation
levels. Improper use of voltmeters, jumper is given with the appropriate consequences:
wires, continuity testers, etc. could perma- DANGER -- warns against an immediate hazard which
nently damage the processor. WILL result in severe personal injury or death.
WARNING -- warns against hazards or unsafe condi-
tions which COULD result in severe personal injury or
death.
CAUTION
CAUTION -- warns against potential hazard or unsafe
Most electronic components are suscepti- practice which could result in minor personal injury, or
product or property damage.
ble to damage caused by electrical static
discharge (ESD). In certain cases, the hu- The statements listed below are specifically applicable
man body can have enough static electric- to this refrigeration unit and appear elsewhere in this
manual. These recommended precautions must be un-
ity to cause resultant damage to the derstood and applied during operation and maintenance
components by touch. This is especially of the equipment covered herein.
true of the integrated circuits found on the
truck/trailer microprocessor.
WARNING
Auto-Start
Do not attempt to service the DataLink mod-
Your refrigeration unit is equipped with Auto-Start in ule. Breaking the warranty seal will void the
both Start--Stop and Continuous Run modes. The unit
may start at any time when the Start/Run--Off Switch warranty.
(SROS) is in the Start/Run position. A buzzer will sound
for 5 seconds before the unit is started. When
performing any check of the refrigeration unit (e.g.,
checking the belts, checking the oil), make certain that WARNING
the SROS is in the OFF position.
Under no circumstances should ether or
any other starting aids be used to start en-
gine.

1--1 62-11352
 WARNING WARNING
Beware of V-belts and belt driven compo- Do not use a nitrogen cylinder without a
nents as the unit may start automatically. pressure regulator. Cylinder pressure is
Before servicing unit, make sure the approximately 159.9 Bars (2350 PSIG). Do
Start/Run - Off switch is in the OFF posi- not use oxygen in or near a refrigerant sys-
tion. Also disconnect the negative battery tem as an explosion may occur. (See
cable. Figure 7-29)

WARNING WARNING
Under no circumstances should ether or Personal protection equipment must be
any other starting aids be used to start en- utilized when performing coil cleaning.
gine.

CAUTION
WARNING
Observe proper polarity when installing
Inspect battery cables for signs of wear, ab- battery, negative battery terminal must be
rasion or damage at every Pre--Trip inspec- grounded. Reverse polarity will destroy the
tion and replace if necessary. Also check rectifier diodes in alternator. As a precau-
battery cable routing to ensure that clamps tionary measure, disconnect positive bat-
tery terminal when charging battery in unit.
are secure and that cables are not pinched
Connecting charger in reverse will destroy
or chafing against any components. the rectifier diodes in alternator.

WARNING CAUTION
Keep hands and arms away from unit when Remove DataLink module and unplug all
operating without belt guard in place. Nev- wire harness connectors before performing
er release a unit for service without the belt any arc welding on any part of the unit.
guard securely tightened in place.
Do not remove wire harness from module
unless you are grounded to the unit frame
WARNING with a static safe wrist strap.

Do not start unit without installing the evapo-

rator panels as unit damage or body harm CAUTION
may result.
When changing oil filters, the new filters
should be primed (partially filled) with clean
WARNING oil if possible. If the filters are not primed,
the engine may operate for a period with no
Do not use a disposable refrigerant con- oil supplied to the bearings.
tainer to store the charge as an explosion
may occur.

WARNING
Never run unit with discharge service valve
frontseated.
Never remove fill plug with pressure in
compressor.

62-11352 1--2
 9

CAUTION CAUTION
For units with R404A and POE oil, Do not vapor charge R404a systems. Only
the use of inert gas brazing proce- liquid charging through the receiver (King)
dures is mandatory; otherwise com- valve is acceptable.
pressor failure will occur. For more
information see 98--50553--00 --
Technical Procedure on Inert Gas CAUTION
Brazing
Extreme care must be taken to ensure the
hose is immersed in the oil at all times when
CAUTION adding oil to the compressor using the
closed system method. Otherwise air and
Use only ethylene glycol anti-freeze (with moisture will be drawn into the compressor.
inhibitors) in system as glycol by itself will
damage the cooling system. Always add
pre-mixed 50/50 anti-freeze and water to ra-
diator/engine. Never exceed more than a CAUTION
60% concentration of anti-freeze. Use a low
Do not over tighten or damage the enclos-
silicate anti-freeze meeting GM specifica-
ing tube assembly of the SV2 or SV4 valves.
tions GM 6038M for standard life coolant or
Torque to 17-ft pounds (23 Nm). Also make
use Texaco Havoline extended life coolant
sure all parts are placed on the enclosing
or any other extended life coolant which is
tube in proper sequence to avoid premature
Dexcool approved and has 5/150 (5
coil burnout.
years/150,000 miles) on the label.

CAUTION
CAUTION
Do not overtorque keypad screws.
Do not get anti--seize oil/compound onto
clutch contact surfaces. Thoroughly clean
off oil/compound with contact or brake
cleaner if this occurs.
CAUTION
Use the appropriate board assembly when
replacing the microprocessor logic board.
CAUTION There are two different microprocessor
logic board assemblies: one with a plastic
Overtorquing of fan mounting bolts could cover that is attached to the board with
result in the stripping of fan hub threads. In metal standoffs, and one without the cover.
this event, the fan must be replaced. Thread DO NOT drill out the standoffs to remove
stripping will occur at 30 ft--lbs (40.7 Nm) or the plastic cover or permanent damage to
more. the microprocessor logic board will result.

CAUTION CAUTION
Only a refrigerant drum containing R404A Do not allow the insulated jumper wire be
should be connected to this refrigeration used to configure the unit to touch any
unit in order to pressurize the system. Any ground.
other gas or vapor will contaminate the sys-
tem which will require additional purging
and evacuation of the high side (discharge)
of the system.

1--3 62-11352
1.3 SAFETY DECALS

62--03958--00 Heat Warning

62-11352 1--4
 9

1--5 62-11352
 9

SECTION 2 - UNIT DESCRIPTION

2.1 INTRODUCTION This manual contains Operating Data, Electrical Data
and Service Instructions for the refrigeration units listed
in Table 2-1.
WARNING Additional support manuals are listed in Table 2-2.
The model/serial number plate is located inside the unit
Beware of V-belts and belt driven compo- on the frame as shown in Figure 2-3.
nents as the unit may start automatically.
Before servicing unit, make sure the
Start/Run--Off switch is in the OFF position.
Also disconnect the negative battery cable.

Table 2-1. Model Chart

Refrigerant
Engine Speed
Models R-404A Compressor Engine
LB KG High Low
V1903--M--
Extra XT NDL935N0CBA 05G 37cfm E3B
V2203-DI
Ultra XT NDL9340N0AM0 05G 41 cfm E3B
20 9 1700 1350
V1903--M--
X2 1800 NDL935N0CMA 05G 37cfm E3B
V2203-DI
X2 2100 NDL934N0AMA 05G 41cfm E3B

Table 2-2. Additional Support Manuals

Manual Number Equipment Covered Type of Manual

62-10601 Units With Standard Microprocessor Operator’s Manual
62-10600 Units With Standard Microprocessor Easy To Run
2.2 DI Engines
62-11335 Parts List
V2203L--DI--E3B--CTD--2
1.9 IDI Engines
62-11350 Parts List
V1903--M--E3B--CTD--1
2.2 DI Engines
62-11362 Workshop
V2203L--DI--E3B--CTD--2
1.9 DI Engines
62-11363 Workshop
V1903--M--E3B--CTD--1
62-11053 Compressor (05G TWINPORT)) Parts List
62-11052 Compressor (05G TWINPORT) Workshop

2--1 62-11352
2.2 GENERAL DESCRIPTION The temperature controller is a microprocessor solid
state controller (Refer to Section 2.5). Once the
The unit is a one piece, self-contained, fully charged, controller is set at the desired temperature, the unit will
pre-wired, refrigeration/heating “nosemount” diesel operate automatically to maintain the desired
powered unit for use on insulated trailers to maintain temperature within very close limits. The control system
cargo temperatures within very close limits. automatically selects high and low speed cooling or high
Heating is accomplished by circulating hot gas directly and low speed heating as necessary to maintain the
from the compressor to the evaporator coil. Three desired temperature within the trailer.
electric solenoid valves control the refrigerant circuit to The refrigeration compressor used is either a 05G
operate the heating/cooling system. 37cfm or 41cfm depending on unit model (see
Automatic evaporator coil defrosting is initiated by either Table 2-1), equipped with unloaders as standard
sensing the air pressure drop across the coil with a equipment. Unloaders are used as a compressor
differential air switch or with the defrost timer in the capacity control to unload the compressor during
microprocessor. periods of reduced loads. This provides closer
temperature control, reduces potential for top freezing
The control box includes manual switches, and reduces power required to operate the compressor;
microprocessor, fuses, and associated wiring. Also, the thus reducing fuel consumption.
unit can be equipped with an optional remote light bar
which mounts separately on the front roadside corner of NOTE
the trailer.
Throughout this manual, whenever the “left” or
“right” hand side of the engine is referred to, it is
the side as viewed from the flywheel end of the
engine.

The auto start/stop operation provides automatic

cycling of the diesel engine, which in turn offers an
energy efficient alternative to continuous operation of
the engine with control of temperature by alternate
cooling and heating of the supply air (evaporator outlet
air). The auto start/stop feature is standard equipment.

62-11352 2--2
 9

22

1
21

20
19

18
2
17

16
3 15
14

5 12 13
6 9 10
8 11
7
1. King Valve 12. Lube Oil Filter
2. Hot Gas Solenoid Valve (SV4) 13. Mechanical Fuel Pump
3. Discharge Service Valve 14. Oil Pressure Switch (OP)
4. Compressor Discharge Transducer (CDT), High 15. Engine Speed Sensor (ENSSN)
Pressure Cutout Switch (HP1 and HP2) and 16. Fuel and Speed Actuator (FSA)
Unloader Solenoid Valve 17. Fuel Bleed Valve
5. Compressor -- 05G 18. Engine Air Cleaner
6. Compressor Sight Glass 19 Water Temperature Sensor (WTS)
7. Suction Pressure Transducer (CSP) 20. Fuel Filter
8. Suction Service Valve 21. Location of Engine Speed Control Unit
9. Engine Oil Drain 22. Ambient Air Temperature (AAT)
10. Starter Motor
11. Lube Oil Fill and Dipstick
Figure 2-1. Front View -- X2 2100 Shown

2--3 62-11352
 1 2
1 3

4
3

5
7
6

8
8

1. Condenser Pressure Control 1. Condenser/Radiator

Solenoid Valve (SV1) 2. Radiator Fill Neck (Behind Surround)
2. Defrost Air Switch 3. Radiator Overflow Reservoir (Behind Surround)
3. Filter-Drier 4. DataLink Recorder Location
4. Receiver Sight Glass (Optional) -- See Figure 2-15
5. Receiver 5. Engine Air Cleaner
6. Liquid Line Solenoid Valve (SV2) 6. Alternator -- See Figure 2-8
7. Discharge Check Valve 7. Control Box -- See Figure 2-12
8. Battery Location 8. Model/Serial No. Location

Figure 2-2. Curbside Figure 2-3. Roadside

62-11352 2--4
 9

4 3
5
2

1. SP1, 2 & 3 -- Off of white connector out of back 5. SPK 8 --Ty--wrapped to wiring harness -- left of
of micro compressor
2. SP6 -- Under micro mount -- next to the right 6. SP8 -- Left of compressor cylinder head
engine mount 7. SPK 18 -- Ty wrapped to harness leading to SV2
3. SP5 -- In wiring harness for the fuel solenoid 8. SP 19 -- Behind SV4
4. SPK 6 -- Left of the oil pan

Figure 2-4. Ultra XT and Extra XT Splice Pack Locations

2--5 62-11352
 1

5 6

7 8

1. SPK 19 -- On main harness near king valve 5.

SPK 6 -- On engine harness left of the oil pan
2. SPK 18 -- On main wiring harness above door 6.
SP9 -- On main harness under the engine
latch mount
3. SPK 8 -- On engine wiring harness -- left of and 7. SP1, 2 & 3 -- On J1 harness (white connector
above compressor from micro)
4. SP8 -- On engine wiring harness left of the SP14 -- A breakout on the J1 harness leading to
compressor discharge the DataLink connector
8. SPK 20 On the main harness between the micro
& engine
Figure 2-5. X2 Splice Pack Locations

62-11352 2--6
 9

3
2

1. Evaporator Fan (Blower Wheel) 6. Defrost Termination Thermostat(s)

2. Expansion Valve (DTT)
3. Heat Exchanger 7. Supply Air Sensor (SAS)
4. Return Air Sensor (RAS) 8. Nozzle Cover
5. Evaporator Coil
Figure 2-6. Evaporator Section -- Panels and Grille Removed

2--7 62-11352
2.3 CONDENSING SECTION c. Engine Speed Control Unit (ENSCU) (See
Figure 2-7)
The condensing section consists of an
engine-compressor drive package, condenser fan, The ENSCU is mounted on the roadside frame behind
condenser/radiator coil, refrigerant controls, piping, the door. It provides the RPM signal to the
wiring, defrost air switch, and associated components. microprocessor. The unit has an alarm LED
incorporated within it, which is used to diagnose failures
The drive equipment includes the engine, clutch, air within the ESC system. See Section 6.4 for information
cleaner, muffler, coolant overflow bottle, and drive belts. on diagnosing failures.
Refrigeration components mounted in the condensing
section include the compressor, defrost air switch, filter
drier, and receiver.
2.3.1 Engine
The diesel engine drives the compressor directly
through a nylon drive gear and adapter. The adapter
also includes a V-belt sheave which drives the gearbox.
The condenser/evaporator fan shaft is driven with a
V-belt from the gearbox. The water pump V-belt drives
the alternator.
LED
The engine (refer to Section 2.8) gives excellent fuel
economy and has easy starting characteristics. It is
equipped with spin-on lube oil and fuel oil filters for
easier filter changes.
Engine Transducers and Sensors:
Figure 2-7. Frame Mounted Engine Speed Control
a. Oil Pressure Safety Switch (OP) Unit (ENSCU)
This normally open switch allows the engine to operate
when oil pressure is above 15 ¦ 3 PSIG (1.02 ¦ 0.2 d. Fuel and Speed Actuator (FSA)
Bars). The switch will open and automatically stop the The FSA combines the fuel shutoff solenoid and speed
engine 5 seconds after pressure drops below 12.3 ¦ 3 control solenoid into one component. Engine speed is
PSIG (0.84 Bar). There is a 15-second delay after the controlled by varying rod position.
engine starts to allow the oil pressure to build up before
the microprocessor looks at the input from this switch. e. Engine Speed Sensor (ENSSN)
The switch is located on the front of the engine below the The ENSSN provides the RPM signal to the ENSCU for
fuel solenoid. speed control. It is located on the front of the engine in
b. Water Temperature Sensor (WTS) the gear case cover.
Provides micro with engine coolant temperature
information to be displayed and recorded in the
DataRecorder . The sensor is located on the starter side
of the engine near the #4 Injector.

62-11352 2--8
 9

2.3.2 Alternator/Regulator voltage applied to the field in order to maintain proper

Electrical power for the control system and for charging system voltage.
the battery is provided by the 12 VDC alternator. b. Integral Voltage Regulator Operation (12 VDC)
a. Alternator Operation The regulator is an all-electronic, transistorized device.
No mechanical contacts or relays are used to perform
the voltage regulation of the alternator system. The
CAUTION electronic circuitry should never require adjustment and
the solid state active elements used have proved
Observe proper polarity when installing reliable enough to warrant a sealed unit. The system is
battery. Negative battery terminal must be temperature compensated to permit the ideal charging
grounded. Reverse polarity will destroy the rate at all temperatures.
rectifier diodes in alternator. As a precau- The D+ circuit provides a voltage reading to the micro.
tionary measure, disconnect positive bat- The micro looks at two separate inputs to determine if
tery terminal when charging battery in unit. the engine is running:
Connecting charger in reverse will destroy 1) It looks to see that the oil pressure switch is closed.
the rectifier diodes in alternator. 2) It looks for and alternator output voltage on the D+ cir-
cuit.
The alternator converts mechanical and magnetic With the unit OFF and the alternator not rotating, the D+
energy to alternating current (A.C.) and voltage, by the circuit will be 0 VDC. (See 7.7.7 for information on
rotation of an electromagnetic field (rotor) inside a three improper voltage reading.) With the engine running and
phase stator assembly. The alternating current and
voltage is changed to direct current and voltage, by the alternator rotating, voltage on the D+ circuit will
passing AC energy through a three phase, full-wave match the charging voltage to the battery. This will be
approximately 14.5 VDC.
rectifier system. Six silicon rectifier diodes are used.
The regulator is an electronic switching device. It
senses the system voltage level and switches the

Yellow Yellow

1
2

Red 2
Black
3
4

1. D+ Emulation (Orange)
2. #10-24 AC Terminal
3. #10-24 Ground Screw
4. 1/4-20 Positive Output Cable
Figure 2-8. Alternator and Regulator

2--9 62-11352
2.3.3 Compressor b. Unloaded Operation
The compressor assembly includes the refrigerant com- Pressure from the discharge manifold (Figure 2-9, item
pressor, suction and discharge service valves, high 15) passes through the strainer (9) and bleed orifice (8)
pressure switch, and the suction pressure transducer. to the back of the piston bypass valve (7). Unless bled
The compressor withdraws refrigerant gas from the away, this pressure would tend to close the piston (6)
evaporator and delivers it to the condenser at an in- against the piston spring (5) pressure.
creased pressure and temperature. The pressure is With the solenoid valve (1) energized the solenoid valve
such that refrigerant heat can be absorbed by the sur- stem (2) will open the gas bypass port (3).
rounding air at ambient temperatures.
Refrigerant pressure will be bled to the suction manifold
Compressor Unloaders (10) through the opened gas bypass port . A reduction in
The refrigeration compressor used is a 37 or 41 cfm pressure on the piston bypass valve will take place
model 05G, equipped with unloaders as standard because the rate of bleed through the gas bypass port is
equipment. Unloaders are used as a compressor greater than the rate of bleed through the bleed orifice
capacity control to unload the compressor during (8).
periods of reduced loads. This provides closer When the pressure behind the piston has been reduced
temperature control, reduces potential for top freezing sufficiently, the valve spring will force the piston bypass
and reduces power required to operate the compressor; valve back, opening the gas bypass from the discharge
thus reducing fuel consumption. manifold to the suction manifold.
a. Major Working Parts Discharge pressure in the discharge manifold will close
S Solenoid and valve system the discharge piston check valve assembly (14)
S Spring loaded piston type bypass control valve isolating the compressor discharge manifold from the
individual cylinder bank manifold.
S Spring loaded discharge check valve
The unloaded cylinder bank will continue to operate fully
unloaded until the solenoid valve control device is
de-energized and the gas bypass port is closed.

4
5 7
11
6
2 3

1
10

8 12

9 13

14

15

1. Solenoid Valve 9. Strainer

2. Valve Stem 10. Suction Manifold
3. Gas Bypass Port 11. Cylinder Discharge Valve
4. Spring Guide 12. Valve Plate
5. Spring 13. Cylinder Suction Valve
6. Piston 14. Discharge Piston Check Valve Assembly
7. Piston Bypass Valve 15. Discharge Manifold
8. Bleed Orifice
Figure 2-9. Compressor Cylinder Head Unloaded

62-11352 2--10
 9

4
5 7 11
6
2 3

1
10

12
8

9 13

14

15

1. Solenoid Valve 9. Strainer

2. Valve Stem 10. Suction Manifold
3. Gas Bypass Port 11. Cylinder Discharge Valve
4. Spring Guide 12. Valve Plate
5. Spring 13. Cylinder Suction Valve
6. Piston 14. Discharge Piston Check Valve Assembly
7. Piston Bypass Valve 15. Discharge Manifold
8. Bleed Orifice
Figure 2-10. Compressor Cylinder Head Loaded
c. Loaded Operation 2.3.4 Filter Drier
Discharge pressure bleeds from the discharge manifold The drier is a cylinder shell containing a drying agent
(Figure 2-10, item 15) through the strainer (9) and (8) and screen. It is installed in the liquid line and functions
bleed orifice to the solenoid valve stem (2) chamber and to keep the system clean and remove moisture from the
the back of the piston bypass valve (7). refrigerant.
With the solenoid valve (1) de-energized the solenoid 2.3.5 Receiver
valve stem will close the gas bypass port (3).
Liquid refrigerant from the condenser is pushed into the
Refrigerant pressure will overcome the bypass valve receiver by system pressure. The receiver serves as a
spring (5) tension and force the piston (6) forward liquid reservoir when there are surges due to load
closing the gas bypass from the discharge manifold to changes in the system; as a storage space when pump-
the suction manifold (10). ing down the refrigeration system.
Cylinder discharge pressure will force open the The receiver is provided with either one or two sight
discharge piston check valve assembly (14). glass(es) for the observation of liquid level, and a fusible
Refrigerant gas will pass into the compressor discharge plug safety device.
manifold.
The loaded cylinder bank will continue to operate fully
loaded until the solenoid valve control device is
energized and the gas bypass port is opened.

2--11 62-11352
2.3.6 Compressor Transducers and Sensors 2.4.2 Heat Exchanger
a. Compressor Suction Pressure Transducer (SPT) The heat exchanger is of the “tube in tube” type con-
Provides micro with suction pressure information to be nected in the main suction line and liquid line. Within the
displayed, recorded in the DataRecorder and used to heat exchanger, the cold suction gas is used to cool the
control the refrigeration system. It must be calibrated. It warm liquid refrigerant. This results in greater system
is located in the suction line near the compressor. capacity and efficiency.
b. Ambient Air Temperature Sensor (ATS) 2.4.3 Evaporator Coil
ATS is a temperature control probe which provides mi- The unit evaporator is a tube and fin type. The operation
cro with ambient air temperature information to be dis- of the compressor maintains a reduced pressure within
played, recorded in the DataRecorder and used to the coil. At this reduced pressure, the liquid refrigerant
control the refrigeration system. It is located behind the evaporates at a temperature sufficiently low enough to
condenser grille. absorb heat from the air.
Heating is accomplished by circulating hot gas directly
c. Compressor Discharge Temperature Sensor from the compressor to the evaporator coil. Solenoid
Transducer (CDT) valves control the refrigerant circuit to operate the
Provides micro with discharge temperature information heating/cooling system.
to be displayed, recorded in the DataRecorder and used Automatic evaporator coil defrosting is initiated by either
to control the refrigeration system. It is located on the sensing the air pressure drop across the coil with a
center cylinder head of the compressor. differential air switch or with the defrost timer in the
It will shut the unit down if center compressor head microprocessor.
discharge temperature reaches 310°F (154°C) for three
minutes or 350°F (177°C). If ambient temperature 2.5 SYSTEM OPERATING CONTROLS AND
sensor (AAT) is at 120°F (49°C) or higher, the CDT limits COMPONENTS
are increased to 340°F (171°C) for three minutes. The temperature controller is a Carrier Transicold
controller (Refer to Sections 2.5.2 and 3.1). Once the
controller is set at the desired temperature, the unit will
2.4 EVAPORATOR SECTION operate automatically to maintain the desired
temperature within very close limits.
The evaporator fits into a rectangular opening in the
upper portion of the trailer or rail car front wall. When The microprocessor that is shown on the electrical
installed, the evaporator section is located inside this schematic interfaces with unit components.
box, and the condensing section is outside. Plug-in interchangeable relays provide the
The evaporator assembly consists of an evaporator coil, microprocessor with a means for switching the unit
evaporator fan, expansion valve, two defrost components to achieve a desired operating mode.
thermostats (termination switches). The location of the The control box includes manual switches, a
thermostats is shown in Figure 2-6. The return air microprocessor, fuses, and associated wiring. Also, the
sensor is also shown in Figure 2-6. unit can be equipped with an optional remote light bar
which mounts separately and can be seen in the mirror
2.4.1 Thermal Expansion Valve from the cab of a truck, or on the front of a rail car.
The thermal expansion valve is an automatic device Standard equipment includes an auto start--stop
which controls the flow of liquid to the evaporator ac- feature. This feature provides automatic cycling of the
cording to changes in superheat to the refrigerant leav- diesel engine, which in turn offers an energy efficient
ing the evaporator. The thermal expansion valve alternative to continuous operation of the engine with
maintains a relatively constant degree of superheat in control of temperature by alternate cooling and heating
the gas leaving the evaporator regardless of suction of the supply air (evaporator outlet air).
pressure. Thus, the valve has a dual function; automatic
expansion control and prevention of liquid return to the
compressor.

62-11352 2--12
 9

2.5.1 Special Features The Carrier Transicold microprocessor controller

The following special features are incorporated into the incorporates the following features:
Carrier Transicold Microprocessor: a. Control supply or return air temperature to tight
S Unit Operation and Alarms are displayed in English limits by providing refrigeration control, heat and
or codes. defrost to ensure conditioned air delivery to the
load.
S UltraFresh 2 b. Dual independent readouts of set point and supply
S Large LCD display or return air temperatures.
S Unit Data and Functional Parameters c. Digital readout and ability to select data. Refer to 3.8
S PM Hourmeters for Function Code and 3.9 for Unit Data.
S Fully automated Pretrip d. For alarm digital display identification refer to 3.10.
S Auto Start-Stop e. A pre-trip checkout of refrigeration unit operation.
Refer to Section 3.3
S Automatic Engine Starting. Manual engine starting
exists in units built before April 2007. f. A self-test check on program memory and data
S Functional Parameter locks memory. The self-test is executed each time the
system is switched from “Stop” to “Start.” Errors, if
any, shall be indicated on the display as a ERR.X,
where X is a number corresponding to the number
of the test. The unit shall display this error for 5
seconds and then reset the micro.
ERROR CAUSE
ERR.1 Processor failure
ERR.2 Check chip installation or replace
microprocessor.
ERR.3 Temperature sensor may be
shorted to ground or to 12 VDC or
Possible processor failure
Check for short or chip installation
or replace microprocessor.
Display board to logic board
ERR.4 or communication failure.
Display This can be caused by a defective
ribbon cable or ribbon cable not
plugged in properly.

2--13 62-11352
2.5.2 Component Description And Location Display
The main display has nine characters (each character
has 14 elements), two decimal points or commas and a
CAUTION degree symbol. The display is used to provide the user a
setpoint and box temperature, either in degrees
Under no circumstances should anyone at- Centigrade or Fahrenheit. The comma symbols are
used as the decimal indicators in Europe. When Metric
tempt to repair the Logic, Relay or Display Units is selected in the Functional Parameters, the two
Boards! (see section 7.16) Should a prob- comma icons are used instead of decimal points. When
lem develop with these components, con- English Units is selected in the Functional Parameters,
tact your nearest Carrier Transicold dealer decimal points are used.
for replacement. The display illuminates the entire LCD segment when
the Start/Run--Off is turned OFF. The design appears as
The microprocessor controller is housed in the control shown in the display graphic of Figure 2-11. As the
box on the lower roadside corner of the unit. This internal capacitor discharges the LCD segments fade
controller consists of 3 control boards: out to a blank display. Some units have a change in
a. The Logic Board (Figure 2-13) includes the micropro- information displayed while the capacitor is discharging.
cessor, program memory, and necessary input/out- Instead of the snowflake pattern, the display could
put circuitry to interface with the unit. The Logic Board initially show the snowflake display for a few seconds
is totally self-contained and does not contain any ser- and then display the same data that was being
viceable components. displayed at the time the unit was turned off. For
example, if an alarm was being displayed it may be
b. The Relay Board (Figure 2-12) is mounted to the displayed again.
back of the control box, into which replaceable relays,
and fuses are mounted. The main wiring harness Temperature display is right justified, with unused digits
plugs into this board. blank. A negative sign will be displayed for all setpoint
and box temperatures below zero. The resolution for
c. Display and Keypad box temperature in both Centigrade and Fahrenheit is
The Display and Keypad module is located for operator one-tenth degree.
access at the lower roadside corner of the unit.
The display board is mounted in the Keypad and Display
module. The display board includes the LCD display,
keypad, and keypad interface.
The Display and Keypad module provides the user with
a panel to view and control the functions of the
refrigeration unit. The module consists of a switch,
keypad, and main display. Setpoints and other system
information are selected using the keypad. Figure 2-11
shows the Display and Keypad module.

62-11352 2--14
 9

MODE LEDs DISPLAY

FAULT STAND-- BY

DOOR

-20.0 +34.5° F
SETPOINT BOX TEMPERATURE

FUNCTION
CHANGE ENTER

UNIT PRETRIP AUTO S/S MANUAL

DATA CHECK DEFROST
CONTINUOUS

Figure 2-11. Display and Keypad

2--15 62-11352
 7

1 Glow Plug Relay (GPR) -- 70 amp

2 Starter Solenoid Relay (SSR) -- 70 amp
3 Fuse - F1 (80A)
4 Logic Board
1 5 Fuses - F2 (20A), F4 (15A), F5 (7.5A)
F6 (5A), F9 (5 or 7.5 A), F10 92A), F11, F12 (10A)
6 Relays, Run (RR), Speed (SR)
Unloader Front (UFR), Unloader Rear (URR),
Heat (HR1, HR2, HR3 & HR4), Defrost (DR),
Fault (FR), Out-of-Range (OR), Auto Restart (ARR),
2 Fuel Heater (FHR) -- OPTIONAL
7 Relay Board

6
3

Figure 2-12. Control Box

62-11352 2--16
 9

EEPROM

Figure 2-13. Logic Board -- Refer to Section 7.16.2 for instructions on replacing EEPROM

Indicator LEDs Key Descriptions

The display has two LEDs across the top to indicate The keypad has 8 keys which will allow the operator to
operation status. These indicators are: initiate various functions, display operating data and
S Fault -- Indicates there is an alarm. change operating parameters.
S Stand--By -- Unit running on Standby (Not
applicable for X series units.) UP ARROW and DOWN ARROW Keys
Switch Descriptions These keys allow you to change the
START/RUN START/RUN--OFF Switch (SROS) setpoints or other displayed data of the
system. They also allow you to scroll
When placed in the START/RUN position, this through the Unit Data List, Function
switch provides power to the microprocessor. Parameters List, Alarm List, etc.
The microprocessor performs a self-test (all
segments of display are illuminated). Then EQUAL Key (ENTER)
setpoint and Box Temperature are displayed. The EQUAL key is used for many things
To stop the unit or remove power from the including entering a setpoint, changing a
microprocessor, place the SROS in the OFF Functional Parameter, clearing alarms, and
position. locking the data menu.
MANUAL MANUAL DEFROST Key
DEFROST
The MANUAL DEFROST key is used to
initiate a defrost cycle when the proper
conditions are met.

2--17 62-11352
 AUTO S/S
AUTO START--STOP/CONTINUOUS Key FUNCTION
FUNCTION CHANGE Key
CONTINUOUS The START/STOP CONTINUOUS key is CHANGE The FUNCTION CHANGE key is used to
used to change the operating mode from display the operating parameters. Each
“auto start/continuous run” to “auto time this key is pressed the display will
start/stop.” Each push of the key will advance to the next parameter. This key, in
alternate the operating modes. The conjunction with the UP/DOWN Arrow and
operating status will be stored in memory ENTER keys, will allow the user to change
and will be retained through power outages. the parameters (See Section 3.8.1).
The digital display will indicate when
stop/start is enabled (Also See Section 3.5). d. LIGHT BAR (Optional)
To start the unit in manual start mode, the The Light Bar is an external set of indicator lights which
START/STOP CONTINUOUS selection can be seen in the mirror from the cab of a truck. (See
must be in continuous run mode. Figure 2-14.) They are controlled by the
microprocessor. The lights are:
PRETRIP CHECK Key
PRETRIP Two Light Bar
CHECK Used to initiate a pretrip given that the S Green Light -- Indicates “OK”
proper conditions are met. (Refer to Section
3.3). S Amber Light -- Indicates “Check Unit”. Amber
follows the microprocessor fault light and alarms
UNIT DATA Key can be read on the micro display.
UNIT
DATA The UNIT DATA key is used to display the
unit operating data. This key, in conjunction Eight Light Bar
with the UP/DOWN Arrow keys, will allow These lights correspond to the microprocessor LEDs --
the user to display the unit’s operating data HEAT, COOL, DEFROST, START-STOP, and ALARM.
values (i.e., coolant temperature, battery The ENGINE-AUTO-START light is only illuminated
voltage, etc.) (See Section 3.9). when the unit is operating in Start-Stop. The
OUT-OF-RANGE light is illuminated when the
Out-of-Range Alarm is active.

STANDARD LIGHT BAR

LED LIGHT BAR

Figure 2-14. Light Bar

62-11352 2--18
 9

2.6 DATALINK MODULE (Optional) This recorder eliminates the mechanical recorder and
paper chart, and replaces it with a custom-designed
2.6.1 Brief Description module (see Figure 2-15) that interfaces with the
controller module and the Datalink Toolbox PC based
software program in order to:
WARNING a. Operate as a stand alone device or as part of a net-
work.
Do not attempt to service the DataLink mod-
b. Log data at 2, 15, 30, 60 or 120 minute intervals.
ule. Breaking the warranty seal will void the
warranty. c. Log DataLink alarms.
d. Be custom configured to record up to 13 different sen-
sors.
CAUTION e. Record DataLink/Network generated events as fol-
lows:
Remove DataLink module and unplug all -- Main Setpoint Change
wire harness connectors before performing -- Defrost Initiation
any arc welding on any part of the unit. -- Defrost Termination
-- Pre-Trip Initiation
Do not remove wire harness from module -- Pre-Trip Termination
unless you are grounded to the unit frame -- Alarm Activity
with a static safe wrist strap. -- Controller Software Upgrade
-- Controller Replacement
-- Trailer ID Change
Carrier Transicold has developed a recorder “DataLink”. -- Trip Start
it is a self-contained module which consists of: -- Trip Comment
-- Microprocessor -- Unit Start/Stop
-- Program memory -- Controller Configuration Change
-- Data memory -- Function Parameter Change
-- Internally battery backed real time clock -- Controller System Mode Change (diesel/elect)
-- Control Mode Change
-- 5 thermistor inputs -- In-Range Indicator
-- Fuel Level inputs -- RTC Battery Replaced (Internal Battery)
-- Door open/closed switch -- Remote 1 Setpoint Change
-- Four status LEDs -- Remote 2 Setpoint Change
-- Software ports -- DataLink Alarm Activity
-- Electronic backup power pack -- Power off
-- Power on
-- Data Retrieval
-- RTC Modification
-- DataLink Software Upgrade
-- Network Failure
-- Network Recovery
-- Door Opened/Closed
-- Fuel Level Low/Normal

f. Download files contain the following information:

-- Description Header
-- DataLink Header
-- Memory Configuration
-- Current Values
-- Alarm Table
-- Time and Date
-- Selected Event Data
-- Recorded Sensor Values

2--19 62-11352
 1 2 3

Lin
k

4 4 6 5 4
1. DataLink Module 4. Connector
2. Backup Power Pack 5. Status LEDs
3 Software Port 6 Fuse
Figure 2-15. DataLink Module
2.6.2 Components and Descriptions
Operational Software: Table 2-3 -- DataLink Codes
DataLink Software controls the unit’s operations such CODE TEST
as: waking up at a specified time, requesting information
from other modules in the unit, taking readings from 1 Memory Test 1
probes, etc. 2 Memory Test 2
Program Flash Cards 3 Timer Test 1
The program flash cards are used for installing and 4 Timer Test 2
upgrading DataLink software. 5 Timer Test 3
2.6.3 Functions 6 Converter Test 1
a. DataLink Power-Up
The DataLink may power up in any of 3 ways; normal c. Trip Start Processing
DC power, by the RTC (Real Time Clock) because a For the user to initiate a Trip Start: press the PRETRIP
logging interval has expired, or by plugging the Carrier CHECK key on the control panel or use the DataLink
Transicold computer cable (P/N 22--01737--00) into the Tool Box program to initiate Trip Start.
downloader port.
d. Additional Data Sensors
If the DataLink has awakened because the logging
interval is up, the DataLink will log the appropriate data DataLink can have up to 5 thermistors, 1 fuel level
and power-off when it is through. It will continue to log sensor and 1 door open/closed switch.
data for the next hour (2 minute interval setting) or 8
hours (all other intervals). The DataLink will wake
following a unit safety shut down or when the unit is
switched off.
b. DataLink Diagnostics
The DataLink start up diagnostics processing will occur
each time there is a power up or after a hardware reset.
This processing will test the DataLink hardware for
proper operation. If any critical test fails, then the fault
LED will flash the test code three times to indicate what
test failed. If any of these test fails, the module must be
replaced.

62-11352 2--20
 9

2.6.4 Status LEDs 2.6.5 Message Trip Comment

The DataLink contains four status LEDs. These are as DataLink has the capability to allow the user to enter
follows: comments directly into DataLink. The comments have a
maximum length of 78 characters. Only one comment
-- Fault/Alarm (Red) can be recorded per day. In the event that multiple
-- Battery Status (Yellow) comments are entered, only the last will be saved.
-- Communication (Green)
-- Status/Power/Executing Code (Yellow) 2.6.6 DataLink Communications
a. DataLink Retrieval -- Interrogation
Fail -- Fault/Alarm LED: Data retrieval from the DataLink can be accomplished
The Fault/Alarm LED indicates if a hardware fault or with an IBM or Windows compatible computer
alarm has occurred in the DataLink. If a hardware fault connected using a Carrier Transicold Download cable
occurs, the LED will flash the fault code three times, P/N 22--01737--00 and software program.
then the processor will reset. The fault codes and their The DataLink Toolbox software (DOS program) for a
code numbers are defined in Table 2-3. Fault codes will computer is supplied on a 3.5 inch floppy disk. This
only be displayed on power up. If the DataLink powers software allows downloading, screen view of the data,
up properly, then this LED will indicate an alarm and printing.
condition that has been detected. The alarm LED should
turn on when the alarm is detected, and off when the The ReeferManager for Windows PC Software
alarm goes away. Program can also be used to download data.
If an alarm occurs, then the LED will be on solid until the
alarm goes away.
The out of range values are as follows:
Thermistor Inputs:
Low limit = --58.0_F (--50_C)
High limit = 158_F (70_C)

For sensor input alarms, the alarms can only be cleared

by using DataLink Toolbox PC Program. See 2.6.6
Batt -- Battery Status LED:
The Battery status LED pulses at a rate of 1 second on/1
second off when the battery voltage is greater than or
equal to 6.0V. It will be on solid when the battery voltage
is less than 6.0V but greater than or equal to 1.0V. It will
be off when the battery voltage is less than 1.0V.
Comm -- Communication LED:
The Communication LED will normally be off. Two to
three blinks per minute indicates DataLink is
communicating with micro. If the LED comes on steady
for 5--6 seconds, there is no communications between
DataLink and micro.
Stat -- Status/Power LED:
The Status/Power LED indicates if the DataLink is
powered up. The LED will be off when power is off or the
DataLink is in a sleep mode running off the battery. The
LED will pulse at a rate of 1 second on/1 second off.

2--21 62-11352
 DOOR SWITCH

FUEL LEVEL SENSOR

SPARE VOLTAGE SENSOR

Figure 2-16. DataLink Electrical Schematic

62-11352 2--22
 9

2.7 REMOTE MONITORING -- (Optional) There are presently three (3) protocols supported. The
protocol for the QualComm transmitter, the protocol for
The microprocessor controller is equipped with a RS232 the HUGHES transmitter, and Carrier Communication
communication port. This port can be used to Protocol. The microprocessor will power up and
communicate unit operating data to a mobile satellite transmit a HUGHES protocol packet and continue to
transmitter. This information will then be relayed back to transmit a packet every hour. The microprocessor will
the office via a modem to a computer. transmit in the Carrier, QualComm protocol if a data
packet is requested.
2.8 ENGINE DATA
ULTRA XT X2 2100 EXTRA XT X2 1800
NDL9340N0AM0 NDL934N0AMA NDL935N0CBA NDL935N0CMA
Engine Models V2203-DI E3B V1903--M E3B
Displacement (135 in3) 2.2 liters (114 in3) 1.9 liters
Weight 439 lbs (199 kg) 422 lbs (191 kg)
No. Cylinders 4
Coolant Capacity 1.675 gallons (6.3 liters) (50/50 mix --- never to exceed 60/40)
Oil Capacity with Filter 4 gal (15 liters)
Fuel Winter: Diesel No. 1 Summer: Diesel No. 2
Intake Air Heater 38 to 46 Amps
Extended Service Interval (ESI) packages are standard
CAUTION on X Series units. The ESI package reduces the
frequency of scheduled service intervals.
Use only ethylene glycol anti-freeze (with Oil Change Intervals -- Extended Service Interval
inhibitors) in system as glycol by itself will
damage the cooling system. Always add API MOBIL
Class CG or higher DELVAC
pre-mixed 50/50 anti-freeze and water to ra-
diator/engine. Never exceed more than a 3000 Hours or 2 yr 4000 Hours or 2 yr
60% concentration of anti-freeze. Use a low
silicate anti-freeze meeting GM specifica-
tions GM 6038M for standard life coolant or CAUTION
use Texaco Havoline extended life coolant
or any other extended life coolant which is When changing oil filters, the new filters
Dexcool approved and has 5/150 (5 should be primed (partially filled) with clean
years/150,000 miles) on the label. oil if possible. If the filters are not primed,
the engine may operate for a period with no
a. Lubrication System oil supplied to the bearings.
Oil Pressure:
40 to 60 psig (2.7 to 4.1 Bar) NOTE
(Engine in high speed) The maximum oil change interval is one year for
Oil Pressure Safety Switch Setting Closes: CI oil or two years for Mobil Delvac unless units
are equipped with Extended Service Interval
15 ( ¦ 3) psig (1.02 Bar)
Packages. The only approved synthetic lube oil
Lube Oil Viscosity: is Mobil Delvac. The normal oil change intervals
Outdoor Temperature should be reduced if the equipment is operated
SAE under extreme conditions such as in dirty envi-
Fahrenheit Centigrade ronments.
Below 32_ 0_C 10W30
10W30 or Refer to Section 7.1 for more detailed information on
32_ to 77_F 0_ to 25_C service intervals.
15W40
Over 77_F Over +25_C 10W30 or
15W40

2--23 62-11352
2.9 ENGINE SCREW THREADS 2.12 REFRIGERATION SYSTEM DATA
All threads on internal components on the diesel engine Defrost Air Switch 1.40 (¦ .07) inch
are metric. (DAS) Initiates Defrost: (35 ¦ 1.8 mm) WG
2.10 ENGINE AIR SYSTEM Defrost Termination Opens: 55 ¦ 5.5_F
Temp. (DTT) (12.8¦ 3°C)
The air cleaner is put on the engine to prolong its life and Closes: 40 ¦ 7.5_F
performance by preventing dirt and grit from getting into (4.4 ¦ 4.2°C)
the engine causing excessive wear on all operating
parts. However, it is the responsibility of the operator to Expansion Valve Setting: 8 to 10_F
give the air cleaner equipment regular and constant Superheat (4.4 to 5.6_C)
attention in accordance with the instructions. (Refer to Setting at 0_F
Section 7.7.4) (--17.8_C) box temper-
Clean air is supplied to the engine through the air ature:
cleaner (Refer to Section 6.3.4). The air is necessary for Defrost Timer 1 1/2, 3, 6 or 12 hours
complete combustion and scavenging of the exhaust Expansion Valve MOP 60 psig (4.0 Bar) -- Extra
gases. As the engine piston goes through the intake
stroke, the piston draws clean fresh air down into the XT and X2 1800
cylinder for the compression and power strokes. As the 55 psig (3.7 Bar) -- Ultra
engine goes through its exhaust stroke, the upward XT and X2 2100
movement of the piston forces the hot exhaust gases Fan Clutch Air Gap 0.015 to 0.090I
out of the cylinders through the exhaust valves and the
exhaust manifold. If the air filter is allowed to become Fusible Plug Setting 208_ to 220_F
dirty, the operation of the engine would be impaired. (97.8_ to 104.4_C)
High Pressure Cut--Out Closes: 465 ¦ 10 psig
2.11 COMPRESSOR DATA Switch (HP1) (31.6 ¦ 0.68 Bar)
Compressor Models 05G -- 37/41cfm Opens: 350 ¦ 10 psig
No. Cylinders 6 (23.8 ¦ 0.68 Bar)
No. Unloaders 2 High Pressure Cut--Out Closes: 300 ¦ 10 psig
Control (HP2) (20.4 ¦0.68 Bar)
Dry Weight 130 lbs (59 kg)
Opens: 200 ¦ 10 psig
Approved Oil Mobil Arctic EAL 68
(13.6 ¦ 0.68 Bar)
Oil Charge 6.75 pints (2.8 L)
Refrigeration Charge Refer to Table 2-1
Gearbox Oil Mobil SHC 75--90W: 15oz
(0.44 liters)
Fanshaft Oil Mobil SHC 630: 3.2oz (0.09
liters)
Unit Weight (Approximate) 1600 lb. (725 kg)

62-11352 2--24
 9

2.13 SAFETY DEVICES

System components are protected from damage is accomplished by the safety devices listed in
caused by unsafe operating conditions by automatically Table 2-4.
shutting down the unit when such conditions occur. This
Table 2-4. Safety Devices
Unit Shutdown Safety Devices
Unsafe Conditions Safety Device Device Setting
Low engine lubricating oil Oil pressure safety switch Opens below 15 ¦ 3 psig
pressure (OP) (microprocessor reset) (1.02 ¦ 0.2 Bar)
High engine cooling water Water temperature sensor Refer to Section 3.10
temperature (WTS) (microprocessor reset) AL1 -- ENG HOT
Excessive current draw by control system Fuse (F1) Opens at 80 amps
Excessive current draw by fuel heater (optional) Fuse (F2) Opens at 20 amps
Excessive current draw by speed relay and Fuse (F4) Opens at 15 amps
front unloader
Excessive current draw by auto restart or Fuse (F5) Opens at 7 1/2 amps
out-of-range lights
Excessive current draw by fault light Fuse (F6) Opens at 5 amps
Excessive current draw by Start/Run--Off Fuse (F9) Opens at 5 amps
Switch
Excessive current draw by clutch or defrost Fuse (F11) Opens at 10 amps
light
Excessive current draw by SV1, SV2, SV4, Fuse (F12) Opens at 10 amps
heat light, cool light or rear unloader
Other Safety Devices
Unsafe Conditions Safety Device Device Setting
Excessive compressor High pressure cutout switch Refer to Section 2.12
discharge pressure (HP1) automatic reset
Excessive compressor Compressor discharge Refer to Section 3.10
discharge temperature temperature sensor (CDT) Compressor Discharge
(microprocessor reset) Temperature Alarm

2--25 62-11352
2.14 COMPONENT RESISTANCE & CURRENT DRAW
Table 2-5. Component Resistance & Current Draw

Component Ohms Amps

SV1 7.8 ± 0.3 Ohms 0.10 to 2.0 Amps
SV2 & 4 10.6 ± 0.3 Ohms 0.75 to 2.0 Amps
WTS 670 to 690 Ohms at 100°C ±0.5°C
Unloader 10.6 ± 0.3 Ohms 1.0 to 2.0 Amps
Clutch 2.5 ± 0.2 Ohms 3.0 to 5.0 Amps
Fuel and Speed Actuator 2.8 Ohms ±10% @68°F (20°C) 4 Amps Max
Engine Speed Sensor 22 mAmps Max
Indicator lights (8 Light 4.8 ± 0.2 Ohms NA
Bar Only)
Unit non-running amps 6--9 Amps
Intake Air Heater 38 to 46 Amps
Starter Amps NA 270 -- 380 amps

62-11352 2--26
 9

2.15 REFRIGERANT CIRCUIT DURING COOLING electrically controlled liquid line solenoid valve (SV-2,
(See Figure 2-17) normally closed) which starts or stops the flow of liquid
refrigerant.
When cooling, the unit operates as a vapor compression
refrigeration system. The main components of the The refrigerant flows to the “Liquid/suction” heat
system are the (1) reciprocating compressor, (2) exchanger. Here the liquid is further reduced in
air-cooled condenser, (3) expansion valve, and (4) temperature by giving off some of its heat to the suction
direct expansion evaporator. gas.
The compressor raises the pressure and the The liquid then flows to an externally equalized
temperature of the refrigerant and forces it through the thermostatic expansion valve which reduces the
discharge check valve and into the condenser tubes. pressure of the liquid and meters the flow of liquid
The condenser fan circulates surrounding air over the refrigerant to the evaporator to obtain maximum use of
outside of the condenser tubes. The tubes have fins the evaporator heat transfer surface.
designed to improve the transfer of heat from the The refrigerant pressure drop caused by the expansion
refrigerant gas to the air. This removal of heat causes valve is accompanied by a drop in temperature; thus,
the refrigerant to liquefy; thus liquid refrigerant leaves the low pressure, low temperature fluid that flows into
the condenser and flows through the solenoid valve the evaporator tubes is colder than the air that is
SV-1 (normally open) and to the receiver. circulated over the evaporator tubes by the evaporator
The receiver stores the additional charge necessary for fan. The evaporator tubes have aluminum fins to
low ambient operation and for the heating and defrost increase heat transfer; therefore heat is removed from
modes. The receiver is equipped with a fusible plug the air circulated over the evaporator. This cold air is
which melts if the refrigerant temperature is abnormally circulated throughout the trailer to maintain the cargo at
high and releases the refrigerant charge. the desired temperature.
The refrigerant leaves the receiver and flows through The transfer of heat from the air to the low temperature
the receiver outlet shutoff valve (king valve). The liquid refrigerant causes the liquid to vaporize.
refrigerant then flows through the subcooler. The This low temperature, low pressure vapor passes
subcooler occupies a portion of the main condensing through the “suction line/liquid line” heat exchanger
coil surface and gives off further heat to the passing air. where it absorbs more heat from the high pressure/high
The refrigerant then flows through a filter-drier where an temperature liquid and then returns to the compressor.
absorbent keeps the refrigerant clean and dry; and the

HOT GAS
EXTERNAL EQUALIZER EXPANSION VALVE BYPASS LINE
TXV
BULB FUSIBLE
PLUG
RECEIVER

EVAPORATOR
BYPASS
CHECK
HEAT EXCHANGER VALVE

LIQUID LINE SHUT-OFF (KING) LIQUID

VIBRASORBER VALVE SOLENOID
HOT GAS VALVE (SV2), NC
LINE
DISCHARGE FILTER
SERVICE HP-2 HP-1 SUCTION
SERVICE SUBCOOLER DRIER
VALVE
VALVE
HOT GAS
SOLENOID
(SV4), NC

CONDENSER
PRESSURE
CONTROL
SOLENOID
COMPRESSOR DISCHARGE (SV1), NO
CHECK VALVE

CONDENSER
VIBRASORBER

Figure 2-17. R-404A Refrigerant Circuit -- Cooling

2--27 62-11352
2.16 REFRIGERANT CIRCUIT -- enters the evaporator. Also the liquid line solenoid valve
HEATING AND DEFROSTING (See (SV-2) will remain energized (valve open) as the head
Figure 2-18) pressure control switch (HP-2) will remain closed until
the compressor discharge pressure increases to cut-out
For units with UltraFreeze Refer to Section 4.12. setting (Refer to Section 2.12), at which time switch
For units without UltraFreeze the unit will only heat when HP-2 opens to de-energize the liquid line solenoid valve
the controller is set above +10_F (--12.2_C) as the heat (SV-2) and the valve closes to stop the flow of refrigerant
relays are electronically locked out with set points below to the expansion valve.
+10_F (--12.2_C). Heat lockout can be overridden by When the compressor discharge pressure falls to cut-in
setting CNF4 to “ON”. setting (Refer to Section 2.12), pressure switch (HP-2)
When vapor refrigerant is compressed to a high pressure closes and in turn energizes the normally closed liquid
and temperature in a reciprocating compressor, the solenoid valve (SV-2) which opens, allowing refrigerant
mechanical energy necessary to operate the compressor from the receiver to enter the evaporator through the
is transferred to the gas as it is being compressed. This expansion valve. The function of the hot gas bypass line
energy is referred to as the “heat of compression” and is is to raise the receiver pressure when the ambient
used as the source of heat during the heating cycle. temperature is low (below 0_F = --17.8_C) so that
refrigerant flows from the receiver to the evaporator
2.16.1 Heating and Defrost when needed.
Defrost Mode only: 90 seconds after entering defrost,
NOTE suction pressure is monitored. If suction pressure rises
higher than 57 psig (3.9 Bar), SV1 is opened for 1
Solenoid valve (SV-2) remains open during second to reduce suction & discharge pressure, and the
heating or defrosting to allow additional suction pressure is monitored again after 30 seconds.
refrigerant to be metered into the hot gas cycle Defrost will continue and does not terminate until the
(through the expansion valve) providing defrost termination thermostat(s) (DTT) reach
additional heating capacity until de-energized termination temperature and open, or the compressor
by head pressure control switch HP-2. discharge temperature (CDT) reaches 310_ F
(154.4_C) for 1 minute (2 minutes after defrost initiation.
When the controller calls for heating, hot gas solenoid At defrost termination, SV1 is first opened, then SV4 is
valve (SV-4) opens and the condenser pressure control closed, and the unit shifts to low speed to engage the fan
solenoid valve (SV-1) closes. The condenser coil then clutch. The unit then exits the defrost cycle, and
fills with refrigerant, and hot gas from the compressor resumes normal operation.
HOT GAS
EXTERNAL EQUALIZER EXPANSION VALVE BYPASS LINE
EXPANSION
VALVE FUSIBLE
BULB PLUG
RECEIVER

EVAPORATOR
BYPASS
CHECK
HEAT EXCHANGER VALVE

LIQUID LINE LIQUID

SHUT-OFF (KING) SOLENOID
VIBRASORBER VALVE
HOT GAS VALVE (SV2), NC
LINE
DISCHARGE FILTER
SERVICE HP-2 HP-1 SUCTION
SERVICE SUBCOOLER DRIER
VALVE
VALVE
HOT GAS
SOLENOID
(SV4), NC

CONDENSER
PRESSURE
CONTROL
SOLENOID
DISCHARGE (SV1), NO
CHECK VALVE
COMPRESSOR
CONDENSER
VIBRASORBER

Figure 2-18. R-404A Refrigerant Circuit -- Heating and Defrosting

62-11352 2--28
 SECTION 3 - OPERATION
3.1 STARTING UNIT -- AUTO

FAULT STAND-- BY

SELF TEST

FAULT STAND-- BY

-20.0 +34.5°F

3--1 62-11352
 If the unit is in Auto Start/Stop mode or Continuous
WARNING Run/Auto Operation mode the glow plugs will energize.
The length of time of this heat cycle depends on engine
Under no circumstances should ether or temperature. (See 4.1.5) The buzzer on units so
any other starting aids be used to start en- equipped will sound for 5 seconds, and the diesel engine
gine. will start.
The microprocessor controller monitors box
NOTES temperature, battery voltage, and engine coolant
1. In order to reduce starter cranking and engine temperature. Once the setpoint is reached the
loads, the microprocessor starts and operates controller will shut off the diesel engine to conserve fuel.
in low speed, unloaded cool for the first 15 The controller will not shut off the engine if the battery
seconds after start--up. voltage is not sufficient to restart it.
2. The unit will remain in low speed for 5 minutes The controller will restart the engine if any of the
after engine start-up when: Auto Start/Stop is following criteria have been met:
at any setpoint or Continuous Run setpoint is
below 10_F (--12_C). SBox temperature has moved away from setpoint by
Place the Start/Run--Off switch in the Start/Run ¦ 11°F (¦ 6.1°C)for setpoints in the perishable range
and +11° F (+6.1°C) for setpoints in the frozen range
position.
DURING minimum off time.
The microprocessor controller will run a self test. All of
the mode lights will light, all of the segments on the SBox temperature has moved away from setpoint by
display will be turned on. ¦(3.6°F (2.0°C) AFTER minimum off time for setpoints
in the perishable range or +3.6°F (2.0°C) for setpoints
The display will then show the setpoint temperature on in the frozen range.
the left and the box temperature of the trailer on the
right. The last character (after the degree symbol) SThe battery voltage drops below 11 VDC (12.2 VDC for
shows the temperature units as F (Fahrenheit) or C units with EEPROM Rev 3.25 and higher -- Refer to
(Celsius). Section 3.9.1 for unit data)
SThe engine coolant temperature drops below 34°F
(1°C).

NOTE
Refer to Section 4.1.5 for pre--heat times.

62-11352 3--2
3.2 MANUAL START

WARNING
Under no circumstances should ether or any other starting aids be used to start engine.

1. Place START/RUN - OFF switch to the

START/RUN position. If START/STOP is 2. Press FUNCTION CHANGE key until AUTO OP or
displayed, press AUTO S/S-CONTINUOUS MAN OP is displayed. If MAN OP appears, unit is in
toggle key to place unit in Continuous Run manual start mode.
Mode .

FAULT STAND-BY

MAN OP
SETPOINT BOX TEMPERATURE

FUNCTION
CHANGE ENTER

UNIT PRETRIP AUTO S/S MANUAL

DATA CHECK DEFROST
CONTINUOUS

3. If AUTO OP appears, first press ENTER key, then UP or DOWN arrow key
until MAN OP is displayed. Press ENTER key to lock in manual mode.

4. With MAN OP selected, press

AUTO S/S-CONTINUOUS key
to toggle between Auto
Start-Stop and Manual
Start/Continuous Run modes.

3--3 62-11352
3.3 PRETRIP

FAULT STAND-BY

COOL

PPPP
SETPOINT BOX TEMPERATURE

FUNCTION
CHANGE ENTER

UNIT PRETRIP AUTO S/S MANUAL

DATA CHECK DEFROST
CONTINUOUS

1. Start and run unit until box

temperature is 40_F (4.4°C) or
lower.
2. Press PRETRIP CHECK key to start
PRETRIP. “PPPP” will appear on the display.

The PRETRIP mode is for checking unit operation and f. After 30 seconds, unit cycles to low speed unloaded
evaluating operation of all modes and indicating a failure heat.
when detected. The following details the sequence :
g. After 30 seconds, unit cycles to low speed loaded
a. Unit operating and box temperature is below 40_F heat.
(4.4_C).
h. After 30 seconds, unit cycles to high speed heat and
b. Operator presses the PRETRIP key. If the defrost displays coolant temperature.
thermostat (DTT) is closed, the controller will display
“PPPP.” If DTT is open, no response -- end of test. i. After 30 seconds, unit cycles to high speed cool and
displays defrost interval selected for 30 seconds,
c. Controller displays “PPPP” Pre-trip mode is started. then unit cycles to defrost if DTT is closed.
d. After 30 seconds in high speed cool, unit cycles to j. After standard defrost cycle, Pretrip is terminated and
low speed loaded cool. unit returns to normal operation.
e. After 30 seconds, unit cycles to low speed unloaded This is not a self-diagnosing pretrip test. No specific
cool. pretrip alarms will be generated. Pretrip must be
monitored by the user to verify that the unit operates
through all cycles.

62-11352 3--4
3.4 CHANGING SETPOINT

Press UP arrow key to increase displayed

setpoint.

Press DOWN arrow key to decrease

displayed setpoint.
FAULT STAND-BY

COOL HEAT DEFROST START/STOP IN-RANGE HI AIR

-20.0 +34.5° F
SETPOINT BOX TEMPERATURE

FUNCTION
CHANGE ENTER

UNIT PRETRIP AUTO S/S MANUAL

DATA CHECK DEFROST
CONTINUOUS

Press ENTER key when desired setpoint is

displayed to lock in new setpoint.

New setpoint will flash and then return to original

setpoint if ENTER key is not pressed.

Setpoints of --22_F to +86_F (--30_C to +30_C) may be The setpoint may be changed up or down in whole
entered via keypad. The controller always retains the numbers until the desired setpoint is displayed. The
last entered setpoint in memory. If no setpoint is in display will flash to indicate that the setpoint reading
memory (i.e. on initial startup), the controller will lock out being displayed is a non-entered value. Each time the
the run relay and flash “SP” on the left hand display until UP/DOWN Arrow key is pressed, the 5 second display
a valid setpoint is entered. timer will be reset.
NOTE Pressing the ENTER key will cause the new displayed
The microprocessor configurations allow a min- setpoint value to become active. If the display is flashing
imum and maximum setpoint to be entered, so and the new value is not entered, after 5 seconds of no
that only setpoints within that range may be se- keyboard activity, the display will revert back to the
lected. Refer to Section 7.17.2 for more de- active setpoint.
tailed information on selecting configurations. NOTE
Beginning with software Rev. 3.29 changing
setpoint from the keypad can be locked out by
setting CNF23 to ON. Refer to Section 7.17.

3--5 62-11352
3.5 START--STOP OPERATION

START/STOP

FAULT STAND-BY

START/STOP

-20.0 +34.5° F
SETPOINT BOX TEMPERATURE

FUNCTION
CHANGE ENTER

UNIT PRETRIP AUTO S/S MANUAL

DATA CHECK DEFROST
CONTINUOUS

1. Press the AUTO S/S-CONTINUOUS

toggle key until START-STOP is
displayed. Unit is now in Automatic
Start/Stop mode.
Automatic start/stop is provided to permit The controller will not shut off the engine if the battery
starting/restarting of the diesel-driven compressor as voltage is not sufficient to restart it. Battery voltage
required. This gives the microprocessor automatic above approximately 13.4 volts is required for
control of starting and stopping the diesel engine. The shutdown. This varies depending on ambient. Look at
main function of automatic start-stop is to turn off the battery voltage in data list to find out whether shutdown
refrigeration system near the setpoint to provide a fuel voltage has been reached. If there is a “+” in front of the
efficient temperature control system and then restart number, the voltage is enough to shutdown and restart.
the engine when needed. Start-Stop operation is If only the number appears, the voltage is still too low for
normally used for frozen loads. shutdown.
The unit will remain in low speed for 5 minutes after The controller will restart the engine if any of the
engine start-up. (10 minutes for units with EEPROM following criteria have been met:
prior to Rev. 3.24) If the unit fails to start, shuts down
on a safety, or fails to run for the minimum run time, three SBox temperature has moved away from setpoint by
consecutive times, the fault light will come on. ¦ 11°F (¦ 6.1°C)for setpoints in the perishable range
Low speed Start--up for low coolant temperatures is and +11° F (+6.1°C) for setpoints in the frozen range
available on Configuration 7 (Refer to Table 7-3) for all DURING minimum off time.
units starting with EEPROM REV 3.25. Refer to Section
3.9.1 for unit data. SBox temperature has moved away from setpoint by
The microprocessor controller monitors box ¦(3.6°F (2.0°C) AFTER minimum off time for setpoints
temperature, battery voltage, and engine coolant in the perishable range or +3.6°F (2.0°C) for setpoints
temperature in the frozen range.
Whenever the unit starts in Start--Stop, it will run until: SThe battery voltage drops below 11 Vdc (12.2 VDC for
SIt has run for the predetermined minimum run time. units with EEPROM Rev 3.25 and higher -- Refer to
Section 3.9.1 for unit data)
SThe engine coolant temperature is above 122°F (50°C)
SThe engine coolant temperature drops below 34°F
SThe box temperature is at setpoint.
(1°C).

62-11352 3--6
3.6 CONTINUOUS RUN OPERATION

START/STOP Must Not Be Displayed

FAULT STAND-BY

-20.0 +34.5° F
SETPOINT BOX TEMPERATURE

FUNCTION
CHANGE ENTER

UNIT PRETRIP AUTO S/S MANUAL

DATA CHECK DEFROST
CONTINUOUS

1. Check if START-STOP is displayed. If it

is, press the AUTO S/S-CONTINUOUS
toggle key to place unit in Continuous
Run mode.

In the Continuous Run mode, the diesel engine will run Start-Stop and Continuous operation may be tied to the
continuously providing constant air flow and setpoint ranges for frozen and perishable loads and the
temperature control to the product. The engine will not START-STOP/CONTINUOUS key may be locked out
be allowed to shut off except for safeties if the engine using CNF3 and CNF11. Refer to Section 7.17.
stalls. Continuous Run operation is normally used for
The unit will remain in low speed for 10 minutes if it is in
perishable loads.
frozen continuous mode. If CNF19 is ON, the low speed
startup is 5 minutes.

3--7 62-11352
3.7 MANUAL DEFROST

DEFROST Indicator

FAULT STAND-BY

DEFROST

-20.0 +34.5° F
SETPOINT BOX TEMPERATURE

FUNCTION
CHANGE ENTER

UNIT PRETRIP AUTO S/S MANUAL

DATA CHECK DEFROST
CONTINUOUS

1. Check that box temperature

is 40_F (4.4°C) or lower.
2. Press the MANUAL DEFROST key to
initiate Manual Defrost.

NOTE The defrost mode terminates when the evaporator

Defrost cannot be started when the Evaporator temperature is higher than 55°F (12.8°C). Should the
Coil temperature is above 40°F (4.4°C). defrost cycle not complete within 45 minutes, the defrost
cycle is terminated.
The defrost mode may be initiated in three different
ways if the evaporator coil is below 40°F (4.4°C): After the 45 minute termination, the controller will wait
1.5 hours before attempting another defrost cycle.
1. Defrost is initiated automatically at preset intervals Pressing the manual defrost key will override this mode
by the defrost timer in the microprocessor. and start a defrost cycle.
2. Defrost is initiated by the defrost air switch. If a shutdown alarm occurs, defrost will be terminated.
3. The defrost mode may be manually initiated by
pressing the Manual Defrost Key.

62-11352 3--8
3.7.1 Automatic Defrost The Defrost Timer is reset to zero whenever a defrost
The defrost mode may be automatically initiated by cycle ends (regardless of how it was initiated), and
either of the following two devices when the evaporator begins counting down until the next defrost cycle.
coil temperature (DTT2) is below 40°F (4.4°C): Total defrost cycle time is monitored by the
microprocessor. Once the unit has been in a defrost
a. Defrost Interval Timer cycle for 45 minutes, this timer will terminate the defrost
The defrost interval for the Defrost Timer is set in the cycle, and allow the unit to heat or cool as needed to
maintain temperature control.
Functional Parameter List. Refer to Section 3.8.1.
When a Defrost Cycle is initiated by any method, the Should the defrost cycle not complete within 45 minutes
or if the external defrost signal does not clear at defrost
timer is reset to zero, and will not begin counting until the termination, the defrost cycle shall be terminated. The
defrost cycle has terminated. internal timer will reset for 1.5 hours and the external
When the Start/Run--Off Switch is in the off position, the defrost signal will be ignored for defrost initiation. The
defrost timer will be reset to zero. manual defrost switch will override this mode and start a
new 45--minute cycle. When defrost override is active,
b. Defrost Air Differential Switch the appropriate alarm will be indicated. If the run relay is
de--energized during defrost, defrost will be terminated.
The Defrost Air Differential Switch measures the
difference in air pressure entering the evaporator
against the pressure of the air leaving the evaporator. A TIP
build up of ice will cause the difference to increase. The Manual Defrost Key can be used at any
Once the pressure difference increases to the setting of time to start a Defrost Cycle provided that the
the switch, the contacts will go closed, and initiate a evaporator coil temperature is at or below 40°F
defrost cycle, providing that the evaporator coil (4.4°C).
temperature is at or below 40°F (4.4°C).

NOTE
Refer to Section 5.5 for more detailed informa-
tion on Automatic Defrost.

3--9 62-11352
3.8 FUNCTIONAL PARAMETERS

1. Press FUNCTION CHANGE key until

Function to be changed is displayed.
2. Press ENTER key.

FAULT STAND-BY

DEFROST

DEFR 12.0H
SETPOINT BOX TEMPERATURE

FUNCTION
CHANGE ENTER

UNIT PRETRIP AUTO S/S MANUAL

DATA CHECK DEFROST
CONTINUOUS

3. Press either ↑ UP or ↓ DOWN ARROW key

until desired Function setting is displayed.
NOTE: Function changes will change operation
of unit.
4. Press the ENTER key to lock in new setting.

NOTE pressed and held for one second, the list will be
advanced one item at a time. This list will be circular,
The ability to change functional parameters meaning once the end of the list is reached the list will go
from the keypad can be locked out using a to the first entry. While the functional parameter is
combination of CNF3 and CNF11. Refer to displayed, the data can be changed by pressing ENTER
Section 7.17 for more detailed information. then pressing either the UP or DOWN Arrow keys. If the
The functional parameters will control selected value is changed, the displayed data will then flash to
operating features of the unit. These parameters can be indicate that the value has not been entered. If the new
displayed by pressing the FUNCTION CHANGE key. All value is not entered in 5 seconds, the display will revert
functional parameters are retained in memory. The back to the last entered value. If the ENTER key is
following sections describe the list of functions which pressed, the display will stop flashing to indicate that the
can be modified via the keypad. A description of the value has been entered. The new value will continue to
function will be displayed on the left side with the be display for 5 seconds before reverting back to the
corresponding data on the right side. The function default display. Each time a key is pressed, the 5 second
parameter list can be scrolled through by pressing the delay will be reset. To select a different functional
FUNCTION CHANGE key or by using the UP/DOWN parameter the FUNCTION CHANGE key must be
Arrow keys. With each FUNCTION CHANGE key push, pressed first.
the list will be advanced one. If the function key is

62-11352 3--10
3.8.1 FUNCTIONAL PARAMETERS Manual Glow Override
The following table has columns for Code and English The auto start glow time can be manually overridden
displays. English is the default setting. Change through this function. The messages is displayed as
Functional Parameter to Code to see Code display NORM GLOW or ADD GLOW. If the ADD GLOW
format. selection is entered, the control will add 30 seconds of
glow to the pre--heat times listed in Table 4-1. This
feature must be selected before pre--heat cycle begins.
Table 3-1. Function Codes At ambients above 77° F (25°C), this override will only
CODE ENGLISH DATA affect the second or third start attempt. The “ADD
GLOW” time is deselected when the current engine start
FN0 DEFR Defrost Time Interval sequence is finished. This parameter will not change
FN1 ON HIGH AIR High Air Flow due to the Code vs English selection.
FN1 OFF NORM AIR Normal Air Flow Defrost Interval
Start--Stop The defrost interval is displayed with the description
FN2 OFF T DEFR or FN0. The data for the interval will be displayed
Minimum Off-time
with one decimal place and then the capital letter H for
Start--Stop hours (i.e. DEFR 12.0H). The defrost intervals are 1.5,
FN3 ON T
Minimum On-time 3, 6 or 12 hours.
REM Controlling Probe - Airflow
FN4 A
PROBE Return Air
The status of the speed control solenoid override is
SUP Dual Controlling Probe - displayed as HIGH AIR or NORM AIR. The code display
FN4 B
PROBE Return and Supply Air is FN1. The high air setting is “ON” and the NORM AIR
Degrees Temperature Unit setting is “OFF.” If the display shows HIGH AIR, the unit
FN5 is locked into high speed.
F or C Displayed in _C or _F
TIME Off-Time
FN6 ON Maximum Off-Time 30 Min The off-time selection for the auto start mode is
STRT
displayed with the description OFF T or FN2. The
Temperature and Minimum off-times are 10, 20, 30, 45 or 90 minutes. The data for
TEMP Off-Time Based the off-time will be displayed with two digits and then the
FN6 OFF
STRT Restarting For AutoStart/- capital letter M for minutes (i.e. OFF T 20M).
Stop
On-Time
FN7 MOP STD Unloader Control
The on-time selection for the auto start mode is
FN10 ON AUTO OP Auto Start Operation displayed with the description ON T or FN3. The on-time
FN10 OFF MAN OP Manual Start Operation is 4 or 7 minutes. The data for the on-time will be
displayed with two digits and then the capital letter M for
FN11 T RANGE Out-of-Range Tolerance minutes (i.e. ON T 4M).
Code vs English -- Code vs. English display format Controlling Probe
Manual Glow Override -- Normal or add 30 sec The number of controlling probes is displayed with the
Alarm Reset -- Alarm reset or no alarms following abbreviations: REM PROBE selects the
return air sensor as the controlling probe. SUP PROBE
Code Vs English Messages sets the supply air probe for all setpoints above +11°.
For setpoints of +10° or below, the unit will always
The description for messages of the functional control on return air regardless of selection. The code
parameters, unit status and alarms can be displayed in display is FN4. The 1-probe setting is “A” and the
English or Codes through this function selection. The 2-probe setting is “B.”
two choices will be displayed as, ENGLISH or CODES.
With this parameter set to CODES, all display Standard Units Select
descriptions will be set to their code display. This The standard unit selects how all parameters are
parameter will not change due to this selection. Refer to displayed. The two choices are DEGREES F and
each section for the alternate display description. DEGREES C. This parameter also controls whether
pressure data is displayed in psig or bars. The code
display is FN5. The selections are “F” or “C”.
Maximum Off Time
The descriptions for the maximum off time are TEMP
STRT OR TIME STRT. The code display is FN6 and the
selections are “ON” or “OFF.” “ON” corresponds to
TIME STRT. With the unit in time start, the control will
force the engine to restart 30 minutes after shutoff.

3--11 62-11352
MOP STD Out-of-Range Selection
This function code allows the standard MOP equations The out-of-range temperature tolerance selection is
to be offset by a fixed pressure amount. The displayed with the description T RANGE or code FN11.
descriptions are MOP STD, MOP-- AND MOP+. The The selection are 2, 3, or 4. These selections are the
display is FN7 and the selections are 0, +4 and --5. The temperature values in degrees C.
MOP+ is equal to +4 psig (0.3 Bar). The MOP-- is equal Alarm Reset
to --5 psig (0.3 Bar).
Alarms can be reset through this function. The
Start Mode Selection messages are displayed as ALARM RST or ALARM
The selection for starting the unit are displayed AUTO CLR. If ALARM RST is displayed there is at least one
OP (code FN10 ON) for auto start operation or MAN OP alarm present. Pressing the enter key will clear all
(code FN10 OFF) for manual start operation. alarms. There are no alarms present if ALARM CLR is
displayed. This parameter will not change due to the
To start the unit in manual start mode, the START/STOP code vs. English selection.
CONTINUOUS selection must be in “continuous run”
mode.

62-11352 3--12
3.9 UNIT DATA

FAULT STAND-BY

COOL

SUCT 25P
SETPOINT BOX TEMPERATURE

FUNCTION
CHANGE ENTER

UNIT PRETRIP AUTO S/S MANUAL

DATA CHECK DEFROST
CONTINUOUS

1. Press UNIT DATA key to

scroll thru data list one item
at a time.

2. To scroll through the list faster,

use the UP or DOWN
ARROW keys.

3. Data will display for 5 seconds

4. Press the ENTER key to

display data for 30 seconds.

The UNIT DATA key can be used to display the unit will change at a rate of one item every 0.5 seconds. This
operating data values. The data values will be displayed list will be circular, meaning once the end of the list is
for 5 seconds and then the display will revert back to the reached the list will go to the first entry. Each time the
normal display if no further action is taken. The following UNIT DATA key or the UP/DOWN Arrow key is pressed,
sections describe the list of data which can be displayed the display time will be reset to 5 seconds. If the ENTER
via the keypad. The description of the data will be key is pressed, the display time will be set to 30
displayed on the left side with the actual data on the right seconds. The position in the unit data list will remain at
side. The unit data list can be scrolled through by the last selected value except if power is removed. If the
pressing the UNIT DATA key. With each successive key display were to time out and revert to the default display,
push, the list will be advanced one. If the UNIT DATA, the operator would only have to press the UNIT DATA
UP or DOWN Arrow key is held for one second, the list key to display the same data again.

3--13 62-11352
3.9.1 UNIT DATA Return Air Temperature
The following table has columns for Code and English The return air temperature is displayed with the
displays. English is the default setting. Change description RAS or CD4 on the left hand side. The data
Functional Parameter to Code to see Code display is displayed with one decimal place and the proper unit
format. designator, Degree C or Degree F (i.e. RAS 85.0F). The
display range is --36_F to 158_F (--38_C to 70_C) in 0.5°
increments.
Table 3-2. Unit Data Codes
CODE ENGLISH DATA Supply Air Temperature
CD1 SUCT Suction Pressure The supply air temperature is displayed with the
description SAS or CD5 on the left hand side. The data
CD2 ENG Engine Hours is displayed with one decimal place and the proper unit
CD3 WT Coolant Temperature designator, Degree C or Degree F (i.e. SAS 85.0F). The
display range is --36_F to 158_F (--38_C to 70_C) in 0.5°
CD4 RAS Return Air Temperature increments. This unit data will be displayed only if the
*CD5 SAS Supply Air Temperature SUP PROBE is selected in the controlling probe
*CD6 REM Remote Air Temperature functional parameter. If the probe is bad the display will
read ------ for the data.
CD7 ATS Ambient Air Temperature
Remote Air Temperature
CD8 ------ Not Used
The remote air temperature is displayed with the
Compressor Discharge description REM or CD6. The data is displayed with one
CD9 CDT
Temperature decimal place and the proper unit designator, Degree C
CD10 BATT Battery Voltage or Degree F (i.e. REM 85.0F). The display range is
--36_F to 158_F (--38_C to 70_C) IN 0.5_ increments.
CD11 SBY Standby Hours This unit data will be displayed only if the REM PROBE
CD12 MOD V Future Expansion is selected in the controlling probe functional parameter.
CD13 REV Software Revision If the probe is bad the display will read ------ for the data.
CD14 SERL Serial Number Lower Ambient Temperature
CD15 SERU Serial Number Upper The ambient temperature is displayed with the
description ATS or CD7. The data is displayed with one
CD18 MHR1 Maintenance Hour Meter 1 decimal place and the proper unit designator, Degree C
CD19 MHR2 Maintenance Hour Meter 2 or Degree F, (i.e. ATS 85.0F) . The display range is
CD20 SON Switch On Hour Meter --36_F to 158_F (--38_C to 70_C) in 0.5° increments. If
there is no sensor, then the display will read ------ for the
* Codes 5 & 6 are variable. SAS is displayed when data.
the SUP Probe Function is selected. REM is dis-
played when the REM Probe Function is selected. Evaporator Temperature Display
(See Functional Parameter List in Section 3.8.1.) This data is not applicable for this unit. The code display
is CD8.The display will always show dashes (------).
Suction Pressure
Compressor Discharge Temperature
The suction pressure is displayed with the description
SUCT or CD1. The data is displayed with either integer The discharge temperature is displayed with the
resolution (psig) or tenths resolution (relative bars). (i.e. description CDT or CD9. The data is displayed with the
SUCT 25P). The display will read out in inches of mercury proper unit designator, Degree C or Degree F, (i.e. CDT
for readings below 0 psig. The display range is --20 HG to 85F) . The display range is --40_F to 392_F (--40_C to
420 psig (--0.7 Bars to 29.4 Bars). 200_C). If there is no sensor, then the display will read
------ for the data.
Engine Hours
Battery Voltage
The number of diesel engine hours is displayed with the
description ENG or CD2 on the left hand side. The data The battery voltage is displayed with the description
is displayed with integer resolution and units designator BATT or CD10. The data is displayed with one decimal
H (i.e. ENG 5040H OR CD2 5040H). The display range place and then the capital letter V for volts (i.e. BATT
is 0 to 99999. 12.2V or CD10 12.2V). The voltage reading is displayed
with a “+” plus sign if the battery status is high enough to
Engine Temperature allow unit shut down in “Auto Start/Stop”.
The coolant temperature is displayed with the Standby Hours -- Not Applicable
description WT or CD3. The data is displayed with the
proper unit designator (Degree C or Degree F (i.e. WT This data is not applicable for this unit. The display is
185F or CD3 185F). The display range is --58_F to SBY or CD11.
266_F (--50_C to 130_C).

62-11352 3--14
Mod V -- Future Expansion 3 RA -- Not Applicable
This unit data is not used at this time. The Code display This data is not applicable for this unit. The display is
is CD12. 3RA or CD17.
Software Revision Maintenance Hour Meter 1
The Eeprom software revision number is displayed with The maintenance hour meter 1 setting is displayed with
the description REV or CD13 on the left and Eeprom the description MHR1 or CD18. The maintenance hour
software revision number on the right side. Pressing the meter is compared to one of the hour meters (diesel,
ENTER key for 3 seconds will display REV U2 or CD13A standby, or switch on) determined by its mode. If the
on the left and the board mounted software revision hour meter is greater than the maintenance hour meter
number on the right side. an alarm will be generated. The display is MHR1.
Serial Number Low Maintenance Hour Meter 2
The low serial number of the unit is displayed with the The maintenance hour meter 2 setting is displayed with
description SERL or CD14. The data is the lower 3 digits the description MHR2 or CD19. The maintenance hour
of the serial number burned into the Eeprom. (i.e. SERL meter is compared to one of the hour meters (diesel,
504 or CD14 504). standby, or switch on) determined by its mode. If the
hour meter is greater than the maintenance hour meter
Serial Number High an alarm will be generated. The display is MHR2.
The high serial number of the unit is displayed with the Switch On Hour Meter
description SERU or CD15. The data is the higher 3
digits of the serial number burned in to the Eeprom. (i.e. The number of switch on hours is displayed with the
SERU 001 or CD15 001). description SON or CD20. The data will be displayed
with integer resolution and units designator H (i.e., SON
2 RA -- Not Applicable 2347H OR CD20 2347H). The available display range
This data is not applicable for this unit. The display is will be 0 to 99999. There will be no space between the
2RA or CD16. designator and the number of hours once the hours are
greater than 9999.

3--15 62-11352
3.10 ALARM DISPLAY AND RESET

1. Press FUNCTION CHANGE key.

FAULT LIGHT

FAULT STAND-BY

COOL

ENG OIL
SETPOINT BOX TEMPERATURE

FUNCTION
CHANGE ENTER

UNIT PRETRIP AUTO S/S MANUAL

DATA CHECK DEFROST
CONTINUOUS

2. Press UP/DOWN arrow

key until ALARM RST
is displayed.

3. Press ENTER to clear alarm. ALARM

CLR will be displayed. (Unit will restart if
alarm condition has been corrected and
unit is in Start/Stop or Auto OP.)
The fault light (FL) is turned on only for alarms that above 0° F. For temperatures below 0° F, each item will
specify it. The default display will be overridden if a be displayed for 10 seconds.
alarm is generated. When an alarm is generated, the
display will alternate the default display (setpoint/air Alternate Alarm Reset
temperature) and the active alarm(s). Each item will be Place START/RUN-OFF switch to OFF position. (Unit
displayed for 3 to 10 seconds, and will continue to scroll
through the list. For 5 seconds or the low temperature can now be restarted after alarm condition has been
alternating interval for ambient temperatures at or corrected.)

62-11352 3--16
The following table has columns for Code and English High Pressure Alarm
displays. English is the default setting. Change The high pressure alarm is displayed with the
Functional Parameter to Code to see Code display description HI PRESS or AL2. This alarm is generated if
format. the high pressure switch opens. The fault light (FL) is
turned on and engine will shut down for a minimum of 2
Table 3-3. Alarm Display minutes. This 2--minute timer can be overridden by
turning power off and back on. The alarm will reset when
CODE ENGLISH ALARM DESCRIPTION the control power is cycled as long as the high pressure
AL0 ENG OIL Low Oil Pressure switch has reset, or high pressure has fallen below
350±10 psig (23.8 Bar).
High Coolant
AL1 ENG HOT Temperature Auto Start Failure Alarm
AL2 HI PRESS High Pressure The auto start failure alarm is displayed with the
description STARTFAIL or AL3. This alarm is generated
AL3 STARTFAIL Auto Start Failure if the engine fails to start. The fault light (FL) is turned on.
AL4 LOW BATT Low Battery Voltage The alarm STARTFAIL is also generated if the system
AL5 HI BATT High Battery Voltage fails to heat three consecutive times. Once activated for
this condition, the engine will be prevented from starting
AL6 DEFR FAIL Defrost Override until the alarm is cleared or power is cycled on the
AL7 ALT AUX Alternator Not Charging controller.
AL8 STARTER Starter Motor Alarm will not be generated when the unit is defrosting,
AL9 RA SENSOR Return Air Sensor executing pretrip, or when run relay is open, or the
engine not running. If any of these conditions occur
AL10 SA SENSOR Supply Air Sensor while any of the three (3) error timers are running the
Coolant Temperature timers will be cleared.
AL11 WT SENSOR Sensor If function MAN OP (manual start mode) is selected the
High Discharge start failure alarm will be generated if the engine is not
AL12 HIGH CDT Temperature started in 5 minutes.
Compressor Discharge Low Battery Voltage Alarm
AL13 CD SENSOR Temperature Sensor The low battery voltage alarm is displayed with the
AL15 FUSE BAD Fuse Blown Or Dirty description LOW BATT or AL4. This alarm is generated
Battery Cables if the battery voltage falls below 10 VDC. The fault light
(FL) is turned on and engine will shut down when:
Check Refrigeration
AL16 SYSTEM CK System • The engine is off and Software Version is greater than
or equal to 3.27 and Auto Start has not started
AL17 DISPLAY Display cranking the engine (Initial Startup or Start/Stop
AL18 SERVICE 1 Maintenance Hour Meter 1 restart) -- The fault light is turned on immediately.
AL19 SERVICE 2 Maintenance Hour Meter 2 • The engine is off and Software Version is greater than
or equal to 3.27 and Auto Start has started cranking
AL20 OUT RANGE  Out-of-range the engine (Initial Startup or Start/Stop restart) -- The
 = FAULT LIGHT ON+ fault light is prevented from turning on for 15 seconds.
If the engine fails to start after 15 Seconds, the fault
Low Oil Pressure Alarm light will turn on immediately if the voltage is still lower
than 10 VDC.
The low oil pressure alarm is displayed with the
description ENG OIL or AL0. This alarm is generated if • Engine Running -- Fault light will turn on if the battery
the control senses low oil pressure under the proper voltage is less than 10 VDC for 5 continuous seconds.
conditions. The fault light (FL) is turned on. Engine will If the battery voltage goes to a value greater than or
shut down. Oil pressure switch must be open for 15 equal to 10 VDC the 5 second timer is reset.
seconds to generate alarm. High Battery Voltage Alarm
High Coolant Temperature Alarm The high battery voltage alarm is displayed with the
The high coolant temperature alarm is displayed with description HI BATT or AL5. This alarm is generated if
the description ENG HOT or AL1. This alarm is the battery voltage is above 17 VDC. The fault light (FL)
generated if the control senses a high coolant is turned on and engine will shut down.
temperature 230 to 240_F (110 to 116_C) for 5 minutes Defrost Override Alarm
or immediately if over 240_F (116_C). The fault light
(FL) is turned on and engine will shut down. The sensor The defrost override alarm is displayed with the
is located on the front of the engine near #4 injector. description DEFR FAIL or AL6. This alarm is generated
if the unit is in a defrost override mode (See Section 5.5).

3--17 62-11352
Alternator Auxiliary Alarm Discharge Temperature Sensor Alarm
The alternator auxiliary alarm is displayed with the The compressor discharge temperature sensor alarm is
description ALT AUX or AL7. This alarm is generated if displayed with the description CD SENSOR or AL13.
the alternator auxiliary signal is not present with the This alarm is generated if the sensor is open or shorted.
engine running and the ALT AUX signal is not present If the CNF2 is setup for no discharge sensor, then the
for any 5 consecutive second period. The fault light (FL) high discharge temperature alarm will be disabled since
is turned on. the discharge temperature determines this alarm.
Starter Motor Alarm SBY Motor -- Not Applicable
The starter motor alarm is displayed with the description This alarm is not applicable for this unit. The display is
STARTER or AL8. This alarm is generated if the starter SBY MOTOR or AL14.
motor input signal is not present with starter solenoid
energized. The fault light (FL) is turned on. Fuse Alarm
Return Air Sensor Alarm The fuse alarm is displayed with the description FUSE
BAD or AL15. This alarm is generated when the FUSE
The return air sensor alarm is displayed with the input is sensed low. The fault light (FL) is turned on. The
description RA SENSOR or AL9. This alarm is engine will shut down.
generated if the return air sensor is open or shorted. The
fault light (FL) is turned on if the unit shuts down Display Alarm
because there is no controlling probe. When no communications exist between the main
board and the display board for 8 seconds, the display
Supply Air Sensor Alarm alarm is generated and the display is DISPLAY or AL17.
The supply air sensor alarm is displayed with the Maintenance Hour Meter 1 Alarm
description SA SENSOR or AL10. This alarm is
generated if the supply air sensor is open or shorted. The maintenance hour meter alarm 1 is displayed with
This alarm will be disabled if the REM PROBE is the description SERVICE 1 or AL18. This alarm is
selected in the controlling probe functional parameter. generated when the designated hour meter is greater
The exception to the SA SENSOR alarm being disabled than maintenance hour meter 1.
is if the REM PROBE is selected and configuration bit Maintenance Hour Meter 2 Alarm
15, UltraFresh 2, is active.
The maintenance hour meter alarm 2 is displayed with
Coolant Temperature Sensor Alarm the description SERVICE 2 or AL19. This alarm is
The coolant temperature sensor alarm is displayed with generated when the designated hour meter is greater
the description WT SENSOR or AL11. This alarm is than maintenance hour meter 2.
generated if the coolant temperature sensor circuit is open Out-of-Range Alarm
or shorted. The out-of-range alarm is displayed with the description
Discharge Temperature Alarm RAS OUT or AL20. This alarm is generated when the
refrigerated compartment is out-of-range Refer to
The compressor discharge temperature alarm is Section 3.8.1. The fault light (FL) is turned on.
displayed with the description HIGH CDT or AL12. This
alarm is generated and unit shuts down if the temperature
is sensed above 310_ F (154.4°C) for 3 minutes. If the
discharge temperature exceeds 350_ F (176.7°C), the 3
minute timer will be overridden and the unit will shut down
immediately. If ambient temperature sensor (ATS) is
greater than 120_F (49_C) the CDT limits are increased
to 340_F (171_C) for 3 minutes. The fault light (FL) is
turned on. The compressor discharge temperature sensor
is located in the center head of the compressor.

62-11352 3--18
System Check Alarm (CNF18 must be On) minute supply temperature greater than return by 5°F
The system check alarm is displayed with the (2.8°C) is not done. With a single probe, the heat and
description SYSTEM CK or AL23 if CNF 18 is On. cool 60 or 120 second suction pressure tests will be
run. If both probes are defective none of this logic is
The SYSTEM CK alarm is generated when any of the executed.
following conditions occur: • If the system transitions to heating mode (not null, not
• If the unit is in cool mode (and not in the UltraFresh 2 defrost), a check that the system is heating properly
or UltraFreeze null or heat bands), and the supply air will be performed. This check will start five minutes
temperature becomes 5°F (2.8°C) higher than the re- after the unit transitions to Heat. The system will be
turn air temperature for five continuous minutes. determined to be heating if SAS is greater than
• If the suction pressure becomes greater than 100 (RAS--1.5°C). The check will be performed as long as
the system continues to operate in Heat. If heating is
psig (6.8 Bar) in heat mode for 60 continuous sec- not detected for one minute the system will shut down
onds for both perishable and frozen setpoints. If the for 15 minutes and the SYSTEM CK alarm will be ac-
suction pressure becomes less than --10.2 inHg tivated. The engine will be allowed to restart after the
(--0.34 Bar) for 120 continuous seconds while the re- 15 minutes expires unless the system has failed to
frigerated compartment is in cool mode and while the heat three times in which case the STARTFAIL alarm
return air temperature for the compartment is greater will also be activated. Once three successive failures
than 0°F (--17.8°C) and the ambient temperature is are detected the engine will not be restarted unless
greater than or equal to 40°F (4.4°C) the alarm will be alarms are cleared or power is cycled on the control.
activated.
• If either the return or supply probe fails only the suc- • The SYSTEM CK alarm logic will not be active while
the unit is in defrost, pretrip, or anytime the run relay is
tion pressure logic will be used to test for the alarm de-energized.
conditions. In case of either probe failing, the 5

3--19 62-11352
3.11 STOPPING UNIT

FAULT STAND-- BY

1. To stop the unit, place the START/RUN -

OFF switch tin the OFF position.

The diesel engine will stop and the microprocessor

controller will turn off. The Microprocessor Main Display
and all indicator LEDs will also turn off.

62-11352 3--20
 SECTION 4 - ENGINE

4.1 AUTO START/STOP OPERATION

Automatic start/stop is provided to permit starting/re-
starting of the diesel-driven compressor as required. 0 - 180 Seconds
This feature fully enables automatic control of the diesel ENGINE
engine starting and stopping. The main function of auto- RUNNING
matic engine cycling is to turn off the refrigeration sys- HEAT
tem near setpoint to provide a fuel efficient temperature HEAT
control system and to initiate a restart sequence after 10 SECONDS &
conditions are met. System shut-off is allowed only if the MAX CRANK
battery condition signal is good (+sign in front of voltage
reading in Unit Data List) and Minimum Run Time has
expired and engine coolant temperature is above 122° F
(50° C). The engine coolant temperature shall override
the minimum off time and out-of-range condition to force
engine restarting when the engine coolant temperature PRE 5 SEC. BUZZER
drops below 34_ F (1_C). A restart will also be initiated if 0 to 30 SECONDS
the battery voltage falls below 12.2 VDC. (11.0 VDC for CRANK
units with EEPROM Rev 3.24 and lower -- Refer to Sec- HEAT
tion 3.9.1 for unit data.) A restart will also be initiated if SECOND
box temperature is more than 11_F (6_C) from set point. AND
THIRD
NOTE
ATTEMPTS
The unit will remain in low speed for 5 minutes 15 Seconds
after engine start-up when: Auto Start/Stop is STOP
at any setpoint or Continuous Run setpoint is 0 - 180 Seconds
below 10_F (--12_C). ENGINE
4.1.1 Start/Stop -- Continuous RUNNING
A key is provided to select between continuous run and HEAT
auto start/stop operating mode. In the continuous run HEAT
mode, the diesel engine will not shut down except for 10 SECONDS &
safeties or if the engine stalls. This function also apply to MAX CRANK
the operation of the electric motor. 5 SEC. BUZZER
4.1.2 Auto Mode Indicator FIRST
ATTEMPT
The “Auto Start/Stop” indicator is lit and ARL light
(8--light bar only) will be on to indicate the start/stop
mode has been selected. 0 to 30 SECONDS
4.1.3 Auto Start Failure PRE
If the unit fails to start, shuts down on a safety, or fails to CRANK
run for the minimum run time, three consecutive times, HEAT
the “Auto Start/Failure” is activated.
4.1.4 Auto Start Sequence
Once the starting conditions are met, the start sequence
will begin by energizing the run relay (RR), and after 5 Figure 4-- 1 Auto Start Sequence
seconds energizing the glow plug relay (GPR) for up to
30 seconds in order to supply power to the air intake
heater. (See Figure 4--1.) The buzzer will sound for 5
seconds, and then the starer will engage. The engine
will crank until the engine is sensed to be running based
on the alternator (D+ signal) or for a maximum of 10
seconds for ambient temperatures above 32° F (0° C)
and 20 seconds for ambient temperatures of
32° F (0° C) or lower. The GPR will remain energized
during the crank time, and will continue to heat for up to 3
minutes (See Figure 4--1). Should the engine fail to
start during the first or second attempt, a 15 second null
cycle will elapse before subsequent start attempts. The
RR will remain energized until the next starting
sequence. The heat time remains the same for all start
attempts.

4--1 62-11352
4.1.5 Variable Pre--Heat Time NOTE for X2 units only:
When the unit has cycled OFF in Start/Stop,
The pre--heat time for the first start attempt will vary in and the ambient air temperature is at, or rises to
duration based on engine coolant temperature and the
engine as follows: +115_F (46_C) HR2 will energize and open the
SV4 valve for 45 seconds to equalize the refrig-
Table 4-1. Pre--Heat Time erant system pressures across the high and low
pressure sides of the system. While the SV4
Pre--Heat Time
in Seconds valve is energized, the Heat Light will also be on
Engine Coolant Temperature (8--Light Bar only) even though the engine is not
Pre Post running.
Heat Heat
Less than 33_F (1.0_C) 30 180 4.1.8 Battery Voltage
33_F to 51_F (1.0_C to 11_C) 20 120 Provisions are made to sense when the battery is good
51_F to 78_F (11_C to 26_C) 10 60 (indicated by a +sign in front of voltage reading in Unit
Data List). A good battery is defined as having 13.4v at
Greater than 78_F (26_C) 0 0 75_F (23.9°C). This condition is used to allow shut- off
of the diesel engine.
If the battery voltage falls below 10v during pre--heat
4.1.6 Minimum On Time cycle, the starter will not engage and the start sequence
will continue, this is considered a failed start. The start
The minimum on-time that the engine will run is 4 or 7 sequence will be repeated until the unit starts or three
minutes. Refer to Section 3.8.1 consecutive start attempts have failed.
After the minimum on-time, the unit will go to 6 cylinder Table 4-2. Battery Voltages
compressor for setpoints greater than 10_F (--12_C)
and high speed 6 cylinder compressor for setpoints of Message Voltage
Description
10_F (--12_C) or less. Display Level
LOW BATT 10 Unit will shut down except
The unit will not cycle off if the engine coolant tempera- AL4 or Less during cranking.
ture is less than 122_F (50_C) or if the battery voltage is
too low. In this case, the unit will operate as if in continu- If the unit has cycled off in auto start/-
ous mode. stop mode and battery voltage drops
below 11.0 volts (12.2 volts for Rev.
If both SAS and RAS probes fail and the setpoint is 10_F 3.25 and higher), the unit is automati-
(--12_C) or less, the unit will continue to run and will not 11 to cally started to charge battery. Unit will
cycle off. 13.4 operate until the battery voltage is suf-
ficient (+sign in front of voltage
The unit will cycle off when the box temperature is within
¦0.5_F (¦0.3_C) of setpoint for setpoints in the Perish- reading in Unit Data List) at
able range or +0.5_F (+0.3_C) above setpoint (or lower) which level unit will stop if tempera-
for setpoints in the Frozen range. tures are satisfied.
HI BATT 17
4.1.7 Minimum Off-Time Unit will shut down.
AL5 or more
Keypad provision is provided to select the minimum off--
time of 10, 20, 30, 45 or 90 minutes. Refer to Section 4.1.9 Oil Pressure Signal
3.8.1 When the oil pressure switch is closed it shows that the
engine is running and prevents engagement of the start-
After the minimum off-time, the unit will restart for box er motor when operating in the auto mode. (Refer to
temperatures beyond ¦3.6_F (¦2.0_C) of setpoint for Section 2.3 for oil pressure switch settings.)
the Perishable range or above +3.6_F (+2.0_C) of set-
point for the Frozen range. 4.1.10 Maximum Off-Time
Provision for a keypad selectable feature is provided
The minimum off-time is overridden if the temperature which will cause the engine to be started 30 minutes af-
is more than ¦11_F (¦6_C) from setpoint in the perish- ter the engine has stopped regardless of the box tem-
able range or +11_F (+6_C) in the frozen range. perature. Refer to Section 3.8.1

62-11352 4--2
 SECTION 5 - TEMPERATURE CONTROL
5.1 HEAT/COOL MODE 5.1.2 Heating
The system is configured for cooling mode during en- NOTE
gine start and during the 15 second oil pressure delay.
Whenever the unit shifts to heat or defrost, HR1
Hot gas heating is applied by energizing the HR1 and HR2 and HR2 energize simultaneously. When switch-
relays which will energize the hot gas and condenser pres- ing from heat (or defrost) to cool, HR1 de-ener-
sure control solenoids. These relays will also control the
remote heat and cool lights (8--Light Bar only). gizes 2 seconds before HR2. This allows time for
SV1 to open and clear the condenser of liquid be-
For UltraFreeze Refer to Section 4.12.
fore SV4 closes. This will eliminate any high pres-
5.1.1 Cooling sure buildup which could occur. During this time,
There are two control ranges, Frozen and Perishable. only on a remote 8--light bar, the heat and cool
The Frozen range is active with set points at or below lights will be on together. The heat and cool dis-
+10_F (--12_C) and the Perishable range is active at set play on the control panel change immediately.
points at or above +11_F (--11_C).
The controller automatically selects the mode(s) neces-
sary to maintain box temperature at set point. NOTE for X2 units only:
Refer to Section 4.11 for description of UltraFresh 2. When the unit has cycled Off in Start/Stop, and
If the unit is in high speed loaded cool, the microproces- the ambient air temperature is is at, or rises to
sor will provide --12 VDC (ground) terminal 38 to ener- +115_F (46_C) HR2 will energize and open the
gize the speed relay. A set of normally open contacts SV4 valve for 45 seconds to equalize the refrig-
(SR) close to energize the speed control solenoid erant system pressures across the high and low
(SCS). The engine will be in high speed.
pressure sides of the system. While the SV4
When the unit is running in high speed loaded cool and valve is energized, the Heat Light will also be on
with the evaporator coil temperature below 40_F (8--Light Bar only) even though the engine is not
(4.4_C) to close at least one defrost termination thermo-
stat, a pre-trip may be initiated by depressing the PRE- running.
TRIP key. The operator now may verify the pre-trip se-
quence. (Refer to Section 3.3) Refer to Section 2.16 for description of heating cycle.
As the trailer temperature falls toward set point, the mi-
croprocessor will place the unit in low speed loaded Refer to Section 4.12 for description of UltraFreeze.
cool. The temperature at which this occurs is not fixed
but depends upon the rate at which the trailer tempera- The controller automatically selects the mode(s) neces-
ture is approaching set point. sary to maintain box temperature at set point. The heat-
ing modes are as follows with descending tempera-
The speed relay (SR) de-energizes to open the circuit to tures:
the speed control solenoid (SCS). Engine speed de-
creases from high speed to low speed. (a) Low Speed Unloaded Heating, (b) Low Speed
Loaded Heating, (c) High Speed Loaded Heating
As the trailer temperature falls closer to set point, the
controller will shift the operation from low speed loaded The controller will shift the unit into low speed unloaded
cool to low speed unloaded cool to further reduce heat when the trailer temperature falls below set point
cooling capacity. To do this, the microprocessor will (compressor in four cylinder heating). The
provide --12 VDC (ground) to terminals 57 or 57 & 56, microprocessor will provide --12 VDC (ground) to
completing the ground path for the unloader relays terminals 37, 55 and 57 to complete the ground paths
(UFR & URR). The coils energize to close the UFR & for the heat relays (HR1 and HR2) and unloader front
URR contacts. One or both unloaders (UF and UR) may relay (UFR). When these relays energize, several
energize to unload the compressor (Refer to Section things happen. This opens the (N.C.) contacts to the
5.9). cool light on an 8--light bar and solenoid valve (SV2).
With decreasing temperature, the unit will shift to low SV2 now operates in conjunction with the head pressure
speed unloaded heat Refer to Section 4.12. control switch (HP2). (Refer to section 2.16)
Unit will remain in various stages of heating until the box Also, HR1 closes a set of normally open contacts to en-
temperature increases enough to place the unit in the ergize solenoid valve SV1 to close the condenser outlet
low speed unloaded cool mode. As the box temperature line.
increases, the unit will shift to low speed loaded cool ,
and then to high speed cool mode (speed relay ener- When the unloader front relay (UFR) energizes, a set of
gizes). N.O. contacts (UFR) close to energize the compressor
front unloader (UF). Compressor will be in four cylinder
NOTE heating.
High Speed Cool is locked out for 10 minutes af-
ter switching from Null to Cool, or from High Energizing HR2 closes two sets of N.O. contacts. Sole-
noid SV4 energizes and opens to allow hot refrigerant
Speed Cool to Low Speed Cool, when CNF15 is vapor to enter the evaporator (section 2.16). The other
ON (UltraFresh II enabled). There is no delay set of HR2 contacts supply power to the heat light on an
when CNF15 is OFF. 8--light bar.

5--1 62-11352
If more heating capacity is required, the unit will shift to NOTE
low speed 6 cylinder (fully loaded) heating. The High speed heat is locked out for 1 minute after
microprocessor will remove the --12 VDC voltage switching from cool to heat, when CNF15 is ON
(ground) to the UF Relay to de-energize the front
unloader relay, which in turn, de-energizes the (UltraFresh II enabled). High speed heat is
compressor unloaders (compressor shifts from four locked out for 5 minutes after switching from
cylinder to six cylinder operation). cool to heat, when CNF15 is OFF.
When maximum heating capacity is required, the unit
will shift to high speed loaded heat. The microprocessor
energizes the HR1, HR2, and speed relay (SR) coils.
Terminals 37, 55 and 38 will be pulled low. The only
change from the low speed loaded heat mode is that the
speed relay is now energized. SR contacts close to en-
ergize the speed control solenoid (SCS). The engine will
be in high speed.

62-11352 5--2
 NOTE
The following temperature control operating sequence diagrams are after pulldown and do not show over-
rides.

RISING BOX
TEMPERATURE
High Speed
6 Cylinder Cool +3.6_F ( +2.0_C )
+3.2_F (+1.8_C ) Low Speed
4 Cylinder Cool +2.7_F (+1.5_C )
+2.3_F (+1.3_C ) Low Speed
2 Cylinder Cool +1.8_F (+1.0_C )
+1.4_F (+0.8_C ) Low Speed
2 Cylinder Null
Cool/Null Pulses)
Setpoint Setpoint
Low Speed
2 Cylinder Null
(Null/Heat Pulses)
-1.4_F (-0.8_C)
-1.8_F (-1.0_C) Low Speed
4 Cylinder Heat
-2.3_F (-1.3_C )
-2.7_F (-1.5_C ) Low Speed
6 Cylinder Heat
-3.2_F (-1.8_C )
-3.6_F (-2.0_C )
High Speed
FALLING BOX 6 Cylinder Heat
TEMPERATURE

Figure 5-1. UltraFresh II Perishable Setpoint - Continuous Run Temperature Control

5--3 62-11352
 RISING BOX
TEMPERATURE

High / Low Speed

6 Cylinder Cool
+0.6_F (+0.3_C )
+0.2_F (+0.1_C )
Low Speed Setpoint
Setpoint Auto S/S Control Point
6 Cylinder Cool --0.3_F (-0.2_C)
-0.7_F (-0.4_C) Low Speed
2 Cylinder Cool -1.2_F (-0.6_C)
-1.5_F (-0.8_C) Low Speed
2 Cylinder Null
(Cool / Null Pulse)
Setpoint --3.0_F (--1.7_C )
Cont. Run Control Point
-3.2_F (-1.8_C )
-3.6_F (-2.0_C )
Low Speed
2 Cylinder Null
(Cool / Null Pulse)
-4.4_F (-2.5_C )
-4.8_F (-2.6_C )
Low Speed
4 Cylinder Heat
FALLING BOX
TEMPERATURE

Figure 5-2. UltraFreeze - Start/Stop And Continuous Run Temperature Control

62-11352 5--4
 Low Speed 6 Cylinder RISING BOX
Cool TEMPERATURE
High Speed
6 Cylinder Cool +3.6_F ( +2.0_C ) *

+2.0_F (+1.8_C ) +2.0_F (+1.1_C )

+1.5_F (+0.8_C ) Low Speed

2 Cylinder Cool
+0.5_F (+0.3_C )
Start/Stop Off Cycle
Setpoint Setpoint
Start/Stop Off
Cycle -0.5_F (-0.3_C)
-1.0_F (-0.5_C )
-1.5_F (-0.8_C)
Low Speed Low Speed
6 Cylinder Heat 4 Cylinder Heat
-3.2_F (-1.8_C )
-3.6_F (-2.0_C ) *
High Speed Low Speed
FALLING BOX 6 Cylinder Heat 2 Cylinder Null
TEMPERATURE Cool/Null Pulses)
* During the minimum off time the unit will restart at the override temperature selected in the
functional parameter list.

Figure 5-3. Start-- Stop - Perishable Temperature Control Operating Sequence During
Minimum Run Time

RISING BOX
TEMPERATURE
High Speed +3.6_F ( +2.0_C ) *
6 Cylinder Cool
+2.5_F (+1.4_C )

+2.0_F (+1.8_C ) Low Speed 6

Cylinder Cool
+0.5_F (+0.3_C ) Start/Stop Off
Cycle
Setpoint Setpoint
Start/Stop Off
Cycle -0.5_F (-0.3_C)
Low Speed
6 Cylinder Heat
-1.5_F (-0.8_C )

-2.0_F (-1.1_C) Low Speed

High Speed 6 Cylinder Heat
-3.6_F (-2.0_C ) * 6 Cylinder Heat
FALLING BOX
TEMPERATURE

* During the minimum off time the unit will restart at the override temperature selected in the
functional parameter list.

Figure 5-4. Start-- Stop - Perishable Temperature Control Operating Sequence After
Minimum Run Time

5--5 62-11352
5.2 ULTRAFRESH 2 TEMPERATURE CONTROL 5.2.1 Heat/Cool/Null Switching Operation
(CNF 6 must be set to OFF and CNF 15 must
be set to ON) There are three possible modes for UltraFresh 2 control
temperatures. These are Heat, Cool and Null. When not
UltraFresh 2 is an advanced method of temperature in pulldown, UltraFresh 2 controls the unit based on the
control for both Perishable and Frozen ranges. It pro- following: (Refer to the temperature control operating
duces a reduced capacity state by mixing heating and sequence diagrams).
cooling modes (Pulsed Null Mode). Configuration (CNF a.On a temperature pull down toward set point, the sys-
15) must be set to ON and the unit must be operating in tem will exit COOL and enter NULL at 1.4°F (0.8°C)
Continuous Run for UltraFresh 2 to operate. above setpoint.
UltraFresh 2 uses both the supply and return air sensors b.Should the box temperature begin to rise, the system
to control compartment temperature. will exit NULL and go back to COOL at 3.6°F (2.0°C)
above set point.
UltraFresh 2 only operates when set point is in the
perishable range above10_F (--12_C) and the unit is set c.On a temperature pull up toward set point, the system
for continuous run operation. will exit HEAT and enter NULL at 1.4°F (0.8°C) below
set point.
The sensor that is selected under the Functional d.Should the box temperature begin to drop, the system
Parameters for the temperature control is known as the will exit HEAT and enter NULL at 1.8°F (1.0°C) below
“Selected Probe.” This is the probe that will be used to set point.
determine when the temperature is at setpoint.
5.2.2 Null Band Operation
The “Active Probe” is the sensor actually used by the Null Band consists of:
microprocessor to perform the temperature control. It is
the same as the “Selected Probe,” unless that sensor is a. Pulsed Null Mode Operation
not installed or is defective or if supply is the selected Reduced capacity is produced between the Heat and
probe in Frozen Range. Cool Modes by a mode known as Pulsed-Null. This
mode is not a constant operating mode, but only
SELECTED PROBE ACTIVE PROBE operates for a few seconds at a time. During
Pulsed-Null, the heat and cool valves are opened
Return Air Sensor Return Air Sensor (only) simultaneously to reduce either the heating or cooling
Supply Air Sensor (for set- capacity. In the Null Band (Refer to the following charts),
points in the Perishable the unit will pulse between Cool and Null, or Heat and
Supply Air Sensor Range) Null in 10 second increments. The capacity in the Null
Return Air Sensor (for set- Band is varied by adjusting the pulse rate.
points in the Frozen Range) When in the null mode the HEAT and COOL LCDs on
the microprocessor display will blank out. The heat and
cool lights (on 8--light bar) will flash back and forth
In the case of a bad probe, the remaining probe will be approximately every 10 seconds. Only the Green LED
used for temperature control. will be lit on the two--light bars.

62-11352 5--6
 • Cool Mode
SV1 SV2 SV4 Engine
(HR1 De--Energized) (HR4 De--Energized) (HR2 De--Energized) Speed UL1 UL2
OPEN OPEN CLOSED LOW UNLOAD UNLOAD
• Null Mode
SV1 SV2 SV4 Engine
(HR1 De--Energized) (HR4 De--Energized) (HR2 Energized) Speed UL1 UL2
OPEN OPEN OPEN LOW UNLOAD UNLOAD
• Heat Mode
SV1 SV2 SV4 Engine
(HR1 Energized) (HR4 Energized) (HR2 Energized) Speed UL1 UL2
OPEN / CLOSED BY
CLOSED HP2 OPEN LOW UNLOAD UNLOAD

Pulsed Null Mode operation will modify the length of 5.4 CARGO PROTECT MODE
each Mode in 10 second cycles. That is, if the unit is in
the Cool Null Pulse band, the unit may run in Cool for up When both the return air sensor (RAS) alarm and the
to nine seconds, then Null for one second, if the Control supply air sensor (SAS) alarm are active, the unit will
Temperature is away from setpoint. As the Control enter Cargo Protect Mode for temperature control.
Temperature comes closer to setpoint, the length of When the setpoint is in the frozen setpoint range, the
Cool time will decrease, and the amount of Null time will unit will run low speed loaded cool. In the perishable
increase. However, the combination of the two will setpoint range, the unit will shutdown. (See Section
always equal 10 seconds. The same is true for the Heat 5.1.1 for definition of perishable & frozen setpoints).
Null band. 5.5 DEFROST CYCLE
NOTE
5.3 ULTRA FREEZE TEMPERATURE CONTROL The unit will be in high speed in defrost mode.
(CNF 6 must be set to OFF and CNF5 and
CNF 17 must be set to ON) If both defrost thermostats (klixons) are open (no volt-
age at 31), defrost cannot be initiated by any means. (A
few models may have only one DTT).
NOTE Defrost is an independent cycle overriding cooling and
In high ambient temperatures [120_F (48.9°C) heating functions to de-ice the evaporator as required.
and above], the unit will operate only in Low The controller displays “DF” during defrost mode on the
Speed. right hand temperature display. The left hand display will
continue to display the setpoint.
In defrost the microprocessor provides a --12 VDC
For frozen setpoints, a modified UltraFresh 2 (ground) to terminals 37 (HR2), 55 (HR1), and 38 (SR)
temperature control is used to keep the unit from over to shift the unit into high speed heat. The processor also
cooling and driving the box temperature far below provides a --12 VDC (ground) to terminal 53 (DR) . This
setpoint. UltraFreeze operates the same as UltraFresh closes the N.O. defrost relay contacts to energize the
2 except as noted in this section. UltraFreeze control will defrost light on the remote 8--light bar. The defrost and
be used anytime a frozen setpoint is selected in both heat LEDs on the keypad display will also be illuminated.
continuous and start/stop operation.
Additionally, the N.C. defrost relay contacts open to
While UltraFreeze is active the Ultra Fresh 2 unloader de-energize the clutch (CLH) to stop the evaporator fan.
cooling logic is not used. Defrost will continue and does not terminate until the
microprocessor senses both defrost termination
5.3.1 Ultra Freeze Offset thermostats [DTT(s)] reach termination temperature
In continuous run a --3_F (--2.4°C) offset is added which (Refer to Section 2.12) and open, or the compressor
will force the unit to control to 3_F (+2.4°C) below discharge temperature (CDT) reaches 310_ F
setpoint. When the unit calls for high speed cool and the (154.4_C) for 1 continuous minute.
high speed is delayed the unit will be allowed to run 6 If the unit should remain in Defrost for 45 minutes, the
cylinder low speed cool. Fail Safe Defrost Termination logic will stop the Defrost
Cycle (Refer to Section 5.5.3.b.), and put the unit into
5.3.2 Ultra Freeze Start/Stop Cargo Protect mode (Refer to Section 5.4).
In start/stop operation the unit’s control will not have the If the problem corrects itself, (defrost termination
3_F offset and will control to setpoint by cycling the unit thermostats open during a future defrost cycle in less
on and off according to the standard frozen mode than 45 minutes for example), the unit will automatically
start/stop startup and shutdown logic. The exception to resume its normal functions.
this is when a low battery voltage or low engine coolant The defrost mode may be initiated by three different
temperature prevents a normal shutdown when the box ways if the evaporator coil is cold enough for one of the
temperature reaches set point. When the unit is forced defrost klixons (DTT) to be closed (box temperature be-
to continue to run theUltra Freeze logic will control to the low approx. 40_F (4.4°C). (Refer to Section 2.12).
3_F below setpoint offset. These methods are:

5--7 62-11352
5.5.1 Defrost Initiation NOTE
a. Defrost Timer Initiation In addition to loading and unloading the front
A defrost timer initiation is a keyboard selection (Refer unloader based on the suction pressure (Refer
to Section 3.8.1). The Defrost Timer runs and accumu- to section 5.6.2), after the unit has been in the
lates time when the unit is operating, and at least one of Defrost Cycle for more than 90 seconds, the
the DTTs is closed. The timer does not accumulate time
during defrost mode or during auto-start off cycles. The suction pressure will be monitored to help keep
defrost timer is reset to zero whenever a defrost cycle is it from going too high. If the suction pressure
initiated, or the unit is turned off. rises to 57 psig (3.9 Bar), HR1 will de--energize
b. Defrost Air Switch Initiation to open SV1 for one second, then energize
A defrost air switch (DA) is used to initiate a defrost again. The opening of SV1 will decrease the
cycle. The switch has a set of normally open contacts discharge pressure, which will keep the suction
that close to initiate the cycle. pressure lower. This will not occur more than 2
The switch is an air pressure differential switch which times each minute.
measures air pressure differential across the evapora-
tor coil and initiates the defrost cycle when the air pres- 5.5.3 Normal Defrost Termination
sure differential increases enough to close the switch
contacts, such as would happen when excessive frost a. Defrost Termination at Low Speed
builds up on the evaporator coil surface. The defrost cycle terminates with HR1 and speed relay
When the defrost air switch contacts close, there is a de--energizing. This places the engine in low speed,
+12 VDC potential to terminal 33 on the microprocessor. and opens the SV1 solenoid valve. HR2 will turn off 2 se-
The microprocessor looks for voltage at terminal 31. conds later,closing SV4. The defrost relay will de-ener-
Voltage at 31 indicates that at least one defrost gize 5 seconds after HR1 to engage the clutch. If the
termination thermostat is closed. The unit will shift to the temperature control requires high speed, there will be a
defrost mode if voltage is present at both 31 and 33. 2 second delay after the defrost relay is de-energized
c. Manual Defrost Initiation and then the engine will go to high speed.
The defrost cycle may be initiated by pushing the b. Fail Safe Defrost Termination
MANUAL DEFROST key.
Should the defrost cycle not complete within 45 minutes
5.5.2 Normal Defrost Mode (Ambient tempera- or if the defrost air switch contacts do not open at defrost
tures less than 80_F (26.7_C) termination, the defrost cycle is terminated. The internal
The defrost mode may be initiated by either of the three timer is reset for 1.5 hours and the defrost air switch is
methods described above. Once a Defrost Cycle has ignored for defrost initiation. The manual defrost switch
been initiated, Defrost will continue and does not termi- will override this mode to start another defrost cycle.
nate until the microprocessor senses both defrost ter- When defrost override is active, the Defrost Fail alarm
mination thermostats ([DTT(s)] reach termination tem- will be indicated.
perature and open, removing the 12 VDC signal to
terminal 31 of the microprocessor, or the compressor If the run relay is de-energized during defrost (due to a
discharge temperature (CDT) reaches 310_F shut down alarm, or the Start/Run Off Switch being
(154.4_C) for 1 continuous minute. turned off) defrost will be terminated.
The defrost relay is energized during defrost mode
which opens the normally closed contacts of the defrost
relay. This de-energizes the clutch and stops the evapo-
rator fan.
In addition, the speed and heating outputs (SR, HR1 &
HR2) are enabled to apply high-speed heat for hot gas
heating.
The compressor operates at maximum capacity on die-
sel and diesel/electric units during defrost. The suction
pressure signal can force the unloaders to be unloaded.
The compressor will operate on either 4 or 6 cylinders
during the Defrost Cycle depending on suction pres-
sure.

62-11352 5--8
5.5.4 High Ambient Defrost (Ambient Air Temper- Stage 3 (Defrost Termination) is the termination of
ature is Greater Than 80_F (26.7_C) defrost. Defrost will terminate when the microproces-
sor senses both defrost termination thermostats
When the ambient temperature is greater than 80_F [DTT(s)] have reached termination temperature and
(26.7_C) the following stages are performed for defrost open, or the compressor discharge temperature
(Refer to Table 5-1). (CDT) reaches 310_ F (154.4_C) for 1 continuous
minute.
Stage 1 (Pump Down) -- the unit runs in low speed with High Ambient Defrost termination begins with HR1
both unloaders energized and SV1, 2 and 4 de--ener- and HR4 de--energizing, and UFR energizing. This
gized for a minimum of thirty seconds and then opens the SV1 and SV2 valves turns off the Heat
checks the suction pressure. The unit enters Stage 2 Light and turns on the Cool Light (8--light bar), and un-
when the suction pressure is less than 10 PSIG. The loads the Front Unloader. After the suction pressure
unit will enter Stage 2 automatically regardless of has risen by 10 psig, or in a maximum of 15 seconds,
suction pressure after 5 1/2 minutes. the SR and HR2 will de--energize and the engine will
go to low speed, and SV4 will close. URR will ener-
Stage 2 (Defrost). HR1 will be energized to close the gize and unload the Rear Unloader. After 5 seconds
SV1 valve. HR2 will energize to open the SV4 valve, the DR will de-energize to engage the clutch and turn
and turn off the Cool Light and turn on the Heat Light off the Defrost Light (8--light bar). After another 5 sec-
(8--light bar). HR4 will energize to allow HP2 to con- onds the unit will return to normal temperature con-
trol SV2 valve opening and closing. DR is energized trol.
turn on the Defrost Light (8--light bar) and to de--ener-
gize the clutch to stop the evaporator fan. SR will be If the unit should remain in High Ambient Defrost for
energized to put the engine into high speed. The front 45 minutes, the Fail Safe Defrost Termination logic
unloader relay (UFR) will be energized to unload the will stop the Defrost Cycle (Refer to Section 5.5.3.b.),
front unloader. and put the unit into temperature control mode.

Table 5-1. Stages for High Ambient Defrost (Ambient temperature Greater Than 80_F (26.7_C)
SV1 SV2 SV4
STAGE UR UF SPEED
(HR1) (HR4) (HR2)
OPEN CLOSED CLOSED Low
1 Energ Energ
(De-energ) (Energ) (De-energ) De-energ
CLOSED HP2 OPEN High
2 De-energ Energ
(Energ) Control (Energ) Energ
OPEN OPEN OPEN Low
3 De-energ Energ
(De-energ) (De-energ) (Energ) De-energ
De-energ = De-energized Energ = Energized

5.6 UNLOADER OPERATION

5.6.1 Unloading in Temperature Mode There are two modes of unloader operation, tempera-
ture control and suction pressure control.
The compressor is equipped with unloaders (electroni-
cally controlled by the microprocessor) for capacity con-
trol. a. Temperature Control Within 1.4_F (0.8_C)
The capacity controlled cylinders are easily identified by of Setpoint
the solenoid which extends from the upper side of the
cylinder head. When the solenoid coil is energized the 1. Either “COOL” or “HEAT” will be displayed depending
cylinders unload. The unloaded cylinders operate with on the mode of operation. For units with an 8--light
little or no pressure differential, consuming very little bar, the corresponding light will be illuminated.
power. A de-energized solenoid coil reloads the cylin-
ders.
2. If in low speed cooling, unloader relays (UFR, or UFR
NOTES & URR) may energize to unload those compressor
cylinders. Refer to Table 5-2.
1. The unloader relay is locked in for a mini-
mum of 2 minutes once it is energized due
to suction pressure. 3. The heat mode forces the rear unloader (UR) to a
loaded condition (de-energized) for 4 cylinder opera-
2. There is a delay of 30seconds betweende-- tion. In low speed heating, the front unloader relay
energizing one unloader and de-energizing (UFR) may energize to unload the front compressor
the other unloader. cylinders.

5--9 62-11352
 Table 5-2. Unloading in Temperature Mode 5.6.2 Suction Pressure Operation of Unloaders
SETPOINT SETPOINT The microprocessor will monitor suction pressure of the
refrigeration system and control the unloaders to load
AT OR BELOW ABOVE (de--energize) as the suction pressure drops and unload
10_F (--12_C) 10_F (--12_C) (energize) as the suction pressure rises. A suction pres-
Cool High Speed 6 sure transducer is used to signal the microprocessor
when to load or unload the compressor.
Cool Low Speed 4
Cool High Speed 6 During the diesel heating and defrosting cycles, the rear
Cool Low Speed 2 unloader is always loaded, forcing the compressor to
Heat Low Speed 4 operate with at least four cylinders loaded.
Cool Low Speed 6 Heat Low Speed 6 NOTE
Cool Low Speed 4 Heat High Speed 6 The following information applies to all units.
However, the UR and UF in XT and X2 model
will operate with the overrides described earlier
b. Perishable Set Point (+10_F (--12_C) or higher) with a higher priority than this logic.
Cooling Unloader Control (UltraFresh I) (CNF 15
OFF) a. At ambient temperatures of 90_F (32.2_C)
During perishable cooling the unloaders are energized or below:
when the temperature approaches setpoint. If the sup- When the system is operating at high speed and the
ply air temperature probe alarm is not active, the unload- suction pressure is greater than 33 PSIG (2.2 Bar), the
ers are energized when the supply air temperature front unloader is unloaded. As the suction pressure
decreases 5.4_F (3_C) below setpoint. The compressor drops below 64 PSIG (4.3 Bar), the front bank is loaded.
will stay unloaded until the supply air temperature rises
above setpoint. If the supply probe is alarm is active, the
unloaders are energized when the return air tempera- When the system is operating at low speed and the
ture is less than 9_F (5_C) above setpoint. It will stay suction pressure is greater than 35 PSIG (2.4 Bar), the
unloaded until the return temperature rises to more than front unloader is unloaded. As the suction pressure
14.4_F (8_C) above setpoint. The return air probe logic drops below 64 PSIG (4.3 Bar), rear bank is loaded. If
is disabled for ambient temperature higher than 90_F the suction pressure drops below 35 PSIG (2.4 Bar), the
(32.2_C). front bank is loaded.
c. Perishable Set Point [+11_F (--11_C) and higher] b. At ambient temperatures of 90_F (32.2_C) or
Heating Unloader Control higher:
During perishable heating the front unloader is ener- At ambient temperatures of 90_F (32.2°C) or higher the
gized when the control temperature increases to 0.9_F unloading suction pressure settings relative to ambient
(0.5_C) below setpoint. The unloader will stay ener- temperatures for the front unloader decrease as the
gized until the control temperature decreases to 1.5_F ambient temperature increases. (Refer to Figure 5-5.)
(0.8_C) below setpoint.
c. High Ambient Override for XT and X2 Models
NOTE only (CNF 19 ON)
These switch points may vary slightly depend- NOTE
ing on the amount of overshoot around set- XT and X2 model units (REV 3.25 and higher
point. with CNF 19 ON) use the suction pressure
loading & unloading chart (See Figure 5-5) but
d. Frozen Set Point Unloader Control also use the following overrides during unit op-
CNF 17 UltraFreeze On/Off eration:
For units with UltraFreeze (CNF 17) ON Refer to
Section 5.3. 1. For ambient air temperatures above 125_F (52_C),
or if the Ambient Air Sensor is defective, suction
For units with UltraFreeze (CNF 17) OFF during frozen pressure will determine when the Front or Rear Un-
mode, heating is not allowed. The front unloader is loader will load or unload (See Figure 5-5).
energized when the control temperature decreases to
1.5_F (0.8_C) above setpoint. The unloader will stay 2. For ambient air temperatures between 125_F and
energized until the control temperature reaches 2_F 110_F (52_C to 43_C),the Rear Unloader (UR) will
(1.1_C) above setpoint. The box temperature will operate per the suction pressure chart (See
continue to fall below setpoint as long as the unit is Figure 5-5) for the first 30 seconds after the engine
running. starts. After that time, the UR will be de--energized
and loaded, regardless of suction pressure.
NOTE
3. For ambient air temperatures below 110_F (43_C)
The front cylinder can only be unloaded during the Rear Unloader (UR) will be de--energized regard-
frozen mode. less of suction pressure, while the engine is running.

62-11352 5--10
 R-404A REFRIGERATION SYSTEM
DIESEL OPERATION
SUCTION PRESSURES UNLOADING
70
65
LOW SPEED (UR)
60
55 HIGH
SPEED
50 (UR)
45
SUCTION
PRES- 40 LOW SPEED (UF)
SURE 35
(PSIG)
30
HIGH
25 SPEED
20 (UF)

15
80 90 100 110 120 130
AMBIENT TEMPERATURE (_F)
UF=FRONT UNLOADER
UR=REAR UNLOADER

ABOVE THE LINE = UNLOADED

BELOW THE LINE = LOADED

Figure 5-5 -- SUCTION PRESSURE UNLOADING

d. High Box Temperature Pulldown Logic 5.7 SV1 OPERATION
NOTE
XT and X2 model units (REV 3.25 and higher The SV1 valve will be open (de--energized) whenever
with CNF 19 ON) use the suction pressure the system is operating in the Cool Cycle. The SV1
loading & unloading chart (See Figure 5-5), but valve will be primarily closed (energized) during Heat
also use the following overrides during unit op- and Defrost Cycles.
eration:

When the unit is running in High Speed 4--Cylinder Cool 5.8 SV2 OPERATION
operation, and the suction pressure drops to 10 PSIG
(0.68 Bar) above the normal cut--in point for UF (See
Figure 5-5), the front unloader is loaded for 15 seconds. 5.8.1 SV2 Operation for Ambient Temperatures
If the suction pressure drops below the cut--in point, the Below 50°F (10_C):
front unloader will remain loaded. If the suction pressure
remains above the cut--in point, the front unloader will
unload after the 15 seconds. This cycle will repeat every The SV2 valve will be open (energized) whenever the
2 minutes, until either the suction pressure is low system is operating in the Cool Cycle. The SV2 valve
enough to load the front unloader, or the cycle repeats will open and close during the Heat and Defrost Cycles
10 times. Should the front unloader not remain loaded to control Discharge and Suction pressures.
after 10 attempts, the cycle will be extended to 30--min-
ute intervals.
1. At ambient temperatures above 90_F (32.2_C) 5.9 SPEED SOLENOID OVERRIDES
At ambient temperatures of 125_F (52°C) or higher both
unloaders are controlled to the values shown in When the ambient temperature is 120_F (48.9°C) or
Figure 5-5. above, the unit will operate in Low Speed only.

5--11 62-11352
 SECTION 6 - TROUBLESHOOTING

CAUTION
Under no circumstances should anyone attempt to service the microprocessor! See Section 7.16)
Should a problem develop with the microprocessor, contact your nearest Carrier Transicold dealer
for replacement.

INDICATION/ REFERENCE
TROUBLE POSSIBLE CAUSES
SECTION
6.1 DIESEL ENGINE
6.1.1 Engine Will Not Start
Starter motor will not Battery insufficiently charged Check
crank or low cranking speed Battery terminal post dirty or defective Check
Bad electrical connections at starter Check
Starter motor malfunctions 6.1.3
Starter motor solenoid defective Engine Manual
Open starting circuit 6.1.4
Incorrect grade of lubricating oil 2.8
Oil pressure switch contacts closed Check
Voltage at D+ with engine not running 2.3.2
Water or oil on top of pistons Check
Compressor not turning freely Check
Starter motor cranks No fuel in tank Check
but engine fails to start Air in fuel system 7.6
Water in fuel system Drain Sump
Plugged fuel filters Replace
Fuel solenoid defective Engine Manual
Plugged fuel lines to injector (s) Check
Fuel control operation erratic Engine Manual
Air intake heater defective NO TAG
Fuel pump (FP) malfunction 7.6
Restricted air filter 7.7.4
Problem with ENSCU system 6.4
Fuel pump screen plugged Replace
Starter cranks, engages, Engine lube oil too heavy 2.8
but dies after a few seconds Loose connection at battery Check
Poor/corroded battery cable ends Check
Compressor not turning freely Check

6--1 62-11352
 INDICATION/ REFERENCE
TROUBLE POSSIBLE CAUSES
SECTION

6.1.2 Engine Starts Then Stops

Engine stops after Fuel supply restricted Check
several rotations No fuel in tank Check
Leak in fuel system Check
Faulty fuel control operation Engine
Fuel filter restricted Replace
Injector nozzle(s) defective Engine Manual
Injection pump defective Engine Manual
Fuel pump screen plugged Check
Air cleaner or hose restricted 7.7.4
Safety device open -- Check alarms 2.13 and
Table 3-3
FSA defective Replace
Fuel pump (FP) malfunction 7.6
Problem with ENSCU system 6.4
Air in fuel system 7.6
Starter motor will not Battery insufficiently charged Check
crank or turns slowly Battery cable connections loose or oxidized Check
Battery cables defective Replace
Starter brushes shorted out Engine Manual
Starter brushes hang up or have no contact Engine Manual
Starter solenoid damaged Engine Manual
Run-Stop switch defective Replace
Engine lube oil too heavy 2.8

6.1.3 Starter Motor Malfunction

Starter motor turns Pinion or ring gear obstructed or worn Clean both,
but pinion does not engage remove burrs,
or replace;
apply grease
Starter clutch not engaging Repair or re-
place
Starter motor does not disengage Glow/Crank switch defective (If equipped) Replace
after switch was released Starter motor solenoid defective Engine Manual
Pinion does not disengage Defective starter Engine Manual
after engine is running

6.1.4 Malfunction In the Engine Starting Circuit

No power to starter Battery defective Check
motor solenoid (SS) Loose electrical connections Tighten
Defective starter solenoid relay (SSR ) Check
Defective Glow/Crank switch (if equipped) Check
Voltage at D+ on alternator 2.3.2
FSA does not energize or does Battery defective Check
not remain energized Loose electrical connections Tighten
Oil pressure safety switch (OP) defective Replace
Run relay (RR) defective Replace
Water temperature sensor (WTS) defective Replace
Stop/Fuel solenoid defective Replace
Run-Stop switch defective Replace

62-11352 6--2
 INDICATION/ REFERENCE
TROUBLE POSSIBLE CAUSES
SECTION
6.2 ALTERNATOR
Alternator fails to charge Limited charging system operating time Check
Battery condition Check
Alternator belt loose/broken 7.8
Loose, dirty, corroded terminals, or broken wires Check/Repair
Excessively worn, open or defective brushes Check
Regulator faulty Check
Alternator faulty Replace
Low or unsteady charging rate Alternator belt loose/broken 7.8
Loose, dirty, corroded terminals, or broken wires Check/Repair
Excessively worn, sticky or intermittent brushes Check
Faulty regulator Check
Alternator faulty Replace
Excessive charging rate Regulator leads loose, dirty, corroded terminals, or
(as evidenced by battery wires broken Clean/Repair
requiring too frequent refilling) or Defective regulator Check
charge indicator shows constant Defective battery Replace
“charge with engine idling”
Noisy alternator Defective or badly worn V-belt 7.8
Worn bearing(s) Replace
Misaligned belt or pulley 7.8
Loose pulley Tighten

6.3 REFRIGERATION
NOTE: All Refrigeration System problems should be investigated by following the Quick Check Refrigeration
System Troubleshooting Procedure (Refer to Section 7.10).
6.3.1 Unit Will Not Cool
Diesel engine Malfunctions -- Not running 6.1
Compressor malfunction Compressor drive defective 7.12
Compressor defective 7.12
Compressor unloaders not working NO TAG
Compressor reed valves or valve plate gaskets defective Replace
Refrigeration system Defrost cycle did not terminate 6.3.5
Abnormal pressure 6.3.6
Solenoid valve malfunction 6.3.11
Clutch Failure Check

6--3 62-11352
 INDICATION/ REFERENCE
TROUBLE POSSIBLE CAUSES
SECTION
6.3.2 Unit Runs But Has Insufficient Cooling
Compressor Compressor valves defective NO TAG
Unloader malfunction NO TAG
Refrigeration system Abnormal pressure 6.3.6
Unloader malfunction NO TAG
Expansion valve malfunction 6.3.10
No or restricted evaporator airflow 6.3.9
Clutch Failure Replace
Low refrigerant level 7.10.1
Engine does not Engine malfunction 6.1
develop full rpm Refrigerant pressure 6.3.6
6.3.3 Unit Operates Long or Continuously in Cooling
Trailer Hot Load Allow time to
pull down
Defective box insulation or air leak or door is open Correct

Refrigeration system Abnormal pressure 6.3.6

Temperature controller malfunction (micro) 6.3.8
Refrigerant charge 7.10.1
Solenoid valve malfunction Perform quick
check (7.10)
Fanshaft seal leaking Repair
Compressor Defective 7.12
Compressor valves defective NO TAG
Unloader malfunction 7.12.2
6.3.4 Unit Will Not Heat or Has Insufficient Heating
Refrigeration Head pressure control switch (HP2) defective 7.12.8
Abnormal pressure 6.3.6
Temperature controller malfunction 6.3.8
Solenoid valve malfunction 6.3.11
1/4” check valve (bypass) defective 7.10.3
Clutch Failure Check
Low refrigerant level 7.10.1
SV1 malfunction 7.12.11
SV4 malfunction 7.12.10
Compressor Compressor drive defective 7.12
Compressor defective 7.12
Unloader/Compressor gaskets or valves defective NO TAG
Engine does not develop Engine malfunction 6.1
full rpm

62-11352 6--4
 INDICATION/ REFERENCE
TROUBLE POSSIBLE CAUSES
SECTION
6.3.5 Defrost Cycle Malfunction
Will not initiate defrost Defrost air switch (DA) out of calibration NO TAG
automatically Defrost thermostats (DTT) open or defective Replace
DTT not properly installed in correct location Repair
Defrost air switch (DA) defective Replace
Loose defrost air switch connections Tighten
Air sensing tubes defective or disconnected Check/Repair
Will not initiate defrost manually Microprocessor defective Replace
Loose terminal connections Tighten
Defrost thermostats (DTT) or circuit open or defective Replace or Re-
pair
Keypad defective Replace
Initiates but does not defrost Solenoid valve malfunction, SV1, SV4 6.3.11
Defrost relay (DR) defective Replace
Clutch/Gearbox defective Replace
Low refrigerant level 7.10.1
HP2 malfunction Replace
Frequent defrost Defrost air switch (DA) out of adjustment NO TAG
Wet load Normal
Trailer doors open or there is an air leak Close Doors
Fanshaft seal leaking Repair
Does not terminate or Defrost thermostats (DTT) shorted closed Replace
cycles on defrost Head pressure control switch (HP2) defective 7.12.8
Low refrigerant level NO TAG &
Defrost air switch (DA) out of adjustment or shorted NO TAG
Solenoid SV1 not closing NO TAG
DTT not properly installed in correct location Replace
Repair

6--5 62-11352
 INDICATION/ REFERENCE
TROUBLE POSSIBLE CAUSES
SECTION
6.3.6 Abnormal Pressure
6.3.6.1. Cooling
High discharge pressure Condenser coil dirty 7.15
Condenser fan defective Replace
V-belt broken or loose 7.8
Discharge check valve restricted or other high side Check & 7.12.5
restriction
Noncondensibles in refrigeration system 7.11.10
Solenoid valve (SV1) malfunction 7.12.11
Refrigerant level is over full 7.10.1
Low discharge pressure Compressor valves(s) worn or broken NO TAG
Low refrigerant level NO TAG &
Solenoid valve malfunction NO TAG
Replace
High suction pressure Compressor valves(s) worn or broken NO TAG
Compressor gasket(s) defective Replace
Solenoid or unloader valve malfunction Replace
SV4 defective NO TAG
Low suction pressure Suction service valve partially closed Open
King valve partially closed Open
Filter-drier partially plugged 7.12.6
Low refrigerant level NO TAG &
Expansion valve malfunction NO TAG
No evaporator air flow or restricted air flow 6.3.10
Excessive frost/ice on coil 6.3.9
Solenoid valve (SV2) defective Check
Clutch Failure NO TAG
Replace
Suction and discharge Compressor valves defective NO TAG
pressures tend to equalize Compressor drive defective Replace
when unit is operating

62-11352 6--6
 INDICATION/ REFERENCE
TROUBLE POSSIBLE CAUSES
SECTION
6.3.6.2. Heating
High discharge pressure Solenoid valves (SV-1, SV--2 or SV-4) malfunction 6.3.11
V-belts broken or loose 7.8
Noncondensibles in system Check
Head pressure control switch (HP-2) defective (closed) 7.12.8
Refrigerant level is over full 7.10.1
Low discharge pressure Compressor valve(s) worn or broken NO TAG
Head pressure control switch (HP-2) defective(open) 7.12.8
Solenoid valve (SV-1) malfunction 6.3.11
Low refrigerant charge NO TAG &
Bypass check valve defective NO TAG
Replace
Low suction pressure Low Refrigerant level NO TAG &
Solenoid (SV-1) open NO TAG
Head pressure control switch (HP-2) defective (open) 6.3.11
Bypass check valve defective 7.12.8
Replace
6.3.7 Abnormal Noise
Compressor Loose mounting bolts Tighten
Worn bearings 7.12
Worn or broken valves NO TAG
Liquid slugging 6.3.10
Insufficient oil NO TAG
Drive adaptor loose or defective Tighten or re-
place
Condenser or Loose or striking shroud Check
evaporator fan Bearings defective Replace
Bent shaft Replace
Clutch/Gearbox Defective Replace
V-belts Cracked or worn 7.8
6.3.8 Control System Malfunction
Will not control Sensor(s) defective or incorrectly mounted Check & 7.18
Relay(s) defective Check
Microprocessor controller malfunction 7.16
Bulkhead is damaged or incorrect for application Replace
6.3.9 No Evaporator Air Flow or Restricted Air Flow
Evaporator coil blocked Frost on coil Check
Dirty coil 7.14
Debris (shrink wrap or cardboard) caught behind bulkhead Clean
Return air bulkhead is not in good condition or is attached Check/Replace
incorrectly or is not correct for application
No or partial evaporator V-belt broken or loose 7.8
air flow Clutch/Gearbox defective Replace
Evaporator fan loose or defective Check
Evaporator air flow blocked in trailer (box) Check
Debris (shrink wrap/cardboard) caught in bulkhead Clean
Air chute is not in good condition or is attached incorrectly Check/Replace

6--7 62-11352
 INDICATION/ REFERENCE
TROUBLE POSSIBLE CAUSES
SECTION
6.3.10 Expansion Valve Malfunction
Low suction pressure and/or Low refrigerant charge NO TAG &
high superheat External equalizer line plugged NO TAG
Ice formation at valve seat Clean
Wax, oil or dirt plugging valve or orifice 7.11.10
Broken capillary tube on TXV 7.12.7
Power Assy failure or partial loss of element/bulb charge Replace
Superheat setting too high (Defective TXV) Replace
King valve partially closed Replace
Filter drier is restricted Open
7.12.6
Low superheat and liquid Superheat setting too low NO TAG
slugging in compressor External equalizer line plugged Open
Ice holding valve open 7.11.10
Foreign material in valve Clean
Pin and seat of expansion valve eroded or
held open by foreign material 7.12.7
Heat exchanger is leaking internally Replace
Fluctuating suction Improper TXV bulb location or installation 7.12.7
pressure Low TXV superheat setting 7.12.7
Incorrect TXV is installed Replace
6.3.11 Solenoid Valve Malfunction
Solenoid valve does not No power to valve Check
function properly Improper wiring or loose connections Check
Coil defective NO TAG
Valve improperly assembled NO TAG
Coil or coil sleeve improperly assembled NO TAG
Movement of plunger restricted due to:
a. Corroded or worn parts NO TAG
b. Foreign material lodged in valve NO TAG
c. Bent or dented enclosing tube NO TAG
Defective HR (1,2,3) Replace
Solenoid valve closes but Foreign material lodged under seat Clean
refrigerant continues to flow Defective seat Replace

6.4 Electronic Speed Control Troubleshooting

Table 6-1. ENSCU LED Fault Chart (See following pages for troubleshooting trees)
The following diagnostic tables are intended to assist technicians in diagnosing problems with Electronic Speed
Control Engine Units. These tables are not intended to replace a good technician’s knowledge of the control and
electrical systems, but to supplement it.
It is important to verify the reported LED alarm and then correctly identify the appropriate table for that condition.
When using these tables, do not skip any steps. The tables are formatted in a logical troubleshooting sequence and
skipping around the tables will most likely lead to errors in diagnosis.
A few testing procedures call for the use of a jumper wire. This is necessary due to the tight fit of the pins when seated in
the connecter. Crimp female terminal (CTD P/N 22--50098--61A) to one end of a 2” piece of wire and leave the other
end of the wire bare in order to check for proper voltages and resistances as outline in the tables.

62-11352 6--8
 Fault LED display pat- Failed component
tern
1 Engine Over Speed: more than 2,530 RPM One Long–One ENSSN or mechanical engine
Short problem
2 No signal from ENSSN for 2 seconds after RPM Two Long–One ENSSN or wiring problem
is greater than 1,000 RPM for 10 seconds, OR Short
for 5 seconds while engine cranking (no voltage
at pin 18 of ENSCU).
3 Actuator (FSA) wiring disconnected or open cir- Two Long–Three FSA or wiring problem
cuit. Coil Resistance Spec: 2.8 ohm +/- 10%. Short
4 ENSCU supply voltage is greater than 26V. Two Long–Seven ENSCU or alternator problem
Short

6--9 62-11352
 START HERE
Start unit.
NO Using strobe light YES
07-00177-01 or equivalent,
NOTE : Ensure the run relay is check engine RPM.
energized during test . With ENSSN Is RPM equal to or over 2,530?
unplugged during testing , unit will
stall & go through start sequence
again . Unit will not start . This is
normal . Check for high
Check high speed mechanical
Verify there is at least 11 VDC going resistance or an
stop on injection pump assembly
into the ENSSN 12V terminal ? YES open in the ENSSNG
for loose screws or tampering.
ground circuit. YES Are the screws loose?
Did you find and
NO correct the condition?
YES

Check for high

resistance or Set proper high speed RPM
an open System per this manual
between ENSCU OK Did you find and
System correct the condition?
terminal 25 & YES
ENSSN 12V OK NO
terminal. YES
Did you find
and correct Remove new ENSCU
NO System
the condition? and re-install old
OK
ENSCU back into unit,
NO ENSCU is not the fault.
Review results of
above tests with your
NO supervisor. If Check for proper internal mechanical
necessary, go to the operation of injection pump assembly
Using jumper wire, check for beginning of the and governor assembly. Did you
5 VDC at ENSCU terminal 10. table & test again. find and correct the condition?
Do you have 5 VDC at
terminal 10? YES
NO

NO

YES Review results

NO Replace ENSCU. Did you of above tests System
find and correct the condition? with your super OK
visor. If
necessary, go
YES to the
Check for open or high beginning of the
resistance on circuit between Replace ENSSN.. Did you table &
NO find and correct the condition? test again.
ENSSN and ENSCU. Did you
find and correct the condition?

NO YES
YES

Remove new ENSSN System

and re-install old OK
System ENSSN back into unit,
OK ENSSN is not the fault.
Review results of
above tests with your
supervisor. If
necessary, go to the
beginning of the table
& test again.

Figure 6--1. ESC Diagnostic Tree -- 1 Long, 1 Short LED Code (Engine RPM is Over 2530 RPM)

62-11352 6--10
 START HERE
NO
Verify unit starts, go into
high speed and stall after
running for a few seconds?
Using jumper wire,
verify there is at least 11
VDC at ENSCU terminal 25? Check for high
YES resistance or an
Verify there is at least 11 open in the
VDC going into the YES ENSSNG ground YES
ENSSN 12 V terminal? circuit.
Did you find and
correct the condition?
Check for high
resistance or an System
NO
open between OK
ENSCU terminal
System
25 & ENSSN YES
OK Using jumper wire, check for
12 V terminal. .
5 VDC at ENSCU terminal
Did you find
10. Do you have 5 VDC at
and correct YES terminal 10?
the condition?

YES

NO

Replace ENSCU.
Did you find and correct
the condition?

NO

NO

Remove new ENSCU Check for open or high

System resistance on circuit
and re-install old OK YES NO
ENSCU back into between ENSSN and ENSCU.
unit, ENSCU is not Did you find and correct the
the fault. Review condition?
results of above
tests with your Replace ENSSN. Did you
supervisor. If Remove new ENSSN
find and correct the
necessary, go to the and re-install old
condition?
beginning of the table & ENSSN back into unit,
test again. ENSSN is not the fault.
Review results of
NO
above tests with your YES
supervisor. If
necessary, go to the
beginning of the table
& test again. System
OK

Figure 6--2. ESC Diagnostic Tree -- 2 Long, 1 Short LED Code (FSA Electrical Failure)

6--11 62-11352
 START HERE
Go to Condition 2 in Does the engine starter
NO engage & turn the engine
microprocessor diagnostic
table Figure 6-- 6 over?

YES

NOTE: Ensure FSA is un-

Check for high resistance plugged for testing. Verify the Using jumper wire, are the
or an open on the FSA ground proper voltage going into FSA proper voltages present
NO
circuit terminal 2. YES terminal1. 12 VDC when RS at ENSCU terminal 7?
Did you find and correct switch is first turned on for the
the condition? pull in voltage, 1 VDC for
hold in voltage & 0.8 VDC
during starter engagement. YES
YES Do you have the correct
NO voltage?
NO
System
OK YES Check for open or high
With the FSA disconnected, Replace ENSCU. Did you find resistance on circuit
check the resistance of the and correct the condition? between FSA and ENSCU..
FSA coil. Spec is YES Did you find and correct
2.5 to 3.1 ohms. the condition?
Is ohm reading within spec?
NO YES
Remove the FSA from the NO
NO engine & inspect. FSA should
move freely without binding and Remove new ENSCU
shaft should be straight. Is and re-install old Review results
FSA functioning properly? System
ENSCU back into unit, of above tests
Replace the FSA. Did OK
ENSCU is not the fault. with your super
you find and correct NO Review results of above visor. If
the condition? tests with your necessary, go
YES
supervisor. If necessary, to the
go to the beginning of beginning of the
the table & test again. table &
NO Review results test again.
of above tests
with your super
Remove new FSA visor. If
and re-install old necessary, go
FSA back into to the
unit, FSA is not beginning of the
the fault. Review table &
YES
results of above test again.
tests with your
supervisor. If
necessary, go to the
beginning of the table &
test again.

System
OK

Figure 6--3. ESC Diagnostic Tree -- 2 Long, 3 Short LED Code (No Speed Sensor Input To ENSCU)

62-11352 6--12
 START HERE
With the SROS switch ON
and the ENSCU
wire 13 removed from the
connector (connector
plugged in), check voltage
at ENSCU terminal 13. Is Check voltage output at
Replace ENSCU. Did you
NO
voltage 26 VDC or higher? YES alternator. Is voltage 26
find and correct the condition?
NOTE: With connector VDC or higher?
unplugged, unit will not
start but will crank. YES
Check voltage while unit
is cranking. To remove
wire from connector,
NO YES use a pocket screwdriver Replace alternator.
and push in the Did you find and
NO
rectangular white lock. correct the condition?

Starting at terminal NO YES

Remove new ENSCU System 13 at the ENSCU,
and re-install old OK check circuit for
ENSCU back into induced voltage
unit, ENSCU is not the creating the 26 VDC Remove new System
fault. Review results signal. alternator or voltage OK
of above tests with Did you find and regulator and
your supervisor. If correct the condition? re-install old
necessary, go to the alternator back into
beginning of unit, alternator is not
the table & test again. YES the fault. Review
results of above
tests with your
NO
supervisor. If
System necessary, go to the
OK beginning of the
table & test again.

Review results
of above tests
with your super
visor. If
necessary, go
to the
beginning of the
table &
test again.

Figure 6--4. ESC Diagnostic Tree -- 2 Long, 7 Short LED Code (ENSCU voltage is over 26 VDC)

6--13 62-11352
6.5 Microprocessor Troubleshooting Guide
The following diagnostic tables are intended to assist technicians in diagnosing problems with the standard
microprocessor. These tables are not intended to replace a good technician’s knowledge of the control and electrical
systems, but to supplement it.
When using these tables, it is important to verify the reported symptom or problem and then correctly identify the
appropriate table for that particular condition. Using the incorrect table will lead to an incorrect diagnosis.
When using these Diagnostic Tables, it is very important not to skip any steps. Follow the flow of the tables in the order
that they are laid out. These tables are formatted into a logical troubleshooting sequence. Skipping around the tables
will most likely lead to errors in diagnosis.
Throughout the tables, the steps will point the technician to areas to look at or check for a problem. Most of the steps
will lead the technician to a circuit or other area of the unit to check, test, and possibly repair other than the
microprocessor. Some steps will point to a possible problem with the microprocessor. Whenever reaching one of
these steps, it is a very good practice to install the new microprocessor, then verify unit operation PRIOR TO writing
hours into the new microprocessor. Once the technician is satisfied that a new microprocessor is required, the hours
should be entered. Should the problem remain even with the new microprocessor in place, once all repairs are made,
the original microprocessor is to be reinstalled into the unit, to avoid unnecessary costs to the customer or having the
Warranty Request rejected if there is no problem found with the returned microprocessor.
All steps leading to replacement of the microprocessor have a number associated with them. When filling out the MPR
tag that will be attached to the returned part, write the step number on the upper half of the tag in the Failure Description
Field. Include the same information in the Failure Description Field when entering the warranty claim information on
line. This will show which diagnostic table was used and the path that was followed to determine the micro was at fault.

62-11352 6--14
 NOTE: RS switch must be on for remainder of
testing. Check state of battery charge. Check
START HERE The SROS
NO
condition and tightness of battery cables at bat- YES System
switch is ON. Does the mi-
tery, starter and engine block. On older micros, OK
cro power up?
check the two small wires coming from the bat-
tery cable. Does the micro power up?
Check for voltage at J1 jump-
er terminal A. Voltage should NO
be at least 11 VDC. Is voltage Is the unit equipped with
NO Disconnect shutdown op-
higher than 11 VDC? shutdown options and/or
telematics system (remote YES tions and/or telematics sys-
tem and install J1 jumper.
communication?)
NO
Is there at NO
least 11 Is there at Replace Did disconnecting the shut-
NO YES
VDC at SROS least 11 SROS down options allow the unit to
terminal 3? volts at SROS switch. Did operate?
terminal 2? NO you find and YES
YES
correct the YES
Repair wiring for an open or high Is the condition?
resistance between SROS ter- F9 fuse Fault is one of the unit shutdown op-
System tions and/or telematics system.
minal 3 and J1 terminal A. blown?
OK Diagnose shutdown option and repair
YES
as required.
YES System Replace the fuse and look
OK NO
for shorted wires between Remove J1 jumper
RS terminal 2 & F9 fuse. and reinstall
shutdown options
Remove J1 jumper NO and/or telematics
and reinstall shut- System system.
down options and/or OK
telematics system.
Remove J1 jumper Remove new switch and reinstall old
Is there and reinstall switch. Switch is not the fault. Review
NOTE: Take care not to voltage at F9 shutdown options results of above tests with your su-
short ribbon cable ter- fuse terminal and/or telematics pervisor. If necessary, go to the be-
minals during testing. B (side system. ginning of the table & test again.
YES
Check voltage between closest to re-
terminals 45 and 58 and lays)?
59 and 60. Voltage Repair wiring for an open or high Remove J1 jumper
should read 11 VDC or NO resistance between F9 terminal and reinstall
higher. Is voltage within A (side away from the relays) shutdown options
range? and J1 terminal A. and/or telematics
NO YES system.
Repair grounds at
terminals 58 and 60. Repair wiring for an open or high
Did you find and cor- resistance between F9 terminal System
YES rect the condition? YES OK
B and unit battery

NO YES
YES
Check display NO
cable for loose con- YES Check wires for open or
nections. Did you high resistance between J1
Remove new micro and reinstall terminal B and terminals 45
find and correct the old micro. Micro is not the fault.
condition? Replace micro & 59 on micro.
Review results of above tests with ribbon cable. Did
your supervisor. If necessary, go you find and cor-
NO NO to the beginning of the table and NO Remove new micro ribbon
rect the problem?
MPR Code #1 test again. cable and reinstall old cable.
Enter hours from Ribbon cable is not the fault.
Remove J1 jumper old micro into Review results of above tests
Replace micro and operate new micro and with your supervisor. If ne-
YES System and reinstall
system in order to verify re- verify configura- cessary, go to the beginning
OK shutdown options
pair. Do not install micro tions & functional of the table and test again.
and/or telematics
hours at this time. Did you find parameter set-
system.
and correct the condition? tings.

Figure 6--5. Micro Diagnostic Tree -- Cond. 1 -- Start/Run--Off Switch In Start/Run Position --
Micro does not power up

6--15 62-11352
 NOTE: SROS must be on for remainder
START HERE The SROS of testing. Is the unit equipped with shut- Disconnect shutdown op-
is ON. Does the engine down options and/or telematics system YES tions and/or telematics sys-
run? (remote communication)? tem and install J1 jumper.

YES NO
NO
YES Are there any alarms Did disconnecting the shutdown
in the micro? NO options allow the unit to operate?
Does the micro
power up? YES
Repair alarm per this manual. Note: An oil pressure System
System YES OK YES
NO switch stuck closed can generate an “ALT AUX”
OK alarm. Output at the alternator prior to start up can
Go to Cond. 1 generate an “ENG OIL” alarm. Diagnose fault and re- Fault is with one of the unit shut-
Table pair as required. Did you find and correct the condi- NO down options and/or telematics
tion? system. Diagnose shutdown op-
tion and repair as required.
NO Check the F11 & F12 (10A)
Replace the fuse fuses on micro. Is a fuse
YES blown?
NO
Check
alternat-
NO Does the engine starter engage
or D+ System
0 VDC and turn the engine over?
output. OK

If unit has Manual Glow 12 VDC Remove new alternator and rein- YES
Crank Switch, try cranking stall old one. Alternator is not the
the engine. Does the en- fault. Review results with super-
Replace alternator.
gine crank? visor. If necessary, go to the be- Remove J1 jumper
Did you find and cor-
NO rect the condition? ginning of the table and test
NO again. and reinstall shutdown options
and/or telematics system.
Check SROS, SSR re- Does the engine start &
lay, starter solenoid & YES Go to Cond.
System YES stall after a few
starter for proper oper- 3 Table
OK seconds?
ation. Check all asso-
ciated wiring and con-
nectors. Load test bat- NO
tery. Repair or replace
as required. Check ground connections Check the fuel solenoid AH circuit for bad con-
at the battery, starter, engine nection to starter or open winding in fuel solen-
block and inside the control oid. Did you find and correct the condition?
box. Did you find and correct
the condition? NO System
System YES OK
YES
OK Check amperage on glow plugs. Glow
NO plug circuit draws 6 to 7 amps. Each
YES MPR Code #2 glow plug draws 0.7 to 1.2 amps. Did
you find and correct the condition? YES
Remove J1 jumper
and reinstall Replace micro and operate NO
shutdown options system in order to verify re-
Check fuel flow from
and/or telematics pair. Do not install micro
Check for voltage at fuel tanks, through the
system. hours at this time. Did you find YES
the fuel solenoid circuit fuel lines to the injec-
and correct the condition? BP and AH. Is voltage tion pump. Did you find
11 volts or higher? and correct the condi-
tion?
NO
NO NO YES
Enter hours from old Remove new micro and reinstall
micro into new micro old micro. Micro is not the fault. Check for an open or high Review results of above tests
and verify configura- Review results of above tests with resistance in the wiring with your supervisor. If ne-
tions & functional your supervisor. If necessary, go between the battery and NO cessary, go to the beginning
parameter settings. to the beginning of the table and the fuel solenoid. Did you of the table and test again.
test again. find and correct the con-
dition?

Figure 6--6. Micro Diagnostic Tree -- Cond. 2 -- Start/Run--Off Switch In Start/Run Position --
Engine does not operate

62-11352 6--16
 NOTE: SROS must be on for re- Disconnect shutdown op-
mainder of testing. Is the unit equipped tions and/or telematics sys-
START HERE The SROS with shutdown options and/or telemat- YES
tem and install J1 jumper.
is ON. Does the engine ics system (remote communication)?
run?
NO
YES Does the YES
NO micro Is there a START/FAIL
power up? alarm in the micro? Did disconnecting the shutdown
NO options allow the unit to operate?
System YES
OK NO
Repair alarm per this manual. Note: An oil pressure YES
Go to Cond. 1 switch stuck closed can generate an “ALT AUX” alarm.
Table Output at the alternator prior to start up can generate an Fault is with one of the unit shut-
“ENG OIL” alarm. Diagnose fault and repair as re- down options and/or telematics
quired. Did you find and correct the condition? system. Diagnose shutdown op-
Replace the relay tion and repair as required.
Review results of Note: START/FAIL alarm must be cleared to continue
NO
above tests with diagnostic table. Check for battery voltage at F11 & 12
your supervisor. If YES terminal B (side closest to relay). Do you have battery
necessary, go to voltage? System
the beginning of the NO NO OK
table and test again. Does the engine starter engage YES
Check NO and turn the engine over?
If unit has Manual Glow 0 VDC alternat- Remove J1 jumper
Crank Switch, try cranking or D+ Remove new alternator and rein- YES and reinstall shutdown options
the engine. Does the en- output. stall old one. Alternator is not the and/or telematics system.
gine crank? fault. Review results with super-
12 VDC visor. If necessary, go to the be- Does the engine start &
NO NO ginning of the table and test stall after a few
Replace alternator. again. seconds? System
Check RS switch, SSR re- Did you find and cor- OK
lay, starter solenoid & rect the condition? NO
starter for proper opera- YES System
YES Check amperage on YES
tion. Check all associated OK
System glow plugs. Glow
wiring and connectors. YES
OK Does the plug circuit draws YES
Load test battery. Repair
ENSCU flash 6 to 7 amps. Each
or replace as required. NO Check fuel flow from
on LED glow plug draws 0.7
Check ground connections diagnostic code? to 1.2 amps. Did fuel tanks, through the
YES
at the battery, starter, engine YES you find and fuel lines to the injec-
System YES block and inside the control YES correct the condition? tion pump. Did you find
OK YES box. Did you find and correct and correct the condi-
the condition? See Section tion?
Remove J1 NO MPR Code #3 6.4. Did you
Check for voltage
find and cor- Review results of
jumper and reinstall Replace micro and operate between ENSCU pin 13
rect the condi-
shutdown option system in order to verify re- & 19.Do you have at YES above tests with your
and/or telematics system. tion? supervisor. If neces-
pair. Do not install micro least 11 volts at the
hours at this time. Did you find ENSCU? sary, go to the begin-
NO
and correct the condition? ning of the table and
Enter hours from old Review results of NO
NO test again.
micro into new micro Remove new micro and reinstall above tests with your
and verify configura- old micro. Micro is not the fault. supervisor. If neces- Check for an open or high resist-
tions & functional Review results of above tests with sary, go to the begin- ance in the wiring to the ENSCU. YES
parameter settings. NO ning of the table and Did you find and correct the con-
your supervisor. If necessary, go
to the beginning of the table and test again. dition?
System YES test again. Check for a constant
OK voltage between NO
ENSCU pin 13 & 19. Replace micro and operate
Check for an open
system in order to verify re-
Review results of above tests NO or high resistance Do you get a steady
with your supervisor. If ne- reading of at least 11 pair. Do not install micro
between ENSCU pin
hours at this time. Did you find
cessary, go to the beginning 13 and 19. Did you volts when run relay NO
and correct the condition?
of the table and test again. find and correct the is energized?
condition? NO
YES Remove new micro and reinstall
Enter hours from old old micro. Micro is not the fault.
micro into new micro Review results of above tests with
System
and verify configura- Remove J1 jumper your supervisor. If necessary, go
OK
tions & functional and reinstall shutdown options to the beginning of the table and
parameter settings. and/or telematics system. test again.

Figure 6--7. Micro Diagnostic Tree -- Cond. 2 -- Start/Run--Off Switch On -- Engine does not operate

6--17 62-11352
 Go to Cond. 2 START HERE The
Table NO SROS is ON.
Does the engine
start & run? YES

Unit may be running on old software. Check the soft-

ware REV in the data list. Reference the appropriate
service bulletin to see if the functionality you are ex-
YES
pecting is available in your software REV. Depending
upon customer concern, a software update may be re-
quired. Did you find and correct the condition?
NO
Micro may not be configured properly. Verify that the Return to
configurations are set correctly. Scroll through the list top of
using the keypad and compare the settings with those YES this chart.
shown in Table 7-3. Change as necessary. Did you
find and correct the condition?

NO Operate system in
Verify functional parameter settings are correct order to verify NO
as outlined in Section 3.8.1. Did you find and cor- YES repair. Did you find
rect the condition? and correct the
condition? YES
NO
Use Pre--Trip to check unit operation. Refer to
Section 3.3 for Pre--Trip details. (NOTE: This is not
a self--diagnosing test. Pre--Trip must be monitored YES
by the user to verify the unit operates through all System
the cycles. Did you find and correct the condition? OK
NO
YES
Check connections at the battery,
starter, engine block and inside
the control box. Did you find and If micro was
correct the condition? replaced, enter hours
from old micro into
NO new micro & verify
If unit is equipped with a DataLink, down- that configurations
load DataLInk & review unit operation. YES & functional
Did you find and correct the condition? parameter settings
NO
are correct.

Refer to 3 for a description of correct unit operation.

Did you find and correct the condition?
YES

NO
Are you sure the unit is not operating
properly? Operate the system. Did you YES
find and correct the condition?

Remove new micro and NO

reinstall old micro. Micro is not (MPR Code #4)
the fault. Review results of
above tests with your super- Replace micro and operate system in or-
visor. If NO der to verify repair. Did you find and cor- YES
necessary, go to the beginning rect the condition?
of table & test again.

Figure 6--8. Micro Diagnostic Tree -- Cond. 3 -- Start/Run--Off Switch On -- Engine Operates But Not
Properly

62-11352 6--18
 START HERE Is the unit operating
in Defrost?

NO
YES
For units equipped with Speed Control
Solenoid, check solenoid & linkage for
YES
binding. Did you find and correct the
condition?
NO
NO

Check Functional Parameter settings

for air flow. Does the setting show YES
high?

NO

Check setpoint.

Is the micro providing

a ground to SR85
OR SR2? Is box temperature more than 3.5° F System
from setpoint once initial setpoint has YES
OK
been reached?

YES NO NO YES

Do SR Relay contacts 30 & 87 Check for a short to voltage or ground

Check ribbon cable
OR 3 & 5 open when ground on the ground circuit. Did you find and
circuit 38 for is removed from terminal 85 NO
continuity. Did you correct the condition?
OR 1?
find and correct YES
the condition?
NO
NO Is voltage present
NO YES
(MPR Code #6)
YES at the SCS?
Replace the relay.
Repair the short to power
Replace ribbon cable. between the SR Relay
and SCS.
System
OK

System
OK
Enter hours from
Replace micro and operate old micro into
system in order to verify repair. new micro & verify
YES System
Did you find and correct the configurations & YES OK Remove new micro and
condition? functional
parameter settings . reinstall old micro. Micro is not
the fault. Review results of
above tests with your super-
NO visor. If necessary, go to the be-
ginning of table & test again.

Figure 6--9. Micro Diagnostic Tree -- Cond. 6 -- Unit will not run in low speed

6--19 62-11352
 START HERE What does the ReeferManager
“CONNECTION OK” program display on the bottom of the screen of “NOT CONNECTED”
your PC?
Are the dates for
the data on the YES There is no
download screen? serial
connection.
NO
System
Data Recorder date & time OK
may be set wrong. Set the Is the DataLink status
correct date & time. Did you YES light blinking 1
YES
find and correct the condi- second on & 1
tion? second off?
NO Verify the integrity
of the download cable
NO and connections. Did
YES you find and correct
Check power the condition?
YES to DataLink.
Did you have a com-
munication failure
during a download? NO

YES Use an ohmmeter to veri-

Intermittent communication
NO problem. Ensure AC cord is fy the download port wir-
YES ing is correct and doesn’t
properly connected or PC bat-
tery is fully charged. Did you have an open, high res-
find and correct the problem? istance or a short.

NO NO
When viewing the download in
Reports, a specific sensor or
Verify the correct com port is se-
event does not show up in the
Verify PC power saving fea- lected in the PC software. See
data file. Specific sensor and YES
tures are OFF. (i.e. screen Help>Contents>PC Setup for
event data is in the data file. The
saver, monitor time out, hard additional information. Did you
Reports data filter settings may YES disk time out, auto power find and correct the condition?
be set incorrectly or specific
down / sleep mode). Did you
sensors and events may not be
find and correct the condition? NO
recorded. Data Recorder is not
configured properly. Use the
Reports Data Filter pull down NO
Verify com port availability (i.e.
menu to set sensors & events to
Verify the integrity of the Infrared devices turned off, PDA
be viewed OR ReeferManager
download cable and con- YES applications turned off, computer
to correctly setup recording YES nections. Did you find and has 9 pin serial port. DO NOT
parameters. Operate the sys-
correct the condition? connect to USB port. Did you find
tem in order to verify the repair.
and correct the condition?

NO NO

Try another computer

Try another computer System
System or check with super-
or check with super- OK
YES OK visor.
visor.

Figure 6--10. Micro Diagnostic Tree -- Cond. 7 -- Data Recorder Data Download Problems when using
ReeferManager and a download cable.

62-11352 6--20
 SECTION 7 -- SERVICE

WARNING
Beware of V-belts and belt driven components as the unit may start automatically. Before
servicing unit, make sure the Start/Run--Off switch is in the OFF position. Also disconnect
the negative battery cable.

CAUTION
For units with R404A and POE oil, the use of inert gas brazing procedures is mandatory;
otherwise compressor failure will occur. For more information see 98--50553--00 -- Technical
Procedure on Inert Gas Brazing
NOTE
To avoid damage to the earth’s ozone layer, use a refrigerant recovery system whenever removing re-
frigerant. When working with refrigerants you must comply with all local government environmental
laws.

7--1 62-11352
7.1 MAINTENANCE SCHEDULE
ACTION/-
SYSTEM OPERATION REFERENCE
SECTION
a. Daily Maintenance
Pre-Trip Inspection - before starting 7.2
Check Engine Hours Check
Check Engine Oil Level Check
Download recorder data (if equipped with DataLink)
b. Every Service Interval or Annually
Unit 1. Check unit mounting bolts Check
2. Check engine and compressor mount bolts Check
3. Check door latches & hinges Check
4. Check gauges, switches and electrical connections Check
5. Check all belt tensions 7.8
6. Check control box Check
7. Check gearbox and fanshaft for oil leaks Check
8. Check fanshaft, idler and gearbox bearings Check
9. Check clutch air gap and adjust as required Check
Engine 1. Check oil/filter change interval (refer to section f. of this table) 7.7.2
2. Check for oil leaks Check
3. Check low oil pressure safety 2.13
4. Clean crankcase breather 7.7.5
5. Check engine speeds Table 2-1
Fuel System 1. Clean fuel pump strainer 7.6.3
2. Change fuel filter(s) (refer to section f. of this table) 7.6.3
3. Check fuel heater (optional) ---
Cooling Sys- 1. Clean radiator/condenser fin surface 7.7.1 and 7.15
tem 2. Check antifreeze concentration 7.7.1
3. Check water pump Check
4. Check water temperature sensor functions 2.8
Exhaust Sys- 1. Check mounting hardware Check
tem 2. Check muffler and exhaust pipes Check
Air Intake 1. Change air cleaner element Check
System 2. Check and replace air filter indicator if needed 7.7.4
Starting Sys- 1. Check battery condition Check/Replace
tem 2. Clean battery connections and cable ends Check/Replace
3. Check battery hold down clamps Check
4. Check starter operation Check
Charging 1. Check alternator brushes and replace if necessary Check
System 2. Check alternator output 2.14

62-11352 7--2
 ACTION/-
SYSTEM OPERATION REFERENCE
SECTION
b. Every Service Interval or Annually (Continued)
Refrigeration 1. Check air switch hoses & calibration 4.15
System 2. Check & clean evaporator coil and defrost drain hoses 7.14
3. Check operating refrigerant pressures Check
4. Check refrigerant level Check
5. Check compressor oil level Check
6. Check and empty compressor shaft seal reservoir Check and empty if
needed
7. Check all sensor calibrations Check
8. Check manual defrost operation Check
9. Check Compressor drive coupling Check
10. Perform Pre--Trip inspection 7.2
c. Every 6000 Hour Maintenance (Normal Operating Conditions) with conventional coolant
Cooling Sys- 1. Drain and flush cooling system (12,000 hours with Extended Life
Section 7.7.1
tem Coolant)
d. Every 10,000 Hour Maintenance
Perform complete 2000 and 3000 hour Preventive Maintenance and the following:
Fuel System 1. Clean and adjust injector nozzles. Engine Service Guide
e. Every 12,000 Hour Maintenance with extended life coolant
Cooling Sys- 1. Drain and flush cooling system (6,000 hours with Conventional
Section 7.7.1
tem Coolant)

f. Oil And Filter Change Intervals

Oil & Filter Change Interval using Oil & Filter Change Interval us-
API Class CG engine oil ing Mobil Delvac engine oil*
Standard Oil Filter 2000 hrs/1yr 4000 hrs/1yr
ESI Oil Filter 3000 hrs/2 yrs 4000 hrs/2 yrs

* Mobil Delvac is the only approved synthetic oil. Maximum oil drain interval is two (2) years.

These maintenance schedules are based on the use of approved oils and regular pretrip inspections of the unit. Failure
to follow the recommended maintenance schedule may affect the life and reliability of the refrigeration unit.

7--3 62-11352
7.2 PRETRIP INSPECTION

WARNING
Inspect battery cables for signs of wear, abrasion or damage at every Pre--Trip inspection and replace
if necessary. Also check battery cable routing to ensure that clamps are secure and that cables are
not pinched or chafing against any components.

The following pretrip inspection should be performed before every trip and at regular maintenance intervals. Copy
the following pages to use as a guide.

BEFORE STARTING ENGINE OK ADJUST

Drain water from bottom of fuel tank j j
Drain water from water separator on fuel j j
filter (if applicable)
Coolant Level: check and add if necessary j j
Condenser Coil Cleanliness: Check the j j
coil for cleanliness, straighten fins if ne-
cessary
Radiator Coil Cleanliness: Check the coil j j
for cleanliness, straighten fins if necessary
Air Cleaner Hoses: insure their secure, no j j
leaks
Air Cleaner Indicator: check operation (if j j
applicable)
Engine Oil Level: check and add if neces- j j
sary
Belts: Check condition and tension of belts j j
Bearings: Check all fan and idler bearings j j
Door Latches/Hinges: Check for proper j j
operation
Condenser Fan Blades: Check condition j j
Battery: Check fluid level & w/hold down j j
bolts
Battery cables and terminals, are secured/- j j
clean
Evaporator Section: check coil(s) for j j
cleanliness and clear of debris
Air Chute: Make sure it is installed prop- j j
erly (if applicable)
Check bulkhead and return air screen j j
Defrost Water Drains: No debris & drain j j
properly
Place in Continuous Run, and start unit. j j

62-11352 7--4
 IMMEDIATELY AFTER STARTING OK ADJUST
ENGINE
Starter: Check for proper engagement j j
Fuel Leaks: Check fuel lines/filters for j j
leaks
Oil Leaks: Check oil lines/filters for leaks j j
Exhaust System: Check for leaks j j
Condenser Fan: Check for proper air flow. j j
Evaporator Fan: Check for proper air flow. j j
Ensure fan clutch engages properly -- no j j
slip or unusual noises
Check for unusual noises -- alternator, fan
shaft, water pump, idler and gearbox bear- j j
ings, etc.
Verify Compressor Oil Level j j
Comments / Notes:

AFTER OPERATING UNIT FOR 15 MINUTES OK ADJUST

OR MORE
Check refrigerant level j j
Check compressor oil level j j
Check for proper temperature control j j
Check auto--start/stop operation j j
Initiate Pre--Trip
List Alarms occurring during Pre--Trip

Allow Defrost to terminate automatically, ending

the Pre--Trip. j j

7--5 62-11352
 OPERATE IN HIGH SPEED COOL AND RECORD
(from Microprocessor Unit Data List)
SUCT Suction Pressure
WT Engine Water Temperature
RAS Return Air Sensor
SAS Supply Air Sensor
ATS Ambient Air Temperature
CDT Compressor Discharge Temperature
BAT Battery Voltage
REV Controller Software Revision
SERL Serial Number Lower
SERU Serial Number Upper

CHECK AND RECORD THE FOLLOWING

FUNCTION SETTING
DEFR Defrost Timer
HIGH/NORM AIR High or normal air flow
OFF T Start/Stop min OFF time
ON T Start/Stop min ON time
REM/SUP PROBE Controlling with Return or Supply probe
Degrees F or C Compressor Discharge Temperature
TIME STRT Maximum Off time is 30 min
TEMP STRT Temp and min off time based on restarting in auto start/stop
MOD STD Unit unloader control
AUTO MAN OP Auto start or manual start operation
T RANGE Out of range tolerance

FINAL OK ADJ
Download recorder data (if equipped with DataLink) j

62-11352 7--6
7.3 GRILLE INSERT REMOVAL (See Figure 7-1)
Removal of insert will ease in condenser coil cleaning. b. Remove the 2 bolts on top of the grille insert.
(Refer to Section 7.15). c. Swing insert down and lift out of locating holes.
a. Remove the 3 bolts on each side of the grille insert. d. Reverse above steps to install new grille insert.

GRILLE INSERT MOUNTING BOLTS SURROUND

GRILLE INSERT

LUBRICATE LATCHES AND PINS

Figure 7-1. Door Latch Maintenance And Grille Insert Removal

7--7 62-11352
7.4 SURROUND REMOVAL
a. Place the SROS in the “OFF” position and disconnect c. Remove the bolts that secure the surround to the unit.
the positive battery cable. d. Reverse above steps to install new surround.
b. Open both side and front doors.

SURROUND MOUNTING BOLTS

SURROUND MOUNTING BOLTS

Figure 7-2. Surround Removal

62-11352 7--8
7.5 DOOR LATCH MAINTENANCE AND CABLE 7.5.2 Side Door Latch Cable Replacement
REPLACEMENT a. Remove circular clip that secures the cable to the
Proper maintenance is important for smooth operation paddle assembly.
of the latch assembly and the latch pins that are moun- b. Remove the lower cable from the paddle assembly
ted on the unit’s frame (See Figure 7-1). In order to and the lower latch.
keep the movable parts clean and lubricated, CTD re- NOTE
commends the use of a de--greasing cleaner and LPS 2
lubricant. This lubricant should be available at any local The lower cable is threaded through the upper
automobile and truck parts suppliers. cable eyelet and the lower latch assembly.
(See Figure 7-3)
7.5.1 Front Door Latch Cable Replacement
a. Remove circular clip that secures the cable to the c. Remove the upper cable from the upper latch.
paddle assembly. d. Reverse above steps to install new cable.
b. Slide cable from paddle and rotate other end out of
latch assembly.
c. Reverse above steps to install new cable.

UPPER CABLE

REMOVE CIRCULAR CLIP

UN--THREAD THE LOWER
CABLE FROM THE UPPER
CABLE AND
LATCH ASSEMBLY PADDLE ASSEMBLY

Figure 7-3. Side Door Latch Lower Cable Removal

7--9 62-11352
7.6 PRIMING FUEL SYSTEM
7.6.1 Mechanical Fuel Pump c. Continue to pump S--L--O--W--L--Y (up/down once
The mechanical fuel lift pump is mounted on the engine per second) approximately 100 more strokes to fill the
next to the injection pump. This pump has a manual filter and bleed the air out of the lines.
plunger for priming the fuel system when the fuel tank d. Start engine. It may be necessary to continue to
level has been run too low. (See Figure 7-4). pump until the engine starts.
To prime the fuel system, use the following steps: e. Depress and turn the top of the manual plunger clock-
wise to lock in place.
a. Turn the bleed valve (Red) counter-clockwise until
fully opened. f. When engine is running smoothly, turn bleed valve
clockwise until fully closed.
b. Turn the top of the manual fuelpump plungercounter--
clockwise to unlock it. S--L--O--W--L--Y (up/down
once per second) pump the manual plunger until posi-
tive pressure (resistance) is felt. This may take up to
200 strokes. This will indicate fuel flow.

Red
Fuel Bleed
Valve

Manual
Fuel Pump
Plunger

Figure 7-4. Priming Fuel Pump

62-11352 7--10
7.6.2 Electrical Fuel Pump
If the unit is equipped with an optional electrical fuel
pump, it will be mounted on the fuel tank mounting
bracket. Use the following steps to bleed out the fuel
system:
3
a. Turn the bleed valve (Red) counter-clockwise until
fully opened. (See Figure 7-4)
b. Place unit in Manual Start Mode. (ManOp).
(Refer to Section 3.8.1.) Once the Run Relay ener-
gizes the fuel pump will start.
c. Allow the electric pump to operate for 2 to 3 minutes. 1
d. Place the controller in Auto Op to start engine.
e. When the engine is running properly, turn bleed valve 4
clockwise until fully closed. 2 1
7.6.3 Servicing Fuel Pump
The fuel screen may become plugged or restricted with
foreign particles or wax as a result of using the wrong 1. Hollow Bolt
grade of fuel or untreated fuel in cold weather. This will 2. Banjo
cause the engine to lose power. The screen must be 3. Filter
cleaned on a regular schedule such as unit pre-trip or 4. Copper Rings
when the oil and fuel filters are changed (Refer to Figure 7-5. Mechanical Fuel Pump and Inlet
Section 7.1). Screen
a. Turn hollow bolt counter-clockwise to loosen and
remove (Item 1, Figure 7-5). 7.7 ENGINE SERVICE & COMPONENTS
7.7.1 Engine Cooling System
NOTE
Once the bolt is removed fuel may drain from The engine is cooled by circulating a liquid coolant
through the engine to pick up the heat, then to the
the fuel line. Take care to drain fuel into a proper radiator where air moving through the
container. condenser/radiator removes the heat, and the cooled
coolant is returned to the engine to continue the cycle.
b. Remove banjo fitting (item 2) and let it hang loose,
making sure to keep copper rings (item 4) for replace- The radiator, externally and internally, must be kept
ment. clean for adequate cooling. The upper drive V-belt must
be adjusted periodically to prevent slippage in the
c. Unscrew the screen (Item 3), (Turn pulleys in order to provide maximum air flow through the
counter-clockwise) and remove. Check, clean and radiator. (Refer to Section 7.8.3)
reassemble.
d. Inspect copper rings (Item 4) for damage and replace
if necessary with new rings. CAUTION
e. To install reverse steps a. thru c. Use only ethylene glycol anti-freeze (with
inhibitors) in system as glycol by itself will
damage the cooling system.
Always add pre-mixed 50/50 anti-freeze and
water to radiator/engine. Never exceed
more than a 60% concentration of anti--
freeze. Use a low silicate anti-freeze meet-
ing GM specifications GM 6038M or equal.

7--11 62-11352
To service the cooling system: 7.7.2 Lube Oil Filters
a. Remove all foreign material from the radiator coil by To check the engine oil level:
reversing the normal air flow if possible. (Air is pulled Run the unit to bring the engine
in through the front and discharges out the top of the up to operating temperature,
Cap shut the unit off, and unscrew
unit.) Compressed air or water may be used as a Dipstick
cleaning agent. It may be necessary to use warm wa- the cap/dipstick. Wipe the dip-
ter mixed with any good commercial dishwasher de- stick clean and insert the cap
tergent. Rinse coil with fresh water if a detergent is into the oil fill tube without
used. threading it into the oil fill tube.
Remove the dipstick again and
NOTE check oil level. DO NOT add oil
Draining the coolant from the engine petcock if the level is in the “safe” range.
will leave approximately 1 quart (.9 liters) of If needed, add oil as indicated
coolant in the block. To completely drain the by markings on dipstick until
level is in the “safe” range.
coolant, the lower radiator hose must be re-
moved. QTS 2 1 SAFE
b. Drain coolant. To Change Engine Oil and Filters:
c. Install hose and fill system with clean, untreated wa- After warming up the engine, stop engine, remove drain
ter to which 3 - 5% of an alkaline based radiator clean- plug from oil reservoir and drain engine lube oil. Remove
er is added -- 6 oz (151 grams) to 1 gallon (3.78 liters) oil filter. Drain and discard properly. Lightly oil gasket on
of water. OR filter before installing. Tighten per the filter
d. Close drain cock and fill system with clean, untreated manufacturer’s directions.
water to which three to five percent of an alkaline
based radiator cleaner should be added [six dry
ounces (151 grams) to one gallon (3.78 liters) of wa- CAUTION
ter].
e. Run engine 6 to 12 hours and drain system while When changing oil filters, the new filters
warm. Rinse system three times after it has cooled should be primed with clean oil. If the filters
down. Refill system with water. are not primed, the engine may operate for a
f. Run engine to operating temperature. Drain system period with no oil supplied to the bearings.
again and fill with 50/50 water/anti-freeze mixture.
(see Caution Note and Refer to Section 2.8) NEVER Replace filter(s) and add lube oil. (Refer to Section 2.8)
POUR COLD WATER INTO A HOT ENGINE, how- Warm up engine and check for leaks.
ever hot water can always be added to a cold engine.

62-11352 7--12
LUBE OIL & FUEL FLOW DIAGRAMS 7.7.3 Electronic Speed Control (ESC)
Refer to Section 8 for schematic wiring diagram. Refer
5 to Section 6.4 for ESC diagnostic alarms and diagnostic
6 trees.
3

1 4

11

10 8
9

1 Fuel Tank 6 Fuel Warmer (Opti

2 Fuel Supply Line 7 Fuel Bleed Valve
3 Electric Fuel Pump 8 Injection Pump ENSSN
(Optional) 9 Injector Nozzles FSA
4 Mechanical Lift Pump 10 Fuel Leak-off Line
5 Fuel Filter 11 Fuel Return Line Figure 7-8. Electronic Speed Control
Components

Figure 7-6. Fuel System Diagram Engines with electronic speed control have no speed or
fuel solenoids. Engine speed is controlled by way of
three components: the engine speed control unit (EN-
5 SCU), the fuel and speed actuator (FSA) and the engine
1 speed sensor (ENSSN). The FSA performs the same
function as the solenoids. The ENSSN performs the
same function as the RPM sensor.
2 The ENSCU is mounted on the roadside frame behind
4 the upper door. It receives a signal from the ENSSN to
control the engine to the correct RPM. The output is to
the ENSCU which controls the actual engine speed. The
3 unit has an alarm LED incorporated within it, which
blinks at different rates depending on the alarm
condition, and are used to diagnose failures within the
ESC system.
1 Engine Block
2 Oil Pan
3 Full Flow Oil Filter
4 Engine Oil Connection
5 Oil Pressure Switch
Figure 7-7. Lube Oil Flow Diagram

7--13 62-11352
 7.7.5 Engine Crankcase Breather
The engine uses a closed type breather with the
breather line attached between the intake manifold and
the cylinder head cover. (See Figure 7-10)
The breather assembly should be disassembled and
cleaned once a year or at every 2000 hours mainte-
nance interval (whichever comes first). See 7.1

1
2
LED 3

Figure 7-9. Frame Mounted Engine Speed Control

Unit (ENSCU) 4

The FSA combines the fuel shutoff solenoid and speed

control solenoid into one component. Engine speed is
controlled by varying rod position further in or out of the
FSA.
1. Screw
The ENSSN provides the RPM signal to the ENSCU for 2. Breather Cover
speed control. 3. Breather Valve
7.7.4 Engine Air Cleaner 4. Breather Tube
a. Inspection Figure 7-10. Engine Crankcase Breather
The air cleaner should be inspected regularly for leaks.
A damaged air cleaner or hose can seriously affect the 7.7.6 Intake Air Heater
performance and life of the engine. The air cleaner is The Tier 4 engine uses an Air Intake Heater rather than
designed to remove contaminants from the air entering glow plugs to provide additional heat during engine
the engine. An excessive accumulation of these starting when the engine coolant temperature is below
contaminants in the air cleaner will restrict the air and 79°F (26°C). When the engine coolant temperature is
allow less air to the engine, causing excessive exhaust below this, the intake heater will come on prior to the en-
smoke and reducing engine power., Therefore a service gine cranking to warm the air that will go into the cylin-
schedule must be set up and followed. The air cleaner ders, then continues to heat during cranking, and after
filter element requires replacement when dirty. the engine starts.
b. Air Cleaner Service Indicator (Optional) a. To check out the Intake Air Heater:
An optional air cleaner indicator can be connected to the 1. Disconnect the wire lead to the heater terminal.
engine air intake manifold. Its function is to indicate
when the air cleaner requires replacement. During op- 2. Measure the resistance between the + terminal and
eration: When a plugged air cleaner causes the intake the heater body.
manifold pressure to drop to 20” (500 mm) WG, the indi- 3. If the resistance is infinity, the intake air heater is
cator will move to the red line. The air cleaner should open (faulty) and should be replaced.
then be replaced and the indicator reset by pressing the
reset button. 4. If the resistance is less than shown in 2.14, the
heater is shorted (faulty) and should be replaced.
c. Service Procedure
1. Stop the engine, and open roadside door.
2. Release 2 clips on air cleaner housing and remove + TERMINAL
bottom cover.
3. Remove filter element, wipe clean inside of air clean-
er housing and install new filter element.
4. Wipe clean inside of bottom cover and re-install. HEATER BODY
5. Re-secure 2 clips on air cleaner housing and close
roadside door.

Figure 7-11. Intake Air Heater

62-11352 7--14
b. To replace the heater: The belt tension gauge can be used to adjust all belts.
1. Remove the manifold inlet hose. The readings which we specify for Carrier Transicold
units are applicable only for our belts and application, as
2. Disconnect the wire lead to the + terminal. the tension is dependent on the size of the belt and dis-
3. Remove the four (4) bolts securing the flange and tance between sheaves. When using this gauge, it
should be placed as close as possible to the midpoint
heater to the intake manifold. between two sheaves. (See Figure 7-13.)
4. Remove the flange and the intake air heater. The V-belts must be kept in good condition with the
proper tension to provide adequate air movement
NOTE across the coils.
To avoid short--circuiting the heater, ensure that
the heater and the heater lines are vertical
when assembling the heater to the side of the
intake manifold.
When replacing the Air Intake Heater, the old
gaskets should be completely removed, and
new gaskets installed.

7.7.7 Alternator / Regulator Figure 7-12. Belt Tension Gauge

(Part No. 07-00253)
With the unit OFF and the alternator not rotating, the D+
circuit should be 0 VDC. If voltage is present when the
unit is OFF, the regulator has failed and needs to be re-
placed. (See 2.3.2. for information on proper voltage of
D+ circuit.)
7.8 SERVICING & ADJUSTING V-BELTS

WARNING
Beware of V-belts and belt driven compo-
nents as the unit may start automatically.
Before servicing unit, make sure the Place gauge
Start/Run--Off switch is in the OFF position. here
Also disconnect the negative battery cable.
Keep hands and arms away from unit when
operating without belt guard in place. Never
release a unit for service without the belt
guard securely tightened in place
Gearbox to
7.8.1 Belt Tension Gauge Fanshaft Idler
Use a belt tension gauge (tester) P/N 07-00253, shown Bolt
in Figure 7-12 whenever V-belts are adjusted or re-
placed. Figure 7-13. Gauge Placement
A belt tension gauge provides an accurate and easy
method of adjusting belts to their proper tension. Prop-
erly adjusted belts give long lasting and efficient service.
Too much tension SHORTENS belt and bearing life, and
too little tension causes slippage and excessive belt
wear. It is also important to keep belts and sheaves free
of any foreign material which may cause the belts to slip.

7--15 62-11352
 Gearbox to fanshaft Belt Note:
1 -- Loosen the pivot bolt
2 -- Using 1/2” ratchet, rotate idler until appropriate tension
is obtained.
3 -- Torque pivot bolt to correct tension

Upper Belt Idler Use 1/2” ratchet here

(Gearbox to Fanshaft)

Torque to 80 ft-lbs (108 Nm)

Pivot Bolt

Torque Pivot Bolt to 80 ft-lbs

(108 Nm)

Gearbox to Fanshaft Belt

Upper Belt
Alternator

Lower Belt Idler

(Engine to Gear-
box)

Torque Adjusting Bolt to 15

to 16 ft-lbs (20 to 22 Nm)

Water Pump/Alternator/Crank-
shaft Belt

Figure 7-14. V-Belt Arrangement

62-11352 7--16
 Table 7-1. Belt Tension (See Figure 7-14)
Replacement Belt Replacement Belt Tension After 15 Minutes of
BELTS Initial Tension Running Time
Lbs Mkg Lbs Mkg
Water Pump/Alternator/Crankshaft 45 to 55 6.2 to 7.6 45 to 55 6.2 to 7.6
Gearbox to fanshaft 140 19.4 70 to 80 9.7 to 11.1
Engine to Gearbox 140 19.4 70 to 80 9.7 to 11.1

7.8.2.Water Pump/Alternator/Crankcase V-Belt 7.8.3 Gearbox To Fanshaft And Engine To Gearbox

The water pump V-belt is driven by a sheave on the en- V-Belts
gine crankshaft. Frayed, cracked or worn belts must be
replaced. Adjustment is achieved by altering the posi- a. Gearbox to Fanshaft V-Belt (Upper Belt)
tion of the alternator.
When replacing a V-belt, avoid excessive force when
applying tension to the V-belt to prevent damage to the
WARNING
water pump bearings. (Refer to Table 7-1.) Beware of V-belts and belt driven compo-
a. Make sure negative battery terminal is disconnected nents as the unit may start automatically.
and remove old belt. Before servicing unit, make sure the
b. Place V-belt on alternator sheave and then loosely in- Start/Run--Off switch is in the OFF position
stall alternator in position with two bolts. or the unit is in Maintenance mode. Also
c. Check the center alignment of the engine drive, alter- disconnect the negative battery cable.
nator and water pump sheaves to ensure proper Keep hands and arms away from unit when
alignment. Pulley misalignment will create excess operating without belt guard in place. Nev-
belt wear and shorten alternator bearing life. The cen-
ter line of all three sheaves must be in line. er release a unit for service without the belt
guard securely tightened in place.
d. Pivot alternator to place tension on belt using hand
force only. Do not use pry bar or excessive force as it
may cause bearing failure. For correct belt tension To Replace V-belt for Steel Fan:
see Table 7-1. Tighten pivot and adjustment bolts. 1. Disconnect negative battery cable and remove V-belt
e. Reinstall negative battery cable. guard.
2. DO NOT START UNIT UNTIL V-BELT GUARD IS
RE--INSTALLED.
3. Loosen idler pulley.
4. Remove old belt and replace with new belt. (See
Figure 7-16.)
NOTE
Belt tension should be measured at the center
of the belt. (See Figure 7-13.)

5. Using a belt tension gauge (Figure 7-12) on the belt,

rotate idler pulley so that the gauge reads the correct
tension (Refer to Table 7-1).
6. Torque idler retaining bolt. (See Figure 7-14).
NOTE
Both belts must be checked and re--tensioned
after a brief run-in period. (See step NO TAG)

7. Reinstall belt guard and reconnect negative battery

cable. Start and operate unit in high speed for 15
minutes. Disconnect negative battery cable and
Remove belt guard Repeat steps 5. and 6.
8. Replace belt guard.
9. Reconnect battery cable.

7--17 62-11352
To Replace V-belt for Plastic Fan: b. Engine To Gearbox V-Belt (Lower Belt)
1. Disconnect negative battery cable and remove V-belt 1. Disconnect negative battery cable and remove V-belt
guard. guard and then loosen idler bolt.
2. DO NOT START UNIT UNTIL V-BELT GUARD IS 2. Match mark adapter to engine flywheel with a marker
RE--INSTALLED. (See Figure 7-16A) for ease of reassembly.
3. Loosen idler pulley. 3. Remove six bolts (M8 x 1.25 x 20mm lg) securing
4. Remove the 3 bolts that secure the fan to the clutch adapter drive sheave to engine flywheel,
assembly (See Figure 7-15). Figure 7-16A.
5. Slide fan away from the clutch and slide belt between 4. Insert 2 of the six bolts (M8 x 1.25 x 20mm lg) into the
assemblies. threaded holes (jacking holes) provided on engine
adapter. Jack adapter from engine flywheel. Remove
6. Remove belt from lower pulley and discard. the 2 screws from adapter. Insert a pry bar between
7. Slide new belt onto clutch groove and reposition fan engine flywheel and adapter, Figure 7-16A and slide
the adapter-sheave toward the compressor enough
blade to clutch with 3 bolts. Torque bolts to 18 to 22 ft to change the V-belt as shown in Figure 7-16B. Re-
lbs. (24.4 to 30 Nm). place V-belt.
8. Install belt onto idler and lower pulley. 5. Pry the adapter back toward the engine flywheel until
9. Using a belt tension gauge (Figure 7-12) on the belt, the bolts will start in the engine flywheel. Apply thread
rotate idler pulley so that the gauge reads the correct sealer (Loctite #262) to the bolts used to secure
tension (Refer to Table 7-1). adapter to flywheel. Tighten all bolts evenly and then
torque to a value of 28 ft-lb (38 Nm).
10. Torque idler retaining bolt. (See Figure 7-14).
6. Place V-belt on the Gearbox sheave and adjust belt
NOTE tension as indicated in Table 7-1. Install V-belt guard.
Both belts must be checked and re--tensioned DO NOT START UNIT UNTIL V-BELT GUARD IS
INSTALLED.
after a brief run-in period. (See Step NO TAG)
7. Reconnect negative battery cable. Start unit and run
11. Reinstall belt guard and reconnect negative battery for 15 minutes to allow for belt stretch.
cable. Start and operate unit in high speed for 15 8. Turn off unit and then disconnect the negative battery
minutes. Disconnect battery and Remove belt cable. Remove belt guard and belt and recheck belt
guard. Repeat steps 9. and 10. tension. Install belt guard. Reinstall the negative bat-
12. Replace belt guard. tery cable.
13. Reconnect battery cable.

Slide belt between fan

blade and clutch assembly.

Figure 7-15. Upper Belt Replacement -- Plastic

Fan

62-11352 7--18
 BELT NEW BELT
ADAPTER
MATCH MARK

FLYWHEEL ADAPTER FLYWHEEL

ATTACHING SCREWS

Figure A Figure B

Figure 7-16. Removing V-Belt from Engine Adapter Drive Sheave

7.9 FANSHAFT ASSEMBLY -- SEE Figure 7-18

For Plastic Fan:
WARNING c.Remove the retaining bolts that secure the Curbside
of fan shroud and remove fan shroud from unit.
Beware of V-belts and belt driven compo-
d. Remove the 3 bolts that thread through the back of
nents as the unit may start automatically. the clutch rotor/pulley forward into the condenser fan.
Before servicing unit, make sure the Carefully remove the condenser fan from unit. (See
Start/Run--Off switch is in the OFF position Figure 7-18)
or the unit is in Maintenance mode. Also For All Units:
disconnect the negative battery cable.
Keep hands and arms away from unit when NOTE
operating without belt guard in place. Never The armature--retaining bolt is a LEFT HAND
release a unit for service without the belt THREAD BOLT.
guard securely tightened in place
e. Remove the clutch armature. A standard 5/8-11 x 1”
7.9.1 Clutch Removal right hand thread bolt can be threaded through the
center to jack the armature off the shaft.
CAUTION f. Use spanner socket P/N 07-00303-02 to remove the
spanner nut that secures the clutch rotor.
Do not get anti-seize oil/compound onto
clutch contact surfaces. Thoroughly clean NOTE
off oil/compound with contact or brake The spanner nut is a LEFT HAND NYLOCK
cleaner if this occurs. THREAD NUT.

For All Units: g. Slide off and remove the clutch rotor/pulley. If the ro-
tor will not slide off easily, remove the condenser fan
a. Place the Start/Run--Off switch in the OFF position hub adapter from the fan. Place the adapter back-
and disconnect the negative battery cable. wards against the fanshaft hub, and thread three
b. Loosen the fan belt idler and remove upper drive belt. 5/16-18 x 2--3/4” long bolts from the back of the rotor
forward into the hub adapter. Tighten the bolts evenly
For Steel Fan: to pull the rotor off the fanshaft hub.
c. Remove the top 8 bolts (4 along top and 2 down each h.Unplug the clutch coil connector from the wiring har-
side) that hold fan shroud to condenser frame. ness, then remove the clutch coil. Be sure to retain
d. Remove the 3 bolts that thread through the back of all shims on fanshaft hub, correctly positioned
the clutch rotor/pulley forward into the condenser fan on fanshaft pin.
hub. Carefully remove the condenser fan & hub as-
sembly from unit. (See Figure 7-18)

7--19 62-11352
7.9.2 Blower Wheel And Fanshaft Removal 7.9.3 Fanshaft Installation
a. Place the Start/Run--Off switch in the OFF position
and disconnect the negative battery cable. a. Install key (included) into the shaft keyway.
b. Remove bulkhead and air chute (if equipped). Re- NOTE
move evaporator back panel. If it is necessary to drive the key into place, be
c. Remove the bolts that secure the upper DTT mount- sure to support the shaft while tapping the keys
ing plate and SAS mounting clamp to the nozzle cov- into place.
er. Hang harness down out of way, using care to pre-
vent cutting wires on evaporator coil. b. Position the fanshaft so that the housing is in the nor-
d. Remove the remaining bolts in the nozzle cover and mal mounting position, with the shaft horizontal and
carefully remove it from the pod. the vent hole facing directly up. Remove both pipe
plugs (1/8” NPT) from fanshaft.
NOTE c. Ensure that oil in the fanshaft is at proper level. If not,
The nozzle cover (P/N 58-04469-00) is sealed fill the fanshaft with oil (07-00373-00) until oil is at the
with a gasket (CTD P/N 42-00506-00). If the bottom of the level hole on the bottom of the fanshaft
gasket is damaged during removal, it MUST be (approximately 3 oz/89 ml). Apply pipe thread sealant
replaced. to the pipe plug on the side of fanshaft housing and
tighten. Reinstall pipe plug on hub to prevent oil spill-
age.
e. Remove the two 1/4-20 X 1” lg. bolts from the blower
wheel split-taper bushing. Insert them into the d. Install the fanshaft into the unit with the four fanshaft
threaded holes. Tighten bolts evenly to push the mounting bolts and torque bolts to 28 to 30 ft-lb (38 to
blower wheel away from the bushing. 41 Nm), making sure the plug for the vent is pointing
up.
f. Remove blower wheel and bushing from fanshaft.
g. Remove the fanshaft seal ring clamp and carefully NOTE
peel seal from pod (use a putty knife if needed). To aid in fanshaft alignment, install two 3/8”-16 x
1 1/2” studs (bolts with heads cut off) into the
NOTE fanshaft mounting hub. Once the first two fan-
The fanshaft seal (CTD P/N 42-00372-00) is shaft mounting bolts are loosely installed, re-
caulked to the pod. If seal is damaged during re- move the studs and install bolts.
moval, it MUST be replaced.
e. Apply pipe thread sealant to barb fitting and install into
h. Remove the four 3/8” bolts from the fanshaft. vent hole. Slide hose vent onto barb fitting.
i. Remove vent from fanshaft. f. Apply caulk to the fanshaft seal and place on the fan-
j. Remove fanshaft from unit. shaft. Place fanshaft seal ring clamp on seal and
torque to 50 ft--lbs (68 Nm).
k. Inspect key, keyway and shaft for wear.

62-11352 7--20
 Nozzle Cover -- Fanshaft
Be sure to adjust cover Fanshaft Seal --
placement so that blower Torque to 50 in ---
wheel is centered in lbs (5.6 Nm)
opening. Split Taper Bushing --Torque
Bolts Evenly, 10--11 ft-lbs.
(13.5 -- 15 Nm)

Blower Wheel
Torque Nozzle
Drain Hole
Cover Bolts to 20 Secure Fanshaft Seal Ring
inch-lbs. (2.3 Nm) Nozzle Cover Gasket Clamp Tightly around Seal and
Do Not Over--tighten! Pod
Fanshaft
Torque to 50 inch-lbs (5.6 Nm)

IMPORTANT: Make sure there is even clearance between blower wheel and pod
(approx. 1/4”), and between blower wheel and nozzle cover (approx. 1/4”). Nozzle cover
center venturi lip should overlap into blower wheel ID slightly.
Figure 7-17. Evaporator Blower Wheel and Nozzle Cover

7.9.4 Blower Wheel Installation

a. Make sure the key is properly placed in the keyway. d. Slowly and evenly torque blower wheel bolts to 10–11
Slide blower wheel and bushing onto shaft. ft-lbs. (14 to 15 Nm)
b. Loosely attach blower wheel to bushing and slide as- e. Position nozzle cover so that blower wheel is cen-
sembly forward until blower wheel touches pod (this tered in cover opening. Torque nozzle cover bolts to
will set approximate clearance between blower wheel 20 inch-lbs (2.3 Nm).
and pod).
f. Rotate blower wheel and check that clearance is
c. Loosely attach the nozzle cover to pod with retaining approximately 1/4.” Adjust nozzle cover and/or blow-
bolts. Install SAS and mounting clamp with at least er wheel if necessary.
1/2” of sensor protruding into the nozzle. Re-attach
the klixon. g. Re-install evaporator panel, re-attach air chute and
bulkhead (if equipped).
h. Reconnect negative battery cable.

7--21 62-11352
7.9.5 Clutch Installation
e. Install the new armature retaining bolt and washer.
CAUTION Use spanner wrench P/N 07-00396-01 (at the 2
o’clock position) to hold the armature, then torque the
Do not get anti-seize oil/compound onto retaining bolt to 25 to 30 ft--lbs. (34 to 41 Nm)
clutch contact surfaces. Thoroughly clean NOTE
off oil/compound with contact or brake
The armature--retaining bolt is a LEFT HAND
cleaner if this occurs.
THREAD BOLT.

NOTE f. Measure the clutch air gap with the air gap tool
Starting with the 50--00236--05 clutch, the ori- (CTD P/N 07-00432-00). The gap should be be-
entation of the clutch coil MUST be on the bot- tween 0.015 and 0.090 inches (0.38 and2.3 mm). If
it is not, remove entire clutch. If gap is less than
tom. Secure the harness to the lower right fan- 0.015” (0.38 mm), remove enough of the fan shaft
shaft mounting bolt using the cushion clamp hub shims to increase the gap to approximately
provided. 0.020” (0.51mm). Shims (CTD P/N 50-00232-30
are 0.010” (0.25mm) each. If the gap is more than
a. Place clutch coil onto fanshaft hub, with coil harness 0.090” (2.3 mm), add enough shims to reduce gap
on bottom. Make sure all original shims are cor- toapproximately0.020”(0.51mm).Reinstallclutch
rectly positioned on fanshaft pin, and then slide assembly and re--measure to verify air gap.
coil onto hub so fanshaft pin fits into notch in coil. g. Reinstall upper drive belt.
NOTE h. Re-attach the condenser fan (and hub assembly if ap-
plicable) to the clutch rotor. Thread the 3 bolts from
The fanshaft pin is used to position the coil to behind the clutch rotor into the condenser fan hub,
properly locate the wire harness to the frame. and torque the bolts to 18 to 22 ft-lbs (24 to 30 Nm).
b. Install rotor spacer and rotor onto the fanshaft. i. Re-install fan shroud, if applicable and the upper drive
belt and adjust idler to attain a belt tension of 70 to 80
c. Install the new spanner nut (included in mounting ac- ft-lbs (95 to 108 Nm).
cessory kit (CTD P/N 50-00236-21.) Use CTD span-
ner socket 07-00303-02 and torque to 80-85 ft-lbs j. For Steel Fan Only: Remove condenser fan shroud
(108 to 115 Nm.) spacers/supports that may have been inserted. Re--
install upper 8 bolts that hold shroud to condenser
NOTE frame.
The spanner nut is a LEFT HAND NYLOCK k. Plug the clutch coil connector back into the wiring har-
THREAD NUT. ness. Tie-wrap harness as needed to secure.
l. Re-connect negative battery cable.
d. Slide the armature into place on the fanshaft, making m. Check unit for proper clutch operation.
sure the key is in place and the keyway lines up cor-
rectly with the shaft key.
WARNING
Do not start unit without installing the evapo-
rator panels as unit damage or body harm
may result.

62-11352 7--22
 Apply thin layer of anti-seize compound to
smooth fanshaft hub surface behind threads

Fanshaft Hub, Clutch air-gap is set with

shims that mount here over fanshaft pin

Torque 3 Bolts 18 to 22 ft---

lbs.(24 to 30 Nm)

Condenser Fan Hub Clutch

Adapter Rotor

Clutch
Armature

Torque 4 Bolts 10 to 11
ft--lbs.(14 to 15 Nm)

Retaining Bolt, Torque 25 to 30 ft---

lbs. (34 to 41 Nm), Left Hand
Thread, use Service Tool
07-00396-01 for anti-rotation of arma-
ture

Clutch Coil, orient with harness on bot-

tom, fanshaft pin fits into notch in coil.
Spanner Nut, Torque 80 to 85 ft--lbs. (108 to
115 Nm.) Left Hand Thread, use Service Tool
07-00303-02

Figure 7-18. Steel Condenser Fan and Clutch

7--23 62-11352
 Fanshaft Hub, Clutch air-gap is set with
shims that position over fanshaft pin

Condenser Fan mounting bolts

Torque 3 Bolts 18 to 22 ft--lbs.(24 to Apply thin layer of anti-seize
30 Nm) compound to smooth fan-
shaft hub surface behind
threads

Condenser Fan Clutch

Rotor

Clutch
Armature

Retaining Bolt, Torque 25 to 30 ft---

lbs. (34 to 41 Nm), Left Hand Rotor
Thread, use Service Tool Spacer
07-00396-01 for anti-rotation of arma-
ture

Clutch Coil, orient with harness on bot-

tom, fanshaft pin fits into notch in coil.
Spanner Nut, Torque 80 to 85 ft--lbs. (108 to
115 Nm.) Left Hand Thread, use Service Tool
07-00303-02
Figure 7-19. Plastic Condenser Fan and Clutch

CAUTION
Overtorquing of fan mounting bolts could result in the stripping of fan hub threads. In this event, the
fan must be replaced. Thread stripping will occur at 30 ft--lbs (40.7 Nm) or more.

62-11352 7--24
7.10 CHECKING THE REFRIGERATION SYSTEM f. On units with automatic start/stop the microproces-
sor must be set for “MAN OP” and “CONTINUOUS
This refrigeration troubleshooting procedure is de- RUN” operation (Refer to Sections 3.2 and 3.6) and
signed to test the major components used in this Carrier left in there during the entire test. Unit must be re-
Transicold trailer refrigeration unit. This procedure, de- turned to “AUTO OP” at end of test.
signed primarily to test the system’s mechanical compo-
nents, can also point out many electrical problems. A The following tools are required to perform this proce-
sound knowledge of electrical and refrigeration funda- dure:
mentals and Carrier Transicold heat, cool and defrost 1. Refrigeration Ratchet
cycle operations is essential to perform this procedure. 2. Refrigeration manifold gauge set
NOTE (2 required)
The following troubleshooting procedures are 3. 5 feet square plastic sheet (2--4 mil)
designed to test the major components used in 4. 8 -- 10 inch adjustable end wrench
trailer refrigeration units using R--404A. The fol- 5. Wire cutters
6. DC volt ohm meter
lowing rules MUST be followed to ensure accu- 7. 07--50006--00 Quick Check Jumper Kit
rate results: which includes:
(1) Coil Tester (2--wire plug with 24” wire
a. Read and be sure to thoroughly understand all direc- leads and spring clips)
tions for each step before beginning that step. (1) Circuit Tester (male and female 2--wire
plugs wired together with bare wire for volt
b. Successfully complete each step in sequence. age test)
c. Repair any problems immediately and repeat the step (1) Bypass plug (2--wire plug with jumper
before continuing the procedure unless otherwise loop
noted. (1) 4’ jumper wire with spring clips
d. Operate the unit in High Speed Cool for 20 minutes
prior to starting this procedure Before starting test, install a manifold gauge set on com-
pressor service valve gauge ports, and a second man-
If possible, operate with a 35°F (1.7°C) setpoint, fully ifold gauge set with the high pressure gauge connected
loaded [unplug both unloaders when box temperature to the king valve. All gauge lines must be purged of air
reaches 35°F (1.7°C)]. This action allows the com- which could enter the system.
pressor oil to come up to operating temperature.
When these conditions are met, plug in both unload- The procedure may now be started. It may be helpful to
ers. refer to the refrigeration flow diagram (Section 2.16)
when following this procedure.
e. The ambient (air entering the condenser) air temper-
ature should be above +60°F (15.6°C). 7.10.1 Checking Refrigerant Charge and High Am-
bient Compressor Operation
NOTE a. Start the unit [setpoint at 11°F (--11.7°C)]. Allow the
Ambient temperatures below 60°F (15.6°C) unit to run until the engine reaches high speed. [The
could cause inaccurate results in any step of engine may start in low speed and remain there for 15
this procedure. In low ambient conditions it may seconds or until the engine coolant temperature
reaches 79°F (26°C)]. Partially cover the condenser
be necessary to partially cover the condenser to raise the discharge pressure to 20 to 30 PSIG (1.4
air inlet to restrict the air flow through the to 2.0 BAR) higher than it was.
condenser and raise the discharge pressure.
b. Check the receiver tank sight glasses for proper re-
This will simulate a warmer ambient frigerant charge. (Refer to Section 7.11.3.)
temperature.
c. See Sections 7.11.11 and b. for instructions on adding
refrigerant to the system.
d. Cover the condenser further to raise the discharge
pressure to 350 to 375 PSIG (23.8 to 25.5 BAR). This
ensures that the compressor can achieve sufficient
discharge pressure to operate in high ambient tem-
peratures. (It may be necessary to unplug the front
unloader).
e. Uncover the condenser. The unit should be left run-
ning in High Speed Cool.

7--25 62-11352
7.10.2 Compressor Unloader Valve Operation 7.10.3 SV4 And By--Pass Check Valve Seating
a. Units With Individual Wires Connected To The Ability During Cool
Unloaders: a. Slowly frontseat the king valve (receiver tank outlet
1. With the unit still running in High Speed Cool, remove valve) and pump down the low side of the system to
the white positive wire from the unloader coil(s). 0 PSIG. Do not allow the system to run in a vacu-
um.
2. Note the suction pressure.
b. Shut off unit and observe the suction and discharge
3. Using a jumper wire attached to the positive starter or pressures at the compressor. They should not equal-
battery post, apply 12 VDC to the front unloader coil ize in less than 30 seconds. If they do, it will indicate:
terminal. The suction pressure should rise noticeably 1. The by--pass check valve is leaking.
[approx. 5 to 10 PSIG (0.34 to 0.68 BAR)].
NOTE 2. Internal leakage inside the compressor -- unloader
valves, reed valves or head gaskets.
If no change in suction pressure occurs, check
the unloader coil ground connection and the coil 3. SV4 is leaking and not properly seated.
resistance before making any repairs to the un- NOTE
loader solenoid valve. This problem can be verified by carefully feeling
the refrigerant lines for hot/cold spots, or by
4. Remove the jumper wire and the suction pressure listening for internal leakage.
should drop.
5. Repeat steps 3. & 4. to cycle the unloader 3 to 4 times c. Any leakage, internal or external, found while per-
to verify consistent operation. forming this step MUST be repaired before continu-
ing.
6. Repeat steps 2. to 5. to check the rear unloader.
d. The unit should be OFF at the end of this step.
7. See Section 7.12.2 for unloader repair.
7.10.4 Discharge Line Check Valve Leakage, And
8. Reconnect the unloader wires. SV2 Seating & Opening Ability
9. Leave the unit running in High Speed Cool. a. Midseat (open) the hand valves on the manifold
b. Units With Unloaders Plugged Into the Wiring gauge set connected to the compressor. This action
Harness will allow the high pressure refrigerant in the dis-
charge line to bleed to the low side of the system, and
1. With the unit still running in High Speed Cool, unplug the gauge readings will balance out.
the unloader coil(s) from the wire harness.
b. After a short time (10 to15 seconds), frontseat (close)
2. Note the suction pressure. the hand valves on the manifold gauge set connected
3. Plug the front unloader wires into the coil tester. to the compressor and observe the high side gauge.
A continuous rise in pressure would indicate that the
4. Connect the black test lead to a good ground (negat- Discharge Check Valve is allowing pressure to leak
ive) connection. back into the compressor.
5. Momentarily connect the white test lead to the posit- NOTE
ive starter or battery post, apply 12 VDC to the front
unloader coil terminal. The suction pressure should If the check valve is leaking internally, it does
rise noticeably [approx. 5 to 10 PSIG (0.34 to 0.68 not have to be repaired until after completing
BAR)]. this procedure. It will have no effect on the re-
NOTE maining steps. See Section 7.12.10.
If no change in suction pressure occurs, check
c. Very slowly open the king valve to allow refrigerant to
the unloader coil ground connection and the coil pass through the filter--drier to the liquid line solenoid
resistance before making any repairs to the un- valve (SV2). Bring the king valve to the midseat posi-
loader solenoid valve. tion. SV2 should remain closed and there should be
no rise in suction pressure. A rise in suction pressure
6. Remove the white lead from the positive starter or indicates that SV2 is leaking and not properly seated.
battery post and the suction pressure should drop. See Section 7.12.10.
7. Repeat steps 5. and 6. to cycle the unloader 3 to 4
times to verify consistent operation.
8. Repeat steps 2. to 5. to check the rear unloader.
9. Reconnect the unloader wires.
10. Leave the unit running in High Speed Cool.

62-11352 7--26
d. Place the Start/Run--Off switch in the RUN position. b. For Units With The Unloader(s) and SV2
Observe the suction pressure gauge. After 5 seconds Plugged Into the Wire Harness:
SV2 will energize and open, causing the suction pres- 1.Unplug the front unloader from the wire harness, and
sure to rise to a maximum pressure of the MOP set- remove the white wire from SV3 valve.
ting of the TXV.
e. If the suction pressure does not rise, it could indicate 2. Unplug SV2 and connect the circuit tester between
the wire harness and the SV2 valve.
a restricted or blocked liquid line or TXV valve. Check
to be sure that the SV2 is energized and open. 3. Adjust setpoint to 77°F (25°C) or higher and start the
unit. The unit will run in low speed for 15 seconds,
NOTE then go into High Speed Heat. (It may be necessary to
This step does not check the superheat setting place the unit in High Airflow so that the engine will run
or the MOP of the expansion valve. Superheat in high speed).
must be done separately as outlined in Section 4. Connect a voltmeter to the circuit tester wires at SV2.
7.12.7. Observe the voltmeter and compressor discharge
gauge readings. The compressor discharge pressure
f. The unit should be OFF at the end of this step. will rise because SV1 should be closed, with only SV4
7.10.5 HP2 and SV2 for Cycling During Heat and De- open. When the discharge pressure rises to
frost 300 PSIG (20.4 BAR), the HP2 switch contacts will
open causing SV2 to close. This can be seen by the
a. For Units With Individual Wires Connected To
the Unloaders and SV2 voltmeter reading dropping to 0 VDC, and the com-
pressor discharge pressure decreasing. When the
1. Disconnect the white (positive) wire from the unload- discharge pressure drops to 200 PSIG (13.6 BAR),
ers. the HP2 switch contacts will close and open SV2
2. Adjust setpoint to 77°F (25°C) or higher and start the causing the discharge pressures to rise and 12 VDC
unit. The unit will run in low speed for 15 seconds, to show on the voltmeter. This action shows proper
then go into High Speed Heat. (It may be necessary to cycling of SV2 by HP2. Immediately reconnect the
place the unit in High Airflow so that the engine will run wire to SV3. (The HP2/SV2 cycling interval will de-
in high speed). pend on the ambient and box temperatures)
3. Connect a voltmeter to the positive terminal of SV2 5. Remove circuit tester from SV2 valve, plug front un-
(refer to wiring schematic if necessary -- Section 7) loader back into wire harness, and make sure the
leaving all wires to both HP2 and SV2 connected. Ob- wires to the SV3 valve are properly connected.
serve the voltmeter and compressor discharge gauge
readings. The compressor discharge pressure will 6. The unit should be “OFF” at the end of this step.
rise because SV1 should be closed, with only SV4 NOTE
open. When the discharge pressure rises to
This procedure does not check the actual set-
300 PSIG (20.4 BAR), the HP2 switch contacts will
open causing SV2 to close. This can be seen by the tings for the HP2 switch. If the switch opens and
voltmeter reading dropping to 0 VDC, and the com- closes within 15 to 20 PSIG (1.0 to 1.4 BAR) of
pressor discharge pressure decreasing. When the the rated settings, the switch is functioning
discharge pressure drops to 200 PSIG (13.6 BAR), properly. To actually determine the opening and
the HP2 switch contacts will close and open SV2 closing settings of the switch. (Refer to Section
causing the discharge pressures to rise and 12 VDC 2.12.)
to show on the voltmeter. This action shows proper
cycling of SV2 by HP2. Immediately reconnect the
wire to SV3. (The HP2/SV2 cycling interval will de-
pend on the ambient and box temperatures)
4. Refer to Section 7.12.10 for information on repairing
SV2 and Section 7.12.8 to replace HP2.
5. Reconnect wire to front unloader, and make sure
wires to SV2 are on coil.
6. The unit should be “OFF” at the end of this step.
NOTE
This procedure does not check the actual set-
tings for the HP2 switch. If the switch opens and
closes within 15 to 20 PSIG of the rated set-
tings, the switch is functioning properly. To actu-
ally determine the opening and closing settings
of the switch. (Refer to Section 2.12.)

7--27 62-11352
7.10.6 SV1 for Seating, Sv4 for Opening 5. Start the unit. Allow the unit to run 30 to 45 seconds.
a. For Units With Individual Wires Connected To The suction pressure should fall to approximately
the Unloaders and SV2 0 PSIG/BAR, and the receiver pressure near or below
200 PSIG (13.6 BAR). Closely monitor both high
1.Unplug the wire harness from the engine oil pressure pressure gauges while connected the wire to the HP2
switch, and install the bypass jumper plug into the switch. Compressor discharge pressure will begin to
wire harness. rise. Receiver pressure should not rise. When the
compressor discharge pressure reaches 390 PSIG
2. Remove the white wire from SV4 front unloader and (26.6 BAR), shut the engine off using the engine stop
one wire from the HP2 switch. lever near the injection pump. (The microprocessor
3. Readjust setpoint to 20° to 25° F (11° to 14° C) above will remain energized.) The compressor discharge
box temperature (high speed heat operation). (It may pressure will drop off, but the receiver pressure
be necessary to run the unit in “COOL” prior to this should not change. Any rise in receiver pressure in-
step.) dicates internal leakage at the SV1 valve.
4. Start the unit. Allow the unit to run for 30 to 45 6. Observe the suction gauge. Momentarily energize
seconds. The suction pressure should fall to approx- SV4 by connecting the white wire of the coil tester to
imately 0 PSIG/BAR, and the receiver pressure to the positive (+) starter post or battery post. The valve
near or below 200 PSIG (13.6 BAR). Closely monitor should open and the suction pressure begin to rise.
both high pressure gauges while connecting the wire Remove the wire and observe the pressures. The
to the HP2 switch. Compressor discharge pressure valve should close, and the suction pressure should
will begin to rise. Receiver pressure should not rise. stop rising. Energize the valve 2 to 3 times to verify
When the compressor discharge pressure reaches consistent valve operation.
390 PSIG (26.6 BAR), shut the engine off using the 7. Reconnect unit harness wires to SV4, front unloader,
engine stop lever near the injection pump. (The mi- and remove the bypass plug from the wire harness,
croprocessor will remain energized.) The com- and reconnect harness to the engine oil safety switch.
pressor discharge pressure will drop off, but the re-
ceiver pressure should not change. Any rise in receiv- 8. The unit should be “OFF” at the end of this step.
er pressure indicates internal leakage at the SV1
valve. 7.10.7 SV1 Defrost Operation
5. Observe the suction gauge. Using a jumper wire, mo- a. Place the unit into defrost manually.
mentarily energize SV4 by clipping one end to the b. Make sure the unit goes into defrost properly and the
post on SV4 and toughing the other end to the posit- engine is running in High Speed.
ive (+) starter post or battery post. The valve should
open and the suction pressure begin to rise. Remove NOTE
the jumper and observe. The valve should close, and If the ambient temperature sensor is above
the suction pressure should stop rising. Energize the 80°F (26.6° C), the high ambient defrost cycle
valve 2 or 3 times to verify consistent valve operation. will be initiated.
6. Reconnect the unit’s harness wires to SV4 and the
front unloader. Remove the bypass plug from the wire c. Check that the fan clutch has disengaged and the fan-
harness and reconnect harness to the engine oil shaft is not turning.
safety switch. d. The unit should come out of defrost automatically.
7. The unit should be “OFF” at the end of this step. The engine will shift to low speed, engage the fan
clutch, and resume High Speed Cool.
b. For Units With Unloaders, HP2 and SV3 Plugged
Into the Wire Harness: NOTE
1. Unplug the wire harness from the engine oil pressure Return unit to “AUTO OP” (Refer to Section 3.2)
safety switch, and install the bypass jumper plug in at end of this procedure in order to resume
the wire harness. normal operation.
2. Unplug the Front Unloader and the HP2 switch.
3. Unplug the wiring harness from SV4, and install the
coil tester. Connect the black wire to a good ground.
Clip the white wire onto an insulated portion of the
black wires so it does not touch any metal.
4. Re--adjust set point to 20 to 25°F (11° to 14° C) above
box temperature (high speed heat operation). (It may
be necessary to run the unit in “COOL” prior to this
step.)

62-11352 7--28
7.11 GENERAL REFRIGERATION SYSTEM 7.11.2 Connecting Manifold Gauges to King Valve
PROCEDURES
a. Backseat king valve. (turn stem completely
counterclockwise until it stops) to close off gauge
CAUTION connection and attach high pressure manifold gauge
line to king valve.
Do not vapor charge R-404A. Only liquid b. Open king valve 1/2 turn (clockwise). Purge manifold
charging through the receiver (king) valve gauge line.
is acceptable. 7.11.3 Checking The Refrigerant Charge

NOTE
NOTE
High speed operation at some conditions may
To avoid damage to the earth’s ozone layer, use create high turbulence inside the receiver. If it is
a refrigerant recovery system whenever remov- difficult to see the refrigerant settling properly in
ing refrigerant. When working with refrigerants
the receiver sight glass, unplug the speed sole-
you must comply with all local government envi-
noid, forcing low speed operation. There should
ronmental laws, U.S.A. EPA section 608. be less turbulence in the receiver and the liquid
Whenever the system is opened, it must be refrigerant should settle properly.
evacuated and dehydrated. (Refer to Section
7.11.10) NOTE
The ambient (air entering the condenser) air
The following equipment is required to service the temperature should be above 40°F (4.4°C)
refrigeration system:
a. Start unit in cooling mode. Run approximately ten
a. Appropriate returnable refrigerant drum, preferably minutes -- until the refrigeration system is warmed up
125lb (57 kg) net capacity. Also, a 50 lb. and the box temperature is less than 45°F (7.2C).
(23 kg) net capacity returnable drum may be used.
Refrigerant removal will be faster and more complete b. Partially block off air flow to condenser coil so
with the larger drum. discharge pressure rises to 230 PSIG (15.65 BAR),
or 20 -- 30 PSIG (1.4 -- 2.0 BAR) above what it was
b. Refrigerant manifold gauge set. during step a above.
c. Vacuum pump, preferably 5 cfm (8m3H), c. Check the lower sight glass to determine charge. The
P/N 07-00176-11. system is correctly charged when the lower sight
glass is not empty and the upper sight glass is
d. A good vacuum indicator such as a thermocouple not full.
vacuum gauge (vacuum indicator, P/N 07-00414-00).
(Do not trust a manifold compound (suction) gauge to d. If the system appears to be overcharged: Remove re-
determine when the system has been drawn into a frigerant through the king valve to correct refrigerant
“good” vacuum because of its inherent inaccuracy.) level.
e. Weight scales (0 to 300 lb. (0 to 91 kg) range, mini- e. If the refrigerant system appears to be undercharged:
mum). Verify that there are no leaks in the system, then add
liquid refrigerant through the king valve.
f.A 12 foot length of 3/8 ” (I.D.) evacuation hose or 3/8”
copper tubing with 3/8” female flare adapter on each
end. Do not use hose or tubing of smaller diameter or
the removal process will take considerably longer.

WARNING
Do not use a disposable refrigerant con-
tainer to store the charge as an explosion
may occur.

7.11.1 Connecting Manifold Gauges To Com-

pressor
a. Backseat suction and discharge service valves (turn
counterclockwise) to close off gauge connection and
attach manifold gauges to service valves.
b. Open valves two turns (clockwise). Purge manifold
gauge lines.

7--29 62-11352
7.11.4 Refrigerant System Leak Checking 7.11.5 Pumping Down An Operational Compressor
a. If the system was opened and repairs completed, To service an operable compressor, pump the re-
leak check the unit and replace the filter drier. frigerant into the condenser coil and receiver as fol-
b. The recommended procedure for finding leaks in a lows:
system is with a electronic leak detector. (A halide
torch will not work on units with HFC refriger- a. Attach the manifold gauges. (Refer to Section 7.11.1)
ants, such as R-404A). Testing joints with soapsuds b. Frontseat the compressor suction service valve by
is satisfactory only for locating large leaks, or pin- turning fully clockwise until it stops.
pointing small leaks once a general area has been
located. c. Start the unit and run in cooling until a slight vacuum
(1--2” Hg) is reached. Shut the unit down.
c. If the system is without refrigerant, charge system
with 1 to 2 ounces (0.03 to 0.06 Kg. ) of refrigerant so d. Frontseat the compressor discharge service valve
that the system pressure is between 15 to 20 PSIG and wait 5 minutes to verify vacuum is maintained. If
(1.0 to 1.4 BAR),. Remove refrigerant drum and leak the pressure rises above 0 PSIG (0 Bars), open the
check all connections. compressor discharge service valve and repeat steps
c. and d. until a vacuum is maintained.
e. Disconnect the negative battery cable.
CAUTION 7.11.6 Refrigerant Removal From An Inoperative
Compressor.
Only a refrigerant drum containing R404A
To remove the refrigerant from a compressor that is
should be connected to this refrigeration not operational in order to service or repair only the
unit in order to pressurize the system. Any compressor, do the following:
other gas or vapor will contaminate the sys-
tem which will require additional purging a. Attach the manifold gauges. (Refer to Section 7.11.1)
and evacuation of the high side (discharge) b. Disconnect the negative battery cable.
of the system. c. Completely frontseat both the compressor discharge
and suction service valves..
d. Remove refrigerant using a refrigerant recovery
system and repair any leaks. d. Recover refrigerant with a refrigerant reclaimer.
e. If the leak was not found with 15 to 20 PSIG (1.0 to 1.4 e. The compressor is now ready for repair,
BAR), the system pressure may be increased by maintenance, or component replacement.
connecting a dry nitrogen cylinder to the gauges, and f. After making necessary repairs, leak test and
increasing the system pressure to 100 to 150 PSIG evacuate the compressor. (Refer to Section 7.11.7.)
(6.8 to 10.2 BAR.)

WARNING
Do not use a nitrogen cylinder without a
pressure regulator. Cylinder pressure is
approximately 2350 PSIG (159.9 BAR). Do
not use oxygen in or near a refrigerant sys-
tem as an explosion may occur. (See
Figure 7-29)

f. Once the leak is identified, release the refrigerant &

nitrogen vapor pressure from the system, and repair
the leak.
g. Repeat steps c. to f. to verify that repaired area does
not leak.
h. Evacuate and dehydrate the unit. (Refer to Section
7.11.10.b.)
i. Charge unit with refrigerant. (Refer to Section
7.11.11 b.)

62-11352 7--30
7.11.7 Leak Testing, Evacuating and Putting the compressor reed valves or other internal compo-
Compressor Back Into Service nents. See Section 7.12.
a. Slowly open the Compressor Suction Service Valve d. Disconnect the negative battery cable.
to break the vacuum, then open the valve enough to
bring the pressure to 15 -- 20 psig (XX Bars), then e. Frontseat (close by turning clockwise) discharge
frontseat the valve again. Connect a line from a dry service valve and the refrigerant will be trapped
nitrogen cylinder pressure regulator, and increase the between the compressor discharge service valve and
pressure to 100 psig (xx Bars). the manual shut-off valve (king valve).
b. Leak test the compressor. If no leaks are detected, f. Check the manifold gauge pressure prior to opening
bleed the pressure off the compressor. If any leaks the refrigeration system. If the pressure rises, there
are detected, bleed off the pressure, and repair the may be residual liquid refrigerant in the evaporator, or
leak(s). Repeat steps NO TAG until no leaks are de- the SV4 valve may be leaking by, or the receiver by-
tected. pass check valve may be leaking by. Listen for any
sounds of internal leakage at these components. Re-
c. Using refrigerant hoses designed for vacuum service, connect the negative battery cable, and re--open the
connect a vacuum pump to center connection of man- suction service valve, start the unit, and repeat steps
ifold gauge set. Evacuate compressor to or below c. thru e. If the system can not be pumped down, the
500 microns. Close off pump valve, isolate vacuum entire refrigerant charge must be removed from the
gauge and stop pump. Wait 5 minutes to verify that system. (Refer to Section 7.11.9.)
vacuum holds at or below 500 microns.
d. Slowly open the Compressor Suction Service Valve NOTE
to break the vacuum, then fully open the valve, clos- Whenever the Compressor Discharge Service
ing it back in about 1 turn to allow a good pressure Valve is in the front--seated position, the
reading to the gauge. Then fully open the Compres- negative battery cable should be disconnected
sor Discharge Service Valve, also turning it back in 1 to prevent accidental starting of the unit.
turn.
e. Backseat compressor service valves and disconnect g. Before opening up any part of the system, a slight
manifold gauge set. positive pressure should be indicated on the pressure
f. Reconnect negative battery cable. gauge.
g. Start unit and check for correct refrigerant level and h. When opening up the refrigerant system, certain
correct unit operation. parts may frost. Allow the part to warm to ambient
temperature before dismantling. This avoids internal
h. Once vacuum is maintained, recharge high side with condensation, which allows moisture to enter the sys-
R-404a to proper charge. Backseat compressor ser- tem.
vice valves and disconnect manifold gauge set.
i. The low side of the refrigeration system is now ready
NOTE for repair, maintenance, or component replacement.
See Section 7.11.9 for instructions on removing j. After making necessary repairs, leak test and evacu-
refrigerant from the refrigeration system. ate the low side of the refrigeration system. (Refer to
Sections 7.11.4 and 7.11.10.c.)
7.11.8 Pumping Down The Unit NOTE
In order to service the components downstream of the Store the refrigerant charge in an evacuated
king valve (and back to the compressor, such as the dri- container if the system must be opened be-
er, TXV, evaporator coil, heat exchanger, evaporator
coil, and suction line), the refrigerant in the system can tween the compressor and the receiver. When-
be pumped down into the condenser and receiver tank ever the system is opened, it must be evacuated
by following this procedure and dehydrated. (Refer to Section 7.11.10)

a. Attach the manifold gauges. (Refer to Section 7.11.1)

b. Frontseat the receiver manual shut-off valve (king
valve) by turning clockwise. Start unit and run in cool-
ing mode. Place the Start/Run--Off switch in the OFF
position when compressor suction pressure ap-
proaches 1 PSIG (0.07 BAR).

CAUTION
Do not allow suction pressure to go below
0 PSIG/BAR.

c. If the compressor does not pump down to 1 PSIG

(0.07 BAR) there may be a problem with the

7--31 62-11352
7.11.9 Removing The Refrigerant Charge 7.11.10 Evacuation And Dehydration
In some cases the entire refrigerant charge must be re- Moisture is the enemy of refrigerant systems. The pres-
moved from the system in order to perform repairs. For ence of moisture in a refrigeration system can have
example, to service such components as the compres- many undesirable effects. The most common are cop-
sor discharge service valve, the discharge check valve, per plating, acid sludge formation, “freezing-up” of me-
SV1, SV4, the condenser, the receiver tank, the king tering devices (TXV) by free water, and formation of
valve, and the hot gas bypass check valve, the refriger- acids, resulting in metal corrosion.
ant must be removed from the system and stored in a
separate container. a. Evacuation and dehydration of compressor
a. Attach manifold gauges. (Refer to Section 7.11.1.) NOTE
b. Connect a 3/8” line from the King Valve to an empty Standard service hoses are not suitable for
refrigerant drum. evacuation purposes. Deep vacuum type
c. Start the unit and run in Cool. Cover the condenser to hoses should be used whenever evacuating a
raise the discharge pressure. refrigeration system.
d. When the discharge pressure has raised 30 -- 50
PSIG (2.0 to 3.4 BAR) above normal, open the valve 1. Attach manifold gauges. (Refer to Section 7.11.1.)
of the empty refrigerant container, and let the 2. If the compressor has been pumped down (Refer to
refrigerant flow into it. Sections 7.11.5 or 7.11.6) and the system pressure
e. Monitor the suction pressure. As it approaches 0 has been sealed off by having both the discharge and
PSIG, shut the unit off, and close the line to the the suction service valves front seated (closed) and
previously empty refrigerant drum. there is no pressure in the compressor, add a small
amount of refrigerant by opening the suction service
NOTES valve and letting some of the refrigerant from the sys-
tem into the compressor until the suction pressure
Refrigerant will flow from the system into the reaches 15 to 20 PSIG (1.0 to 1.4 BAR.) Close the
evacuated drum until system pressure is suction service valve. Increase the pressure to 50 to
equivalent to container temperature. For 100 PSIG (3.4 to 6.8 BAR) using dry nitrogen.
example, if a drum is at 90°F (32.2°C) in a 3. Leak test the compressor (Refer to Section 7.11.4) to
R404A system, when the system pressure verify there are no leaks, particularly around any
reaches 204 PSIG (13.9 BAR) no further areas that have just been installed or assembled.
transfer will take place. (For this reason, it is 4. Purge the pressure to the atmosphere. Leave the
possible to remove only approx. 77 to 83 % of manifold gauge hand valves open.
refrigerant by this method). 5. Connect a vacuum pump to the center tap of the man-
ifold gauge set.
It is good practice to place a USED
REFRIGERANT tag on drums that are used for 6. Open the vacuum pump and electronic vacuum
this purpose. gauge valves, if they are not already open. Start the
vacuum pump. Evacuate unit until the electronic va-
Install a drier in the charging line when cuum gauge indicates 2000 microns. Close the elec-
recharging this refrigerant into the system if tronic vacuum gauge and vacuum pump valves. Shut
off the vacuum pump. Wait a few minutes to be sure
there is the slightest possibility that moisture the vacuum holds.
had entered the system.
7. Evacuate unit to 500 microns. Close off vacuum
pump valve and stop pump. Wait five minutes to see if
f. Connect a refrigerant recovery system to the unit to vacuum holds below 1,000. (It is normal for the vacu-
remove the remaining refrigerant charge. Refer to in- um gauge to rise after the vacuum pump is stopped.)
structions provided by the manufacture of the refrig- This checks for residual moisture and/or leaks. If the
erant recovery system. pressure rises, repeat steps 6. and 7. until it holds. If
g. The entire refrigeration system is now ready for the vacuum holds, continue with step 8.
repair, maintenance, or component replacement. 8. Open the suction service valve, then the discharge
h. After making necessary repairs, leak test and service valve. Start and operate the unit.
evacuate the low side of the refrigeration system. 9. Check the refrigerant level and adjust as necessary.
(Refer to Sections 7.11.4 and 7.11.10.c.)
10. Remove the manifold gauge set and install caps on
all service valves.

62-11352 7--32
b. Evacuation and dehydration of system c. Evacuation and dehydration of the Low Side of
Evacuate and dehydrate only after pressure leak test. the Refrigeration System
(Refer to Section 7.11.4)
NOTE
Keep the ambient temperature above 60_F (15.6_C) to Standard service hoses are not suitable for
speed evaporation of moisture. If ambient temperature evacuation purposes. Deep vacuum type
is lower than 60_F (15.6_C), ice might form before mois-
ture removal is complete. Heat lamps, heat guns, or oth- hoses should be used whenever evacuating a
er alternate sources of heat may be used to raise sys- refrigeration system.
tem temperature.
1. Attach manifold gauges. (Refer to Section 7.11.1.)
NOTE
2. If the low side of the refrigeration system has been
Standard service hoses are not suitable for pumped down so that the system pressure has been
evacuation purposes. Deep vacuum hoses sealed off between the king valve and the suction
should be used whenever evacuating a refriger- service valves and there is no pressure in the low side
ation system. of the system, add a small amount of refrigerant by
opening the king valve slightly, and energizing the
1. Remove refrigerant using a refrigerant recovery sys- SV2 valve and letting some of the refrigerant from the
tem. (Refer to Section 7.11.9.) receiver into the low side of the system until the
suction pressure reaches 15 to 20 PSIG (1.0 to 1.4
2. The recommended method to evacuate and dehy- BAR.) This should be approximately 2 to 3 ounces
drate the system is to connect three evacuation (0.06 to 0.09 Kg.) of refrigerant. Close the king valve
hoses as shown in Figure 7-20 to the vacuum pump and de--energize the SV2. Increase the pressure to
and refrigeration unit. Also, as shown, connect an 50 to 100 PSIG (3.4 to 6.8 BAR) using dry nitrogen.
evacuation manifold, with evacuation hoses only, to
the vacuum pump, electronic vacuum gauge, and 3. Leak test the low side of the system (Refer to Section
refrigerant recovery system. 7.11.7) to verify that there are no leaks, particularly
around any areas that have just been installed or
3. With the unit service valves closed (back seated) and assembled.
the vacuum pump and electronic vacuum gauge
valves open, start the pump and draw a deep 4. Purge the pressure to the atmosphere. Leave the
vacuum. Shut off the pump and check to see if the manifold gauge hand valves open.
vacuum holds. This operation is to test the evacuation 5. Connect three evacuation hoses as shown in
pump and hose setup for leaks. Repair if necessary. Figure 7-20 to the vacuum pump and refrigeration
4. Midseat the refrigerant system service valves. unit. Also, as shown, connect an evacuation manifold
-- with evacuation hoses only -- to the vacuum pump,
5. Open the vacuum pump and electronic vacuum electronic vacuum gauge, and refrigerant recovery
gauge valves, if they are not already open. Start the system.
vacuum pump. Evacuate unit until the electronic vac- 6. With the unit service valves closed (back seated) and
uum gauge indicates 2000 microns. Close the elec- the vacuum pump and electronic vacuum gauge
tronic vacuum gauge and vacuum pump valves. Shut valves open, start the pump and draw a deep vac-
off the vacuum pump. Wait a few minutes to be sure uum. Shut off the pump and check to see if the vac-
the vacuum holds. uum holds. This operation is to test the evacuation
6. Break the vacuum with dry nitrogen. Raise system pump and hose setup for leaks. Repair if necessary.
pressure to approximately 2 PSIG (0.14 BAR). 7. Midseat the refrigerant system service valves.
7. Purge nitrogen from system. 8. Open the vacuum pump and electronic vacuum
8. Repeat steps 5. through 7. one time. gauge valves, if they are not already open. Start the
vacuum pump. Evacuate unit until the electronic
9. Evacuate unit to 500 microns. Close off vacuum vacuum gauge indicates 2000 microns. Close the
pump valve and stop pump. Wait five minutes to see if electronic vacuum gauge and vacuum pump valves.
vacuum holds. This checks for residual moisture Shut off the vacuum pump. Wait a few minutes to be
and/or leaks. If the vacuum holds, continue with step sure the vacuum holds.
10.. If the pressure rises, repeat steps 6. to 9. until it
holds. 9. Break the vacuum with dry nitrogen. Raise system
pressure to approximately 2 PSIG (0.14 BAR).
10. With the unit still in a vacuum, the refrigerant charge
may be drawn into the system from a refrigerant con- 10. Purge nitrogen from system.
tainer on weight scales. The correct amount of refrig-
erant may be added by observing the scales. (Refer
to Table 2-1)

7--33 62-11352
 10

8
11
12 1. Refrigerant Recovery Unit
2. Refrigerant drum
3. Evacuation Manifold
9 4. Valve
7
5. Vacuum Pump
6. Vacuum Gauge
7. King Valve
8. Receiver
13 9. Condenser
10. Evaporator
4 4
11. Discharge Service Valve
12. Suction Service Valve
3 13. Compressor

1
4
6

2 5

Figure 7-20. Vacuum Pump Connection

11. Repeat steps 8. through 10. one time evacuating the 13. Open the king valve, the suction service valve, then
unit to 500 microns. the discharge service valve. Start and operate the
12. Close off vacuum pump valve and stop pump. Wait unit.
five minutes to see if vacuum holds. This checks for 14.Check the refrigerant level and adjust as necessary.
residual moisture and/or leaks. If the vacuum holds,
continue with step 13. If the pressure rises, repeat 15. Remove the manifold gauge set and install caps on
steps 9. to 11. until it holds. all service valves.

62-11352 7--34
7.11.11 Adding A Refrigerant Charge b. Adding A Full Charge
a. Adding A Partial Refrigerant Charge
CAUTION
CAUTION Do not vapor charge R--404A. Only liquid
Do not vapor charge R--404A. Only liquid charging through the receiver (king) valve
charging through the receiver (king) valve is acceptable.
is acceptable.
1. Dehydrate unit to 500 microns and leave in deep vac-
uum. (Refer to Section 7.11.10.b.)
NOTE 2. Place drum of refrigerant on scale and connect charg-
The ambient (air entering the condenser) air ing line from drum to king valve. Purge charging line at
temperature should be above 40°F (4.4°C) king valve.
3. Note weight of drum and refrigerant.
1. Attach manifold gauges. (Refer to Section 7.11.1.)
4. Open liquid valve on drum. Midseat king valve and al-
2. Connect a second manifold test set discharge gauge low the liquid refrigerant to flow into the unit until the
to the king valve. Connect the suction pressure hose correct weight of refrigerant has been added as indi-
to manifold dead head port. Connect a charging line cated by scales. Correct charge will be found in
between the center tap of the second gauge set and Table 2-1.
refrigerant drum. Open the LIQUID valve on drum
and purge all hoses. NOTE
3. Place drum of refrigerant on scale and note weight. It is possible that all liquid may not be pulled into
4. Start the unit. Adjust the setpoint so that the unit will the receiver, as outlined in step d. In this case,
run in high speed cool mode. frontseat the receiver valve (king valve), then
5. Run the unit for approximately ten minutes -- until the start and run the unit in cooling until the correct
refrigeration system is warmed up and the box amount of refrigerant is added.
temperature is less than 45°F (7.2°C) and then
partially block off air flow to condenser coil so 5. When the scale indicates that the correct charge has
discharge pressure will rise 10 PSIG (0.68 BAR). been added, close liquid line valve on cylinder and
6. Check the appropriate sight glass to determine backseat the king valve. Remove charging hose.
charge. (See Step 9. for determination of charge.) If 6. Start unit and check for noncondensibles. (Refer to
undercharged proceed with step 7. Section 7.11.12).
7. Frontseat the king valve, and monitor the second set
of manifold gauges. When the king valve pressure
drops below the pressure in the refrigerant drum,
open the manifold gauge set discharge valve and al-
low liquid refrigerant to flow into the system.
8. While monitoring the appropriate sight glass, careful-
ly weigh the refrigerant into the system. Because the
unit is in this charging state, it is not possible to accu-
rately determine when the system is full; therefore,
never charge the system with more than 3 lbs. (1.4
kg) of refrigerant at a time.
9. After metering 3 lbs (1.4 kg) of refrigerant into the
system, close the valve of the manifold gauge set
connected to the king valve. Open the king valve,
partially block the air flow to the condenser coil and
allow the system to balance out (approximately 4--5
minutes and the box temperature is less than 45°F
(7.2°C). Check sight glass(es) to determine charge:
Charge the system until the refrigerant level is at cen-
ter line of the lower sight glass. THE LOWER SIGHT
GLASS SHOULD NOT BE EMPTY AND THE UP-
PER SIGHT GLASS SHOULD NOT BE FULL.
10. Start unit and check for noncondensibles. (Refer to
Section 7.11.12).

7--35 62-11352
7.11.12Checking For Noncondensibles TIP
“Noncondensibles” are gasses such as air, nitrogen, Once the refrigerant is removed from the
etc. that can find their way into the refrigeration system system into a recovery cylinder / drum, the
from leaks on the low side of the system while that part noncondensible gas(ses) will begin to rise to
of the system is operating in a vacuum, or due to poor the top of the cylinder. Do not move the cylinder
service practices. These noncondensibles generally do
not mix with the refrigerant but find their way to the while evacuating and dehydrating the system.
highest point of the system, (receiver and condenser) When re--charging the system, ONLY OPEN
since they are lighter than the refrigerant. Because they THE LIQUID VALVE ON THE RECOVERY
do not condense into a liquid they take up valuable DRUM. This will draw the refrigerant from the
space inside the system so that there is not as much bottom of the cylinder, leaving the
room for the refrigerant charge. This causes the
pressure on the discharge side of the system to become noncondensible gas(ses) at the top of the tank.
higher than normal. The greater the volume of It may be necessary to add new refrigerant to fill
noncondensibles, the higher the discharge pressure will the system.
read above normal.
It can be difficult and time--consuming to check for non- 7.11.13 Checking Compressor Oil Level
condensibles. Whenever the discharge pressure is a. Operate the unit in high speed, fully loaded cool for at
higher than normal, use the system troubleshooting least 15 minutes. Unplug wires to the unloaders if
guide (Refer to Section 6.) Noncondensible gasses in necessary to ensure 6 cylinder operation.
the refrigeration system are only one of the pos-
sible causes for higher than normal discharge pres- NOTE
sures. Check the oil sight glass on the compressor to
To check for noncondensibles, proceed as follows: ensure that no foaming of the oil is present after
a. Attach manifold gauges. (Refer to Section 7.11.1.) 15 minutes of operation. If the oil is foaming
b. Stabilize system to equalize pressure between the check the refrigerant system for flood-back of
suction and discharge side of the system. The engine liquid refrigerant. Correct this situation before
needs to be off for several hours. If necessary, open performing step 2.
the high and low side valves on the manifold gauge
set to equalize the pressures. b. After 15 minutes, and when the box temperature has
c. It is a good idea to also open the trailer or refrigerated dropped below 45°F (7°,C) initiate a defrost cycle.
container doors so that the inside and outside This will allow any residual oil in the system to be
temperatures are also equalized. returned to the compressor.
d. Measure temperature at any of the copper tubing in NOTE
the condenser. Operate the unit in defrost for 3--5 minutes only.
e. Check pressure at the compressor discharge service Do not allow the unit to terminate defrost
valve and at the king valve. automatically. The sudden reduction of crank-
f. Determine saturation pressure as it corresponds to case pressure at defrost termination could
the condenser temperature using the Temperature- cause a temporary increase in oil circulation
Pressure Chart, Table 7-6. and give a false oil level reading.
g. If gauge reading is 3 PSIG (0.2 BAR) or higher than
the calculated P/T pressure in step NO TAG, noncon- c. After 3 to 5 minutes of defrost operation, turn the unit
densibles are present. off and wait 5 to 15 seconds. Observe the compres-
h. Remove refrigerant from the entire refrigeration sor oil level in the sightglass. (See Figure 7-21.) Oil
system using a refrigerant recovery system. (Refer to level should be between the Minimum and Maximum
Section 7.11.8) marks.
i. Evacuate and dehydrate the refrigeration system.
(Refer to Section 7.11.10.b.)
j. Charge the unit with refrigerant. (Refer to Section
7.11.11 b.)

-- Maximum

-- Minimum

Figure 7-21. Oil Level in Sight Glass

62-11352 7--36
7.11.14 Adding Oil with Compressor in System threads. Install the oil port plug and tighten,Evacuate
the compressor crankcase. Close the gauge man-
ifold have valves and open both service valves be-
WARNING fore starting the unit.

Never run unit with discharge service valve 1

frontseated. 10 2
Never remove fill plug with pressure in 9
compressor.

Two methods for adding oil are the oil pump method and 8
closed system method.
a. Oil Pump Method 7
One compressor oil pump that may be purchased is a
Robinair, part no. 14388. This oil pump adapts to a one
U.S. gallon (3.785 liters) metal refrigeration oil container
and pumps 2-1/2 ounces (0.0725 liters) per stroke when 6
connected to the oil fill (item 3, Figure 7-22). There is no
need to remove pump from can after each use. 5 3
When the compressor is in operation, the pump check 4
valve prevents the loss of refrigerant, while allowing the
technician to develop sufficient pressure to overcome
the operating suction pressure to add oil as necessary. 1. High Pressure Switch Connection
2. Suction Service Valve
Backseat suction service valve and connect oil charging 3. Oil Fill Plug
hose to oil fill (Item 3, Figure 7-22). Purge the oil hose at 4. Bottom Plate
oil pump. Add oil as necessary (Refer to Section 2.11). 5. Oil Drain Plug
b. Closed System Method 6. Oil Level Sight Glass
7. Oil Pump
When an oil pump is not available, oil may be drawn into 8. Unloader Solenoid
the compressor through the oil fill port or through the 9. Discharge Thermistor Connection
suction service valve. 10. Discharge Service Valve
Figure 7-22. Compressor
CAUTION 7.11.15 Adding Oil to Service Replacement
Compressor
Extreme care must be taken to ensure the Service replacement compressors may or may not be
hose is immersed in the oil at all times. shipped with oil.
Otherwise air and moisture will be drawn If compressor is without oil:
into the compressor.
Add correct oil charge (Refer to Section 2.11) through
1. Attach manifold gauges. (Refer to Section 7.11.1.) the suction service valve flange cavity or by removing
the oil fill plug (See Figure 7-22)
2. Pump down compressor to remove the pressure
from it. Refer to Section 7.11.5. 7.11.16 To remove oil from the compressor:
3. Now, connect the suction connection of the gauge a. Close suction service valve (frontseat) and pump unit
manifold to the compressor suction service valve down to 1 to 2 PSIG (0.07 to 0.1 BAR). Shut off unit
port, and the common connection of the gauge man- and front seat discharge service valve. Use a
ifold to a vacuum pump. Remove the plug from the refrigerant reclaimer to remove any remaining
compressor oil fill port, and insert a suitable fitting to refrigerant.
permit one of the gauge hoses to be connected to it. b. Slowly remove the oil drain plug (item NO TAG
Remove the discharge hose from the gauge man- Figure 7-22) from the compressor and drain the prop-
ifold; connect one end to the compressor oil fill port, er amount of oil. Replace the plug securely back into
and immerse the other end in an open container of the compressor.
refrigeration oil. Start the vacuum pump, and pull the
compressor into a 10”-15” vacuum. Stop the pump. c. Open service valves and run unit to check oil level,
Watch the oil level in the sight glass. As it reaches the repeat as required to ensure proper oil level. (Refer to
minimum mark, stop the flow of oil from the contain- Section 7.11.13 for the proper method of checking the
er. (Refer to Section 2.11). oil level.)
4.Break any remaining vacuum (raise to 0 BAR/PSIG)
with refrigerant remaining in the system (crack open
the suction service valve), or from a fresh drum of re-
frigerant. Clean the threads of the oil port plug, and
apply a thread sealant such as teflon tape to the

7--37 62-11352
7.12 REFRIGERATION SYSTEM COMPONENT j. Slide the engine drive adapter away from the engine.
REPLACEMENT k. Disconnect wiring to unloader valve assemblies,
7.12.1Replacing The Compressor Compressor Discharge Temperature Sensor (CDT),
NOTES Compressor Suction Pressure Transducer (CSP)
and the wiring to the high pressure cutout switch
The service replacement compressor is sold (HP1) and the head pressure control switch (HP2).
without shutoff valves (but with valve pads). Identify wiring and switches if necessary. (See
The valve pads should be installed on the re- Figure 7-23.)
moved compressor prior to return shipping.
Customer should retain the original HP1, HP2, l. Remove 10 bolts from the engine-compressor bell
housing.
CDT, SPT, related fittings, unloader valves and
coils for use on replacement compressor. m. Disconnect ground strap from frame.
Check oil level in service replacement com- n. Attach sling or other device to the compressor.
pressor before starting the unit. (Refer to Sec-
tions 2.11, and 7.11.13) o. Slide compressor away from the engine enough to
clear bell housing of engine and remove compressor
from unit.
If compressor runs, pump down the compressor . (Refer
to Section 7.11.5.) p. Once compressor is on table, inspect the nylon drive
assembly for wear, sharp edges. Replace if needed.
Refer to Section 7.11.6 if compressor is inoperative. (See Figure 7-24).
a. Disconnect negative battery cable. q. Drain oil from defective compressor before shipping.
b. Remove the two rear compressor bracket mounting r. The original unloader valves must be transferred to
bolts (compressor shockmount end). the replacement compressor. Transfer the plug ar-
c. Block up engine. rangement that was removed from the replacement
compressor to the original compressor as a seal. If
d. Verify that all refrigerant has been pumped from com- piston is stuck, it may be extracted by threading sock-
pressor. et head cap screw into top of piston. A small Teflon
e. Loosen and unscrew the suction and discharge ser- seat ring at bottom of piston must be removed with
vice valve flange bolts by two complete revolutions the piston. If it remains in the head it must be re-
and leave threads engaged. moved before the unloader valve is installed.
f. Break seal between service valves and compressor s. Remove the HP1 / HP2 assembly (See Figure 7-23.)
by taping on the service valve flange, then remove and install on new compressor after checking switch
bolts from valve flanges. settings. Remove Compressor Discharge Tempera-
ture sensor (CDT), and install on new compressor.
g. Remove fuel filter bracket (if necessary) and any oth- Install compressor frame to new compressor (if re-
er interfering components from the compressor bell moved with defective compressor).
housing.
t. Transfer the brackets from the old compressor to the
h. Loosen lower belt idler and remove belt from gearbox. new one as needed. Use new locknuts.
i. Remove the 6 bolts that secure the engine drive
sheave adapter.

COMPRESSOR

HP1

HP2
CDT

Figure 7-23. Pressure Switch and Sensor

62-11352 7--38
 10
7
3
6
4
2 1. Compressor
2. Bolts
3. Compressor Bell Housing
4. Key
8 5. Compressor Drive Gear
9 6. Locking Tab
5 7. Nylon Drive Gear
8. Drive Sheave Bolts
9. V-Belt
10. Engine Adapter Drive Sheave

1
Figure 7-24. Compressor Drive Assembly

u. Install compressor in unit by reversing steps b. 7.12.2 Compressor Unloader Valve

through r. Use new locknuts when replacing com-
pressor bolts. Torque to 46 ft/lb (64 Nm). (Refer to The compressor unloaders (located on the compressor
Section 7.19.1 -- drive gear installation.)Install new cylinder heads) are controlled by relays UFR and URR
gaskets on service valves and tighten bolts uniformly. and the temperature controller. (Refer to Section 5.9)
a. To checkout the unloader valves:
NOTE
1. Attach manifold gauges. (Refer to Section 7.11.1.)
Remanufactured compressors are shipped
without oil. Do not start unit without adding oil. 2. Start the unit in cooling with the set point within 1 to
2_F (0.6 to 1.1_C) of the refrigerated compartment
See Section 2.11 for correct charge. temperature.
w. Fill compressor with oil. See oil specification Section 3. Unplug both unloader coils. The compressor should
2.11. be operating with all 6 cylinders. Note suction pres-
sure.
x. Evacuate compressor. (Refer to section 7.11.10.a.)
4. Use jumper wires connected to the unit battery to en-
v. Fully backseat (open) both suction and discharge ergize the UF (front unloader). Note discharge and
service valves. suction pressures, the suction pressure should rise
w. Reconnect battery cable and ground strap. approximately 3 PSIG (0.2 BAR), and the discharge
should drop approximately 5 to 15 PSIG (0.35 to 1.05
x. Check refrigerant level. BAR).
y. Check compressor oil level. (Refer to Section 5. Disconnect UF from the jumper wires so that it is
7.11.13) Add oil if necessary. de-energized and note pressures. Suction pressure
z. Start unit and check for noncondensibles. should drop and discharge pressure should rise by
the same amounts they changed in step 3 above.
aa. Check compressor unloader operation. (Refer to
Section 7.12.2) 6. Repeat steps 4. & 5. for UR (rear unloader). At the
end of the test, shut the unit off, remove jumper wires
ab. Pump the system down (Refer to Section 7.11.8.) and plug both unloaders back in to unit harness, be-
and replace the drier (Refer to Section 7.12.6.) fore placing the unit back in service.
NOTE
If either unloader coil energizes and the suction
and discharge pressures do not change, the
unloader assembly, including the coil, must be
checked and repaired / replaced as required.

7--39 62-11352
b. To replace the unloader coil: c. To replace the unloader valve internal parts:
NOTE 1. Attach manifold gauges. (Refer to Section 7.11.1.)
The coil may be removed without pumping the 2. Pump down the unit. (Refer to Section 7.11.8)
compressor down or removing any pressure Frontseat both the discharge and suction service
valves to isolate the compressor.
from the compressor.
3. Remove coil retaining cap (if equipped), and coil.
1. Disconnect leads. Remove retainer, if equipped. Lift 4. Remove enclosing tube assembly (item 2.,
coil from stem. (See Figure 7-25) Figure 7-25) using installation/removal tool supplied
2. Check unloader coil resistance with an ohm meter. with repair kit (item 3).
Correct resistance should be between 7.5 and 10.5 5. Check plunger for restriction due to: (a) Corroded or
ohms. worn parts; (b) Foreign material lodged in valve; (c)
3. Verify coil type, voltage and frequency of old and new Bent or dented enclosing tube.
coil. This information appears on the coil housing. 6. Install new parts. Do not over--tighten enclosing tube
4. Place new coil over enclosing tube and retainer and assembly. Torque to a value of 20 to 22 ft-- lbs (27 to
connect wiring. 30 Nm).
7. Remove supplied installation/removal tool. Install coil
Note: When installing and retaining cap (if equipped).
coil, make sure roll pin is 8. Evacuate and dehydrate the compressor. (Refer to
1.
fitted into stem nut, and Section 7.11.10.a.)
coil seats properly onto
Use tool pin to keep it from rotat- 9. Start unit and check unloader operation (Refer to
torque stem ing. Section 7.12.2.a).
nut to
d. To replace the entire unloader assembly:
20-22 ft-lbs 2.
1. Pump down the compressor and remove the refriger-
3. 9. ant pressure from it. (Refer to Section 7.11.5.)
4. 10. 2. Remove the coil from the unloader stem as described
in the section on replacing the unloader coil.
5.
3. Loosen and remove the three (3) Allen head screws
6. securing the valve body to the compressor head.
7. Torque 3 Bolts to
12-16 ft-lbs 4. Gently tap the side of the unloader valve body to
break the seal with the compressor head. Remove
the unloader valve from the compressor head.
11.
5. Remove and inspect the screen located in the ma-
12. chined area of the cylinder head. Remove any foreign
8. material from screen, and insert back into the head.
6. Install the new gasket onto the new unloader valve.
1. Coil Assembly 7. Valve Body Rotate the gasket until the holes in the gasket are
2. Stem/Enclosing Tube 8. Gasket, Valve Body aligned with the holes in the unloader valve body. The
Assy 9. Pin, Anti-Rotation (fits three (3) holes are not evenly spaced around the
3. Installation/Removal into top of stem nut) valve body, and there is only one (1) way that the
valve can be correctly installed. Once the correct ori-
Tool 10. Bolts, Valve Body (3) entation of the gasket is found, the tab on the gasket
4. Spring, Plunger 11. Washers (3) can be used as a guide as it will be pointed toward the
5. Plunger Assembly 12. Piston top side of the head when installed.
6. “O” Ring 7. Compress the piston ring on the new unloader piston,
and insert the unloader piston into the unloader bore,
using care to not damage or break the piston ring.
Figure 7-25. Unloader Solenoid Valve Ring compression pliers (CTD P/N 07--00223--00)
are designed for this purpose.
8. Insert and tighten the three (3) Allen screws evenly.
Torque to 12 to 16 Ft. Lbs. (16.3 to 21.7 Nm)
9. Pressurize and leak test compressor (Refer to Sec-
tion 7.11.4.)
10. Evacuate and dehydrate compressor. (Refer to
Section 7.11.10.a.)

62-11352 7--40
7.12.3 Compressor Discharge Temperature Sensor Check and verify the reading. If the reading is 0 (zero)
(CDT) the SPT is correctly calibrated and can be reinstalled.
The Compressor Discharge Temperature Sensor (CDT) If the reading is not correct, or if the transducer is be-
is located in the center compressor head. This sensor ing replaced, continue to step e. below to calibrate it.
reads the temperature of the discharge gas in the com- e. Connect wiring to new suction pressure transducer.
pressor. The microprocessor monitors this temperature Before installing suction pressure transducer into
and will shut the unit down if the temperature rises to the compressor, display the suction pressure in the Unit
shutdown value (Refer to Section 2.3.6 for CDT shut- Data List on the micro display. While the suction
down temperature). pressure is being displayed, press and hold the
See Table 7-5 to test the CDT. ENTER key for 5 seconds. Once calibrated, the
display will read “0”. When the display reads “0”
To replace the CDT: install suction pressure transducer into compressor.
a. Attach manifold gauges. (Refer to Section 7.11.1.)
NOTE
b. Pump down the compressor and remove the refriger- If display doesn’t indicate zero, check suction
ant pressure from it. (Refer to Section 7.11.5). pressure transducer and microprocessor
c. Disconnect the wire connector to the CDT, and re- wiring.
move the CDT from the compressor head.
d. Apply high temperature thread sealant (such as Te- f. Install new suction pressure transducer onto the
flon tape) to the new CDT threads and install. Tighten schrader fitting and reconnect starter wire.
securely. g. If the schrader valve allowed the removal of the SPT
e. Leak test the compressor. (Refer to Section 7.11.4.) without removing all the refrigerant from the
compressor, the unit is ready to be started and
f. Evacuate and dehydrate the compressor (Refer to checked out. If the schrader valve leaked, and all the
Section 7.11.10.a.) refrigerant was removed, the compressor should be
g. Remove the manifold gauges, and reinstall all service evacuated before starting the unit (Refer to Section
port caps. 7.11.10.a.)
7.12.4 Suction Pressure Transducer (SPT) 7.12.5 Check Valves
Before installing a new suction pressure transducer it A check valve allows refrigerant to travel only in one
must be calibrated. direction.
The calibration can only be performed when the SROS The function of the hot gas bypass check valve is to
is in the Run position and the run relay is de--energized. raise the receiver pressure when the ambient tempera-
This prevents the operator from accidently calibrating ture is low so that refrigerant can flow from the receiver
the unit with the sensor in the system. The reading of the to the evaporator when the unit is in heating or defrost.
sensor must be at atmospheric pressure (0 PSIG/BAR). The function of the discharge line check valve is to
If the sensor reading is greater than 20 PSIG (1.36 BAR) prevent any refrigerant from migrating back into the
or less than --13.6inHg it can not be calibrated. Once the compressor during the unit off cycle or when the unit is
micro is calibrated, the display will show the actual pres- shut off.
sure value.
NOTE
To check and calibrate the SPT:
These check valves are not serviceable and
a. Pump down the compressor and remove the refriger- must be removed and replaced as an assembly.
ant pressure until it is down to 0 to 2 psig (xx Bars).
(Refer to Section 7.11.5)
b. Place the Start/Run--Off switch (SROS) in the OFF
position and unplug the starter solenoid wire from the
starter solenoid. Place the SROS in the Start/Run
position and let unit fail to start. This will de-energize
run relay.
c. Disconnect the wiring, unscrew and remove the SPT.
There is a schrader fitting in the connecting fitting,
and no refrigerant pressure should be lost. If there is
any refrigerant leakage when the SPT is removed, all
the pressure will have to be removed from the com-
pressor before removing the SPT. (Repeat step a.,
but bring the pressure down to 0 PSIG/BAR.
d. With the SPT removed from the compressor it should
read 0 PSIG / BAR in the Unit Data List on the micro.

7--41 62-11352
 f. Evacuate and dehydrate unit. (Refer to Section
7.11.10.b.)
g. Add a complete refrigerant charge to the system.
(Refer to Section 7.11.11. b.)
h. Start the unit and check the refrigerant charge. Add
charge if necessary. (Refer to Sections 7.11.3 and
7.11.11)
7.12.6 Checking And Replacing Filter-Drier
07--00457--00 Check for a restricted or plugged filter-drier by feeling
the liquid line inlet and outlet connections of the drier
cartridge. If the outlet side feels cooler than the inlet
side the filter-drier is restricted and should be changed.
To replace the filter--drier:
Figure 7-26. Discharge Check Valve a. Pump down the unit per Section 7.11.8.
(Non--Serviceable) b. Loosen the inlet and outlet fittings.
c. Remove bracket, then remove drier.
d. Install and lubricate o--rings on drier.
e. Position drier so that arrow points in downward
direction (the direction of the refrigerant flow.)
f. Tighten fittings on drier.
g. Secure clamp.
h. Open the king valve slightly to pressurize the drier,
then close the king valve. Check drier connections for
leaks.
i. Once there are no leaks, evacuate & dehydrate the
low side of the refrigeration system. (Refer to Section
7.11.10.c.)
j. Start the unit and check refrigerant level.
Figure 7-27. Hot Gas Check Valve
(Non--Serviceable) 7.12.7 Thermostatic Expansion Valve
To replace the check valves: The thermostatic expansion valve (TXV) is an automat-
ic device which maintains relatively constant superheat
a. Attach manifold gauges. (Refer to Section 7.11.1.) of the refrigerant gas leaving the evaporator regardless
b. Store the refrigerant in an evacuated container. (Re- of suction pressure. The valve functions are: (a) auto-
fer to Section 7.11.8) matic response of refrigerant flow to match the evapora-
tor load and (b) preventing liquid refrigerant from enter-
c. Using a pipe cutter, cut the valve stub--outs on valve ing the compressor. Unless the valve is defective, it sel-
and unsweat the remaining stub--out from the con- dom requires any maintenance.
necting copper in the unit.
NOTE NOTE
Inert brazing techniques MUST be followed Superheat cannot be adjusted on the braze--in
during replacement of valves. For more infor- TXV. If the superheat is out of adjustment, the
mation see 98--50553--00 -- Technical Proce- valve must be replaced.
dure on Inert Gas Brazing.
The expansion valve and bulb location are
NOTE shown in Figure 2-6.
When replacing the discharge check valve,
When conducting the following test the suction
place the magnetic discharge check valve tool
pressure must be at least 6 PSIG (0.4 BAR) be-
(07--00457--00) on top of the check valve cap
low expansion valve maximum operating pres-
(Figure 7-26) to pull the plunger from the body
sure (MOP). (Refer to Section 2.12)
seat. This step is not necessary for the Hot Gas
Bypass Check Valve.
Use a wet rag to prevent the new check valve
and the system tubing from overheating
whenever brazing.
d. Silver braze in the new valve using caution so as to
not overheat the new valve or the copper tubing.
e. Pressurize the system and leak test the new
connections.

62-11352 7--42
a. To measure superheat: b. To replace the TXV:
1. Remove evaporator panel from rear of unit and then 1. Pump down the unit by closing the king valve. (Refer
remove Presstite from expansion valve bulb and suc- to Section 7.11.8)
tion line.
2. Remove insulation (Presstite) from expansion valve
2. Loosen one TXV bulb clamp and make sure area un- bulb and then remove bulb from suction line.
der clamp (above TXV bulb) is clean.
3. Remove Presstite from the expansion valve power
3. Place thermocouple above (parallel with) the TXV head.
bulb and then secure loosened clamp making sure
both bulbs are firmly secured to suction line as shown 4. Cut TXV from system tubing close to TXV body.
in Figure 7-28.
NOTE
4. Connect an accurate gauge to the 1/4” port on the Use a wet rag to prevent system tubing from
suction service valve.
overheating whenever brazing.
5. Run unit until stabilized. Set controller 10_F (5.5_C)
below box temperature. 5. Unsolder TXV stubs from piping.
6. From the temperature/pressure chart (Refer to 6. Inspect strainer for debris. Clean if possible. Replace
Table 7-6), determine the saturation temperature cor- if strainer is torn. Install new strainer, with cone of
responding to the evaporator outlet pressure. screen pointing into liquid line at inlet to the valve.
7. Note the temperature of the suction gas at the expan- 7. Position new valve.
sion valve bulb.
8. Wrap valve with wet rags to keep TXV cool whenever
8. Subtract the saturation temperature determined in brazing and clean all tube stubs in system tubing so
Step NO TAG from the average temperature mea- new valve fits easily.
sured in Step NO TAG The difference is the super-
heat of the suction gas. 9. Solder valve in place and cool connections with wet
rag.
10. Pressure test braze joints for leaks.
11. The thermal bulb is located at 5 or 7 o’clock position
on the suction line (See Figure 7-28). This area must
be clean to ensure positive bulb contact. Apply ther-
mal mastic and strap thermal bulb to suction line and
insulate both with presstite.
12. Wrap TXV power head with presstite.
13. Evacuate by placing vacuum pump on suction ser-
vice valve. (Refer to Section 7.11.10.)
14. Open king valve and start the unit. Check refrigerant
level. (Refer to Section 7.11.3)

3.
4.
2.
5.
1.

1. Suction Line
2. TXV Bulb Clamp
3. Nut and Bolt (Clamp)
4. Thermocouple
5. TXV Bulb (At 5 or 7 o’clock
position)
Figure 7-28. Thermostatic Expansion Valve
Bulb and Thermocouple

7--43 62-11352
7.12.8 High Pressure Cutout Switches b. To replace a high pressure cutout switch:
1. Pump down the compressor and shut the unit off.
(Refer to Section 7.11.5)
WARNING
Do not use a nitrogen cylinder without a WARNING
pressure regulator. Cylinder pressure is
approximately 2350 PSIG (159.9 BAR). Do Never run unit with discharge service valve
not use oxygen in or near a refrigerant sys- frontseated.
tem as an explosion may occur. (See
Figure 7-29) 2. Frontseat the discharge service valve in order to isol-
ate the compressor.
1 3. Disconnect the negative battery cable.
4
4. Recover any remaining refrigerant using a reclaimer
1. Cylinder Valve until the pressure in the compressor is 0 PSIG /
2 5 BARS.
and Gauge
2. Pressure Regulator 5. Disconnect wiring from defective switch. The high
3. Nitrogen Cylinder pressure switches (HP1 & HP2) are located in the
4. Pressure Gauge center cylinder head. (See Figure 7-22) Unscrew the
defective switch.
3 6 [0 to 400 PSIG
(0 to 27.2 BAR)] 6. Install new switch after verifying switch part number
and settings. (Refer to Section 2.12)
5. Bleed-Off Valve
6. 1/4 inch Connection 7. Evacuate and dehydrate the compressor. (Refer to
Section 7.11.10.a.)
8. Open the discharge and suction service valves.
Figure 7-29. Typical Setup for Testing A 9. Reconnect the negative battery cable.
High Pressure Switch 10. Start the unit and check the refrigerant charge (See
Table 2-1.)
a. To check High Pressure Switch (HP1 or HP2)
7.12.9 Receiver Sight Glass Assembly
Remove switch as outlined in steps 1. through 5. in the Or Fusible Plug
following section.
To replace the receiver sight glass assembly or the
1. Connect ohmmeter or continuity light across switch fusible plug:
terminals. Ohmmeter will indicate resistance and
continuity light will be lighted if switch closes after re- a. Remove refrigerant from the unit and store the refrig-
lieving pressure. erant in an evacuated container. (Refer to Section
7.11.8)
2. Connect switch to a cylinder of dry nitrogen. (See
Figure 7-29) b. Unscrew the sight glass assembly. Wrap threads with
Teflon tape or spread some high quality thread
3. Set nitrogen pressure regulator higher than cutout sealing compound on pipe threads of new sight glass
point on switch being tested. Pressure switch cutout assembly or fusible plug and install. The torque value
and cut-in points are shown in Section 2.12. for either the sight glass assembly or the plug is 20-25
4. Close valve on cylinder and open bleed-off valve. ft-lbs (27 to 34 Nm)
5. Open cylinder valve. Slowly close bleed-off valve and c. Leak check receiver sight glass or fusible plug per
increase pressure until the switch opens. If light is Section 7.11.4.
used, light will go out. If an ohmmeter is used, the d. After leak checking unit, evacuate and dehydrate as
meter will indicate open. Note the pressure reading at outlined in section 7.11.10.
the time the switch contacts opened.
e. Check the refrigerant charge, and add refrigerant if
6. Slowly open bleed-off valve (to decrease pressure) necessary. (Refer to Section 7.11.3)
until switch closes (light will light or ohmmeter will
move) and note the pressure reading at the time the f. Check for noncondensibles. (Refer to Section
switch contacts closed.. 7.11.12).
7. Repeat steps 5. and 6. several times to verify the
consistency of the switch operation.
8. Compare the readings from 5. and 6. with the values
in Section 2.12. If the actual readings are more than
¦ 10 PSIG (0.7 BAR) away from the specification the
switch should be replaced.

62-11352 7--44
7.12.10 SV2/SV4 4.Tighten enclosing tube assembly according to the fol-
lowing chart and leak check the valve (Refer to Sec-
tion 7.11.4)
CAUTION SEAL DESCRIPTION TORQUE VALUE
Do not over tighten or damage the TEFLON (WHITE) 250 in--lbs (28 Nm)
enclosing tube assembly. Torque to value NEOPRENE (BLACK) 100 in--lbs (11 Nm)
shown in directions only. Also make sure all
parts are placed in the enclosing tube in 5. Install coil assembly and retainer.
proper sequence to avoid premature coil c. Leak test valve.
burnout.
6. For SV2 repairs, where the system was pumped
down, follow the directions for putting the system
NOTE back into service in Section 7.11.10.b.
Coils may be replaced without removing the re-
7. For SV4 repairs where all the refrigerant was
frigerant or pumping the unit down. removed from the system, follow the directions for
putting the system back into service in Section
a. To replace the coil: 7.11.10.b.
1. Unplug the coil from wiring harness, remove the coil 8.Start unit and check refrigerant charge per Section
retainer and coil assembly. 7.11.3.
2. Verify coil type and voltage. This information appears d. Check refrigeration cycles.
on the coil housing.
3. Place new coil over enclosing tube and retainer and 1.
connect wiring.
b. To replace the internal parts:
To service the liquid line solenoid valve (SV2) pump the
unit down. (Refer to Section 7.11.8)
To service the hot gas solenoid (SV4), remove and store 3.
the refrigerant charge in an evacuated container. (Refer
to Section 7.11.10) 2.
1. Remove coil retainer and coil assembly from valve. 4.
Remove enclosing tube assembly and related items. 5.
2. Check for foreign material in valve body.
6.
3. Install new parts.
NOTE 7.
Rebuild kit (P/N 14--00150--51) contains both a
black neoprene seal and a white teflon seal. Use 8.
the one that matches seal in existing valve. The
valve with the teflon seal can be identified by two
9.
dimples in the housing. (See Figure 7-30)
10.

1. Retainer 6. Gasket
2. Coil Assembly 7. Piston Assy
DIMPLES 3. Enclosing Tube Assy 8. Body
4. Plunger Spring 9. Bracket Adapter
5. Plunger Assy 10. Manual Stem
Assembly

Figure 7-31. SV2 and SV4

Figure 7-30. SV2/SV4 MARKING

7--45 62-11352
7.12.11 SV1 b. To replace the SV1 coil:
To obtain proper heating and defrost, the normally open
(N.O.) SV1 solenoid valve must energize and close NOTE
tightly during the heat and defrost cycles. If the valve The coil may be replaced without removing the
does not close tightly due to physical damage, foreign refrigerant or pumping the unit down.
material or wear, refrigerant leakage through the valve
can reduce heating capacity. 1. Remove top locknut, spacer cup and nameplate.
During normal heat or defrost cycles the following condi- 2. Disconnect wiring and remove coil.
tions will be observed when the valve is operating prop-
erly: 3. Replace coil by reversing steps 1. and 2.
a. Receiver refrigerant level will drop quickly at the initia- c. To replace the SV1 internal components:
tion of heating or defrost mode. 1. Remove and store the refrigerant charge in an eva-
b. Suction pressure will rise slowly to 90 to100 PSIG cuated container. (Refer to Section 7.11.9.)
(6.12 to 6.80 BAR). 2. Remove the top locknut, spacer cup, nameplate, coil
c. Discharge pressure will drop quickly, but begin to rise assembly and spacer.
to a minimum of 250 PSIG (17.0 BAR) within 15 to 20 3. Using a 12 point, 1-3/8 inch box wrench, loosen the
minutes. enclosing tube locknut and bleed off remaining refrig-
a. To check SV1: erant.
If suction and discharge pressures remain low and the 4. Remove enclosing tube and locknut assembly. The
receiver level does not drop, the valve may be inopera- gasket is inside the enclosing tube.
tive and can be checked by the following method: 5. Remove seat disc from inside of body, check for ob-
1. Attach manifold gauges. (Refer to Section 7.11.1.) structions, foreign material and wear inside valve
body.
2. Re-adjust the setpoint to 20 to 25°F (11.1 to 13.9°C)
above box temperature so that the unit will be able to 6. Place the seat disc into the valve body with the small-
start. (It may be necessary to run unit in Cool prior to er diameter end facing up.
this step). 7. Place the enclosing tube locknut over the enclosing
3. With the unit off, disconnect the oil pressure safety tube. Install spacer over enclosing tube making sure it
switch and place a jumper across the plug terminals. is seated properly in the enclosing tube locknut. Tight-
en enclosing tube locknut to a torque value of 250
4. Remove the wires from SV4, Front Unloader, and the inch-lb (28 Nm). Do not over--tighten.
HP2 switch.
5. Start the unit. Allow the unit to run 30 to 45 seconds. 8. Leak test the refrigeration system. (Refer to Section
The suction pressure should fall to approximately 7.11.4.)
0 PSIG/BAR and the receiver pressure near or below 9. Install coil assembly, nameplate and top locknut or
200 PSIG (13.6 BAR). Closely monitor both high screw.
pressure gauges while connecting the wire to the HP2
switch. Compressor discharge pressure will begin to 10. Dehydrate and evacuate the system. (Refer to
rise. Receiver pressure should not rise. When the Section 7.11.10.) Charge unit with refrigerant per
compressor discharge pressure reaches 390 PSIG Section 7.11.11. b.
(26.5 BAR), shut the engine off using the stop lever on 11.Start unit and check operation. (Refer to Section 2)
the injection pump. (The microprocessor will remain
energized). The compressor discharge pressure will
drop off, but the receiver pressure should not change.
Any rise in receiver pressure indicates internal leak-
age at the SV1 valve. See below for instructions on
valve repair and replacement.
6. Observe the suction gauge. Using a jumper wire, mo-
mentarily energize SV4. The valve should open and
the suction pressure begin to rise. Remove the jump-
er and observe. The valve should close and the suc-
tion pressure should stop rising. Energize the valve
two or three times to verify consistent valve opera-
tion.
7. Place the Start/Run--Off switch in the OFF position.
Reconnect the wires to SV4, Front Unloader, and the
the oil safety switch.

62-11352 7--46
 1.
2.
3.

4.

5.

6.

7.
9.
8.

10.

11.

SV-1
1. Locknut/Screw 7. Enclosing Tube
2. Spacer Cup 8. Gasket
3. Nameplate 9. Closing Spring
4. Coil 10.Seat Disc
5. Spacer 11. Body
6. Enclosing Tube
Locknut
Figure 7-32. SV--1
7.13 CHECKING THE REFRIGERATION SYSTEM 7.13.2 Defrost Air Switch (DA)
DURING A DEFROST CYCLE
NOTE
7.13.1 Condenser Pressure Control and Hot Gas
Solenoid Valves (SV1 & SV4) Box temperature must be 40_F (4.4°C) or lower
to initiate defrost.
a. Connect a discharge pressure gauge to the manual
shut--off valve (king valve) and another gauge to the
compressor discharge service valve. Connect a a. To check the defrost air switch:
gauge to the compressor suction service valve. 1. Run unit in high speed cooling and place a jumper
b. Start unit with controller set at least 10_F (5.5_C) wire across the air switch terminals. This will start the
below indicated box temperature to obtain high speed defrost cycle as it simulates the action of the defrost
cooling. Press the MANUAL DEFROST key to initiate air switch. Bypassing the switch in this manner oper-
defrost. [Box temperature must be below 40_F ates all components involved in defrost.
(4.4_C).] The hot gas solenoid valve (SV4) will 2. Unit should remain in defrost until both DTT switches
energize and the hot gas line will be hot to the touch open [evaporator coil temperature reaches
on both sides of the valve. The condenser pressure approximately 55_F (12.8_C)]. At this point the
control solenoid (SV1) will close and suction pressure defrost cycle will terminate and the unit will resume
will rise approx 10 to 15 PSIG (0.68 to 1.02 BAR) after automatic operation.
approximately 5 minutes of unit operation. Refer to
Section 5.1.2 if unit does not heat properly. 3. If the above test indicates satisfactory operation, the
defrost air switch (DA) calibration may be checked
c. Unit should remain in defrost until both DTT switches and set using a Dwyer Magnehelic gauge (P/N
open evaporator coil temperature reaches 07-00177) or similar instrument.
approximately 55_F (12.8_C). At this point the
defrost cycle will terminate and the unit will resume
automatic operation.

7--47 62-11352
b. To check the calibration of the defrost air switch:
1. Make sure magnehelic gauge is in proper calibration.
NOTE
2
The magnehelic gauge may be used in any
position, but must be re-zeroed if position of 5
gauge is changed from vertical to horizontal or
vice versa. USE ONLY IN POSITION FOR
WHICH IT IS CALIBRATED. The Defrost Air
switch MUST be in the same orientation as it will 6 3
be in when installed in the unit. 4
1
2. With air switch in vertical position, connect high pres-
sure side of magnehelic gauge to high side connec-
tion of air switch. (See Figure 7-33)
1. Ohmmeter or Continuity Device
3. Install tee in pressure line to high side connection. Tee 2. Adjustment Screw (0.050 socket head size)
should be approximately half-way between gauge and
air switch or an improper reading may result. 3. Low Side Connection
4. Pressure Line or Aspirator Bulb
4. Attach an ohmmeter or continuity tester to the air
switch electrical contacts to check switch action. (P/N 07-00177-01)
5. Magnehelic Gauge (P/N 07-00177)
NOTE 6. High Side Connection
Use a hand aspirator (P/N 07-00177-01), since
blowing into tube by mouth may cause an incor- Figure 7-33. Defrost Air Switch Test Setup
rect reading. 7.13.3 Solid State Defrost Timer
5. With the gauge reading at zero, apply air pressure Refer to Section 5.5.a. for description.
very slowly to the air switch. An ohmmeter will
indicate continuity when switch actuates. The switch
contacts should close and the ohmmeter needle
should move rapidly to 0, or the continuity tester light
will come on. Any hesitation in the ohmmeter or
flickering of the continuity tester light indicates a
possible problem with the switch, and it should be
replaced.
6. Refer to Section 2.12 for switch settings. If switch fails
to actuate at correct gauge reading, adjust switch by
turning adjusting screw clockwise to increase setting
or counterclockwise to decrease setting.
7. Repeat checkout procedure until switch actuates at
correct gauge reading.
8. After switch is adjusted, place a small amount of paint
or glycerol on the adjusting screw so that vibration will
not change switch setting.

62-11352 7--48
7.14 EVAPORATOR COIL CLEANING 7.15 CONDENSER COIL CLEANING

WARNING WARNING
Personal protection equipment must be Personal protection equipment must be
utilized when performing coil cleaning. utilized when performing coil cleaning.

The use of recycled cardboard cartons is increasing Remove all foreign material from the condenser coil by re-
across the country. The recycled cardboard cartons versing the normal air flow. (Air is pulled in through the
create much more fiber dust during transport than new front and discharges over the engine.) Use an FDA
cartons. The fiber dust and particles are drawn into the approved cleaning agent whenever possible. Com-
evaporator where they lodge between the evaporator pressed air or water may be used as a cleaning agent. It
fins. If the coil is not cleaned on a regular basis, some- may be necessary to use warm water mixed with any good
times as often as after each trip, the accumulation can commercial dishwasher detergent. Rinse coil with fresh
be great enough to restrict air flow, cause coil icing, re- water if a detergent is used.
petitive defrosts and loss of unit capacity. Due to the
“washing” action of normal defrost the fiber dust and Remove the grille insert in order to do a more thorough
particles may not be visible on the face of the coil but job in cleaning the condenser and radiator. (See
may accumulate deep within. Figure 7-1.)
Clean the evaporator coil on a regular basis, not only to
remove cardboard dust, but to remove any grease or oil
film which sometimes coats the fins and prevents water
from draining into the drain pan.
Cardboard fiber particles after being wetted and dried
several times can be very hard to remove. Therefore,
several washings may be necessary.
a. Remove rubber check valves (kazoos) from drain
lines (front of refrigerated compartment).
b. Remove evaporator bulkhead and back panel, then
spray coil with a mild detergent solution such as
Oakite 164 or any good commercial grade automatic
dish washer detergent such as Electrosol or Cascade
and let the solution stand for a few minutes and re-
verse flush (opposite normal air flow) with clean water
at mild pressure. A garden hose with spray nozzle is
usually sufficient. Make sure drain lines are clean.
c. Replace evaporator bulkhead, back panel, and drain
hose kazoos and run unit until defrost mode can be
initiated to check for proper draining from drain pan.

7--49 62-11352
7.16 MICROPROCESSOR CONTROLLER Although there is less danger of electrical static dis-
charge (ESD) damage in the outdoor environment --
NOTE where the microprocessor is likely to be handled -- prop-
er board handling techniques should always be
The erasable, programmable, read only stressed. Boards should always be handled by their
memory (EEPROM) chip (component U3 on edges, in much the same way one would handle a
the microprocessor logic board) has a label on it photograph. This not only precludes the possibility of
listing the revision level of the software. ESD damage, but also lowers the possibility of physical
damage to the electronic components. Although the mi-
croprocessor boards are fairly rugged when assembled,
they are more fragile when separated and should al-
CAUTION ways be handled carefully.
When welding is required on the unit frame, or on the
Under no circumstances should a techni- front area of the trailer, ALL wiring to the microprocessor
cian electrically probe the processor at any MUST be disconnected. When welding is performed on
point, other than the connector terminals other areas of the trailer, the welder ground connection
where the harness attaches. Microproces- MUST be in close proximity to the area being welded. It
is also a good practice to remove both battery cables be-
sor components operate at different volt- fore welding on either the unit frame or the trailer to pre-
age levels and at extremely low current lev- vent possible damage to other components such as the
els. Improper use of voltmeters, jumper alternator and voltage regulator.
wires, continuity testers, etc. could perma- 7.16.1 Replacing Keypad, Window or Door
nently damage the processor.
Should damage to the keypad of the microprocessor oc-
cur, it is possible to replace only the keypad.
All replacement keypads are packaged with replace-
CAUTION ment gaskets.
Most electronic components are suscepti- a. Keypad Removal
ble to damage caused by electrical static 1. Place the (SROS) in the “OFF” position and
discharge (ESD). In certain cases, the hu- disconnect the negative battery cable. Attach a
man body can have enough static electric- grounded wrist strap to your wrist (CTD P/N
07--00304--00) and ground it to a good unit frame
ity to cause resultant damage to the compo- ground, so that the technician is connected to the
nents by touch. This is especially true of the same ground plane as the unit.
integrated circuits found on the truck/trailer 2. Open the roadside side door of the unit and loosen the
microprocessor. (2) hex/slotted head 1/4--20 bolts that hold the control
box cover/bezel assembly onto the front of the control
As mentioned above, some microprocessor inputs op- box. Lift the cover and use prop rod to hold cover up.
erate at voltage levels other than the conventional 12
VDC. Connector points and the associated approximate 3. Remove the wires connected to the SROS. Unplug
voltage levels are listed below for reference only. Under the 14--pin cable from the display board.
no circumstances should 12 VDC be applied at these 4. Loosen the (4) 5mm X 20mm hex head bolts that se-
connection points. cure the display board to the control box cover.
Grounded wrist cuffs are available from Carrier (P/N 5. Unplug the 10--pin ribbon cable that attaches the
07-00304-00). These should be worn whenever working keypad board to the display board. Remove the (4)
near or handling a microprocessor or the display. Phillips head screws that attach the display board to
the keypad board and place the display board aside.
Table 7-2. Connection Point Voltage
6. Remove the (11) Phillips head screws that attach the
Connection Point Approximate Voltage keypad and window to the bezel. Gently remove the
ATS, CDT, RAS, SAS, 2.5 VDC (Variable) window and keypad from the bezel. Discard the old
WTS keypad.
MP23 5.0 VDC NOTE
All gaskets must be replaced any time the
keypad is removed from the bezel.

62-11352 7--50
b.Keypad Installation proper sealing at bezel. Torque screws to 12 in.lbs.
(1.3 Nm).
4. Hold the display board in place and connect the rib-
CAUTION bon cable from the keypad and window assembly
while you can still see the pins on the circuit board.
Do not overtorque screws.
5. Place display board onto the (2) locating pins and se-
cure display board with the (4) 3/8” lg Phillips head
1. Remove both gaskets from the clear window. Ensure screws. Torque screws to 12 in.lbs. (1.3 Nm).
that the surface is completely free of old gasket ma-
terial and install the new gaskets. 6. Remove old gasket from door mounting bracket.
7. Ensure surface is completely free of old gasket ma-
NOTE terial and install new gasket.
The two window gaskets are different. The gas-
8. Plug 10--pin wire harness into new display board and
ket for the window and bezel is notched for reconnect wires to SROS.
clearance around the detents.
9. Secure the bezel to the control door with the (4) 5mm
2. Place the clear window and new keypad on the (3) X 20mm lg. hex head bolts. Torque bolts to 26 in. lbs.
alignment pins of the bezel. (3 Nm).
3. Loosely install the (11) Phillips head screws, [(8) 3/4” 10. Reconnect wiring harness (14--pin connector) from
lg and (3) 3/8” lg with a blunt tip] to the keypad board. microprocessor.
Check alignment of window and keypad to endure 11. Reconnect negative battery cable and check unit op-
eration.

DETENT SPRINGS DETENTS

DISPLAY WINDOW
KEYPAD DOOR
WINDOW GASKET DISPLAY BEZEL

DISPLAY BOARD

WINDOW GASKET
NOTE: GASKET IS
NOTCHED
KEYPAD BOARD FOR CLEARANCE AROUND
DETENTS.

MOUNTING BRACKET/CONTROL BOX GASKET

Figure 7-34. Display Module Assembly

7--51 62-11352
7.16.2 Replacing EEPROM with a notch in the outline of the chip drawn on the
a. Start the unit and verify operation. board. The new chip must be installed with the
notch in exactly the same position. Using the re-
b. Disconnect the negative battery cable. moval tool (CTD P/N 07--00297--00), remove the chip
c. Locate the microprocessor logic board. from the socket.
d. Connect the wrist strap (CTD P/N 07--00304--00) to g. Place the new small tie--wrap (included in the parts
your wrist and secure the clamp onto a good ground kit) under the EEPROM socket. Open the box con-
such as the bare metal hinge holding the micro as- taining the new EEPROM and hold it with one hand by
sembly in place or other non--painted metal area. The both ends. Attach the installation tool
wrist strap must be connected and worn whenever (CTD P/N 07--00298--00) on the EEPROM while
working and handling the logic board and the EE- holding the tool with your thumb on the silver pad.
PROM. This allows the entire tool to be grounded through
your hand. (See Figure 7-35.) After positioning the
e. Locate the EEPROM. (See Figure 7-35) Carefully notch on the EEPROM in the correct direction, care-
cut and remove the tie--wrap holding the EEPROM in fully align the pins with the socket. Gently push the
place. EEPROM into the socket
f. Note the orientation of the EEPROM before removing
it. There is a small notch in one end that will match up

Figure 7-35 -- EEPROM Insertion Tool

h. For REV 3.32 (EEPROMs with DataTrak) only: Place k. Start the unit and verify operation.
decal onto a visible location inside the control box.
i. Secure the logic board back into place, and close the NOTE
control box door. Adjustments to hour meters, Functional Para-
meters and Configurations are not necessary
j. Reconnect the negative battery cable.
as these settings are contained within the logic
board itself, and replacing the EEPROM will not
affect or change their settings.

62-11352 7--52
7.17 MICROPROCESSOR REPLACEMENT and 7.17.2 To Reach The Configuration List
CONFIGURATION From The Keypad:
7.17.1 To Remove and Replace a. Place the SROS in the “OFF” position.
Microprocessor Logic Board:
b. With the unit off, locate the serial port plug behind the
control panel. Remove the protective cap to gain ac-
cess to the wire terminals. Place an insulated jump-
CAUTION er wire between wires SPA and SPB at the serial port
plug.
Use the appropriate board assembly when
replacing the microprocessor logic board. NOTE
There are two different microprocessor If the unit is equipped with optional equipment
logic board assemblies: one with a plastic such as DataLink, a Remote Control Panel, or
cover that is attached to the board with DataTrak, the serial port is already connected
metal standoffs, and one without the cover. into that circuit. The optional equipment must
DO NOT drill out the standoffs to remove be temporarily disconnected to allow access to
the plastic cover or permanent damage to the serial port.
the microprocessor logic board will result.

a. Before removing the microprocessor, turn the SROS

to the “OFF” position and disconnect the negative CAUTION
battery cable. Attach a grounded wrist strap (CTD
P/N 07--00304--00) to your wrist and ground it to a Do not allow the insulated jumper wire be
good unit frame ground. used to configure the unit to touch any
b. Open the roadside side door of the unit and loosen ground.
the (2) bolts holding the cover / display assembly
onto the front of the control box. Lift cover and use c. Place the SROS switch in the “RUN” position. The
prop rod to hold cover up.. FAULT light will come on, and the micro display will
read “CNF1 TV” or “CNF1 DI”. Remove the jumper
c. Unplug the (2) ribbon cables from the micropro- wire from the serial port and reinstall the
cessor but leave them connected to the relay board protective cap, or reconnect to the optional
and display. equipment mentioned above. The configuration
d. Loosen the (5) hex head screws securing the screen will now remain available for five minutes.
microprocessor. Scroll through the configuration list using the
“FUNCTION” key and compare the settings with
e. Push microprocessor down. The top of the those shown in Table 7-3. If any of the configurations
microprocessor will unhook from the standoff pins. need to be changed, continue with the following
Remove the microprocessor from the control box. steps.
f. Take the new microprocessor from the anti--static d. To change the configuration selection:
bag and install in the control box, following steps 2. to
6. in reverse order. 1) Bring the configuration to be changed onto the
display. Press the “ENTER” key to allow
NOTE change access to the displayed configuration.
The microprocessor is secured at the top with 2) Press either the “UP” or “DOWN” keys to dis-
(3) control box standoff pins. The play available selections for that configuration.
microprocessor MUST interlock with standoffs. Leave the correct selection on the screen. The
selection display will flash, warning the operator
Use caution when lowering control box that the displayed value has not been entered.
cover. Do not get harness pinched behind Press the “ENTER” key to enter the new selec-
the gasket. tion into memory. (The display will revert to the
original selection if no further action is taken for
g.Place the removed microprocessor back into the the next five seconds.)
anti--static bag and part box for return.
3) Continue to scroll through the configuration list
h.Reconnect negative battery cable and check by pressing the “FUNCTION” key. Change any
microprocessor configurations.
other configurations as required.
NOTE BEFORE STARTING THE UNIT e. When finished, place the SROS in the “OFF” position,
When replacing a microprocessor it is important to then back to the “RUN” position to start the unit.
check that the configurations are compatible with the
unit model into which it will be installed.

7--53 62-11352
7.17.3 Hour Meters To set Maintenance Hour Meters:
To set Engine and Switch--On Hour Meters: The microprocessor has 2 programmable maintenance
The Engine and Switch On hour meters can be set to hourmeters which are also set via the serial port. These
any value using the ReeferManager pc software pro- maintenance hourmeters are compared to one of the
gram via the serial port, if the meters have less then 5 hour meters (diesel or switch on). If the hour meter is
hours on them. This allows a replacement microproces- greater than the maintenance hourmeter then the
sor to be set to the same hours as the microprocessor it proper service alarm is triggered to alert the operator
is replacing. When programming the hour meters, the that unit maintenance is due. These hour meters can be
Switch On Hour Meter does not appear in ReeferMa- reset following performance of the required
nager. Internal to the microprocessor there is an addi- maintenance by again connecting the ReeferManager
tional Hour Meter for Idle Hours. The Switch On Hour program to the microprocessor serial port, and resetting
Meter actually displays a sum of Engine and Idle Hours. them to a new service interval.
For programming purposes, the Idle Hours can be cal-
culated by taking the Switch On Hours and subtracting
the Engine Hours.
The microprocessor has 2 programmable maintenance
hourmeters which are set via the serial port. These
maintenance hourmeters are compared to one of the
hour meters (diesel, standby, or switch on). If the hour
meter is greater than the maintenance hourmeter then
the proper service alarm is triggered.

62-11352 7--54
 Table 7-3 Configuration Table
CONFIGU-
DESCRIPTION
RATION
NOTES
OFF
Long glow cycle (Std Emission DI Engines) * These settings are optional and can be set to cus-
CNF1 (DI)
See CNF25 tomer specifications or left at default values. All oth-
Note 1 ON er settings (not marked with *) MUST be set as
Short glow cycle (LE DI Engines, TV Engines)
(TV) shown for proper unit operation.
OFF CDT not used 1. CNF1 determines the length of the glow cycle,
CNF2
ON CDT used which varies depending on the type of engine
in the unit. When CNF 25 is ON, the CNF1
CNF3 OFF Max Set Point +86°F (All functions locked) setting is not used and either setting can be
Note 3 ON Max Set Point +90°F (Modified function lock) selected.
OFF All trailer units must be OFF 2. CNF9 allows selection of how the unit will react
CNF4 under an Out--Of--Range condition. An Out---
ON Not used for Trailer or Rail models Of--Range condition is described as the box
OFF Not used for Trailer or Rail models temperature having arrived at setpoint, then
CNF5 drifting away from setpoint. With this CNF in
ON All R--22 and R--404A trailer units the OFF position, once the box temperature
OFF Trailer or Rail unit has been Out--Of--Range for 15 minutes, the
CNF6 ALARM light will be turned on and the alarm
ON Not used for Trailer or Rail models display “OUT RANGE” will be displayed al-
ternately with the default display of the setpoint
OFF Normal speed warm--up Rev. 3.25 and and box temperature. With this CNF in the ON
CNF7 position, once the box temperature has been
ON Low speed only engine warm--up higher only
Out_Of_Range for 45 minutes, the unit will
OFF All trailer units shut down, and the same alarms as described
CNF8 above will be displayed.
ON Not used for Trailer or Rail models
3. CNF3 & CNF11
CNF9 OFF Out--of--range alarm only Standard Function Lock allows the Func-
Note 2 ON Out--of--range alarm and unit shut down tion Key and the Start/Stop--Continuous Run
Key to be locked so that no changes can be
OFF Not used for Trailer or Rail models made.
CNF10
ON Not used for Trailer or Rail models
Modified Function Lock is the same as
CNF11 OFF Functions changes normal Standard Function Lock except that with the
Note 3 setpoint at or between +32 and +42_F (0 and
ON Functions & Start Stop locked
5.6°C), the unit will always operate in Continu-
OFF R--22 ous Run. If the setpoint is outside this range,
CNF12 either Start/Stop or Continuous Run can be
ON R--404A selected.
OFF Refrigeration unit (Trailer, Rail, or Truck) The maximum setpoint and function lock are
CNF13 controlled via a combination of CNF3 and
ON Heat only unit (Solara) CNF11:
OFF Standard unit
CNF14 CNF11 OFF / CNF3 OFF: Maximum set
ON Reversible Multi--Temp
point 86_F (30°C) -- No function lock
OFF UltraFresh 1 enabled
CNF15 CNF11 ON / CNF3 OFF: Maximum set
ON UltraFresh 2 enabled
point 86_F (30°C) -- Standard function lock
OFF Alt Aux alarm only
CNF16 CNF11 OFF / CNF3 ON: Maximum set
ON Alt Aux alarm shuts unit down
point 90_F (32.2°C) -- No function lock
OFF UltraFreeze disabled
CNF17 CNF11 ON / CNF3 ON: Maximum set
ON UltraFreeze enabled
point 90_F (32.2°C) -- Modified function lock
OFF SYSTEM CK alarm Off
CNF18
ON SYSTEM CK alarm On 4.CNF20 allows the Fahrenheit / Celsius function to
be locked. In order to change the units setting,
OFF OFF on all units except XT and X2 models. CNF20 must be OFF. The units setting can then be
CNF19
ON XT and X2 units (Rev U3 3.23 & higher) changed in the functional parameters list. If CNF20
is ON the units setting cannot be changed from the
CNF20 OFF °F / °C Unlocked
functional parameters list.
Note 4 ON °F / °C Locked

7--55 62-11352
 Table 7-3. Configuration Codes (Continued)
CONFIGU-
DESCRIPTION
RATION
OFF Normal Multi--Temp Logic Rev. 3.23 and
CNF21
ON Multi--Temp Frozen Priority Logic higher only
CNF22 OFF For future use. Do not turn on.
OFF Set Point not Locked Rev. 3.29 and
CNF23
OFF Set Point Locked higher only
OFF All trailer units are OFF
CNF24
ON Truck units only
All Engines with glow plugs. CNF1 settings
OFF
are used for glow timing. Rev. 3.31 and
CNF25
Tier 4i Engine with air heater. CNF1 settings higher only
ON
are NOT used for glow timing.
CNF26 OFF For future use. Do not turn on.
CNF27 OFF For future use. Do not turn on.
CNF28 OFF For future use. Do not turn on.
CNF29 OFF For future use. Do not turn on.
CNF30 OFF For future use. Do not turn on.
CNF31 OFF For future use. Do not turn on.
CNF32 OFF For future use. Do not turn on.

62-11352 7--56
7.18 TEMPERATURE SENSOR CHECKOUT At least one lead from the sensor (RAS, terminals D1
and E1 or SAS, terminals D2 and E2) must be discon-
An accurate ohmmeter must be used to check resis- nected from the unit electrical system before any read-
tance values shown in Table 7-4. ing is taken. Not doing so will result in a false reading.
Due to variations and inaccuracies in ohmmeters, ther- Two preferred methods of determining the actual test
mometers or other test equipment, a reading within 2% temperature at the sensor, are an ice bath at 32_F (0_C)
of the chart value would indicate a good sensor. If a sen- or a calibrated temperature tester.
sor is bad, the resistance reading will usually be much
higher or lower than the resistance values given in
Table 7-4.

Table 7-4. Sensor Resistance (RATS, SAS, ATS, DTTs, WTS)

°F °C Ohms °F °C Ohms °F °C Ohms °F °C Ohms
-40 -40 336,500 18 -7.8 49,060 76 24.4 10,250 134 56.7 2,809
-38 -38.9 312,600 20 -6.7 46,230 78 25.6 9,760 136 57.8 2,697
-36 -37.8 290,600 22 -5.6 43,580 80 26.7 9,299 138 58.9 2,590
-34 -36.7 270,300 24 -4.4 41,100 82 27.8 8,862 140 60.0 2,488
-32 -35.6 251,500 26 -3.3 38,780 84 28.9 8,449 142 61.1 2,390
-30 -34.4 234,200 28 -2.2 36,600 86 30.0 8,057 144 62.2 2,297
-28 -33.3 218,200 30 -1.1 34,560 88 31.1 7,686 146 63.3 2,208
-26 -32.2 203,400 32 0 32,650 90 32.2 7,334 148 64.4 2,124
-24 -31.1 189,700 34 1.1 30,850 92 33.3 7,000 150 65.6 2,042
-22 -30 177,000 36 2.2 29,170 94 34.4 6,684 155 68.3 1,855
-20 -28.9 165,200 38 3.3 27,590 96 35.6 6,384 160 71.1 1,687
-18 -27.8 154,300 40 4.4 26,100 98 36.7 6,099 165 73.9 1,537
-16 -26.7 144,200 42 5.5 24,700 100 37.8 5,828 170 76.7 1,402
-14 -25.6 134,800 44 6.6 23,390 102 38.9 5,571 175 79.4 1,281
-12 -24.4 126,100 46 7.7 22,160 104 40.0 5,327 180 82.2 1,171
-10 -23.3 118,100 48 8.9 20,990 106 41.1 5,095 185 85.0 1,072
-8 -22.2 110,500 50 10 19,900 108 42.2 4,874 190 87.8 983
-6 -21.1 103,600 52 11.1 18,870 110 43.3 4,665 195 90.6 902
-4 -20 97,070 54 12.2 17,900 112 44.4 4,465 200 93.3 829
-2 -18.9 91,030 56 13.3 16,980 114 45.5 4,275 205 96.1 762
0 -17.8 85,400 58 14.4 16,120 116 46.7 4,095 210 98.9 702
2 -16.7 80,160 60 15.5 15,310 118 47.8 3,923 215 101.7 647
4 -15.6 75,270 62 16.6 14,540 120 48.9 3,759 220 104.4 598
6 -14.4 70,720 64 17.7 13,820 122 50.0 3,603 225 107.2 553
8 -13.3 66,460 66 18.9 13,130 124 51.1 3,454 230 110.0 511
10 -12.2 62,500 68 20.0 12,490 126 52.2 3,313 235 112.8 473
12 -11.1 58,790 70 21.1 11,880 128 53.3 3,177 240 115.6 438
14 -10.0 55,330 72 22.2 11,310 130 54.4 3,049 245 118.3 406
16 -8.9 52,090 74 23.3 10,760 132 55.6 2,926 250 121.1 378

7--57 62-11352
 Table 7-5. Sensor Resistance (CDT)
°F °C Ohms °F °C Ohms °F °C Ohms °F °C Ohms °F °C Ohms
-40 -40 3,360,000 18 -7.8 189,690 76 24.4 102,460 134 56.7 28,160 260 126.7 3,290
-38 -38.9 3,121,020 20 -6.7 461,170 78 25.6 97,600 136 57.8 27,040 270 132.2 2,850
-36 -37.8 2,900,710 22 -5.6 434,790 80 26.7 92,990 138 58.9 25,970 280 137.8 2,490
-34 -36.7 2,697,500 24 -4.4 410,080 82 27.8 88,630 140 60.0 24,960 290 143.3 2,170
-32 -35.6 2,509,940 26 -3.3 386,940 84 28.9 84,510 142 61.1 23,980 300 148.9 1,910
-30 -34.4 2,336,720 28 -2.2 365,260 86 30.0 80,600 144 62.2 23,050 310 154.4 1,680
-28 -33.3 2,186,670 3 -1.1 344,930 88 31.1 76,890 146 63.3 22,160 320 160.0 1,480
-26 -32.2 2,028,680 32 0 325,860 90 32.2 73,380 148 64.4 21,310 330 165.5 1,310
-24 -31.1 1,891,780 34 1.1 307,970 92 33.3 70,040 150 65.6 20,500 340 171.1 1,160
-22 -30 1,765,060 36 2.2 291,180 94 34.4 66,880 155 68.3 18,980 350 176.7 1,040
-20 -28.9 1,647,700 38 3.3 275,410 96 35.6 63,880 160 71.1 16,940 360 182.2 920
-18 -27.8 1,538,950 40 4.4 260,590 98 36.7 61,040 165 73.9 15,450 370 187.8 830
-16 -26.7 1,438,120 42 5.5 246,670 100 37.8 58,330 170 76.7 14,070 380 193.3 740
-14 -25.6 1,344,580 44 6.6 233,570 102 38.9 55,770 175 79.4 12,870 390 198.9 670
-12 -24.4 1,257,770 46 7.7 221,260 104 40.0 53,330 180 82.2 11,750 400 204.4 600
-10 -23.3 1,177,150 48 8.9 209,670 106 41.1 51,010 185 85.0 10,750 410 210.0 540
-8 -22.2 1,102,240 50 10 198,760 108 42.2 48,800 190 87.8 9,870 420 215.6 490
-6 -21.1 1,032,600 52 11.1 188,490 110 43.3 46,710 195 90.6 9,050 430 221.1 450
-4 -20 967,830 54 12.2 178,820 112 44.4 44,710 200 93.3 8,320 440 226.7 410
-2 -18.9 907,560 56 13.3 169,700 114 45.5 42,820 205 96.1 7,650 450 232.2 370
0 -17.8 851,450 58 14.4 161,100 116 46.7 41,010 210 98.9 7,050 460 237.8 340
2 -16.7 799,180 60 15.5 152,990 118 47.8 39,290 215 101.7 6,510 470 243.3 310
4 -15.6 750,470 62 16.6 145,340 120 48.9 37,660 220 104.4 6,000 480 248.9 280
6 -14.4 705,060 64 17.7 138,120 122 50.0 36,100 225 107.2 5,540 490 254.4 260
8 -13.3 662,690 66 18.9 131,310 124 51.1 34,610 230 110.0 5,130 500 260.0 240
10 -12.2 623,150 68 20.0 124,870 126 52.2 33,200 235 112.8 4,760
12 -11.1 586,230 70 21.1 118,790 128 53.3 31,850 240 115.6 4,410
14 -10.0 551,740 72 22.2 113,040 130 54.4 30,560 245 118.3 4,090
16 -8.9 519,500 74 23.3 107,600 132 55.6 29,330 250 121.1 3,800

62-11352 7--58
7.19 UNIDRIVE TORQUE 7.19.1 Drive Gear (See Figure 7-24)
REQUIREMENTS
When installing a nylon drive gear always:
Extensive damage may occur if the proper hardware
and procedures are not followed. Periodic inspection of 1. Install with black dot facing steel gear attached to
hardware and bolt torque is recommended to insure the compressor.
integrity of the unidrive. 2. Use new bolts and locking tabs included in drive gear
kit.
NOTE
3. Use Locktite or a similar thread locking compound on
A thread locking sealant, flat washer and lock threads of drive gear bolts.
washer must be used on bolts between the
4. DO NOT use Never-Seez or any other lubricating
compressor mounting flange and the engine compound on the nylon drive gear or compressor
bellhousing. The recommended sealant is Loc- steel gear. The gear must be assembled dry.
tite Threadlocker 262. 5. Torque the (6 bolt) nylon drive gear bolts to 30 ft-lbs.
(41 Nm.)
See Figure 7-36 for torque value, size and grade of the
hardware to be used when reassembling the unidrive
assembly.

7--59 62-11352
 M8 x 1.25 x 20 mm lg
(6 Required) 28 ft-lbs (38 Nm)
3/8-16 x 1-3/4 lg Grade 5
(6 Required) 30 ft-lbs (41 Nm)

3/8-24 x 1.00 lg Grade 8

28 ft-lbs (38 Nm)

DIRECT DRIVE

90 ft-lbs (122 Nm)

M12 x 1.25 x 25 mm lg
(3 Required) 65 ft-lbs (88 Nm)

3/8-16 x 1 lg Grade 5 (12 Required)

28 ft-lbs (38 Nm)

Figure 7-36. Unidrive Torque Requirements

62-11352 7--60
 Table 7-6. R-404A Temperature--Pressure Chart

Temperature Pressure Temperature Pressure

_F _C PSIG Kg/cm@ BAR _F _C PSIG Kg/cm@ BAR
--40 --40 4.5 0.32 0.31 32 0 72.5 5.10 5.00
--35 --37 7.1 0.50 0.49 34 1 75.6 5.32 5.21
--30 --34 9.9 0.70 0.68 36 2 78.8 5.54 5.43
--25 --32 12.9 0.91 0.89 38 3 82.1 5.77 5.66
--20 --29 16.3 1.15 1.12 40 4 85.5 6.01 5.90
--18 --28 17.7 1.24 1.22 42 6 89.0 6.26 6.14
--16 --27 19.2 1.35 1.32 44 7 92.5 6.50 6.38
--14 --26 20.7 1.46 1.43 46 8 96.2 6.76 6.63
--12 --24 22.3 1.57 1.54 48 9 99.9 7.02 6.89
--10 --23 23.9 1.68 1.65 50 10 103.7 7.29 7.15
--8 --22 25.6 1.80 1.77 55 13 115.4 8.11 7.96
--6 --21 27.3 1.92 1.88 60 16 126.1 8.87 8.69
--4 --20 29.1 2.05 2.01 65 18 137.4 9.66 9.47
--2 --19 30.9 2.17 2.13 70 21 149.4 10.50 10.30
0 --18 32.8 2.31 2.26 75 24 162.1 11.40 11.18
2 --17 34.8 2.45 2.40 80 27 175.5 12.34 12.10
4 --16 36.8 2.59 2.54 85 29 189.6 13.33 13.07
6 --14 38.9 2.73 2.68 90 32 204.5 14.38 14.10
8 --13 41.1 2.89 2.83 95 35 220.2 15.48 15.18
10 --12 43.3 3.04 2.99 100 38 236.8 16.65 16.33
12 --11 45.6 3.21 3.14 105 41 254.2 17.87 17.53
14 --10 48.0 3.37 3.31 110 43 272.4 19.15 18.78
16 --9 50.4 3.54 3.47 115 46 291.6 20.50 20.11
18 --8 52.9 3.72 3.65 120 49 311.8 21.92 21.50
20 --7 55.5 3.90 3.83 125 52 332.9 23.41 22.95
22 --6 58.1 4.08 4.01 130 54 355.0 24.96 24.48
24 --4 60.9 4.28 4.20 135 57 378.1 26.58 26.07
26 --3 63.7 4.48 4.39 140 60 402.3 28.28 27.74
28 --2 66.5 4.68 4.59 145 63 427.6 30.06 29.48
30 --1 69.5 4.89 4.79 150 66 454.0 31.92 31.30

7--61 62-11352
 SECTION 8 - WIRING DIAGRAM
Plugs used with Schematic 62--04095 Rev --

1 8

2 9
15

15
23

23
8

8
3 10

4 11

5 12

6
16

16
13
1

1
9

9
7 14

J1 White J2 Black J5 White

Plugs onto back of Control Box Plugs onto back of Control Box Plugs onto Relay Board inside Control Box
Component Terminal Component Terminal Component Terminal
SV1 1 SLP--C 1 RS--2 1
MOLP1 (Stby Option) 2 ATS--A 2 RS--3 3
SPK20 ENSCU13 & FP) 3 ATS--B 3 Buzzer (--) 4
CLH 4 WTS--B 4
SP3 (ENSCU16 & DKE) 5 WTS--A 5 GPR--86 6
ARL 6 SPT--C 6 SSR--86 7
UF 7 Buzzer (+) 8
DA 8
SP1, SV4 * 8
HP2--B 9 SLP--B 9 GPR--85 10
UR 10 SAS--A 10 SSR--85 11
DL 11 SAS--B 11
SP5 (FS--B & MP--30) 12 CDT--A 12
PL (Stby Option) 13 CDT--B 13
ORL 15 OP--A 14
SP1 (SV4 & HL) & j1--7* 16 DTT--A 15
CL 17 ALT--D+ 16
SP8 (SV2) 18 SLP--A 17
J1 Jumper 19 RAS--A 19
SPK18 20 RAS--B 20
DKA 21 SPT--A (--) 21
DKC 22 SPT--B (+) 22
FL 23 HP1--A 23

* X2 Only

8--1 62-11352
8--2 62-11352
 Index
A E
Air Switch, 2--24 Electronic Speed Control Troubleshooting,
6--8
Alarm Display And Reset, 3--16 Engine Air System, 2--24
Alternator Operation , 2--9 Engine Data, 2--23
Alternator/Regulator, 2--9 Engine Oil, 2--23
Ambient Air Temperature Sensor, 2--12 Engine Screw Threads, 2--24
Engine Speed Control Unit, 2--8
Auto Start Sequence, 4--1
Engine Transducers and Sensors, 2--8
Automatic Defrost, 3--9
Evaporator Coil, 2--12
Evaporator Section, 2--12

C Expansion Valve, 2--24

Cargo Protect Mode, 5--7

F
Changing Setpoint, 3--5
Fail Safe Defrost Termination, 5--8
Compressor Data, 2--24
Fan Clutch Air Gap, 2--24
Compressor Discharge Temperature Fanshaft Oil, 2--24
Transducer, 2--12
Filter Drier, 2--11
Compressor Suction Pressure Transducer,
Fuel and Speed Actuator, 2--8
2--12
Functional Parameters, 3--10, 3--11
Compressor Transducers And Sensors, 2--12
Fusible Plug, 2--24
Continuous Run Operation, 3--7
Cool Mode, 5--1
G
Cooling, 5--1
Gearbox Oil, 2--24

D H
Data Ohms And Amps, 2--26 Heat Exchanger, 2--12

DataLink, 2--19 Heat Mode, 5--1

Heat/Cool/Null Switching Operation, 5--6
DataTrak, 2--23
Heating, 5--1
Defrost Air Switch, 2--24, 5--8
High Ambient Defrost , 5--9
Defrost Cycle, 5--7 High Pressure Cut--Out Control, 2--24
Defrost Function, 5--8 High Pressure Cut--Out Switch, 2--24
Defrost Initiation, 5--8
Defrost Termination at Low Speed, 5--8 I
Defrost Thermostats, 2--24 Indicator LEDs, 2--17
Defrost Timer, 5--8 Integral Voltage Regulator Operation, 2--9
Display, 2--14 Introduction, 2--1

Index --1 62--11352

 Index
K S
Key Descriptions, 2--17
Safety Decals, 1--4
Safety Devices, 2--25
L Safety Precautions, 1--1
LEDs, 2--21
Speed Solenoid Overrides, 5--11
Light Bar, 2--18
Lubrication System, 2--23 Start--Stop Operation, 3--6

Stopping Unit, 3--20

M Suction Pressure Operation , 5--10

Manual Defrost, 3--8, 5--8 SV1 Operation (Defrost Only), 5--11

Manual Start -- Glow & Crank, 3--3 SV2 Operation (Heating and Defrost), 5--11
Microprocessor Troubleshooting Guide, 6--14
Switch Descriptions, 2--17

N
Normal Defrost Termination, 5--8 T
Null Band Operation, 5--6
Thermal Expansion Valve, 2--12

P Thermostatic Expansion Valve, 2--24

PRETRIP, 3--4

U
R
Receiver, 2--11 UltraFreeze Temperature Control , 5--7

Refrigerant Circuit -- Heating & Defrosting, UltraFresh 2 Temperature Control , 5--6

2--28
Unit Data, 3--13, 3--14
Refrigerant Circuit --Cooling, 2--27
Refrigeration Charge, 2--24 Unit Weight, 2--24
Refrigeration System Data, 2--24 Unloader Operation, 5--9

62--11352 Index --2

 North America Central America
Carrier Transicold and Mexico
700 Olympic Drive Ejercito Nacional No. 418 Carrier Transicold Division,
Athens, GA 30601 USA Piso 9, Torre Yumal Carrier Corporation
Tel: 1--706--357--7223 Col. Chapultepec Morales Truck/Trailer Products Group
Fax: 1--706--355--5435 11570 Mexico, D.F. P.O. Box 4805
Tel: (5255) 9126.0300 Syracuse, N.Y. 13221 U.S A
Fax: (5255) 9126.0373
www.carrier.transicold.com

A member of the United Technologies Corporation family. Stock symbol UTX

©2008 Carrier Corporation D Printed in U. S. A. 1008