Spectrum SB Mantenimiento Ingles

Spectrum SB
TK 51296-2-MM (Rev. 4, 04/05)
Copyright© 2001 Thermo King Corp., Minneapolis, MN, U.S.A. Printed in

U.S.A.
The maintenance information in this manual covers unit models:
Spectrum SB 30-2 (002008) System Spectrum SB 30-2 (918596)
Spectrum SB 30-2 TIER 2 (002193) System Spectrum SB 30-2 TIER 2 (920367)
For further information, refer to:

Spectrum SB Operator’s Manual TK 51297
Spectrum SB Parts Manual TK 51302
Spectrum SB with Tier 2 Engine Parts Manual TK 52934
THERMOGUARD µP-IV Multi-Temp Microprocessor Controller Software Diagnosis TK 50033
Manual
TK486 Engine Overhaul Manual TK 50136
X214, X418, X426, and X430 Compressor Overhaul Manual TK 6875
Diagnosing TK Refrigeration System TK 5984
Tool Catalog TK 5955
Evacuation Station Operation and Field Application TK 40612
ElectroStatic Discharge (ESD) Training Guide TK 40282
TC Trailer Unit Refrigeration Systems Identification, Training, and Diagnostic Guide TK 40660
The information in this manual is provided to assist owners, operators and service people in
the proper upkeep and maintenance of Thermo King units.
This manual is published for informational purposes only and the information so provided should
not be considered as all-inclusive or covering all contingencies. If further information is required,
Thermo King Corporation should be consulted.
Sale of product shown in this manual is subject to Thermo King’s terms and conditions
including, but not limited to, the Thermo King Limited Express Warranty. Such terms and
conditions are available upon request. Thermo King’s warranty will not apply to any
equipment which has been “so repaired or altered outside the manufacturer’s plants as,
in the manufacturer’s judgment, to effect its stability.”
No warranties, express or implied, including warranties of fitness for a particular

purpose or merchantability, or warranties arising from course of dealing or usage of
trade, are made regarding the information, recommendations, and descriptions
contained herein. Manufacturer is not responsible and will not be held liable in contract
or in tort (including negligence) for any special, indirect or consequential damages,
including injury or damage caused to vehicles, contents or persons, by reason of the
installation of any Thermo King product or its mechanical failure.
2
Recover Refrigerant
At Thermo King, we recognize the need to preserve the environment
and limit the potential harm to the ozone layer that can result from
allowing refrigerant to escape into the atmosphere.
We strictly adhere to a policy that promotes the recovery and limits

the loss of refrigerant into the atmosphere.
In addition, service personnel must be aware of Federal regulations

concerning the use of refrigerants and the certification of
technicians. For additional information on regulations and technician
certification programs, contact your local Thermo King dealer.
R-404A
WARNING: Use only Polyol Ester-based refrigeration compressor oil in
R-404A. See Thermo King Parts Manual for part number.
Do not mix Polyol Ester and standard synthetic compressor oils. Keep Polyol
Ester compressor oil in tightly sealed containers. If Polyol Ester oil becomes
contaminated with moisture or standard oils, dispose of properly–DO NOT USE.
When servicing Thermo King R-404A unit, use only those service tools certified
for and dedicated to R-404A refrigerant and Polyol Ester compressor oils.
Residual non-HFC refrigerants or oils will contaminate R-404A systems.
3
4
Table of Contents
List of Figures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
General Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Battery Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Refrigerant Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Refrigerant Oil Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Electrical Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
High Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Low Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Microprocessor Service Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Welding Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
First Aid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
First Aid, Refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
First Aid, Refrigerant Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
First Aid, Engine Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
First Aid, Electrical Shock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Belt Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Refrigeration System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Electrical Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Electrical Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Smart Reefer Multi-Temp µP-IV Microprocessor Temperature Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Electric Standby (Model 50 Units Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Maintenance Inspection Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Unit Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Host Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Spectrum Remote Evaporators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Diesel Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Thermo King X430L Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Smart Reefer Multi-Temp µP-IV Microprocessor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
CYCLE-SENTRY Start-Stop Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
DAS (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Remote Control Box (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Sequence of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Defrost . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
System Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Refrigeration System Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Zone 1 Cool, Zone 2 Cool, and Zone 3 Cool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Zone 1 Cool, Zone 2 Cool, and Zone 3 Heat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Design Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Opening the Front Doors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Opening the Secondary Door Latch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Serial Number Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
5
Table of Contents
Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Zone 1/Host On/Off Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Zone 2 On/Off Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Zone 3 On/Off Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Diesel/Electric Switch (Model 50 Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Keypad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Computer Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Printer Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Unit Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Unit Protection Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Unit Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Manual Pretrip Inspection (Before Starting Unit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Starting Unit With Electronic Full Pretrip Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Selection of Operating Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Restarting Unit—Diesel Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Restarting Unit—Electric Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
After Start Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Loading Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Single Temperature Loading Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Post Load Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Post Trip Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Electrical Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Australian Bosch Alternator - Model 30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
120 Amp Charging System Diagnostic Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Field Current Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Prestolite Alternator - Model 50 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
105 Amp Charging System Diagnostic Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Battery Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Fuse Link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Air Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Smart Reefer Multi-Temp µP-IV Microprocessor Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Unit Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Wire Harness Routing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
AC Components (Model 50 Units Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Electrical Contactors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Evaporator Heaters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Auto Phase System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Engine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Engine Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
EMI 3000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Engine Lubrication System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Engine Oil Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Oil Filter Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Low Oil Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Engine Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
ELC (Extended Life Coolant) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Antifreeze Maintenance Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Bleeding Air from the Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Engine Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Engine Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Fuel Line Routing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Fuel Return Line Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Bleeding the Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
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Draining Water from Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

Fuel Filter/Water Separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Fuel Filter/Water Separator Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Engine Speed Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Injection Pump Timing Tier 1 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Injection Pump Timing Tier 2 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Injection Pump Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Injection Pump Reinstallation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Fuel Solenoid System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Trochoid Feed Pump Tier 2 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Cold Start Device Tier 2 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Engine Valve Clearance Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Positive Crankcase Ventilation (PCV) Tier 2 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Crankcase Breather Tier 1 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
EMI 3000 Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Air Restriction Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Starters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Model 30 Belt Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Model 30 Fan Belt Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Model 50 Belt Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Model 50 Compressor Belt Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Model 50 Fan Belt Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Clutch (Model 50) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Drive Bushing Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Dowel Pin Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Refrigeration Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Refrigerant Charge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Testing the Refrigerant Charge with an Empty Trailer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Testing the Refrigerant Charge with a Loaded Trailer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Testing for an Overcharge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Adjusting Refrigerant Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Moisture Indicating Sight Glass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Refrigerant Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Compressor Sump Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Checking Compressor Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
High Pressure Cutout Switch (HPCO) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
High Pressure Switch (HPSW) Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Evacuating and Charging Smart Reefer Multi-Temp Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Set-up Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Evacuating the System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Charging the System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
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Refrigeration Service Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117

Low Side Pump Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Compressor Coupling Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
Compressor Coupling Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Condenser Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
Discharge Vibrasorber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
In-Line Check Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Receiver Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Filter Drier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Expansion Valve Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Heat Exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
Evaporator Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
Accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
Suction Vibrasorber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
High Pressure Cutout Switch and High Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
Discharge Pressure Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
High Pressure Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
Throttling Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
Liquid Line Solenoid Valve (LLS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
Hot Gas Solenoid Valve (HGS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
Suction Line Solenoid Valve (SLS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
Check Valve Repair (SLCV, SLCV2, SLCV3, LRCV, and PVC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
Check Valve Replacement (SLCV, SLCV2, SLCV3, LRCV, and PVC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
Condenser Inlet Solenoid Valve (CIS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
Condenser Inlet Check Valve (CICV) Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
Condenser Inlet Check Valve (CICV) Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
Receiver Tank Pressure Solenoid Valve (RTPS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
Purge Valve (PV) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
Compressor Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
Checking Compressor Oil Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
Priming New Compressor Installations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
Structural Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
Unit and Engine Mounting Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
Unit Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
Condenser, Evaporator, and Radiator Coils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
Defrost Drains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
Unit Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
Defrost Damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
Condenser and Evaporator Fan Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
Condenser Fan Blower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
Evaporator Fan Blower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
Fan Shaft Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
Fan Shaft Assembly Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
Idler Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
Idler Assembly Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
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Mechanical Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141

Electric Standby Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
Refrigeration Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
Remote Evaporator Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
Refrigeration System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
Remote Evaporator Maintenance Inspection Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
Remote Evaporator Unit Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
Unit Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
Defrost . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
Operating Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
Unit Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
Unit Protection Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
Serial Number Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
Remote Evaporator Electrical Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
Smart Reefer Multi-Temp µP-IV Microprocessor Controlled Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
Unit Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
Remote Evaporator Refrigeration Service Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
Expansion Valve Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
Evaporator Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
Solenoid Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
Liquid Return Check Valve Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
Liquid Return Valve Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
Heat Exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
Remote Evaporator Structural Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
Unit Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
Defrost Drains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
Evaporator Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
Remote Evaporator System Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
Diagrams Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
9
Table of Contents
10
List of Figures
Figure 1:Front View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Figure 2:S-3 Spectrum Remote Evaporator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Figure 3:TK486E Tier 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Figure 4:TK486V Tier 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Figure 5:Zone 1 Cool, Zone 2 Cool, and Zone 3 Cool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Figure 6:Zone 1 Cool, Zone 2 Cool, and Zone 3 Heat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Figure 7:Door Latch Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Figure 8:Opening Secondary Door Latch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Figure 9:Compressor Serial Number Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Figure 10:Engine Serial Number Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Figure 11:Unit Serial Number Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Figure 12:Laminated Serial Number Plate (Located Where Shown Above) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Figure 13:Front View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Figure 14:Back View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Figure 15:Engine Compartment (TK486E Shown, Other Engine Similar) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Figure 16:Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Figure 17:Typical Components Inside Control Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Figure 18:Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Figure 19:Single Temperature Load, Host On and Remote Off, Bulkhead Open/Removed . . . . . . . . . . . . . . . . 51
Figure 20:Same Temperatures in each Compartment, Host and Remote Running, Bulkhead Closed . . . . . . . 52
Figure 21:Check Points for Alternator Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Figure 22:Prestolite Terminal Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Figure 23:Control Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Figure 24:Air Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Figure 25:Tier 1 Wire Harness Routing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Figure 26:Tier 2 Wire Harness Routing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Figure 27:Host Unit Air Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Figure 28:High Voltage Tray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Figure 29:Tier 1 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Figure 30:Tier 2 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Figure 31:ELC Nameplate Located On Expansion Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Figure 32:Engine Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Figure 33:Tier 1 Engine Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Figure 34:Tier 2 Engine Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Figure 35:Fuel Return Line Replacement Decal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Figure 36:Fuel Return Line Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Figure 37:Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Figure 38:Tier 1 Injection Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Figure 39:Tier 2 Injection Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Figure 40:Filling Fuel Filter/Water Separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Figure 41:Tier 1 Engine Speed Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Figure 42:Tier 2 Engine Speed Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Figure 43:Component Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Figure 44:Top Dead Center One and Four . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Figure 45:Timing Mark Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Figure 46:Correct Injection Timing Mark Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Figure 47:Tier 2 Index Mark Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Figure 48:Tier 2 Index Mark Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Figure 49:Marking Gear Case . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Figure 50:Place Injection Angle Sticker on Gear Case . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
11
List of Figures
Figure 51:Injection Angle Sticker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

Figure 52:Removing Injection Pump Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Figure 53:Injection Angle Mark Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Figure 54:Injection Angle Mark . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Figure 55:Injection Pump Serial Number Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Figure 56:Examples of Injection Pump Index Mark Alignment with Injection Angle Sticker . . . . . . . . . . . . . . . . 81
Figure 57:Timing Mark Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Figure 58:Align Flat Sides of Crankshaft Gear with Flat Sides of Inner Rotor in Timing Gear Cover . . . . . . . . . 82
Figure 63:Injection Pump Gear Tool. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Figure 64:Fuel Solenoid Location Tier 1 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Figure 65:Fuel Solenoid Location Tier 2 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Figure 66:Fuel Solenoid Timer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Figure 67:Simplified Schematic Diagram of Fuel Solenoid System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Figure 68:Main Wire Harness Connector Pin Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Figure 69:Fuel Solenoid Connector Pin Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Figure 70:Relay Socket Terminal Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Figure 71:Fuel Solenoid Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Figure 72:Trochoid Feed Pump Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Figure 73:Trochoid Feed Pump Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Figure 74:Trochoid Feed Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Figure 75:Cold Start Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Figure 76:Remove Engine Coolant Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Figure 77:Remove Cold Start Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Figure 78:Clean Piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Figure 79:Top Dead Center One and Four . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Figure 80:Adjusting the Valve Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Figure 81:Tier 2 PCV Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Figure 82:Tier 2 PCV System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Figure 83:Tier 1 Crankcase Breather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Figure 84:EMI 3000 Air Cleaner Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Figure 85:EMI 3000 Air Filter Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Figure 86:EMI 3000 Air Cleaner System Model 30 Shown Model 50 Similar . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Figure 87:Air Restriction Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Figure 88:Tier 1 Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Figure 89:Tier 2 Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Figure 90:Model 30 Belt Arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Figure 91:Condenser Blower Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Figure 92:Model 50 Belt Arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Figure 93:Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Figure 94:New Style, Bonded Drive Bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Figure 95:Old Style Drive Bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Figure 96:Press Old Bushings Out Of Hub With Tool 204-1116 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Figure 97:Press New Bushing Into Hub With Tool 204-1116 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Figure 98:Pressing New Dowel Pin Into Flywheel Using Manual Pin Tool 204-1117 . . . . . . . . . . . . . . . . . . . . 106
Figure 99:Driving New Dowel Pin Into Flywheel With Impact Pin Tool 204-1118 . . . . . . . . . . . . . . . . . . . . . . . 106
Figure 100:Moisture Indicating Sight Glass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
12
List of Figures
Figure 101:Compressor with 4-Quart Sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109

Figure 102:Compressor with 7-Quart Sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Figure 103:High Pressure Cutout Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Figure 104:Multi-Temp Evacuation and Charging (Two Zone Unit Shown Other Units Similar) . . . . . . . . . . . 113
Figure 105:Compressor Coupling Removal Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Figure 106:Keyway Tool P/N 204-972 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
Figure 107:Compressor Coupling Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
Figure 108:Cross Section of In-line Check Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Figure 109:Location of Expansion Valve Bulb . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
Figure 110:Throttling Valve Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
Figure 111:Inspect the Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
Figure 112:Inspect for Wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
Figure 113:Inspect for Damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
Figure 114:Throttling Valve Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
Figure 115:Suction Line Check Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
Figure 116:Check Valve with Cap Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
Figure 117:Compressor Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
Figure 118:Unit and Engine Mounting Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
Figure 119:Defrost Damper Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
Figure 120:Condenser Blower Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
Figure 121:Evaporator Fan Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
Figure 122:Fan Shaft Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
Figure 123:Idler Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
Figure 124:Spectrum S-3 Evaporator Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
Figure 125:Spectrum S-3 Evaporator - Front View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
Figure 126:Spectrum S-3 Evaporator - Back View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
Figure 127:Serial Number Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
Figure 128:Check Valve with Cap Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
13
List of Figures
14
Safety Precautions
Thermo King recommends that all service be
DANGER: Avoid engine operation in
performed by a Thermo King dealer. However,
confined spaces and areas or
you should be aware of several general safety
circumstances where fumes from the
practices:
engine could become trapped and cause
serious injury or death.
The symbol appears next to a point that is
particularly important WARNING: Make sure your gauge
manifold hoses are in good condition
DANGER: Denotes the possibility of before using them. Never let them come in
serious injury or death. contact with moving belts, fans, pulleys or
hot surfaces. Defective gauge equipment
WARNING: Denotes the possibility of can damage components or cause serious
serious equipment damage or serious injury.
personal injury.
WARNING: Always wear goggles or safety
CAUTION: Denotes the possibility of glasses when working on a unit.
minor to severe equipment damage or Refrigerant liquid, oil and battery acid can
personal injury. permanently damage your eyes. See “First
Aid” on page 18.
General Practices
WARNING: Use extreme caution when
DANGER: Do not operate the compressor drilling holes in a unit. Holes might
with the discharge service valve closed. weaken structural components. Holes
This condition increases internal pressure, drilled into electrical wiring can cause a
which can cause an explosion. fire or explosion.
DANGER: Never apply heat to a sealed WARNING: Exposed coil fins can cause
refrigeration system or container. Heat lacerations. Service work on the
increases internal pressure, which might evaporator or condenser coils is best left to
cause an explosion. a certified Thermo King technician.
DANGER: Refrigerant in the presence of WARNING: Do not apply heat to a closed

an open flame, spark or electrical short cooling system. Before applying heat to a
produces toxic gases that are severe cooling system, drain it. Then flush it with
respiratory irritants. water and drain the water. Antifreeze
contains water and ethylene glycol. The
DANGER: Keep your hands, clothing and ethylene glycol is flammable and can
tools clear of fans when working on a unit ignite if the antifreeze is heated enough to
that is running. Loose clothing might boil off the water.
entangle moving pulleys or belts, causing
serious injury or possible death. WARNING: Be careful when using
ladders or scaffolding to install or service
DANGER: Do not inhale refrigerant. Use a unit. Observe the manufacture’s safety
caution when working with refrigerant or labels and warnings.
a refrigeration system in any confined
area with a limited air supply, such as a CAUTION: Make sure all mounting bolts
cargo area or garage. Refrigerant are tight and are the correct length for
displaces air and can cause oxygen their applications. Improper torque and
depletion, resulting in suffocation and incorrect bolt lengths can damage
possible death. equipment.
15
Safety Precautions
NOTE: In the USA, EPA Section 608

CAUTION: When being transferred,
Certification is required to work on refrigeration
refrigerant must be in liquid state to avoid
systems.
possible equipment damage.
Battery Removal CAUTION: When transferring

refrigerant, use a process that prevents or
DANGER: Disconnect the negative greatly restricts refrigerant from escaping
battery terminal (-) first when removing a into the atmosphere. Refrigerant damages
battery. Connect the positive terminal (+) the earth’s upper ozone layer.
first when installing a battery.
This order is important because the frame is Refrigerant Oil Hazards
grounded to the negative battery terminal. If the
negative terminal is still connected, a complete WARNING: Protect your eyes from
circuit exists from the positive terminal of the contact with refrigerant oil. The oil can
battery to the frame. Metal objects contacting the cause serious eye injuries. Avoid
positive side and the frame simultaneously will prolonged or repeated contact with
cause sparks or arcing. If there are sufficient refrigerant oil. To prevent irritation, wash
hydrogen gases emitted from the battery, an your hands and clothing thoroughly after
explosion might occur, causing equipment handling the oil.
damage, serious injury, even death.
CAUTION: Use the correct oil in Thermo
King systems to avoid damaging
Refrigerant Hazards equipment and invalidating its warranty.
DANGER: Do not use a Halide torch.
When a flame comes in contact with CAUTION: Do not mix refrigerant oils
refrigerant, toxic gases are produced. because that can cause system damage.
These gases can cause suffocation, even
death. CAUTION: Use dedicated equipment to
prevent contaminating systems with the
DANGER: Store refrigerant in proper wrong type of oil.
containers, out of direct sunlight and away
from intense heat. Heat increases pressure CAUTION: Store refrigerant oil in an
inside storage containers, which can cause approved sealed container to avoid
them to burst. moisture contamination.
DANGER: Do not use oxygen (O2 ) or CAUTION: Do not expose the refrigerant
compressed air for leak testing. Oxygen oil to the air any longer than necessary.
mixed with refrigerant is combustible. The oil will absorb moisture, which results
in much longer evacuation times and
WARNING: Wear butyl lined gloves when possible system contamination.
handling refrigerant to help prevent
frostbite. CAUTION: Wipe up spills immediately.
Refrigerant oil can damage paints and
CAUTION: Refrigerant in a liquid state rubber materials.
evaporates rapidly when exposed to the
atmosphere, freezing anything it contacts.
Be careful when handling refrigerant to
protect your skin from frostbite.
16
Safety Precautions
Electrical Hazards WARNING: Do not wear jewelry, watches

or rings because they increase the risk of
High Voltage shorting out electrical circuits and
DANGER: Lethal amounts of voltage are damaging equipment or causing severe
present in some electrical circuits. Use burns.
extreme care when working on an
operating refrigeration unit. Microprocessor Service
Precautions
WARNING: Do not make rapid moves Take precautions to prevent electrostatic
when working on high voltage circuits in discharge when servicing the microprocessor and
refrigeration units. Do not grab for falling its related components. Even tiny amounts of
tools because you might accidentally touch current can severely damage or destroy electronic
a high voltage source. components.
WARNING: Use tools with well insulated Observe the following precautions when servicing
handles. Never hold uninsulated metal a microprocessor control system to avoid
tools near exposed, energized conductors. damaging electronic components. Refer to the
appropriate microprocessor diagnosis manual and
WARNING: Treat all wires and the Electrostatic Discharge Training Guide (TK
connections as if they were high voltage 40282) for more information.
until a meter and wiring diagram indicate • If the microprocessor has a power switch, turn
otherwise. it OFF before connecting or disconnecting the
battery.
WARNING: Never work alone on high
voltage circuits in the refrigeration unit. • Disconnect power to the unit.
Another person should be nearby to shut
• Avoid wearing clothing that generates static
off the unit and provide aid in the event of
electricity (wool, nylon, polyester, etc.).
an accident.
• Wear a wrist strap (P/N 204-622 or its
WARNING: Safety glasses, rubber- equivalent) with the lead end connected to the
insulated gloves and cable cutters should microprocessor’s ground terminal. These
be near your work area, in the event of an straps are available from most electronic
electrical accident. equipment distributors. DO NOT wear these
straps with power applied to the unit.
WARNING: Use caution when working
with electrical circuits that contain • Avoid unnecessary contact with the electronic
capacitors. Some capacitors hold a components.
significant charge that might cause burns • Store and ship electronic components in
or shocks if accidentally discharged. Make antistatic bags and protective packaging.
sure capacitors are discharged before
working on electrical circuits. • Leave electronic components in their antistatic
packing materials until you’re ready to use
them.
Low Voltage
• After servicing any electronic components,
WARNING: Control circuits used in check the wiring for possible errors before
refrigeration units are low voltage (12 to restoring power to the unit.
24 volts dc). This voltage is not dangerous,
but the large amount of amperage • Never use a battery and a light bulb to test
available from the alternator can cause circuits on any microprocessor-based
severe burns if accidentally shorted to equipment.
ground with metal objects, such as tools.
17
Safety Precautions
Welding Precautions INHALATION: Move victim to fresh air and use

CPR (cardio pulmonary resuscitation) or
Take precautions before electrically welding any mouth-to-mouth resuscitation to restore breathing,
portion of the unit or the vehicle to which it is if necessary. Stay with victim until emergency
attached. Ensure that welding currents are not personnel arrive.
allowed to flow through the unit’s electronic
circuits.
First Aid, Refrigerant Oil
Observe the following precautions when welding EYES : Immediately flush with water for at least
to avoid damaging electronic components. 15 minutes. CALL A PHYSICIAN. Wash skin
• If the microprocessor has a power switch, turn with soap and water.
it OFF before connecting or disconnecting the INGESTION: Do not induce vomiting.
battery. Immediately contact local poison control center or
physician.
• Disconnect power to the unit.
• Disconnect all wire harnesses from the First Aid, Engine Coolant
microprocessor. EYES : Immediately flush with water for at least
• If there are any electrical circuit breakers in 15 minutes. CALL A PHYSICIAN. Wash skin
the control box, switch them OFF. with soap and water.
• Close the control box. INGESTION: Do not induce vomiting.
Immediately contact local poison control center or
• Components that could be damaged by physician.
welding sparks should be removed from the
unit. First Aid, Electrical Shock
• Use normal welding procedures, but keep the Take IMMEDIATE action after a person has
ground return electrode as close to the area received an electrical shock. Get quick medical
being welded as practical. This will reduce the assistance, if possible.
likelihood of stray welding currents passing
through any electronic circuits. The source of the shock must be quickly stopped,
by either shutting off the power or removing the
victim. If the power cannot be shut off, the wire
First Aid should be cut with an non-conductive tool, such as
a wood-handle axe or thickly insulated cable
First Aid, Refrigerant cutters. Rescuers should wear insulated gloves
In the event of frostbite, protect the frozen area and safety glasses, and avoid looking at wires
from further injury, warm the area rapidly and being cut. The ensuing flash can cause burns and
maintain respiration. blindness.
EYES : For contact with liquid, immediately flush If the victim must be removed from a live circuit,
eyes with large amounts of water. CALL A pull the victim away with a non-conductive
PHYSICIAN. material. Use wood, rope, a belt or coat to pull or
SKIN: Flush area with large amounts of warm push the victim away from the current. DO NOT
water. Do not apply heat. Remove contaminated TOUCH the victim. You will receive a shock from
clothing and shoes. Wrap burns with dry, sterile, current flowing through the victim’s body. After
bulky dressing to protect from infection. CALL A separating the victim from power source,
PHYSICIAN. Wash contaminated clothing before immediately check for signs of a pulse and
reuse. respiration. If no pulse is present, start CPR
(cardio pulmonary resuscitation). If a pulse is
present, respiration might be restored by using
mouth-to-mouth resuscitation. Call for emergency
medical assistance.
18
Specifications
Engine
Model: Ending Second Quarter 2005 TK486E (Tier 1)
Starting Second Quarter 2005 TK486V (Tier 2)
See “Diesel Engine” on page 28 and the photos on page 28
to identify the engine in the unit.
Number of Cylinders 4
Cylinder Arrangement In-line vertical, number 1 on flywheel end
Firing Order 1-3-4-2
Direction of Rotation Counterclockwise viewed from flywheel end
Fuel Type No. 2 diesel fuel under normal conditions
No. 1 diesel fuel is acceptable cold weather fuel
Oil Capacity 13 qt. (12.3 liters) crankcase
Fill to full mark on dipstick
Oil Type API Classification CI-4 or better
(ACEA Rating E3 or better for Europe)
Oil Viscosity 5 to 122 F (-150 to 50 C): SAE 15W-40
-13 to 104 F (-25 to 50 C): SAE 10W-40
-13 to 86 F (-25 to 30 C): SAE 10W-30
-22 to 32 F (-30 to 0 C): SAE 5W-30
Engine rpm: Low Speed Operation 1450 ± 25 rpm
High Speed Operation 2200 ± 25 rpm
18 psi (127 kPa) minimum in low speed
Engine Oil Pressure
45 to 57 psi (310 to 390 kPa) in high speed
Intake Valve Clearance 0.006 to 0.010 in. (0.15 to 0.25 mm)
Exhaust Valve Clearance 0.006 to 0.010 in. (0.15 to 0.25 mm)
Valve Setting Temperature 70 F (21 C)
Fuel Injection Timing: TK486E (Tier 1) 10 Degrees BTDC (timed on No. 1 cylinder)
TK486V (Tier 2) See “Injection Pump Timing Tier 2 Engine” on page 79
Fuel Injection Nozzle Opening Pressure:
TK486E (Tier 1) 2,800 to 3,000 psi (19,600 to 20,600 kPa)
TK486V (Tier 2) 3,100 to 3,300 psi (21,600 to 22,600 kPa)
Low Oil Pressure Switch (Normally Closed) 17 ± 3 psi (117 ± 21 kPa)
Engine Coolant Thermostat 180 F (82 C)
Coolant System Capacity 7.5 qt (7.1 liters)
Radiator Cap Pressure 7 psi (48 kPa)
19
Specifications
Engine (continued)
Engine Coolant Type ELC (Extended Life Coolant), which is “RED”. Use a 50/50
concentration of any of the following equivalents:
Chevron Dex-Cool
Texaco ELC
Havoline Dex-Cool®
Havoline XLC for Europe
Shell Dexcool®
Shell Rotella
Saturn/General Motors Dex-Cool®
Caterpillar ELC
Detroit Diesel POWERCOOL® Plus
CAUTION: Do not add “GREEN” or “BLUE-GREEN”
conventional coolant to cooling systems using “RED”
Extended Life Coolant, except in an emergency. If
conventional coolant is added to Extended Life Coolant,
the coolant must be changed after 2 years instead of
5 years.
Drive: Model 30 Direct to compressor; belts to fans, alternator, and water
pump
Model 50 Centrifugal clutch to compressor; belts to electric standby
motor, fans, alternator, and water pump
Belt Tension
Model 30 Tension No. on TK Gauge P/N 204-427
Alternator Belt 67
Lower Fan Belt (Engine to Idler) 67
Upper Fan Belt (Fan to Idler) 74
Model 50
Alternator Belt 29
Compressor Drive Belts 79
Fan Belt 74
Water Pump Belt 35
20
Specifications
Refrigeration System
Compressor Thermo King X430L
Refrigerant Type R-404A
Compressor Oil Charge: 4-Quart Sump* 4.3 qt (4.1 liters)**
7-Quart Sump* 6.9 qt (6.6 liters)**
Compressor Oil Type Polyol Ester type P/N 203-513
Throttling Valve Setting: Model 30 27 to 29 psi (186 to 200 kPa)
Model 50 23 to 25 psi (159 to 172 kPa)
Heat/Defrost Method: Engine Operation Hot gas
Electric Operation Hot gas and electric heater strips (host only)
High Pressure Cutout 470 +7/-35 psi (3241 +48/-241 kPa)
Automatic reset @ 375 ± 38 psi (2586 ± 262 kPa)
High Pressure Control Switch: Opens 300 +25/-0 psi (2068 +172/-0 kPa)
Closes 200 ± 20 psi (1379 ± 138 kPa)
* See “Compressor Sump Sizes” on page 109 to determine the sump size.
** When the compressor is removed from the unit, oil level should be noted or the oil removed from the compressor should be
measured so that the same amount of oil can be added before placing the replacement compressor in the unit.
Electrical Control System

Voltage 12.5 Vdc
Battery One, group C31, 12 volt battery
Circuit Breaker CB1—Zone 2 Fan Motors 30 amp, auto reset
Fuse Link Rating 110 amps @ 72 F (22 C)
Fuse F2—Electric Contactors 5 amp
Fuse F3—Zone 1 Damper 15 amp
Fuse F4—High Speed (Throttle) Solenoid 15 amp
Fuse F6—Zone 1 (Host) Solenoids 15 amp
Fuse F12—Zone 3 Fan Motors 25 amp
Fuse F13—Zone 3 Solenoids 15 amp
Fuse F20—Control Circuit Power 40 amp
Fuse F22—Host Unit Controls 25 amp
Fuse F23—Starter Circuit 40 amp
Other Fuses 2 or 5 amp
Battery Charging: Model 30 12 volt, 120 amp, brush type alternator
Model 50 12 volt, 105 amp, brush type alternator
Voltage Regulator Setting 13.8 to 14.3 volts @ 77 F (25 C)
NOTE: Fuse F7 (Bypass resistor for Prestolite Alternator) must be removed for the Bosch Alternator.
The Bosch alternator has the word “BOSCH” on the end opposite the pulley (see Figure 21 on page 53).
21
Specifications
Electrical Components
NOTE: Disconnect components from unit circuit to check resistance.
Current Draw (Amps) Resistance—Cold
at 12.5 Vdc (Ohms)
Fuel Solenoid: Pull-in Coil 35 to 45 0.2 to 0.3
Hold-in Coil 0.5 24 to 29
Damper Solenoid 5.7 2.2
High Speed (Throttle) Solenoid 2.9 4.3
Condenser Inlet Solenoid 1.3 9.6
Liquid Line Solenoid in Host Unit 1.5 8.3
Liquid Line Solenoids in Remote Units 1.3 9.6
Hot Gas Solenoids 1.5 8.3
Suction Line Solenoids 1.3 9.6
Receiver Tank Pressure Solenoid 0.7 17.0
Purge Valve 0.7 17.0
Air Heater 70.0-89.0 0.14
Starter Motor: TK486E (Tier 1) 250-375*
TK486V (Tier 2) 350-475*
*On-the-engine cranking check. Bench test is approximately 140 amps.
Smart Reefer Multi-Temp µP-IV Microprocessor Temperature

Controller
Temperature Controller Electronic Smart Reefer® Multi-Temp µP-IV Microprocessor
with digital thermostat, thermometer and fault indicator
monitor
Setpoint Range Factory default setting -20 to 80 F (-29 to 27 C)
Programmable setpoint range -25 to 90 F (-32 to 32 C)
Digital Temperature Display -40 to 99.9 F (-40 to 40 C)
Internal Defrost Timer: Temperature Pulldown 2, 4, 6, 8 or 12 hours (selectable, standard setting 4)
Temperature In-range 4, 6, 8 or 12 hours (selectable, standard setting 6)
Defrost Initiation Coil must be below 45 F (7.2 C)
Defrost Termination Terminates defrost with coil temperature above 57 F (14 C)
Defrost Interval Timer Terminates defrost 30 to 45 minutes (programmable) after
initiation if coil sensor has not terminated defrost
22
Specifications
Electric Standby (Model 50 Units Only)

Electric Motor and Overload Relay
Voltage/Phase/Frequency Horsepower Kilowatts rpm Full Load Overload Relay
(amps) Setting (amps)
230/3/60 14.0 10.4 1755 37.8 40
460/3/60 14.0 10.4 1755 18.9 20
Electric Heater Strips

Number 3
Power Rating 1000 watts (each)
Standby Power Requirements

Supply Circuit Breaker: 230/3/60 70 amps
460/3/60 40 amps
Extension Cord Size: 230/3/60 8 AWG Power Cable, 25-50-foot length
230/3/60 6 AWG Power Cable, 75-foot length
460/3/60 10 AWG Power Cable, up to 75-foot length
23
Specifications
24
Maintenance Inspection Schedule
Host Unit
Every Every Annual/
Pretrip 1,500 3,000 4,500 Inspect/Service These Items
Hours Hours* Hours
Microprocessor
• Run Pretrip Test (refer to Pretrip Test in the Operator’s Manual).
Engine
• Check fuel supply.
• Check engine oil level.
• • • • Inspect belts for condition and proper tension (belt tension tool
P/N 204-427).
• • • • Check engine oil pressure hot, on high speed (should display “OK”).
• • • • Listen for unusual noises, vibrations, etc.
• • Check air cleaner restriction indicator (change filter when indicator
reaches 25 in.). Replace EMI 3000 air cleaner element (see“EMI
3000 Air Cleaner” on page 94) at 3,000 hours or two years
(whichever occurs first) if indicator has not reached 25 in.
• • • Drain water from fuel tank and check vent.
• • • Inspect/clean fuel transfer pump inlet strainer (prefilter).
• • • Check and adjust engine speeds (high and low speed).
• • • Check condition of drive coupling bushings per Service Bulletin
T&T 171.
• Check condition of engine mounts.
• • • Replace standard (silver) fuel filter/water separator.
• Replace EMI 3000 (black) fuel filter/water separator.
Engine Oil Change Intervals (see below)
NOTE: The engine oil change interval is extended to 3,000 hours
when equipped with the EMI 3000 oil filter and oil with API
Rating CI-4 or better (ACEA Rating E3 for Europe). EMI 3000
filters are black with gold lettering.
NOTE: Change engine oil and filter (hot).
• • • Standard blue (or silver) oil filter.
• EMI 3,000 (black) oil filter. Requires oil with API Rating CI-4 or better
(ACEA Rating E3 for Europe).
— Change ELC (red) engine coolant every 5 years or 12,000 hours.
Units equipped with ELC have an ELC nameplate on the expansion
tank (see page 68).
— Test fuel injection nozzles at least every 10,000 hours.
— Replace fuel return lines between fuel injection nozzles every 10,000
hours.
* 3,000 hours or two years, whichever occurs first.
25
Maintenance Inspection Schedule
Host Unit (Continued)

Every Every Annual/
Hours Hours* Hours
Electrical
• • • Inspect battery terminals and electrolyte level.
• • • Inspect wire harness for damaged wires or connections.
• • • • Check operation of damper door (closes on defrost initiation and
opens on defrost termination).
• Inspect alternator wire connections for tightness.
— Inspect electric motor, replace bearings yearly or every 6,000 hours.
Refrigeration
• • • • Check refrigerant level.
• • • Check for proper suction pressure.
• • • Check throttling valve regulating pressure.
• Check compressor oil level and condition.
• Check compressor efficiency and pump down refrigeration system.
— Replace dehydrator and check discharge and suction pressure every
two (2) years.
Structural
• • • • Visually inspect unit for fluid leaks.
• • • • Visually inspect unit for damaged, loose or broken parts (includes air
ducts and bulkheads).
• • • Inspect tapered roller bearing fanshaft and idlers for leakage and
bearing wear (noise).
• • • Clean entire unit including condenser and evaporator coils and
defrost drains.
• • • Check all unit and fuel tank mounting bolts, brackets, lines, hoses,
etc.
• • • Check evaporator damper door adjustment and operation.
* 3,000 hours or two years, whichever occurs first.
Remote Evaporator(s)
Every Every Annual/
Hours Hours* Hours
Electrical
• • • Inspect/replace DC fan motors.
Structural
• • • • Visually inspect unit for damaged, loose, or broken parts.
• • • Clean entire unit including evaporator coils and defrost drains.
• Check all unit mounting bolts, brackets, lines, hoses, etc.
26
Unit Description
General Description
The Spectrum SB is a multi-temperature
refrigeration system designed to control the
temperatures in two or three compartments
(zones). The system allows any compartment to
be set at any temperature.
In the Spectrum SB 30/50-2 unit the evaporator in
the host unit controls one compartment (Zone 1),
and a remote evaporator controls the other
compartment (Zone 2). The Spectrum SB 30/50-3
has a second remote evaporator, which controls a
third compartment (Zone 3).
Brief descriptions of the following components AJA920
and features are given below:
Figure 1: Front View
• Host Unit (Zone 1)
• Spectrum Remote Evaporators (Zone 2 and
Spectrum Remote Evaporators
Zone 3) A Spectrum Remote Evaporator is mounted on the
ceiling of each remote compartment to provide
• Thermo King TK486 Engine
temperature control for Zone 2 and Zone 3 (if
• Thermo King X430L Compressor used). A Spectrum Remote Evaporator with two
fans is called an S-2. A Spectrum Remote
• Smart Reefer Multi-Temp µP-IV
Evaporator with three fans is called an S-3. Two
Microprocessor
remote evaporators can be mounted in the same
• CYCLE-SENTRYTM Start-Stop Controls remote compartment to provide more capacity.
• DAS (Optional)
• Remote Control Box (Optional).
Host Unit
The host unit contains the diesel engine, the
compressor, the condenser, an evaporator and the
control box. The Model 50 host unit also contains
an electric motor. The unit is equipped with a AJA984
Smart Reefer Multi-Temp µP-IV Microprocessor, Figure 2: S-3 Spectrum Remote Evaporator
which controls the operation of the host unit and
any remote evaporators. Refrigeration lines and
wire harness connect the host unit to the remote
evaporators.
The host unit mounts on the front of the trailer
with the unit evaporator portion extending into
trailer.
27
Unit Description
Diesel Engine
The unit uses a quiet running engine from the
TK486 engine family. The Thermo King TK486
family of engines are 4-cylinder, water cooled, 1
direct injection diesel engines.
The engine is coupled directly to the compressor
on Model 30 units. A centrifugal clutch transfers
power from the engine to the compressor on the
Model 50. The centrifugal clutch engages when
the engine reaches 400 ± 100 rpm. Belts transmit
power to the fans and the alternator.
During electric standby operation (Model 50 units
only) the centrifugal clutch isolates the engine
from the compressor. The electric motor drives
1. In-Line Injection Pump
the compressor, the fans, and the alternator
through belts. Figure 3: TK486E Tier 1
In the second quarter of 2005 the engines in these

units changed from a TK486E to a TK486V to
meet EPA Tier 2 requirements.
1
The TK486E is an EPA Tier 1 engine.
The TK486V is an EPA Tier 2 engine.
The main difference between a Tier 1 engine and
a Tier 2 engine is the fuel injection pump (see the
following photographs). The Tier 1 engines use an
in-line injection pump. The Tier 2 engines use a
mono-plunger and distributor injection pump. The
mono-plunger and distributor injection pump uses
a higher injection pressure than the in-line
injection pump. The higher injection pressure
atomizes the fuel more efficiently, which reduces 1. Mono-Plunger and Distributor Injection Pump
the emissions. Figure 4: TK486V Tier 2
There are some other differences (see “Engine
Change” on page 65), but the periodic Thermo King X430L Compressor
maintenance is the same. See “Maintenance The unit is equipped with a Thermo King X430L,
Inspection Schedule” on page 25. four-cylinder compressor with 30 cu. in.
(492 cm3) displacement. The unit is also equipped
with a compressor oil filter.
Units built before mid-February 2003 are
equipped with compressors that have a 4-quart
sump. Units built after mid-February 2003 are
sump. See “Compressor Sump Sizes” on page
109.
28
Unit Description
Smart Reefer Multi-Temp µP-IV Features of the CYCLE-SENTRY system are:

Microprocessor • Offers either CYCLE-SENTRY or
The Smart Reefer Multi-Temp µP-IV is a Continuous Run operation.
microprocessor control system designed for a
• Microprocessor controlled all season
Smart Reefer Multi-Temp transport refrigeration
temperature control.
system. The Smart Reefer Multi-Temp µP-IV
integrates the following functions: thermostats, • Maintains minimum engine temperature in
digital thermometers, hourmeters, oil pressure low ambient conditions.
gauge, water temperature gauge, ammeter,
voltmeter, tachometer, mode indicator, • Battery SentryTM keeps batteries fully charged
refrigeration system controller, and diagnostic during unit operation.
system. • Variable preheat time.
The CYCLE-SENTRY system and integral • Preheat indicator buzzer.
defrost timers are standard features. DAS and a
remote control box are optional features. DAS (Optional)
The microprocessor mounts inside a weather tight The DAS (Data Acquisition System) is an
control box. The display is clearly visible through independent data logger that logs information
a transparent cover. Opening the keypad door from dedicated external DAS sensors and inputs.
provides quick access to the microprocessor The DAS features up to six directly connected
keypad. The keypad is used to control the sensors. The DAS is also connected through a
operation of the microprocessor. serial port to the unit microprocessor. This allows
unit operating information to be logged as well.
CYCLE-SENTRY Start-Stop Controls The data can be retrieved using an IBM® PC
A CYCLE-SENTRY Start/Stop fuel saving compatible laptop or desktop computer and
system provides optimum operating economy. Thermo King WinTracTM 4.1 (or higher)
software. The computer is connected to the
WARNING: When the Zone 1/Host Computer Port on the front of the control box.
On/Off switch is in the On position, the Detailed graph or table trip reports can then be
unit may start at anytime without prior created. A brief graphical or tabular report can be
warning. printed on a compatible printer (P/N 204-844 or
NOTE: A buzzer sounds when the unit is P/N 204-1020). The printer is connected to the
automatically preheating. Printer Port on the front of the control box. Refer
to the DAS Data Acquisition System Manual
The CYCLE-SENTRY system automatically
TK 50565 for more information.
starts the unit on microprocessor demand, and
shuts down the unit when all demands are
satisfied. In addition to maintaining the
Remote Control Box (Optional)
compartment temperatures, engine block The remote control box is mounted in a remote
temperature and battery charge levels are location (such as inside the trailer) and is used to
monitored and maintained. If the block operate the unit. Each zone can be turned on and
temperature falls below 30 F (-1 C), the engine off and the setpoints can be changed. Refer to the
will start and run until the block temperature is Operator’s Manual or the appropriate
above 90 F (32 C). If the battery voltage falls to Microprocessor Diagnosis Manual for complete
the programmed limit selected by information about the operation of the remote
CYCLE-SENTRY Battery Voltage (typically control box.
12.2 volts) and Diesel CYCLE-SENTRY mode is
selected, the engine will start and run until the
charge rate falls below that programmed by
CYCLE-SENTRY Amps (typically 5 amperes).
29
Unit Description
Sequence of Operation The zone will stay in defrost until the evaporator
coil temperature rises to 58 F (14 C). If the
The Zone 1/Host On/Off switch must be turned evaporator coil temperature does not rise above
On before any other zone will operate. When the 58 F (14 C) within the Defrost Duration (DDUR)
Zone 1/Host On/Off switch is turned On, the time limit, the microprocessor will terminate
backlight illuminates the display and the operating defrost and display the Alarm Icon. The Defrost
icons appear. The unit will start automatically in Duration can be set for either 30 or 45 minutes.
both Continuous Run and CYCLE-SENTRY
modes.
System Operation
The microprocessor uses a complex program to
determine which operating mode each zone Several operating characteristics of the unit are:
should be in. Therefore, it is difficult to predict • All zones can cool at the same time.
which operating mode an evaporator should be in
by comparing its setpoint to the compartment • All zones can heat at the same time.
temperature. Also, the different versions of • Any zone can cool while any other zone heats.
software that are used have some operational
differences. • When the host zone is in defrost, it may delay
cool or heat in the other zone(s).
Each zone that is turned on will operate in one of
the following modes: • When a zone is in null, the blowers may run
but the zone does not cool or heat.
• Cool
• When a zone is in heat while another zone is
• Heat in cool, the evaporator in the zone that is in
• Defrost heat acts as the condenser.
• Null • The condenser inlet solenoid and the suction

line solenoids are normally open solenoid
During engine operation, engine speed is valves that close when energized.
determined by a combination of the requirements
of each zone and the discharge pressure. The • The liquid line solenoids, the hot gas
diesel engine will operate in High or Low Speed solenoids, the receiver tank pressure solenoid
accordingly. and the purge valve are normally closed
solenoid valves that open when energized.
Defrost • The flow of refrigerant through the system is
controlled by the solenoid valves and the
Defrost is initiated automatically by the check valves.
microprocessor or manually by selecting defrost
from the Defrost Prompt Screen for the desired • If the condenser inlet solenoid is energized
zone. A Demand Defrost cycle will also occur (closed) because a zone is in heat or defrost,
based on the return air temperature and discharge and if the discharge pressure exceeds 400 psi
air temperature or coil temperature. The (2758 kPa), the condenser inlet solenoid is
evaporator coil temperature must be below 45 F de-energized until the discharge pressure
(7 C) to allow defrost. When the Defrost Icon for drops below 250 psi (1724 kPa).
a zone appears, the damper door is closed or the • The receiver tank pressure solenoid and the
fans are turned off. Several defrost features are purge valve are energized (open) when any
programmable. The unit is designed to defrost in zone is in heat or defrost. If the discharge
low speed. pressure exceeds 300 psi (2068 kPa), the
receiver tank pressure solenoid and the purge
valve are de-energized until the discharge
pressure drops below 225 psi (1551 kPa).
30
Unit Description
• During engine operation when all zones are in Refrigeration System Diagrams
cool, the microprocessor will shift the engine
to low speed if the discharge pressure exceeds The following pages show examples of the
425 psi (2930 kPa). High speed is enabled, if refrigerant flow through a three zone system. The
required, when the discharge pressure drops two zone system is similar, except the Zone 3
below 375 psi (2586 kPa). evaporator and its components are removed.
• During engine operation when all zones are in

heat, the microprocessor will shift the engine
to low speed if the discharge pressure exceeds
375 psi (2586 kPa). High speed is enabled, if
required, when the discharge pressure drops
below 300 psi (2068 kPa).
31
Unit Description
Zone 1 Cool, Zone 2 Cool, and Zone 2 Evaporator

Zone 3 Cool 1C. Zone 2 Liquid Line Solenoid (LLS2)—Open
High pressure refrigerant vapor leaves the
2C. Zone 2 Liquid Return Check Valve
compressor and flows through the open CIS to the
(LRCV2)— Closed
condenser where the refrigerant condenses into
high pressure liquid. The liquid refrigerant flows 3C. Zone 2 Suction Line Check Valve
through the receiver tank into the liquid lines. (SLCV2)— Open
The LLS is open so some of the refrigerant flows 4C. Zone 2 Suction Line Solenoid (SLS2)—Open
through the Zone 1 expansion valve into the
5C. Zone 2 Hot Gas Solenoid (HGS2)—Closed
Zone 1 evaporator. There the liquid refrigerant
cools the Zone 1 evaporator as it evaporates into
Zone 3 Evaporator
low pressure vapor. The refrigerant returns to the
compressor through the SLCV and the 1R. Zone 3 Liquid Line Solenoid (LLS3)—Open
accumulator.
2R. Zone 3 Liquid Return Check Valve
The LLS2 is open so some of the refrigerant flows (LRCV3)— Closed
3R. Zone 3 Suction Line Check Valve
(SLCV3)— Open
low pressure vapor. The refrigerant returns to the 4R. Zone 3 Suction Line Solenoid (SLS3)—Open
compressor through the SLS2, the suction line, the
5R. Zone 3 Hot Gas Solenoid (HGS3)—Closed
SLCV2, and the accumulator.
The LLS3 is open so some of the refrigerant flows
Host Unit and Zone 1 Evaporator

1. Liquid Line Solenoid (LLS)—Open
2. Liquid Return Check Valve (LRCV)—Closed
3. Suction Line Check Valve (SLCV)—Open
4. Suction Line Solenoid (SLS)—Open
5. Hot Gas Solenoid (HGS)—Closed
6. Condenser Inlet Solenoid (CIS)—Open
7. Condenser Inlet Check Valve (CICV)—Open
8. Receiver Tank Pressure Solenoid
(RTPS)—Closed
9. Condenser Check Valve (CCV)—Open
10. Bypass Hand Valve
11. Purge Valve (PV)—Closed
12. Purge Check Valve (PCV)—Closed
32
Unit Description
Zone 1
Zone 2
AGA168
Zone 3
Figure 5: Zone 1 Cool, Zone 2 Cool, and Zone 3 Cool
33
Unit Description
Zone 1 Cool, Zone 2 Cool, and Zone 2 Evaporator

Zone 3 Heat 1C. Zone 2 Liquid Line Solenoid (LLS2)—Open
The CIS is closed so high pressure refrigerant
2C. Zone 2 Liquid Return Check Valve
vapor leaves the compressor and flows through
(LRCV2)— Closed
the hot gas line and the open HGS3 into the
Zone 3 evaporator. There the refrigerant heats the 3C. Zone 2 Suction Line Check Valve
Zone 3 evaporator and condenses into high (SLCV2)— Open
pressure liquid. Because the SLS3 is closed, the
4C. Zone 2 Suction Line Solenoid (SLS2)—Open
liquid refrigerant flows through the LRCV3 and
the remote liquid line to LLS and LLS2. 5C. Zone 2 Hot Gas Solenoid (HGS2)—Closed
The LLS is open so some of the refrigerant flows
Zone 3 Evaporator
Zone 1 evaporator. There the liquid refrigerant 1R. Zone 3 Liquid Line Solenoid (LLS3)—Open
2R. Zone 3 Liquid Return Check Valve
(LRCV3)— Open
compressor through the SLCV, and the
accumulator. 3R. Zone 3 Suction Line Check Valve
(SLCV3)— Closed
The LLS2 is also open so some of the refrigerant
flows through the Zone 2 expansion valve into the 4R. Zone 3 Suction Line Solenoid
Zone 2 evaporator. There the liquid refrigerant (SLS3)—Closed
5R. Zone 3 Hot Gas Solenoid (HGS3)—Open
Host Unit and Zone 1 Evaporator

1. Liquid Line Solenoid (LLS)—Open
2. Liquid Return Check Valve (LRCV)—Closed
3. Suction Line Check Valve (SLCV)—Open
4. Suction Line Solenoid (SLS)—Open
5. Hot Gas Solenoid (HGS)—Closed
6. Condenser Inlet Solenoid (CIS)—Closed*
7. Condenser Inlet Check Valve
(CICV)—Closed
8. Receiver Tank Pressure Solenoid
(RTPS)—Open*
9. Condenser Check Valve (CCV)—Closed
10. Bypass Hand Valve
11. Purge Valve (PV)—Open*
12. Purge Check Valve (PCV)—Open
* The microprocessor will open and close these
valves as required to control the head pressure or
compensate for high ambient temperatures.
34
Unit Description
Zone 1
Zone 2
AGA169
Zone 3
Figure 6: Zone 1 Cool, Zone 2 Cool, and Zone 3 Heat
35
Unit Description
Spectrum Spectrum
Design Features SB-30 SB-50
TK486 Diesel Engine • •
X430L Compressor with Ester Base Compressor Oil • •
Compressor Oil Filter • •
230V, 50/60 Hz, 3 Phase Electric Standby - •
380/460V, 50/60 Hz, 3 Phase Electric Standby Motor - Opt
Stainless Steel Evaporator Hardware • •
Tapered Roller Bearing Fanshaft and Idler • •
Premium Drive Belts • •
3000 Hour Cyclonic Air Cleaner • •
3000 Hour Fuel Filter/Water Separator • •
3000 Hour Dual Lube Oil Filter • •
5 Year/12,000 Hour (Service Interval) Extended Life Coolant (ELC) • •
Smart Reefer Multi-Temp µP-IV Microprocessor Controller • •
CYCLE-SENTRY System • •
Refrigerant 404A • •
120 Amp Alternator (Model 30) • -
105 Amp Alternator (Model 50) - •
Spectrum Remote Evaporator(s) • •
Silicone Coolant Hoses • •
Auto Phase - •
Communications (Data Logging with DAS) Opt Opt
Remote Control Panel Opt Opt
Fuel Heater Opt Opt
Frost Plug Heater Opt Opt
Dealer Installed Synthetic Engine Oil Opt Opt
36
Unit Description
Opening the Front Doors

Pull the door latch handle to open the doors and
access the engine compartment. Slam the door to
close it. Do not push the door closed while
holding the door latch handle open or the door
will not close properly.
1. Door Latch
2. Secondary Door Latch Nameplate
Figure 7: Door Latch Location
Opening the Secondary Door Latch

Later model units are equipped with a secondary
door latch. These units also have a secondary door
latch nameplate located below the front doors.
After opening the door latch, reach between the
front doors and lift the spring latch over the spring
catch while opening the door.
1
1. Spring Latch
2. Spring Catch
Figure 8: Opening Secondary Door Latch
37
Unit Description
Serial Number Locations

Unit: Nameplates on the on the bulkhead above
compressor inside the curbside door, and on the
roadside of the evaporator. 1
Engine: Stamped on an nameplate on the valve

cover.
Compressor: Stamped on the end above the oil
pump.
1
1
AJA920
1. Serial Number Location

Figure 11: Unit Serial Number Locations
SP2001

Figure 9: Compressor Serial Number Location
1 AEA1398
Figure 12: Laminated Serial Number Plate

(Located Where Shown Above)
AEA686

Figure 10: Engine Serial Number Location
38
Unit Description
AJA920
Figure 13: Front View
39
Unit Description
ARA104
1. Access Panels
2. Defrost Damper
Figure 14: Back View
40
Unit Description
1 2 3 4 5 6 7 8 9 10
ARD190
16 15 14 13 12 11
1. Discharge Service Valve 9. Filter-Drier

2. Suction Service Valve 10. Receiver Tank Sight Glass
3. Throttling Valve 11. Hand Primer Pump
4. Throttle Solenoid 12. Dipstick
5. Fuel Solenoid 13. Oil Filter
6. Air Restriction Indicator 14. Starter
7. Fuel Bleed Screw 15. Compressor Sight Glass
8. Alternator 16. Compressor Oil Filter
Figure 15: Engine Compartment (TK486E Shown, Other Engine Similar)
41
Unit Description
AJA919
1. Microprocessor Control Panel

2. Display
3. Keypad
4. Switch Panel (3 Temp Unit Shown)
5 Computer Port (Optional)
6 Printer Port (Optional)
Figure 16: Control Panel
42
Unit Description
2
1
ARA015
1. DAS Module (Optional)

2. Fan Relays (FR33, FR32, FR23, and FR22)
3. Fuel Solenoid Relay
4. Relay Board
5. Microprocessor
Figure 17: Typical Components Inside Control Box
43
Unit Description
44
Operating Instructions
Control Panel Zone 1/Host On/Off Switch

Most of the controls used to operate the unit are This switch turns the host unit and the Zone 1
located on the control panel. Refer to the evaporator on and off. When the switch is in the
Spectrum SB Operator’s Manual TK 51297 or the Off position, the display will be off and the
THERMOGUARD µP-VI Multi-Temp display backlight will be off. The switch should
Microprocessor Controller Diagnosis Manual always be placed in the Off position before
TK 50033 for more complete operating servicing the unit. When the switch is in the On
information. position, the display backlight will turn on and the
Standard Display will appear.
WARNING: The unit may start and run
automatically any time the Zone 1/Host
On/Off switch is in the On position.
8 7 6 5
1. Display 5. Zone 3 On/Off Switch (Three Temperature Units Only)

2. Keypad 6. Zone 2 On/Off Switch
3. Computer Port (With DAS Option Only) 7. Diesel/Electric Switch (Model 50 Only)
4. Printer Port (With DAS Option Only) 8. Zone 1/Host On/Off Switch
Figure 18: Control Panel
45
Zone 2 On/Off Switch Icons

This switch turns the Zone 2 evaporator on and An icon will appear next to the appropriate
off. description when the unit is operating in that
mode or if an alarm condition exists. The Zone
NOTE: The Zone 2 On/Off switch will not
Icons indicate which zone is currently displayed.
function unless the Zone 1/Host On/Off Switch
is in the ON position. Cool Icon: Appears when the indicated zone
is operating in Cool mode.
• On position. The Zone 2 evaporator is
enabled. It will run as determined by the Heat Icon: Appears when the indicated zone
microprocessor to keep the temperature in the is operating in Heat mode.
Zone 2 compartment near the Zone 2 setpoint. Defrost Icon: Appears when the indicated
zone is operating in Defrost mode.
• Off position. The Zone 2 evaporator is
disabled and will not operate. High Speed Icon: Appears when the diesel
engine is operating in high speed.
Zone 3 On/Off Switch Electric Icon: Appears when the unit is
This switch is found on three temperature units, operating in optional Electric Standby mode.
but not on two temperature units. It turns the Setpoint Icon: Appearswhen the setpoint is
Zone 3 evaporator on and off. being shown in the lower display.
NOTE: The Zone 3 On/Off switch will not CYCLE-SENTRY Icon: Appears when the unit
function unless the Zone 1 On/Off Switch is in is operating in CYCLE-SENTRY mode.
the ON position. Alarm Icon: Appears when the
• On position. The Zone 3 evaporator is microprocessor detects an alarm condition.
enabled. It will run as determined by the ZO N E 1 Zone Icons: Appear to indicate which zone
ZO N E 2
microprocessor to keep the temperature in the ZO N E 3 is currently being shown in the display. All
Zone 3 compartment near the Zone 3 setpoint. zones will be shown in turn (each for about
• Off position. The Zone 3 evaporator is 10 seconds) when the Zone 1/Host On/Off
disabled and will not operate. Switch is turned on.
Diesel/Electric Switch (Model 50 Keypad

Only) These touch sensitive keys are used to change the
This switch selects Diesel or Electric operation. setpoint, view operating conditions and other unit
To operate with the switch in the Electric position, information, and to control the unit.
the unit must be connected to an electric power HOURMETER Key: Press to display Total Hours,
source that has the correct voltage and frequency. Engine Hours, Electric Hours, Zone 1
Hours, Zone 2 Hours, and Programmable
Display Hours.
The display normally shows the Standard Display OIL PRESSURE Key: Press to display the engine
of return air temperature and setpoint for all zones oil pressure, or the oil pressure status (OK or
whose On/Off switches are turned on. The zones Low). This is a selectable feature.
will alternate in the display with each zone WATER TEMPERATURE Key: Allows selection of
appearing for about 10 seconds. Other operating a Manual Defrost Cycle, and
and unit information can also be shown here. All CYCLE-SENTRY or Continuous Mode.
possible segments and operating icons are shown
OIL PRESSURE Key: Press to display the engine
in Figure 18 on page 45.
oil pressure.
AMPS Key: Press to display the current flow
to or from the unit battery.
46
THERMO KING LOGO Key: Used to initiate a Printer Port

Pretrip Test, print, display the software
revision, display clock/calendar settings, and A serial cable from a printer is connected to the
initiate a Start of Trip. printer port to print a report for the directly
connected DAS sensors. Refer to the Spectrum
CLEAR Key: Press to clear the alarm code SB Operator’s Manual TK 51297, or the DAS
shown on the display. Data Acquisition System Manual TK 50565 for
CODE Key: Press to display any alarm codes more information.
that may be present. [00] means no alarm
codes are present. Unit Indicators
ENTER Key: Press to load a new setpoint or Receiver Tank Sight Glass: The receiver tank
other displayed setting, or to execute a sight glass is used to check the amount of
prompt. refrigerant in the system, and the moisture content
UP and DOWN ARROW Keys: Press to increase of the refrigerant.
or decrease the setpoint or other displayed Compressor Oil Sight Glass: The compressor oil
setting, or to change a displayed prompt. sight glass is used to check the relative level of
SELECT Key: Press to select other prompt or compressor oil in the compressor sump.
display screens. See the following list: Air Restriction Indicator: An air restriction
[DEF1] Defrost Zone 1 Prompt indicator is attached to the intake manifold.
Visually inspect the restriction indicator
[CYCLS] CYCLE-SENTRY Prompt
periodically to assure the air filter is not restricted.
Zone 2 Standard Display Zone 2
Service the air filter when the yellow diaphragm
[DEF2] Defrost Zone 2 Prompt indicates 25 in. of water column. Press the button
Zone 3 Standard Display Zone 3 on the top of the restriction indicator after
[DEF3] Defrost Zone 3 Prompt servicing the air filter. Replace the EMI 3000 air
[AMB.T] Ambient Temperature Display cleaner element (see “EMI 3000 Air Cleaner” on
[BAT.V] Battery Voltage Display page 94) at 3,000 hours or two years (whichever
occurs first) if air clean indicator has not reached
[RPM] Engine RPM Display
25 in.
[HED.P] Head (Discharge) Pressure Display
Remote Status Light (Optional): The remote status
[RET.A] Return Air Temp Zone 1 Display
light indicates the operating status of the unit. The
[DIS.A] Discharge Air Temp Zone 1 Display
green “T” indicates the unit is functioning
[TPDF] Temp Differential Zone 1 Display properly. The amber “K” indicates the unit has a
[COIL] Evap Coil Temp Zone 1 Display check alarm but is still functioning. The green “T”
[RET.A] Return Air Temp Zone 2 Display and amber “K” both flash to indicate the unit has a
[COIL] Evap Coil Temp Zone 2 Display shutdown alarm and is not functioning.
[RET.A] Return Air Temp Zone 3 Display
[COIL] Evap Coil Temp Zone 3 Display Unit Protection Devices
Fuse Link (Current Limiter): The fuse link is
Computer Port located in the positive battery cable. At a current
draw of approximately 110 amps, the fuse link
A serial cable from a computer is connected to the
will melt, cutting all power to the unit. If the fuse
download port to access the Data Logging
link burns out, check for a grounded 2 wire before
functions of the DAS. Refer to the DAS Data
replacing the fuse link. Replace the fuse link by
Acquisition System Manual TK 50565 for more
replacing the positive battery cable.
information.
Fuses: A number of fuses, located on the relay
board, protect various circuits and components.
See “Fuses” on page 58 for more information.
47
High Pressure Cutout: The high pressure cutout is Unit Operation

a pressure sensitive switch that is located in the
compressor discharge manifold. If the discharge Manual Pretrip Inspection (Before
pressure rises above 470 psi (3241 kPa), the Starting Unit)
switch opens the 8D circuit to the fuel solenoid,
which stops the engine. The following Manual Pretrip Inspection should
be completed before starting the unit and loading
High Pressure Relief Valve: The high pressure the trailer. While the pretrip inspection is not a
relief valve is designed to relieve excess pressure substitute for regularly scheduled maintenance
within the refrigeration system. The valve is a inspections, it is an important part of the
spring-loaded piston that lifts off its seat when preventive maintenance program designed to head
refrigerant pressure exceeds 500 psi (3447 kPa). off operating problems and breakdowns before
The valve will reseat when the pressure drops to they happen.
400 psi (2758 kPa). The valve could possibly leak
refrigerant after it has relieved excess pressure. Fuel: The diesel fuel supply must be adequate to
Tapping the valve lightly may help the valve guarantee engine operation to the next check
reseat and seal properly. The valve is point.
non-repairable and requires no adjustment. If the Engine Oil: The engine oil level should be at the
valve fails to reseat properly, remove the FULL mark with the dipstick turned (threaded)
refrigerant charge and unscrew and replace the into oil pan. Never overfill.
valve. Coolant: The engine coolant must have antifreeze
The high pressure relief valve is located on the protection to -30 F (-34 C). Alarm Code 37
receiver tank. Its location is such that when the indicates low coolant. Add coolant in the
pressure is expelled from the valve, it would be expansion tank.
directed away from anyone servicing the unit.
CAUTION: Do not remove expansion
Low Oil Level Switch: The low oil level switch tank cap while coolant is hot.
closes if the oil drops below a certain level and
stays closed for a specified time, the
CAUTION: Do not add “GREEN” or
microprocessor will shut the unit down and record
“BLUE-GREEN” conventional coolant to
Alarm Code 66.
cooling systems using “RED” Extended
Preheat Buzzer: The preheat buzzer sounds when Life Coolant, except in an emergency. If
the CYCLE-SENTRY system energizes the glow conventional coolant is added to Extended
plugs. This should warn anyone near the unit that Life Coolant, the coolant must be changed
the CYCLE-SENTRY system is about to start the after 2 years instead of 5 years.
diesel engine.
Battery: The terminals must be clean and tight.
Overload Relay—Manual Reset (Model 50): An
Belts: The belts must be in good condition and
overload relay protects the standby electric motor.
adjusted to the proper tensions.
The overload relay opens the circuit to the electric
motor if the motor overloads for any reason (e.g., Electrical: The electrical connections should be
low line voltage or improper power supply) while securely fastened. The wires and terminals should
the unit is on electric standby operation. be free of corrosion, cracks or moisture.
Structural: Visually inspect the unit for leaks,
loose or broken parts and other damage. The
condenser and evaporator coils should be clean
and free of debris. Check the defrost drain hoses
and fittings to make sure they are open. Make sure
all the doors are latched securely.
48
Starting Unit With Electronic Full • PRE AMPS will appear on the display
Pretrip Test indicating that the amps check is
running and the pretrip has started.
This procedure is used for a complete checkout of
the trailer, unit, and unit control circuits. It should • The amps check will continue for
be used when first starting the unit for a trip several minutes, then the unit will start
before the cargo is loaded. A full Pretrip test automatically and the operational tests
procedure may take up to 30 minutes and the unit will be performed.
will run unattended.
4. When the Pretrip Test is complete, PASS,
CAUTION: Monitor the return air CHECK, or FAIL will appear on the display
temperatures when performing a Pretrip until a function key (e.g., SELECT or ENTER) is
Test on a loaded trailer. The controller pressed. Continue as follows:
may not maintain setpoints during the • PASS—The unit is running and no alarms
Pretrip Test. have been recorded. The unit has passed
1. Perform a Manual Pretrip Inspection. the pretrip. Go to step 6.
2. Adjust the setpoints to the desired load • CHECK—The unit is running but Check
temperatures (refer to the appropriate Alarms have been recorded. Go to step 5.
Microprocessor Diagnosis Manual for detailed • FAIL—The unit has shut down, recorded
information about adjusting the setpoints). Alarm Code 28, and possibly recorded
a. Use the SELECT key to display the Standard other Shutdown Alarms. Go to step 5.
Display for the zone whose setpoint is to 5. View the Alarms with the CODE key (refer to
be changed. the appropriate Microprocessor Diagnosis
b. Change the setpoint display with the Manual for detailed information about
ARROW keys. alarms).
c. Enter the new setpoint by pressing the a. Correct the alarm conditions.
ENTER key within 5 seconds. b. Clear the alarms with the CLEAR key (refer
3. Initiate a Pretrip Test (refer to the appropriate to the appropriate Microprocessor
Operator’s Manual or Microprocessor Diagnosis Manual for detailed information
Diagnosis Manual for detailed information about alarms).
about the pretrip). This procedure is automatic c. Repeat the Pretrip Test until [PASS]
and can be performed on the way to the appears (the unit passes the pretrip).
loading area or while waiting to load.
6. Recheck the setpoints.
a. Place all the On/Off switches in the On
position. 7. Complete the “After Start Inspection” on
page 51.
b. Clear any alarms.
c. Press and hold the TK key for at least 3 Selection of Operating Modes
seconds. The Thermo King CYCLE-SENTRY system is
• PRE TRIP will appear on the display. designed to save refrigeration fuel costs. The
savings vary with the commodity, ambient
d. Press the ENTER key while PRE TRIP is temperatures and trailer insulation. However, not
displayed. all temperature controlled products can be
• PRE LOAD will appear on the display properly transported using CYCLE-SENTRY
and the pretrip test will start. operation. Certain highly sensitive products
normally require continuous air circulation.
49
The microprocessor has a CYCLS screen, which 2. Place the Zone 1/Host On/Off switch in the
is used to select CYCLE-SENTRY (CYCLS On position.
YES) or Continuous Run (CYCLS No) operation.
3. After a 10 second delay, the unit should
Refer to the appropriate Operator’s Manual or
preheat and start automatically.
Microprocessor Diagnosis Manual for more
information about CYCLE-SENTRY selection. NOTE: When the CYCLE-SENTRY icon is
active, the unit may not start if: the
Your selection of the operating mode for the
compartment temperatures are near their
proper protection of a particular commodity
respective setpoints, the engine is warm, and
should use the following guidelines:
the battery is fully charged.
Examples of Products Normally 4. Place the Zone 2 On/Off switch in the On
Acceptable for CYCLE-SENTRY Operation position to operate the Zone 2 evaporator.
• Frozen foods (in adequately insulated trailers) 5. Place the Zone 3 On/Off switch in the On
position to operate the Zone 3 evaporator.
• Boxed or processed meats
• Poultry Restarting Unit—Electric Operation
• Fish This procedure is used when starting units that
have been shut off for short periods of time. A
• Dairy products unit that has been shut off for a long time should
• Candy be started and put through a full pretrip when first
started.
• Chemicals
1. Place the Diesel/Electric switch in the Electric
• Film position.
• All non-edible products 2. Connect the unit to an appropriate electric
power supply.
Examples of Products Normally Requiring
Continuous Run Operation for Air Flow CAUTION: Always turn the electric
• Fresh fruits and vegetables, especially power supply Off when handling,
asparagus, bananas, broccoli, carrots, citrus, connecting, or disconnecting high voltage
green peas, lettuce, peaches, spinach, power cords.
strawberries, sweet corn, etc. 3. Turn the high voltage power supply On.
• Non-processed meat products (unless CAUTION: Do not start the electric drive
pre-cooled to recommended temperature) motor unless the diesel engine is
• Fresh flowers and foliage completely stopped.
These listings are not all inclusive. Consult your 4. Place the Zone 1/Host On/Off switch in the
grower or shipper if you have any questions about On position. If the microprocessor determines
the operating mode selection of your type of load. that the unit should cool or heat, the
appropriate icon(s) will appear and the electric
Restarting Unit—Diesel Operation motor will start. It may not start if the return
air sensor temperature is within a few degrees
This procedure is used when starting units that of setpoint.
have been shut off for short periods of time. A
unit that has been shut off for a long time should 5. Place the Zone 2 On/Off switch in the On
be started and put through a full pretrip when first position to operate the Zone 2 evaporator.
started. 6. Place the Zone 3 On/Off switch in the On
1. Place the Diesel/Electric switch (if so position to operate the Zone 3 evaporator.
equipped) in the Diesel position.
50
After Start Inspection Loading Procedure

After the unit is running, the following items can 1. Make sure the unit is Off before opening the
be quickly checked to confirm that the unit is doors to minimize frost accumulation on the
running properly. evaporator coil and heat gain in the trailer.
1. Oil Pressure: Check the engine oil pressure in (Unit may be running when loading the trailer
high speed by pressing the OIL PRESS key. The from a warehouse with door seals).
oil pressure should read OK, not Low. 2. Spot check and record load temperature while
2. Ammeter: Check the ammeter reading by loading. Especially note any off-temperature
pressing the AMPS key. The ammeter should product.
indicate normal battery charging current. It 3. Load the product so that there is adequate
may be fairly high right after starting the unit, space for air circulation completely around the
but should taper off as the battery is recharged. load. DO NOT block the evaporator inlet or
3. Compressor Oil: The compressor oil level outlet.
should be visible in the sight glass. 4. Products should be pre-cooled before loading.
4. Refrigerant: Check the refrigerant charge. See Thermo King transport refrigeration units are
“Refrigerant Charge” in the Refrigeration designed to maintain loads at the temperature
Maintenance chapter. at which they were loaded. Transport
refrigeration units are not designed to pull hot
5. Pre-cooling: Make sure that the setpoints are loads down to temperature.
at the desired temperatures and allow the unit
to run for a minimum of 1/2 hour (longer if
possible) before loading the trailer.
Single Temperature Loading
Procedures
This provides a good test of the refrigeration
Additional steps must be taken to insure load
system while removing residual heat and the
temperature requirements are implemented and
moisture from the trailer interior to prepare it
maintained when a multi-temp unit is used to
for a refrigerated load.
refrigerate a single-temperature load.
6. Defrost: When the unit has finished
pre-cooling the trailer interior, manually
initiate defrost cycles in each compartment.
This will remove the frost that builds up while
AJA1222
running the unit to pre-cool the trailer.
Figure 19: Single Temperature Load, Host On and
To manually initiate a Defrost cycle, press the Remote Off, Bulkhead Open/Removed
SELECT key until the [dEF] screen appears,
then press the ENTER key. This will initiate a It is strongly recommended that if the whole load
Defrost cycle in the compartment for the is to be maintained at the same temperature, then
active Zone icon. Refer to the appropriate all bulkhead doors should be stowed in the open
Microprocessor Diagnosis Manual for more position (or, ideally, removed altogether), the host
information about Manual Defrost. unit set to operate on its own and the remote
evaporator(s) switched off. This will provide the
The Defrost cycle should end automatically. best solution if the host units capacity is designed
NOTE: An evaporator will not defrost unless to cool the complete trailer.
its coil temperature is below 45 F (7 C). NOTE: If the bulkheads are removed, a
multi-temp unit may not have the cooling or
heating capacity to maintain a specific
temperature range throughout an entire trailer.
51
If all compartments are to be maintained at the

same temperature and all evaporators are required
to operate, it is recommended that the dividing
bulkhead doors be closed to allow correct
temperature management in each compartment.
AJA1220
Figure 20: Same Temperatures in each

Compartment, Host and Remote Running,
Bulkhead Closed
Post Load Procedure

1. Make sure all the doors are closed and locked.
2. Start the unit if it was shut off to load (see
“Restarting Unit”).
3. Make sure the setpoints are at the desired
settings.
4. One-half hour after loading, manually initiate
defrost cycles in each compartment. If the
evaporator coil sensor temperature is below
45 F (7 C), the evaporator will defrost. The
microprocessor will terminate defrost
automatically when the evaporator coil
temperature reaches 58 F (14 C) or the
evaporator has been in the Defrost mode for
30 or 45 minutes (depending on setting).
Post Trip Checks

1. Wash the unit.
2. Check for leaks.
3. Check for loose or missing hardware.
4. Check for physical damage to the unit.
52
Electrical Maintenance
Australian Bosch Alternator - CAUTION: The F7 fuse must be removed

Model 30 from the relay board on units equipped
with the Australian Bosch alternator. The
120 Amp Charging System voltage regulator will be damaged if the
Diagnostic Procedures unit is turned On with the F7 fuse in place
NOTE: Units manufactured with on the relay board.
CYCLE-SENTRY and alternators with integral Complete the following checkout procedure
regulators MUST use replacement alternators before replacing the voltage regulator or the
with integral regulators. alternator.
CAUTION: Full-fielding alternators with • When testing alternators use accurate
the integral regulator is accomplished by equipment such as a Thermo King
installing a jumper from terminal F2 to P/N 204-615 (FLUKE 23) digital multimeter
ground. Attempting to full-field the and a Thermo King P/N 204-613 amp clamp
alternator by applying battery voltage to or an equivalent.
terminal F2 will cause voltage regulator
failure.
1. Check Point for 2A Amperage 3. Check Point for Sense Circuit and
Excitation Circuit Voltages
2. Check Point for B+ Voltage 4. Position for Full Fielding Jumper
Figure 21: Check Points for Alternator Test
53
• Make sure the drive belts and pulleys of the 8. If battery voltage is present on the sense and
charging system are in good condition and are excitation circuits, connect the alternator
adjusted properly before testing the alternator. harness to the voltage regulator and check the
Worn belts and pulleys or loose belts will voltage on the B pin in the two pin connector
lower the output of the alternator. on alternator harness. The voltage should be 1
to 3 volts.
• The battery must be well charged, the battery
cable connections must be clean and tight, and a. No voltage or a voltage reading below 1
the 2A and excitation circuits must be volt indicates that the rotor or the voltage
connected properly. regulator may be shorted. Perform the
NOTE: All voltage readings should be taken field current test to further isolate the
between the negative battery terminal, or a good problem.
chassis ground, and the terminals indicated, b. A voltage reading above 3 volts indicates
unless stated otherwise. that the field circuit may be open or have
1. Check to make sure that the F7 fuse has been high resistance. The brushes or the rotor
removed from the relay board. If not, it must are probably defective.
be removed, however, the voltage regulator 9. Attach a clamp-on ammeter to the 2A wire
has probably already been damaged. connected to the B+ terminal on the alternator.
2. Set the unit for continuous run operation and 10. Connect a voltmeter between the B+ terminal
place the Zone 1/Host On/Off switch in the and a chassis ground.
Off position.
11. Start the unit and run it in high speed.
3. Check the battery voltage. If the battery
voltage is less than 12 volts, the battery must 12. Connect a jumper wire between the F2
be charged or tested to determine if it should terminal and a chassis ground. This will full
be replaced. field the alternator.
4. Check the voltage at the B+ terminal on the CAUTION: DO NOT full field the
alternator. Battery voltage must be present. If alternator for more than seven seconds
not, check the 2A circuit. while checking the meter readings, or the
electrical system may be damaged.
5. Disconnect the alternator harness from the
voltage regulator by carefully pushing on the 13. Check the amperage in the 2A wire and record
spring clip to release the plug lock. the reading. Check the voltage at the B+
terminal and continue to observe this voltage
6. Set the unit for continuous run operation and for a few seconds to see if it increases,
place the Zone 1/Host On/Off switch in the On decreases, or stays the same. Note the change
position. in voltage and record the voltage reading.
7. Check the voltage at the A pin and at the B pin Amperage in the 2A wire =____amps.
in the two pin connector on the alternator
harness. Voltage at the B+ terminals =___volts.
a. The A pin is the battery sense circuit and The voltage at the B+ terminal should be 13 to
should be at battery voltage. If not, check 18 volts and the amperage in the 2A wire
the sense circuit (2 or equivalent) in the should be at least as high as the rated output of
alternator harness and in the main wire the alternator.
harness. NOTE: An alternator can easily exceed its
b. The B pin is the excitation circuit and rated output. An alternator MUST at least
should be at 10 volts or higher. If not, reach its rated output when full fielded. An
check the excitation circuit (EXC or alternator that has a defective rectifier diode
equivalent) in the alternator harness and in may reach 75 percent of its rated output with
the main wire harness. a full field.
54
14. Stop the unit. 3. The ammeter reading indicates field current.
The following chart shows the field current for
15. Use the readings obtained previously to
a 120 amp alternator with 12 volts applied to
determine the problem by referring to the
the field:
Diagnosis Chart below.
NOTE: This assumes that the alternator did Field Current
Alternator Rating
@ 12 Volts
not charge properly prior to the full field test.
120 Amp 2.0 to 5.0 Amps
Field Current Test a. No field current or a low field current

This test checks the field windings, brushes, and indicates an open circuit or excessive
slip rings. Perform this test with the Zone 1/Host resistance in the field circuit. Replace the
On/Off switch in the Off position. voltage regulator and brush assembly,
inspect the slip rings and repeat the test. If
1. Attach a clamp-on ammeter to the 2A wire the brushes are not the problem, replace
near the B+ terminal on the alternator. the rotor or the alternator.
2. Connect a jumper wire between the F2 b. High field current indicates a short in the
terminal on the alternator and a chassis field circuit. Repair or replace the
ground, and note the ammeter reading. alternator.
Diagnosis Chart
Amperage in 2A Voltage at B+ Problem/Solution
At or above battery voltage and Voltage regulator defective / Replace
At or above rated output
increasing voltage regulator and brush assembly
Approximately 60 percent Approximately equal to battery voltage Receiver diode defective / Repair or replace
of rated output and does not change, or rises slightly alternator
Stator windings, field windings, brush or
Less than or equal to battery voltage diode defective / Perform Field Current Test
Low or no output
and decreasing to check brushes and field coil, or replace
alternator
55
Prestolite Alternator - Model 50 NOTE: The F7 fuse must be installed in the

relay board on units equipped with the Prestolite
105 Amp Charging System alternator. If the F7 fuse is not in place, the
Diagnostic Procedures alternator will not charge properly.
NOTE: Units manufactured with Complete the following checkout procedure
CYCLE-SENTRY and alternators with integral before replacing the voltage regulator or the
regulators MUST use replacement alternators alternator.
with integral regulators. • When testing alternators use accurate
CAUTION: Full-fielding alternators with equipment such as a Thermo King
the integral regulator is accomplished by P/N 204-615 (FLUKE 23) digital multimeter
installing a jumper from terminal F2 to and a Thermo King P/N 204-613 amp clamp
ground. Attempting to full-field the or an equivalent.
alternator by applying battery voltage to
terminal F2 will cause voltage regulator
failure.
1 3
6 5
AGA219
1. EXC Terminal 5. NEG—B- Terminal

2. F2 Terminal 6. POS—B+ Terminal
3. VOLT SENSE Terminal 7. REG—D+ Terminal
4. AC TAP Terminal
Figure 22: Prestolite Terminal Locations
56
• Make sure the drive belts and pulleys of the 7. Check the voltage at the EXC terminal on the
charging system are in good condition and are alternator. Battery voltage must be present. If
adjusted properly before testing the alternator. not, check the EXC circuit.
Worn belts and pulleys or loose belts will
8. Attach a clamp-on ammeter to the 2A wire
lower the output of the alternator.
connected to the B+ terminal on the alternator.
• The battery must be well charged, the battery
9. Connect a voltmeter between the B+ terminal
cable connections must be clean and tight, and
and a chassis ground.
the 2A and excitation circuits must be
connected properly. 10. Start the unit and run it in high speed.
NOTE: All voltage readings should be taken 11. Connect a jumper wire between the F2
between the negative battery terminal, or a good terminal and a chassis ground. This will full
chassis ground, and the terminals indicated, field the alternator.
unless stated otherwise.
CAUTION: Never apply battery voltage to
1. Check to make sure that the F7 fuse is in place terminal F2 or voltage regulator failure
on the relay board. If not, it must be installed will occur.
for the alternator to charge properly.
a. Full alternator output (the alternators rated
2. Set the unit for continuous run operation and output) indicates the alternator is good but
place the Zone 1/Host On/Off switch in the the voltage regulator needs to be replaced.
Off position.
b. If there is LOW or NO output, the
3. Check the battery voltage. If the battery alternator is probably faulty. However, the
voltage is less than 12 volts, the battery must following items are potential causes for
be charged or tested to determine if it should not charging:
be replaced.
• Check the alternator brushes.
4. Check the voltage at the B+ terminal on the
alternator. Battery voltage must be present. If • Check the 2A circuit from the
not, check the 2A circuit. alternator to the battery.
5. Check the voltage at the VOLT SENSE • Properly tension the alternator belt.
terminal on the alternator. Battery voltage • Check the battery cable connections
must be present. If not, check the 2 circuit. and the alternator ground. They must
6. Set the unit for continuous run operation and be clean and tight.
place the Zone 1/Host On/Off switch in the On • The battery must be in good condition
position. and must accept a charge.
• Check for excessive or unusual
amperage draw by the unit control
circuits.
57
Battery • A 15 amp fuse (Fuse F13—Zone 3 Solenoids)

protects the 8-3 circuit, which supplies power
Inspect/clean the battery terminals and check the to solenoids and components in the Zone 3
electrolyte level during scheduled maintenance evaporator.
inspections. A dead or low battery can be the
cause of an ammeter indicating discharge due to • A 25 amp fuse (Fuse F15—Zone 2 Fan
lack of initial excitation of the alternator even Motors) protects the FMR2 circuit, which
after the unit has been boosted for starting. The supplies power to the Zone 2 evaporator fan
minimum specific gravity should be 1.235. Add motors and relays.
distilled water as necessary to maintain the proper • A 15 amp fuse (Fuse F16—Zone 2 Solenoids)
water level. protects the 8-2 circuit, which supplies power
to solenoids and components in the Zone 2
Battery Cables evaporator.
Units with Tier 2 engines use 0-gauge battery • A 40 amp fuse (F20—Control Circuit Power)
cables to ensure reliable starting in extremely cold protects the 2AA circuit, which is the main
weather. Units with Tier 1 engines use 2-gauge power circuit.
negative battery cables and 4-gauge positive
• A 15 amp fuse (Fuse F22—Host Unit
battery cables.
Controls) protects the 8F circuit, which
Make sure to use the 0-gauge battery cables when supplies power to various control relays and
replacing the battery cables for a Tier 2 engine. components.
Refer to the unit Parts Manual for the correct part
• A 40 amp fuse (Fuse F23—Starter Circuit)
numbers. Do not use the 0-gauge battery cables on
protects the 2S circuit, which supplies power
Tier 1 engines because the battery cables are sized
to the starter relay (K5) and the starter
to match the starter performance.
solenoid.
Fuses • A number of 2 and 5 amp fuses protect

microprocessor circuits, control relay circuits,
A number of fuses, located on the relay board, and various components.
protect various circuits and components. The
relay board is located inside the control box.
• A 5 amp fuse (F2—Electric Contactors)
protects the 7EA circuit, which supplies
power to the electric contactors on Model 50
units.
• A 15 amp fuse (F3—Zone 1 Damper) protects
the 29A circuit, which supplies power to the
damper solenoid.
• A 15 amp fuse (F4—High Speed Solenoid)
protects the 7D circuit, which supplies power
to the high speed solenoid.
• A 15 amp fuse (Fuse F6—Zone 1 [Host]
Solenoids) protects the 7K1 circuit, which
supplies power to solenoids and components
in the host unit.
• A 25 amp fuse (Fuse F12—Zone 3 Fan
Motors) protects the FMR3 circuit, which
supplies power to the Zone 3 evaporator fan
motors and relays.
58
Air Heater
The air heater is mounted on the open end of the
intake manifold. It heats the intake air to help the
engine start in cold weather. The air heater is
energized by the microprocessor during preheat,
just before the engine is started.
The heater is probably defective if the resistance
is more than 0.2 ohms and the current draw is less
than 60 amps, or if the current draw is more than
100 amps.
Check the resistance of the air intake heater with
an ohmmeter between the M6 terminal on the
front of the heater and the screw on the back of
the heater (or the heater case). The resistance
should be 0.14 ± 0.02 ohms.
Check the current draw of the heater with a
clamp-on ammeter at the H1 wire near the M6
terminal on the front of the heater. During preheat
the current draw should be approximately 70
amps.
AGA220
1
AEA693
1. Relay Board
1. M6 Terminal
Figure 23: Control Box
Figure 24: Air Heater
Fuse Link
The fuse link is located in the positive battery Smart Reefer Multi-Temp µP-IV
cable. The fuse link protects the electric system Microprocessor Controller
from a short in the 2 circuit. If the fuse link burns Refer to the appropriate Microprocessor
out, check for a grounded 2 wire before replacing Controller Diagnosis Manual for complete service
the fuse link. Replace the fuse link by replacing information about the microprocessor controller
the positive battery cable. and the related components.
59
Unit Wiring AC Components (Model 50

Inspect the unit wiring and the wire harnesses Units Only)
during scheduled maintenance inspections for CAUTION: Model 50 units use high
loose, chaffed or broken wires to protect against voltage ac for electric standby operation.
unit malfunctions due to open or short circuits. Lethal voltage potentials can exist on
connections in the high voltage box. Take
Wire Harness Routing appropriate precautions and use extreme
care when testing the unit.
The wire harness routing across the front of the
engine is different for the Tier 1 and Tier 2
engines. The wire harness is routed behind the Electrical Contactors
starter on the Tier 1 engine. The wire harness is Periodically inspect all contactor points for pitting
routed in front of the starter on the Tier 2 engine. or corrosion and repair or replace as necessary.
The wire harness is attached to a harness routing
bracket, which is attached to the starter, on the Test the contact points of the contactor by
Tier 2 engine. checking the voltage drop across each set of
points when the contactor is energized and the
1 system is operating. If the voltage drop across a
set of points is more than 15 Vac, replace the
contact points as a set.
Test the contactor coil by checking the voltage
across the coil. The contactor coil should be
energized by a minimum of 10 Vdc.
Evaporator Heaters
Test the resistance of each evaporator heater by
disconnecting it from the circuit and checking it
with an ohmmeter. The resistance of each host
evaporator heater should be approximately
1. Wire Harness Behind Starter
122 ohms. The resistance of each remote
Figure 25: Tier 1 Wire Harness Routing evaporator heater should be approximately
106 ohms.
1 2
Auto Phase System
The Auto Phase system automatically adjusts the
phase sequence of the power supply to correspond
with the wiring of the electric motor. The main
components of the system are the phase selection
module (PSM), its two relays, and the two motor
contactors (MC1 and MC2). Contactor MC1 is
wired to retain the phase sequence. Contactor
MC2 is wired to change the phase sequence. The
PSM senses the phase sequence at the heater
contactor and energizes the appropriate motor
1. Wire Harness In Front Of Starter contactor by energizing one of the relays.
2. Harness Routing Bracket
Figure 26: Tier 2 Wire Harness Routing
60
Troubleshooting the Auto Phase System 3. Check MC1 and MC2 to make sure that one of
If the Electric Motor Runs Backwards (Unit Airflow them is not faulty (contacts stuck closed).
Incorrect):
1
1. Turn the electric power supply Off and check
the unit wiring. Refer to the appropriate
wiring diagrams, schematics, and to Figure 28
on page 62.
a. The three wires from the PSM should be
connected to the heater contactor terminals 2
as follows: Brown wire to terminal L1,
Blue wire to terminal L2, and Black wire
to terminal L3.
b. Wires L1, L2, and L3 should be connected
respectively to terminals L1, L2, and L3 AJA920
on the heater contactor and both motor

contactors.
3
c. Wires T1A, T2A, and T3A should be
connected respectively to terminals T1,
T2, and T3 on MC1.
d. Wires T1A, T2A, and T3A should be
connected respectively to terminals T3,
T2, and T1 on MC2.
4
e. Wires T1A, T2A, and T3A should be
ARA104
connected respectively to terminals L1,
L2, and L3 on the overload relay. 1. Condenser Air Out 3. Evaporator Air Out
f. Wires 1, 2, and 3 should be connected 2. Condenser Air In 4. Evaporator Air In
respectively to terminals T1, T2, and T3 Figure 27: Host Unit Air Flow
on the overload relay.
4. If all of the wiring is correct, and the relays
g. Wires Brown, Blue, and Black should be and contactors are acceptable, but the electric
connected respectively to terminals X, Y, motor still runs backwards, switch the Brown
and Z in the power receptacle. wire and the Black wire from the PSM at the
heater contactor: Black to L1, Blue to L2, and
h. Wires Brown, Blue, and Black should be
Brown to L3. If the electric motor now runs
connected respectively to terminals L1,
correctly, it is probably wired incorrectly.
L2, and L3 on MC1.
If the electric motor does not run at all:
i. Wires 7EC, 7EB, and CH should be
connected to the corresponding terminals 1. Make sure that the unit is turned On, the
on the PSM. The 7EH wires should be Diesel/Electric switch is in the Electric
connected to the 7EA and 8 terminals on position, and that the power supply is
the PSM. connected and turned On.
j. The electric motor must be wired 2. Check the CH terminal on the PSM for
correctly. continuity to the CH circuit (chassis ground).
If there is no continuity to the CH circuit,
2. Check the relays on the PSM to make sure that check the CH wire for continuity.
one of them is not faulty (contacts stuck
closed).
61
3. Check for battery voltage (12 volts) at the 4. Check for battery voltage at the 7EB and 7EC
7EA and 8 terminals on the PSM. Battery terminals on the PSM. Battery voltage should
voltage should be present. If not, check the be present on one of these terminals when AC
7EH circuit, the overload relay, the 7EHA voltage is present on L1, L2, and L3. If not,
circuit, the Electric HPCO, the 7EA circuit, replace the relays on the PSM with relays that
the F2 fuse, the 7E circuit, the Diesel/Electric function properly and recheck the voltage on
switch, the 7K1 circuit, the F6 fuse, the run the 7EB and 7EC terminals. If battery voltage
(7K) relay, the F22 fuse, the 8A circuit, the is not present, the PSM is faulty.
Zone 1/Host On/Off switch, the 2AA circuit,
5. Check for battery voltage at the 7EB terminal
the F20 fuse, the 2 circuit, the fuse link, and
on MC1 and at the 7EC terminal on MC2.
the battery. Also make sure that the
Battery voltage should be present at one of
microprocessor display is on and that the
these terminals. If not, check the continuity of
microprocessor is calling for heat or cool.
the 7EB and 7EC wires.
6. Check the continuity of the RED wires on the
motor contactors. The RED wires must have
continuity.
2
1
ARA111
1. Overload Relay 4. PSM Relays

2. HC—Heater Contactor 5. MC2—Motor Contactor
3. PSM—Phase Selection Module 6. MC1—Motor Contactor
Figure 28: High Voltage Tray
62
7. Check the CH circuit at MC1 and MC2 for

continuity to a chassis ground. If the CH
circuits do not have continuity to a chassis
ground, check the CH wires.
8. Check the continuity of the BLK wires on the
motor contactors. The BLK wires must have
continuity.
9. If the CH circuits and BLK wires do have
continuity to CH, the contactor that has
battery voltage present at 7EB (MC1) or at
7EC (MC2) is faulty.
63
64
Engine Maintenance
Engine Change
In the second quarter of 2005 the engines in these
units changed from a TK486E to a TK486V to
meet EPA Tier 2 requirements.
1
The TK486E is an EPA Tier 1 engine.
The TK486V is an EPA Tier 2 engine.
The Tier 1 and Tier 2 engines share many
common parts, however the following major parts
are new on the Tier 2 engine:
• Cylinder Head Assembly
• Injection Nozzles
• Injection Pump
1. In-Line Injection Pump
• Oil Pump
Figure 29: Tier 1 Engine
• Pistons
• Piston Rings
• Starter
• Water Pump
1
The most noticeable difference between a Tier 1
engine and a Tier 2 engine is the fuel injection
pump (see the following photographs). The Tier 1
engines use an in-line injection pump. The Tier 2
engines use a mono-plunger and distributor
injection pump. The mono-plunger and distributor
injection pump uses a higher injection pressure
than the in-line injection pump. The higher
injection pressure atomizes the fuel more
efficiently, which reduces the emissions.
1. Mono-Plunger and Distributor Injection Pump
Figure 30: Tier 2 Engine
65
Engine Maintenance
EMI 3000 Engine Oil Change

EMI 3000 is an extended maintenance interval The engine oil should be changed according to the
package. It was phased in as standard equipment Maintenance Inspection Schedule. Drain the oil
on this unit in the first quarter of 2001. The EMI only when the engine is hot to ensure that all the
3000 package consists of the following key oil drains out. When changing oil, keep unit and
components: trailer level so all the oil can flow from the oil
pan. It is important to get as much of the oil out as
• New EMI 3000-Hour Cyclonic Air Cleaner possible because most of the dirt particles are
Assembly and Air Cleaner Element contained in the last few quarts of oil that drain
• New EMI 3000-Hour Fuel Filter (black with out of the pan. Refill the pan with 13 quarts
gold lettering) (12.3 liters) and check the dipstick level. Run the
unit, and then recheck the oil level. The engine oil
• New EMI 3000-Hour Dual Element Oil Filter level should be at the FULL mark with the
(black with gold lettering) dipstick turned (threaded) into the oil pan. Never
• API Rating CI-4 Mineral Oil (ACEA Rating overfill. See Specifications Chapter for correct
E3 for Europe) type of oil.
• Five Year or 12,000 Hour ELC (Extended Life
Oil Filter Change
Coolant).
The oil filter should be changed along with the
The EMI package allows standard maintenance engine oil. Use a genuine Thermo King extended
intervals to be extended to 3,000 hours, or 2 years, maintenance oil filter.
whichever occurs first.
1. Remove the filter.
NOTE: Units equipped with the EMI 3000
package do require regular inspection in 2. Apply oil to the rubber ring of the new filter
accordance with Thermo King's maintenance and install the filter.
recommendations. 3. Tighten the filter until the rubber ring makes
NOTE: The new EMI 3000 oil filters and new contact, then tighten 1/2 turn more.
EMI 3000 air cleaners are NOT interchangeable
4. Start the unit and check for leaks.
with the oil filters and air cleaners previously
used in trailer units.
Low Oil Pressure
Engine Lubrication System Oil pressure is affected by oil temperature, oil
viscosity, and engine speed. Low oil pressure can
The TK486 family of engines use a pressure usually be traced to the lack of oil, a faulty oil
lubrication system. Refer to the TK482 and pressure regulating valve, or worn bearings. Low
TK486 Engine Overhaul Manual TK 50136 for a oil pressure is not normally caused by a faulty oil
detailed description of the engine lubrication pump. Use the “Low Oil Pressure Flow Chart” on
system. the following page to help diagnose low oil
pressure.
66
Engine Maintenance
Low Oil Pressure Flow Chart
Oil Pressure Low
Check Oil Level
Oil Level Low Oil Level OK or High
Add Oil Oil May Be Diluted

Check Oil Pressure Change Oil and Filter
Check Oil Pressure
Oil Pressure OK Oil Pressure Low Oil Pressure OK
Install Known Good Oil Pressure Gauge

Check Oil Pressure
Oil Pressure OK Oil Pressure Low
Remove Oil Pump (Access the oil pump by removing the

crankshaft pulley, the sound shield and the timing gear cover.)
Check Oil Pump Tolerances
Check Oil Pressure Control Valve for Broken Spring or Sticking Piston
Reinstall Oil Pump

Check Oil Pressure
Oil Pressure OK Oil Pressure Low
Pull Engine
Remove Oil Pan
Check Inlet Screen and Intake Pipe
Pressure Check Engine for Internal Leaks
67
Engine Maintenance
Engine Cooling System

The engine employs a closed, circulating type,
pressurized cooling system. Correct engine
temperatures are controlled and maintained by a
radiator, fan and thermostat. The coolant is
circulated through the system by a belt driven
centrifugal pump. The pump draws the coolant
from the side of the radiator, circulates it through
the cylinder block and head and returns it to the
radiator. A thermostat mounted in the coolant
outlet line from the cylinder head to the radiator
automatically maintains coolant temperature
within the specified temperature range.
All water cooled engines are shipped from the
factory with a 50 percent permanent type AJA1947
antifreeze concentrate and 50 percent water
mixture in the engine cooling system. Figure 31: ELC Nameplate
Located On Expansion Tank
This provides the following:
The following are the Extended Life Coolants
1. Prevents freezing down to -30 F (-34 C). currently approved by Thermo King for use in
2. Retards rust and mineral scale that can cause ELC units for five years or 12,000 hours:
engine overheating. • Chevron Dex-Cool
3. Retards corrosion (acid) that can attack • Texaco ELC (nitrite free)
accumulator tanks, water tubes, radiators and
core plugs. • Havoline Dex-Cool (with nitrates)
4. Provides lubrication for the water pump seal. • Havoline Dex-Cool (nitrite free)
• Shell Dexcool
ELC (Extended Life Coolant)
• Shell Rotella
ELC has been phased into all trailer units
equipped with engines from the TK486 engine • Havoline XLC (Europe)
family. A nameplate on the coolant expansion • Saturn/General Motors Dex-Cool
tank identifies units with ELC.
• Caterpillar ELC
NOTE: The new engine coolant, Texaco
Extended Life Coolant, is RED in color instead • Detroit Diesel POWERCOOL Plus.
of the current GREEN or BLUE-GREEN
CAUTION: Do not add “GREEN” or
colored coolants.
“BLUE-GREEN” conventional coolant to
cooling systems using “RED” Extended
Life Coolant, except in an emergency. If
conventional coolant is added to Extended
Life Coolant, the coolant must be changed
after 2 years instead of 5 years.
68
Engine Maintenance
NOTE: The use of 50/50 percent pre-mixed changing the antifreeze. Change ELC (red) engine
Extended Life Coolant (ELC) is recommended to coolant every five years or 12,000 hours
assure that de-ionized water is being used. If 100 (whichever occurs first).
percent full strength concentrate is used,
Do not mix green or blue-green engine coolant
de-ionized or distilled water is recommended
with ELC (red) engine coolant. See “ELC
over tap water to insure the integrity of the
(Extended Life Coolant)” on page 68 for more
cooling system is maintained.
information about ELC.
Antifreeze Maintenance Procedure The factory recommends the use of a 50/50
antifreeze mixture in all units even if they are not
As with all equipment containing antifreeze,
exposed to freezing temperatures. This antifreeze
periodic inspection on a regular basis is required
mixture will provide the required corrosion
to verify the condition of the antifreeze. Inhibitors
protection and lubrication for the water pump.
become worn out and must be replaced by
2 4 5
1
6 7
3
10
1. Plastic Expansion Tank (Starting 05/2004) 6. Coolant Level Sensor

2. Expansion Tank Cap 7. Radiator
3. Coolant Level Switch 8. Water Pump
4. Aluminum Expansion Tank (Ending 05/2004) 9. Thermostat
5. Radiator Cap 10. Thermostat Housing
Figure 32: Engine Cooling System
69
Engine Maintenance
Checking the Antifreeze 7. If using ELC concentrate, mix one gallon of

ELC concentrate and one gallon of de-ionized
Check the solution concentration by using a
or distilled water in a container to make a
temperature compensated antifreeze hydrometer
50/50 mixture. (Do not add antifreeze and
or a refractometer (P/N 204-754) designed for
then add water to the unit. This procedure may
testing antifreeze. Maintain a minimum of
not give a true 50/50 mixture because the
50 percent permanent type antifreeze concentrate
exact cooling system capacity may not always
and 50 percent water solution to provide
be known.)
protection to -30 F (-34 C). Do not mix antifreeze
stronger than 68 percent permanent type coolant 8. Refill the radiator with the 50/50 antifreeze
concentrate and 32 percent water for use in mixture and make sure to bleed the air from
extreme temperatures. the cooling system as needed.
Changing the Antifreeze Bleeding Air from the Cooling

1. Run the engine until it is up to its normal System
operating temperature. Stop the unit. Jiggle pin thermostats are original equipment on
units that have engines from the TK486 engine
2. Open the engine block drain (located behind
family. Jiggle pin thermostats make it unnecessary
the starter) and completely drain the coolant.
to bleed the air out of the engine block because
Observe the coolant color. If the coolant is
they keep air from being trapped in the engine
dirty, proceed with a, b, and c. Otherwise go
block. Normally, all but about 1.5 qt (1.4 liters) of
to 3.
coolant drain out of the cooling system when it is
CAUTION: Avoid direct contact with hot drained. If approximately half of the Cooling
coolant. System Capacity (see Specifications Chapter)
seems to fill the cooling system after it has been
a. Run clear water into the radiator and allow drained, air has been trapped in the block. Bleed
it to drain out of the block until it is clear. the air out of the block using the following
procedure:
b. Close the block drain and install a
commercially available radiator and block CAUTION: If you suspect that air is
flushing agent, and operate the unit in trapped in the block, do not start the
accordance with instructions of the engine without bleeding the air out of the
flushing agent manufacturer. block.
c. Open the engine block drain to drain the NOTE: If an engine runs with air trapped in the
water and flushing solution. block, the engine may be damaged. The high
water temperature switch may not protect an
CAUTION: Avoid direct contact with hot engine that has air trapped in the block, because
coolant. the high water temperature switch is designed to
protect an engine from overheating due to
3. Run clear water into the radiator, and allow it
failures in the cooling system.
to drain out of the block until it is clear.
1. Loosen the plug on the back of the water
4. Inspect all hoses for deterioration and hose
pump below the thermostat cover until coolant
clamp tightness. Replace if necessary.
comes out of the plug fitting.
5. Loosen the water pump belt. Check the water
2. Tighten the plug.
pump bearing for looseness.
3. Pour coolant into the system until it appears to
6. Inspect the radiator cap. Replace the cap if the
be full.
gasket shows any signs of deterioration.
70
Engine Maintenance
4. Make sure that the amount of coolant that The injection pump forces the fuel, at a very high
goes back into the system is approximately pressure, through the injection nozzles. The
equal to the amount of coolant that came out injection nozzles atomize the fuel as it is injected
of the system. directly into the combustion chambers.
5. Start the unit on low speed heat, let it run for Injection pump leakage, injection nozzle overflow
two minutes, and then shut it off. and excess fuel from the fuel filter orifice are then
all sent back to the fuel tank in the return line.
6. Check the coolant level and add coolant if
necessary.
Fuel Line Routing
7. Repeat steps 5 and 6 until the coolant level
The fuel lines inside the unit are installed and
stabilizes.
routed at the factory. The fuel lines from the fuel
tank connect to the fittings on the bottom of the
Engine Thermostat unit frame. Do not change the factory routing of
For the best engine operation, use a 180 F (82 C) the fuel lines inside the unit. See the fuel line
thermostat year-round. routing diagrams in the Diagrams Chapter.
Engine Fuel System Maintenance

Tier 1 engines use an in-line injection pump. The injection pump and fuel transfer pump are
relatively trouble-free and if properly maintained
Tier 2 engines use a mono-plunger and distributor will usually not require major service repairs
injection pump. between engine overhauls.
The components of the fuel system are: Contamination is the most common cause of fuel
• Fuel tank system problems. Therefore, to ensure best
operating results, the fuel must be clean and fuel
• Inlet strainer (prefilter) tanks must be free of contaminants. Change the
• Priming pump fuel filter/water separator regularly and clean the
prefilter on the inlet side of the fuel transfer pump.
• Fuel transfer pump
NOTE: The injection nozzles should be tested
• Fuel filter/water separator (and repaired if necessary) at 10,000 hour
• Injection pump intervals when used in normal conditions.
Normal conditions are considered to be the use
• Injection nozzles of clean high quality fuel, no used oil blending,
The priming pump is used to manually draw fuel and regular maintenance of the fuel system
from the tank up to the fuel pump if the unit according to the Maintenance Inspection
should run out of fuel. Schedule. Refer to the TK482 and TK486
Overhaul Manual TK 50136 for injection nozzle
testing and repair procedures.
Operation
Fuel is drawn from the fuel tank and through the Whenever the fuel system is opened, take the
prefilter by the fuel transfer pump. The fuel following precautions to prevent dirt from
transfer pump delivers fuel to the fuel filter/water entering the system:
separator. Two orifices in the filter head control 1. Cap all fuel lines.
the pressure in the fuel system by allowing a
certain amount of fuel to return to the tank. One 2. Work in a relatively clean area whenever
orifice is located in the center of the filter head. It possible.
bleeds off water. The other orifice is located 3. Complete the work in the shortest possible
off-center on the filter head. It bleeds off air. time.
Filtered fuel passes through a line from the outlet
fitting on the filter base to the injection pump.
71
Engine Maintenance
Any major injection pump or nozzle repairs 3. Priming pump (hand) replacement or repair.
should be done by a quality diesel injection
4. Fuel transfer pump replacement or repair.
service shop. The necessary service equipment
and facilities are not found in most engine rebuild 5. Injection line replacement.
shops because of the large investment required.
6. Engine speed adjustments.
The following procedures can be done under field
7. Injection pump timing.
conditions:
8. Nozzle spray pattern testing and adjustment.
1. Bleeding air from the fuel system.
9. Minor rebuilding of nozzles.
2. Fuel tank and filter system maintenance.
2
4
5
1. Check Valve (Keeps air from entering fuel

5. Fuel Transfer Pump
system when engine is not running.)
2. Filter Head 6. Inlet Strainer (Prefilter)
3. In-line Injection Pump 7. Priming Pump
4. Bleed Screw 8. Fuel Filter/Water Separator
Figure 33: Tier 1 Engine Fuel System
72
Engine Maintenance
1 2
1. Check Valve (Keeps air from entering fuel

system when engine is not running.)
2. Filter Head 6. Priming Pump
3. Bleed Screw 7. Fuel Filter/Water Separator
4. Mono-plunger and Distributor Injection Pump
Figure 34: Tier 2 Engine Fuel System
73
Engine Maintenance
Fuel Return Line Replacement 3. Install the end cap and clamp. Note that the
end cap has a larger OD than the other hoses
The fuel return lines (hoses) and end cap on the
and requires the larger clamp.
fuel injection nozzles should be changed every
10,000 engine operating hours. The return line kit 4. Install the fuel return lines and clamps. It may
(P/N 10-368) contains new return lines, clamps, be necessary to adjust the banjo fitting slightly
an end cap, and a decal like the one shown below. to obtain the straightest routing for the long
This decal is was added to production units in return line.
January of 2005. The decal is located near the unit
5. Be sure all the fittings are tight and check for
serial plate. The date and engine hours must be
leaks.
entered on the decal when the fuel return lines are
changed. 6. Write the date and engine hours on the decal.
Bleeding the Fuel System

If the engine runs out of fuel, repairs are made to
the fuel system, or if air gets into the system for
any other reason, the air must be bled out of the
Figure 35: Fuel Return Line Replacement Decal
fuel system.
Use the following procedure to replace the fuel NOTE: MAKE SURE the fuel tank vent is kept
return lines and end cap. open. If the vent becomes clogged, a partial
1. Remove the clamps, the end cap, the short fuel vacuum develops in the tank, and this increases
return lines between the injection nozzles, and the tendency for air to enter the system.
the long fuel return line from the injection
nozzle to the banjo fitting on the injection
1 2
pump.
1
2 3
5
3 4
aea751 3
4
1. Stand Pipes 4. Drain Plug
2. Anti-Siphon Screen (Optional) 5. Vent
3
3. Fuel Gauge
Figure 37: Fuel Tank
5
To bleed air from the fuel system:
3 1. Loosen the bleed screw on the Tier 1 injection

pump about two turns. Loosen the bleed screw
on the Tier 2 injection pump about one turn.
1. End Cap 4. Short Fuel Return Lines
2. Larger Clamp 5. Long Fuel Return Lines
3. Smaller Clamps
Figure 36: Fuel Return Line Replacement
2. Discard the old clamps, end cap, and fuel
return lines.
74
Engine Maintenance
1
7. Start the engine and observe the engine run for
a few minutes. If the engine fails to start, or
starts but stops in a few minutes, repeat the
procedure.
Draining Water from Fuel Tank

Water run through the system may damage the
injection pump or nozzles. Damage to the fuel
system will subsequently cause more expensive
damage to the engine. A large accumulation of
water in the bottom of the fuel tank will stop a
diesel engine. Water should be drained off during
scheduled maintenance inspections to prevent
2
breakdowns. Drain the water off after the fuel
tank and unit have remained idle for an hour.
1. Bleed Screw 2. Priming Pump
1. Place a container under the fuel tank to catch
Figure 38: Tier 1 Injection Pump the draining water and fuel.
2. Remove the drain plug from the bottom of the
1
fuel tank.
NOTE: Some fuel tanks have a check valve in
the drain plug fitting. Push the check valve open
with a small screw driver to drain the tank.
3. Let the water and fuel drain into the container
until no water is visible in the fuel draining
from the tank. If the water and fuel do not
drain freely, the vent may be plugged. If so,
clean or replace the vent.
4. Install the drain plug.
Fuel Filter/Water Separator

2
The fuel filter/water separator removes water
1. Bleed Screw 2. Priming Pump from the fuel and returns it to the fuel tank.
Figure 39: Tier 2 Injection Pump
Fuel Filter/Water Separator
2. Unscrew the priming pump handle and Replacement
manually prime the fuel system until air
Replace the fuel filter/water separator at intervals
bubbles are no longer visible in the fuel
according to the Maintenance Inspection
coming out of the bleed screw.
Schedule.
3. Tighten the bleed screw and screw the priming
1. Unscrew the fuel filter/water separator
pump handle back in.
canister with a strap wrench. Drain, and
4. Loosen the injection lines at the injection dispose of properly.
nozzles.
2. Clean the filter head seal surface.
5. Crank the engine until fuel appears at the
3. Lubricate the canister seal with clean fuel.
nozzles.
6. Tighten the injection lines.
75
Engine Maintenance
4. Through one of the small openings in the top 5. Pull the plunger out of the solenoid enough to
of the canister, fill the new fuel filter/water loosen the jam nut. An Allen wrench placed in
separator canister with clean fuel. This will the hex opening in the face of the plunger will
purge the air from the canister. Do not fill keep the plunger from turning. Turn the
canister through the center hole. plunger eye bolt clockwise to increase the
speed and counterclockwise to decrease the
1 2 speed.
6. Replace the ball joint, start the unit and check
the speed. When the speed is correct, tighten
the jam nut and replace the solenoid boot.
NOTE: If the correct speed cannot be set close
enough with half turns of the eye bolt, use the
Allen wrench to turn the plunger in smaller
increments.
ARA160
Low Speed
1. Fill Through Small Opening
2. Do Not Fill Through Center Hole 1. Loosen the jam nut on the low speed
Figure 40: Filling Fuel Filter/Water Separator adjustment screw.
5. Screw the new canister on hand-tight. Using a 2. Use the Service Test Mode to run the unit in
strap wrench, tighten another 1/4 turn. low speed. Adjust the screw to obtain the
correct speed. It should be 1450 ± 25 rpm.
Engine Speed Adjustments 3. Tighten the jam nut and recheck the speed.
When the diesel engine fails to maintain the
1 2 3 4 5
correct engine speed, check the following before
adjusting the speed:
1. Check the fuel inlet screen. Check the speed.
2. Bleed the air out of the fuel system. Check the
speed.
3. Bleed the air out of the nozzles. Check the
speed.
Make the engine speed adjustments with the
engine fully warmed up.
High Speed ARA112
1. Use the Service Test Mode to run the unit in

1. High Speed Solenoid
high speed and check the high speed rpm. It
2. Boot
should be 2200 ± 25 rpm.
3. Ball Joint
2. Shut the unit off. 4. Speed Control Rod
3. Remove the ball joint from the eye bolt in the 5. Low Speed Adjustment Screw
high speed solenoid. Figure 41: Tier 1 Engine Speed Adjustments
4. Remove the boot from the high speed
solenoid.
76
Engine Maintenance
1 2 3 4 5 1
1. High Speed Solenoid

ARA113
2. Boot 2
3. Ball Joint
1. Number One Cylinder Injection Line
4. Speed Control Rod
2. Timing Mark Access Hole
5. Low Speed Adjustment Screw
Figure 43: Component Location
Figure 42: Tier 2 Engine Speed Adjustments
CAUTION: Loosen all of the injection
Injection Pump Timing Tier 1 Engine lines at the injection nozzles to prevent the
possibility of the engine firing while it is
This timing procedure requires fuel pressure at the
being rotated.
injection pump inlet. This can be accomplished by
pumping the priming pump by hand, or by using 3. Remove the injection line for the number one
an electric fuel pump to supply fuel to the fuel cylinder from the delivery valve on the
pump inlet. injection pump and from the injection nozzle.
1. Place the Zone 1/Host On/Off switch in the NOTE: The number one cylinder is the
Off position. cylinder at the flywheel end of the engine.
2. Remove the round cover (plug) from the 4. Remove the rocker arm cover.
timing mark access hole on the front of the
bell housing. The index marks on either side
of this hole and the timing marks on the
flywheel are used to check the injection pump
timing.
77
Engine Maintenance
5. Place the engine at top dead center of the 9. Energize the fuel solenoid by energizing the
compression stroke for the number one run relay [RUNR] with the Relay Board Test
cylinder. Refer to steps a through d. Mode.
a. Rotate the engine in the normal direction 10. Rotate the engine backwards
of rotation (clockwise viewed from the (counterclockwise viewed from the water
water pump end) until the 1-4 timing mark pump end) until the 10 degree BTDC (before
on the flywheel lines up with the index top dead center) timing mark is positioned in
mark in the timing mark access hole. the bottom of the timing mark access hole.
There are two injection timing marks. The 10
degree BTDC timing mark is a horizontal line
1 2
stamped on the flywheel approximately 1.0 in.
(25 mm) before the top dead center mark.The
12 degree BTDC timing mark is a horizontal
line stamped on the flywheel approximately
1.2 in. (30 mm) before the top dead center
mark.
1 2
AEA701
1. Index Mark
2. Top Dead Center Mark for 1 and 4
Figure 44: Top Dead Center One and Four
3
b. Check the rocker arms on the number one
cylinder to see if they are loose.
c. If the rocker arms are loose, the engine is
at top dead center of the compression
1. Index Mark
stroke for the number one cylinder.
2. 12 Degree BTDC Timing Mark
d. If the rocker arms are tight, the engine is at 3. 10 Degree BTDC Timing Mark
top dead center of the exhaust stroke for
Figure 45: Timing Mark Alignment
the number one cylinder. Rotate the engine
360 degrees to place the engine at top dead 11. Pump the priming pump by hand a few times,
center of the compression stroke for the or energize the electric fuel pump if an electric
number one cylinder. fuel pump is being used.
6. Disconnect the 8S wire from the starter 12. Use a clean towel to remove the fuel from the
solenoid to prevent the engine from cranking top end of the delivery valve holder.
when the unit is turned On.
13. Slowly turn the engine in the normal direction
7. Place the Zone 1/Host On/Off switch in the of rotation until you see the fuel rise in the end
On position. of the delivery valve holder. Stop as soon as
you see the fuel rise.
8. Use the microprocessor keypad to enter the
Relay Board Test Mode. Refer to the
appropriate Microprocessor Diagnostic
Manual for detailed information about the
Relay Board Test Mode.
78
Engine Maintenance
14. Check position of the timing marks. The 10 Injection Pump Timing Tier 2 Engine
degree BTDC timing mark on the flywheel
Use this timing procedure when installing a new
should be aligned with the index mark on the
injection pump on a Tier 2 engine. It is not
side of the timing mark access hole. Repeat
necessary to use this timing procedure when
steps 10 through 14 to recheck the timing.
removing and reinstalling the original injection
pump. In that case, align the index marks on the
1 2 injection pump and the gear case as they were
before removing the injection pump.
1. Before removing the old injection pump, note
the alignment of the index marks on the
3 injection pump and the gear case. The index
mark on the injection pump is usually aligned
with the index mark on the gear case. If not,
make a mark on gear case in line with the
index mark on the injection pump (see Figure
49).
1. Index Mark
Figure 46: Correct Injection Timing Mark Alignment
15. If the timing is off by more than 1 degree (0.1
in. [2.5 mm]), loosen the mounting nuts on the
studs that fasten the injection pump to the
engine and rotate the injection pump to change
the timing.
a. Pull the top of the injection pump away
1
from the engine to advance the timing.
1. Index Marks
b. Push the top of the injection pump toward
the engine to retard the timing. Figure 47: Tier 2 Index Mark Location
16. Tighten the injection pump mounting nuts and

recheck the timing. Repeat steps 10 through
16 until the timing is correct.
17. Install the cover in the timing mark access
hole, install the injection line for the number
one cylinder, install the rocker arm cover,
tighten the other injection lines and reconnect
the 8S wire to the starter solenoid when
finished with the procedure.
1 2
1. Index Mark on Injection Pump

2. Index Mark on Gear Case
Figure 48: Tier 2 Index Mark Alignment
79
Engine Maintenance
3. Remove the old injection pump. Use the

2 injection pump gear tool P/N 204-1011 to
1 remove the injection pump gear without
removing the timing gear cover (see “Injection
3
Pump Removal”).
NOTE: Remove the injection pump gear by
removing the nut and lock washer that
1. Index Mark on Injection Pump secure the injection pump gear assembly to
2. Existing Index Mark on Gear Case the injection pump shaft. The injection pump
3. Make New Mark on Gear Case If Needed gear assembly is made of three pieces; the
flange, the gear, and the transfer pump cam.
Figure 49: Marking Gear Case
Do not loosen or remove the four bolts that
2. Clean the area with brake cleaner or fasten the gear to the flange because that
something similar. Place an injection angle changes the timing.
sticker on the gear case so the center line on 1
the sticker is aligned with the index mark on
the injection pump. An injection angle sticker
1
is provided with the new injection pump.
2
1
1
1. Do Not Loosen or Remove These Four Bolts

2. Remove Nut and Lock Washer
1 2 Figure 52: Removing Injection Pump Gear
1. Index Mark on Injection Pump 4. Record the injection angle marked on the old
2. Injection Angle Sticker injection pump (see the following
Figure 50: Place Injection photographs). The injection angle mark is
Angle Sticker on Gear Case located on the side of the pump facing the
engine. The injection angle mark on the pump
does not use a decimal point. Add a decimal
point before the last digit of the injection
0.5 Degrees angle mark to get the injection angle. The
1 injection angle mark in the following
2 photographs is 67. That equals an injection
angle of 6.7 degrees.
3
Examples
Injection Angle Mark Injection Angle
67 6.7 Degrees
85 8.5 Degrees
1. –1.0 Degrees Mark
2. Center Line (0 Degrees Mark)
3. +1.0 Degrees Mark
Figure 51: Injection Angle Sticker
80
Engine Maintenance
5. Record the injection angle marked on the side

1
of the new injection pump.
6. Calculate the injection angle difference by
subtracting the injection angle of the old
injection pump from the injection angle of the
new injection pump.
Examples
Injection Angle of New
8.5 6.1
Injection Pump (Degrees)
– Injection Angle of Old
– 6.7 – 6.7
Injection Pump (Degrees)
= Injection Angle Difference
= +1.8 = –0.6
1. Injection Angle Mark (Degrees)
Figure 53: Injection Angle Mark Location 7. Install the new injection pump on the gear
case and position it so the index mark on the
injection pump is aligned with the mark equal
to the injection angle difference on the
injection angle sticker (see the following
examples). Tighten the injection pump
mounting nuts when the index mark is aligned
as necessary with the injection angle sticker.
1
1
1. Injection Angle Mark
Figure 54: Injection Angle Mark
NOTE: If you cannot read the injection angle

mark, contact Yanmar (e-mail both Koichi
Sawada at koichi_sawada@yanmar.co.jp and
Hisashi Hamada at 2
hisashi_hamada@yanmar.co.jp) with the
injection pump serial number or the engine 1. Injection Pump Index Mark at –0.6 Degrees
serial number and they will provide the injection
2. Injection Pump Index Mark at +1.8 Degrees
angle. The injection pump serial number is
located on the bottom of the sticker on the Figure 56: Examples of Injection Pump Index
Mark Alignment with Injection Angle Sticker
injection pump.
8. Install the injection pump gear, lock washer,
and nut. Torque the nut to 58 to 65 ft-lb (78 to
1 88 N•m).
NOTE: If the timing gear cover was removed to
remove the injection pump gear, make sure the
timing marks on the timing gears are aligned as
shown below. It helps to install the idler gear last
when aligning the timing marks.
1. Injection Pump Serial Number
Figure 55: Injection Pump Serial Number Location
81
Engine Maintenance
3
Injection Pump Removal
1
2 The injection pump drive gear will not fit through
the gear housing when removing the pump, the
gear must be separated from the pump. Using tool
P/N 204-1011, it will not be necessary to remove
the belts, fuel pump, crankshaft pulley, crankshaft
seal or front plate. See Figure 63 “Injection Pump
Gear Tool” on page 84.
1. Note the alignment of the index marks on the
injection pump and the gear case. On the
4
Tier 1 engine, the index mark on the injection
pump is usually aligned with the center (long)
1. Fuel Injection Pump Gear index mark on the gear case. On the Tier 2
2. Idler Gear engine, the index mark on the injection pump
3. Camshaft Gear is usually aligned with the single index mark
4. Crankshaft Gear on the gear case. If not, mark it so the
injection pump can be returned to the same
Figure 57: Timing Mark Alignment
position when it is reinstalled.
NOTE: The oil pump is located in the timing
gear cover on Tier 2 engines. The inner rotor of
the oil pump fits around the crankshaft gear.
Make sure that the flat sides of the inner rotor
are aligned with the flat sides on the crankshaft
gear when installing the timing gear cover.
1
2
5
3
4
7 1
1. Index Marks
6 Figure 59: Tier 1 Index Mark Location
1. Crankshaft Gear
2. Oil Pump Cover
3. Outer Rotor
4. Inner Rotor
5. Timing Gear Cover
6. Flat Sides on Inner Rotor
7. Flat Side on Crankshaft Gear
1 2
Figure 58: Align Flat Sides of Crankshaft Gear with
Flat Sides of Inner Rotor in Timing Gear Cover 1. Index Mark on Injection Pump
2. Center Index Mark on Gear Case
Figure 60: Tier 1 Index Mark Alignment
82
Engine Maintenance
5. Align the threaded holes in the injection pump

gear with the two holes in the tool plate by
rotating the engine crankshaft. Attach the gear
to the tool plate with the screws provided with
the tool plate.
6. Thread the long screw supplied with the tool
plate into the small end of the adapter, also
supplied with the tool plate. Insert the adapter
into the tool plate and rotate to provide a solid
position to force the injection pump shaft from
the gear. Caution should be made to align the
screw over the center of the injection pump
1
shaft.
1. Index Marks
7. Remove the screw and adapter leaving the tool
Figure 61: Tier 2 Index Mark Location plate in place. This holds the gear in proper
tooth alignment until the injection pump is
re-installed.
Injection Pump Reinstallation

1. Position injection pump shaft into gear,
rotating shaft to mate key with keyway in
gear. Take care to make sure the key mates
with the keyway.
2. Secure injection pump to gear case with
previously removed hardware. Make sure to
align the index marks on the injection pump
1 2 and the gear case like they were in step 1 of
“Injection Pump Removal”.
1. Index Mark on Injection Pump
2. Index Mark on Gear Case
NOTE: If a different injection pump is being
installed, see the appropriate injection pump
Figure 62: Tier 2 Index Mark Alignment timing procedure to set the timing.
2. Remove the starter for clearance, remove
3. Remove hardware holding gear to tool plate,
throttle linkage, fuel lines, harness and
then remove tool plate.
mounting hardware from injection pump.
4. Secure the gear to the injection pump shaft
3. Remove the cover plate from the gear case.
with the lock washer and nut. Use a shop rag,
Remove the nut and lock washer which secure
as before, to prevent the lock washer or nut
the gear to the injection pump shaft. Use a
from falling into the gear case. Torque the nut
shop rag to prevent the lock washer or nut
to 43 to 51 ft-lb (59 to 69 N•m) on the Tier 1
from falling into the gear case.
engine, or 58 to 65 ft-lb (78 to 88 N•m) on the
NOTE: The injection pump gear assembly is Tier 2 engine.
made of three pieces; the flange, the gear,
5. Fasten cover plate to gear case and reinstall all
and the transfer pump cam. Do not loosen or
components removed previously to facilitate
remove the four bolts that fasten the gear to
injection pump removal.
the flange because that changes the timing.
4. Use the hardware from the cover plate to
attach the tool plate (with the marked side
pointing up and out) to the gear case.
83
Engine Maintenance
4
2
9 8 7
1. Tier 1 Injection Pump 6. Adapter

2. Tier 2 Injection Pump 7. Tool Long Screw
3. Gear Case 8. Tool Short Screw
4. Cover Plate 9. Tool Plate
5. Cover Plate Bolt
Figure 63: Injection Pump Gear Tool
84
Engine Maintenance
Fuel Solenoid System A fuel solenoid timer is used to control the fuel
solenoid pull-in coil. The fuel solenoid timer
The fuel solenoid is located on the end of the
consists of a small PC board that contains some
injection pump. It contains two coils: the pull-in
electrical components, a four pin wire connector,
coil, and the hold-in coil. The pull-in coil draws
and one removable relay. The relay is called the
approximately 35 to 45 amps at 12 volts. The
fuel solenoid relay. The fuel solenoid timer is
hold-in coil draws approximately 0.5 amps at
mounted inside the control box.
12 volts.
1 2
1
ARA112
AGA337
1. Fuel Solenoid
Figure 64: Fuel Solenoid Location Tier 1 Engine 1. Four Pin Connector
2. Fuel Solenoid Relay (FSR)
Figure 66: Fuel Solenoid Timer
Fuel Solenoid Timer Operation

The fuel solenoid hold-in coil is connected to the
8D circuit. The fuel solenoid relay coil is also
connected to the 8D circuit and it is grounded
through the fuel solenoid timer. The fuel solenoid
pull-in coil is connected to the 2A circuit through
the normally open contacts of the fuel solenoid
relay when the fuel solenoid relay is energized.
1 When the 8D circuit is energized, it supplies
1. Fuel Solenoid power to the fuel solenoid hold-in coil and to the
fuel solenoid relay coil. The hold-in coil is
Figure 65: Fuel Solenoid Location Tier 2 Engine energized and remains energized as long as there
is power on 8D. The fuel solenoid relay is
The pull-in coil must be energized to move the
energized momentarily by the fuel solenoid timer
injection pump governor linkage to the fuel on
when the 8D circuit is first energized. After
position. Once the injection pump governor
approximately 2.5 seconds, the fuel solenoid timer
linkage has been moved to the fuel on position,
de-energizes the fuel solenoid relay by opening
the hold-in coil will keep it in fuel on position
the circuit to ground.
until the 8D circuit is de-energized. The pull-in
coil must be de-energized after a few seconds to
keep it from being damaged.
85
Engine Maintenance
During the time the fuel solenoid relay is 2. Use the microprocessor keypad to enter the
momentarily energized, the fuel solenoid pull-in Relay Board Test Mode. Refer to the
coil is energized by the 2A circuit through the appropriate Microprocessor Operation and
normally open contacts of the fuel solenoid relay Diagnosis Manual for detailed information
and the 8DP circuit. about the Relay Board Test Mode.
When power is removed from the 8D circuit the 3. Energize the fuel solenoid circuits by
fuel solenoid hold-in coil is de-energized, and the energizing the run relay [RUNR] with the
fuel solenoid resets. Relay Board Test Mode.
4. Check the voltage on the 8D circuit (pin A) in
1 the main wire harness connector for the fuel
solenoid. Refer to the following illustrations
2 to identify the pins in the wire connectors.
a. If battery voltage is not present on the 8D
circuit, check the 8D circuit and the
related circuits and components for a fault.
3 b. If battery voltage is present on the 8D

circuit, go to step 5.
AGA310
5 4
1. Fuel Solenoid Relay Contacts AEA704
2. Fuel Solenoid Pull-In Coil Figure 68: Main Wire Harness

Connector Pin Identification
3. Fuel Solenoid Hold-In Coil
4. Fuel Solenoid Timer
5. Fuel Solenoid Relay Coil
Figure 67: Simplified Schematic Diagram
of Fuel Solenoid System
Troubleshooting the Fuel Solenoid

System AEA633
NOTE: The fuel solenoid pull-in coil will 1. Red (8D)

require 35 to 45 amps to turn on the fuel. The 2. White (8DP)
unit’s battery must be in good condition. If the 3. Black (CH)
battery has enough power to crank the engine
over, it has enough power to energize the fuel Figure 69: Fuel Solenoid
Connector Pin Identification
solenoid pull-in coil.
5. Check the CH circuit (pin C) in the main wire
If you suspect that the engine does not run harness connector for continuity to a good
because the fuel solenoid is not operating chassis ground.
correctly, use the following procedure:
a. If there is no continuity between the CH
1. Disconnect the fuel solenoid wire connector circuit and a good chassis ground, check
from the main wire harness. the CH wire for an open circuit.
86
Engine Maintenance
b. If there is continuity between the CH c. De-energize the hold-in coil by removing

circuit in the main wire harness at the fuel the jumper from the red wire (8D—pin A)
solenoid wire connector and a good and the positive battery terminal. The fuel
chassis ground, go to step 6. solenoid should make a definite click
when the hold-in coil is de-energized.
6. Place a jumper wire between the black wire
(CH—pin C) in the fuel solenoid connector d. If the hold-in coil does not function
and a good chassis ground. properly, check the resistance of the
hold-in coil by placing an ohmmeter
7. Test the pull-in coil by momentarily placing a
between the red wire (8D—pin A) and the
jumper between the white wire (8DP—pin B)
black wire (CH—pin C) in the fuel
in the fuel solenoid connector and the positive
solenoid connector. The resistance of the
battery terminal. The fuel solenoid should
hold-in coil should be 24 to 29 ohms. If
make a definite click when the pull-in coil is
the resistance of the hold-in coil is not in
energized and should click again when the
this range, replace the fuel solenoid.
pull-in coil is de-energized.
NOTE: The pull-in coil will draw 35 to 45 e. If the hold-in coil does function properly,
amps so do not leave the jumper connected to go to step 9.
the white wire (8DP—pin B) for more than a 9. Reconnect the fuel solenoid connector and the
few seconds. main wire harness connector.
a. If the pull-in coil does not energize, check 10. Remove the fuel solenoid relay from its socket
the resistance of the pull-in coil by placing and make sure the Zone 1/Host On/Off switch
an ohmmeter between the white wire is in the On position and the unit is in the
(8DP—pin B) and the black wire (CH— Relay Board Test Mode [RUNR].
pin C) in the fuel solenoid connector. The
resistance of the pull-in coil should be 0.2 11. Check the voltage on the 8D circuit at the 86
to 0.3 ohms. If the resistance of the pull-in terminal in the fuel solenoid relay socket.
coil is not in this range, replace the fuel Refer to the following illustration to identify
solenoid. the terminals in the relay socket.
NOTE: If the pull-in coil fails, make sure to a. If battery voltage is not present on the 8D
replace the fuel solenoid relay with relay circuit, check the 8D circuit and the
P/N 41-893. This particular relay is needed related circuits and components for a fault
for the high current flow through the hold-in (minimum voltage is 10 volts).
coil. b. If battery voltage is present on the 8D
b. If the pull-in coil does energize, go to circuit, go to step 12.
step 8. 1 2
8. Test the hold-in coil.
a. Energize the hold-in coil by placing a
jumper between the red wire (8D—pin A)
in the fuel solenoid connector and the
positive battery terminal. 4 3
b. Momentarily energize the pull-in coil by
placing a jumper between the white wire 1. 30 Terminal—2A Circuit
(8DP—pin B) in the fuel solenoid 2. 86 Terminal—8D Wire
connector and the positive battery 3. 87 Terminal—8DP Wire
terminal. The fuel solenoid should make a 4. 85 Terminal to Capacitor and Diode
definite click when the pull-in coil is
Figure 70: Relay Socket Terminal Identification
energized, but should not click when the
pull-in coil is de-energized.
87
Engine Maintenance
12. Check the voltage on the 2A circuit at the 30 5. Energize the fuel solenoid by energizing the
terminal in the fuel solenoid relay socket. run relay [RUNR] with the Relay Board Test
mode.
a. If voltage is not present on the 2A circuit,
check the 2A circuit for an open or a short. NOTE: The fuel solenoid must be energized
when it is being installed. If it is not, the
b. If battery voltage is present on the 2A
plunger and the linkage may not line up
circuit, go to step 13.
correctly and the fuel solenoid will not
13. Test the relay. function properly.
a. Use a jumper to connect the 86 terminal 6. Place the o-ring in the groove in the end of the
on the relay to the positive battery fuel injection pump. Make sure that the o-ring
terminal. is positioned correctly during installation to
avoid damage and leaks.
b. Use another jumper to connect the 85
terminal on the relay to a CH circuit. 7. Install the new fuel solenoid.
c. If the relay does not energize, it is 8. Place the Zone 1/Host On/Off switch in the
defective. Replace the relay. Off position after installing the fuel solenoid.
d. If the relay does energize, the timer is
defective. Replace the fuel solenoid timer
PC board.
14. Turn the unit Off after completing the test
procedure.
Fuel Solenoid Replacement

1. Disconnect the fuel solenoid wire connector
from the main wire harness and remove the AEA635
old fuel solenoid.

1. Fuel Solenoid
2. Connect the new fuel solenoid wire connector 2. O-ring
to the main wire harness.
3. Groove in Fuel Injection Pump
3. Place the Zone 1/Host On/Off switch in the Figure 71: Fuel Solenoid Components
On position.
4. Use the Multi-Temp µP-IV microprocessor
keypad to enter the Relay Board Test mode.
Refer to the appropriate Microprocessor
Operation and Diagnosis Manual for specific
information about the Relay Board Test mode.
88
Engine Maintenance
Trochoid Feed Pump Tier 2 Engine

The Tier 2 engine has a trochoid feed pump on the
fuel injection pump. The trochoid feed pump
supplies fuel to the injection pump at a pressure of
65 to 87 psi (450 to 600 kPa). Check the outlet
pressure of the trochoid feed pump by removing
the plug and attaching a pressure gauge to the port
shown below. The plug has M12x1.25 threads.
You will have to make an adaptor to attach a
pressure gauge. Replace the trochoid feed pump if
the outlet pressure is below 59 psi (410 kPa) or
above 94 psi (650 kPa).
1 2 1
1
1. Allen Head Screws (Do Not Remove)
2. Hex Head Screws
Figure 73: Trochoid Feed Pump Removal
2. Remove the trochoid feed pump from the
2 injection pump.
NOTE: The gear on the trochoid feed pump
is lubricated with engine oil. Some engine oil
might leak out of the injection pump when
the trochoid feed pump is removed. The
1. Trochoid Feed Pump Outlet Pressure Port trochoid feed pump does not need to be timed
2. Trochoid Feed Pump when it is installed.Clean the area on the
Figure 72: Trochoid Feed Pump Location injection pump from which the trochoid feed
pump was removed.
If the seal in the trochoid feed pump fails, it could
allow some fuel to leak into the engine oil. A 3. Place new O-rings on the new trochoid feed
faulty injection nozzle or fuel transfer pump can pump and make sure it is clean.
also dilute the engine oil with fuel. Replace the
trochoid feed pump if the engine oil is being
diluted with fuel and a faulty injection nozzle or
fuel transfer pump is not the cause.
Use the following procedure to replace the
trochoid feed pump.
1. Remove the four hex head screws that attach
the trochoid feed pump to the injection pump.
Do not remove the two Allen head screws.
1
1
1. O-Rings
Figure 74: Trochoid Feed Pump
4. Place the new trochoid feed pump on the
injection pump.
89
Engine Maintenance
5. Install and tighten four hex head screws that 2. Press the GAUGES key before the engine starts
attach the trochoid feed pump to the injection and check the coolant temperature to make
pump. Torque the hex head screws to 6 to sure it is below 32 F (0 C).
7 ft-lb (8 to 10 N•m).
3. Let the engine start, then use the GAUGES key
to check the engine rpm. The engine rpm
Cold Start Device Tier 2 Engine should be approximately 100 rpm higher than
The Tier 2 engine has a cold start device located normal (see Specifications).
on the fuel injection pump. The cold start device
4. Let the engine run to warm up and use the
has a plunger that retracts at engine coolant
GAUGES key to check the coolant temperature
temperatures below 41 F (5 C) to advance the
and engine rpm. When the coolant
injection timing approximately 2 degrees. The
temperature rises above 41 F (5 C), the engine
plunger controls the position of a piston in the
rpm should drop back to normal. Replace the
injection pump to change the timing. The plunger
cold start device if the engine rpm does not
is extended and the injection timing is normal at
drop approximately 100 rpm when the engine
engine coolant temperatures above 41 F (5 C).
warms up.
Check the operation of the cold start device if it is
difficult to start the engine in cold weather.
Cold Start Device Replacement
NOTE: Do not pull the plunger out of a cold
1. Drain the engine coolant.
start device because that will damage it.
2. Remove the banjo bolt that fastens the engine
coolant fitting to the cold start device. Use a
backup wrench on the cold start device if
necessary.
1
3
1. Plunger (Extended)
Figure 75: Cold Start Device
Checking Cold Start Device Operation

Use the following procedure to check the
operation of the cold start device. The engine 1. Banjo Bolt
coolant temperature must be below 32 F (0 C) to 2. Engine Coolant Fitting
start the procedure. 3. Coolant Hoses to Cold Start Device
1. Place the On/Off switch in the On position. Figure 76: Remove Engine Coolant Fitting
90
Engine Maintenance
3. Remove the cold start device from the Engine Valve Clearance
injection pump fitting. Use a backup wrench Adjustment
on the injection pump fitting if necessary.
1. Remove the rocker arm cover.
2. Remove the round cover (plug) from the
timing mark access hole on the front of the
1 bell housing.
CAUTION: Loosen all of the injection
lines at the injection nozzles to prevent the
2 possibility of the engine firing while it is
being rotated.
3. Place the engine at top dead center of the
compression stroke for the number one
cylinder. See steps a through d.
1. Cold Start Device

1 2
2. Injection Pump Fitting
Figure 77: Remove Cold Start Device
4. Make sure the piston inside the injection
pump fitting is clean.
1
AEA701
1. Index Mark
2. Top Dead Center Mark for 1 and 4
Figure 79: Top Dead Center One and Four
a. Rotate the engine in the normal direction
of rotation (clockwise viewed from the
1. Piston water pump end) until the 1-4 timing mark
on the flywheel lines up with the index
Figure 78: Clean Piston
mark in the timing mark access hole.
5. Install the new cold start device with a new
b. Check the rocker arms on the number one
O-ring in the injection pump fitting. Torque
cylinder to see if they are loose.
the cold start device to 22 to 26 ft-lb (30 to 35
N•m). c. If the rocker arms are loose, the engine is
at top dead center of the compression
6. Install the coolant fitting and banjo bolt on the
stroke for the number one cylinder.
cold start device. Torque the banjo bolt to 16
to 18 ft-lb (22 to 25 N•m). d. If the rocker arms are tight, the engine is at
top dead center of the exhaust stroke for
7. Refill the engine cooling system and make
the number one cylinder. Rotate the engine
sure to bleed the air from the cooling system.
360 degrees to place the engine at top dead
center of the compression stroke for the
number one cylinder.
91
Engine Maintenance
4. Use a feeler gauge to check the valve

clearance on both valves for the number one
cylinder, the intake valve for the number two
cylinder, and the exhaust valve for the number
three cylinder. The valve clearance for both
the intake valve and the exhaust valve should
be 0.006 to 0.010 in. (0.15 to 0.25 mm).
NOTE: Check to make sure that the valve
stem cap is in good condition and is
positioned squarely on the top of the valve
stem. Replace the valve stem cap if it shows
significant wear.
5. Adjust the valves if necessary by loosening AEA705
the locknut and turning the adjustment screw Figure 80: Adjusting the Valve Clearance
until the valve clearance is correct. 7. Recheck the valve clearance.
6. Hold the adjustment screw in place and 8. Rotate the engine one full turn (360 degrees)
tighten the locknut. in the normal direction of rotation (clockwise
viewed from the water pump end), and align
the 1-4 timing mark on the flywheel with the
index mark in the timing mark access hole.
This is top dead center of the compression
stroke for the number four cylinder.
9. Check and adjust the exhaust valve for the
number two cylinder, the intake valve for the
number three cylinder, and both valves for the
number four cylinder.
10. Replace the rocker arm cover, the cover for
the timing mark access hole, and tighten the
fuel injection lines when finished.
Valve Adjustments and Cylinder Configurations

Rear Front
Flywheel End Pulley End
Cylinder Number 1 2 3 4
Valve arrangement E I E I E I E I
Piston in No. 1 cylinder is at

TDC on compression stroke
Piston in No. 4 cylinder is at

TDC on compression stroke
92
Engine Maintenance
Positive Crankcase Ventilation The following schematic illustrates the PCV

(PCV) Tier 2 Engine operation. In the unrestricted position, gas flow
exits the crankcase via the push rod passages and
The Tier 2 engine has a Positive Crankcase flows past the orifice and diaphragm. Without a
Ventilation (PCV) system. It uses a spring and PCV system, as air cleaner restriction increased,
diaphragm, located in the valve cover, to maintain vacuum and flow would increase in the breather
a constant flow of crankcase gas regardless of the hose to lower the crankcase pressure. To prevent
intake manifold pressure. This results in a system this, the PCV diaphragm expands into the
with a constantly regulated crankcase pressure passageway, restricting the flow to maintain a
even in the presence of ring wear or a restricted constant, slightly positive crankcase pressure.
air cleaner.
Normal crankcase pressures with a new air
1 cleaner are approximately 1.6 to 6.7 in. (40 to
2 170 mm) of H2O positive pressure.
3 The following items can effect the crankcase
4 pressure readings.
8 Crankcase Typical Cause
Pressure
Effect
Increase Piston Rings Stuck or Worn
Decrease Air Cleaner Dirty or Plugged
Increase Breather Hose Plugged with Dirt or Ice
Decrease PCV Diaphragm Torn
Increase PCV Diaphragm Frozen to Seat in
Valve
6 5
7
1. Diaphragm Cover 5. Baffle Plate

2. Spring 6. Baffle Breather
3. Plate 7. Intake Manifold
4. Diaphragm 8 Breather Hose
Figure 81: Tier 2 PCV Components
1 2
6 3
5
4
Unrestricted Position Partially Restricted Fully Restricted Position
1. Diaphragm 4. Push Rod Passages

2. Spring 5. Baffle Plate
3. Valve Cover 6. To Breather Hose
Figure 82: Tier 2 PCV System
93
Engine Maintenance
Crankcase Breather Tier 1 Air Cleaner

Engine Before the first quarter of 2001, a heavy duty, dry
The crankcase breather is located on top of the element air cleaner was used on this unit. Replace
rocker arm cover. The crankcase breather system this air cleaner when the air restriction indicator
ducts crankcase gases formed in the crankcase reads 25 in. of vacuum.
directly to the air intake. Harmful vapors that
would otherwise collect in the crankcase and EMI 3000 Air Cleaner
contaminate the oil, or escape to the outside, are
drawn back into the engine and burned. A The EMI 3000 air cleaner is a dry element air
restrictor is placed in the breather hose to limit the cleaner. It became standard equipment on this unit
flow gas flow from the crankcase to the intake and in the first quarter of 2001. Replace the EMI 3000
keep the crankcase pressure from getting too low. air cleaner element when the air restriction
indicator reads 25 in. of vacuum, or at 3,000 hours
Normal crankcase pressures with a new air or 2 years, whichever occurs first. The EMI 3000
cleaner are 5 to 10 in. (127 to 254 mm) H2O of air cleaner element has a nameplate that reads
vacuum at 1450 rpm and 7 to 11 in. (178 to “EMI 3000.” It cannot be interchanged with air
279 mm) H2O of vacuum at 2200 rpm. The cleaners used on previous units, however it can be
vacuum will increase as the air cleaner gets dirty retrofit on previous units by using the EMI 3000
and becomes more restrictive. The crankcase Air Cleaner Assembly and the related
breather and the breather hose should be inspected components.
when the air cleaner element is replaced to make
sure they are not plugged or damaged.
NOTE: The breather hose must be routed so it
slopes down from the crankcase breather to the
intake manifold. This prevents condensation
from collecting in the breather hose. The
condensation can plug the breather hose if it
collects and freezes in the hose.
2 3
1 ARA189
Figure 84: EMI 3000 Air Cleaner Assembly
6
5 4 1
Insulation (Covers breather Hose

1. ARA190
to prevent freezing.)
2. Restrictor
3. Crankcase Breather
4. Air Restriction Indicator 1. Dust Ejector Must Point Down When Installed
5. Intake Manifold Figure 85: EMI 3000 Air Filter Element
6. Intake Air Heater
Figure 83: Tier 1 Crankcase Breather
94
Engine Maintenance
1
2 AEA710
3 Figure 87: Air Restriction Indicator
Starters
The Tier 1 and Tier 2 engines use different
starters. The Tier 2 engine has a more powerful
starter to ensure reliable starting in extremely cold
1. EMI 3000 Air Cleaner Assembly weather. Identify the starters by looking at the
2. EMI 3000 Air Filter Element through bolts. The Tier 2 starter has external
3. Air Restriction Indicator through bolts, but the Tier 1 starter does not. Do
not try to put a Tier 1 starter on a Tier 2 engine.
Figure 86: EMI 3000 Air Cleaner System
Model 30 Shown Model 50 Similar
The Tier 1 starter does not fit on the Tier 2 engine
because it is too long. The Tier 2 starter does fit
on the Tier 1 engine. The Tier 2 starter requires
Air Restriction Indicator heavier battery cables (see “Battery Cables” in the
Excessive restriction of the air intake system Electrical Maintenance chapter).
reduces the flow of air to the engine affecting
horsepower output, fuel consumption and engine
life.
An air restriction indicator is installed on the air
intake manifold. Visually inspect the restriction
indicator periodically to assure the air filter is not
restricted. Service the air filter when the yellow
diaphragm indicates 25 in. of vacuum. Press the
reset button on the top of the air restriction
indicator after servicing the air filter.
Figure 88: Tier 1 Starter
95
Engine Maintenance
Belts
Belts should be regularly inspected during unit
pretrip inspections for wear, scuffing or cracking.
Belt tension should also be checked during
scheduled maintenance inspections. Belts that are
too loose will whip and belts that are too tight put
too much strain on the belt fibers and bearings.
Using belt tension gauge, P/N 204-427, is the best
method of checking belts for tightness. Install the
belt gauge in the center of the longest belt span.
Press the plunger so the hook will engage the belt.
Make sure the hook is on the face of the belt, not
in a notch. Release the plunger with a quick
1 motion and without pulling on the belt. Then read
the dial. Use an average of three readings.
1. External Through Bolt
NOTE: Do not attempt to remove or install belts
Figure 89: Tier 2 Starter
without loosening adjustments. Belts that are
installed by prying over pulleys will fail
prematurely due to internal cord damage.
CAUTION: Do not attempt to adjust belts
with the unit running.
CAUTION: With the unit On/Off switch

in the On position, the unit may start
operation at any time without prior
warning. Switch the unit On/Off switch to
the Off position before performing
maintenance or repair procedures.
96
Engine Maintenance
Model 30 Belt Adjustments Upper and Lower Fan Belt Adjustment

The upper fan belt should read 74 and the lower
Alternator Belt Adjustment
fan belt should read 67 on the belt tension gauge.
The alternator belt tension should read 67 on the NOTE: Both the upper and lower fan belts are
belt tension gauge. adjusted at the same time in one procedure.
1. Loosen the alternator pivot bolt and the NOTE: If a fan belt is loose or damaged, replace
adjusting arm bolt. the belt (see “Model 30 Fan Belt Replacement”
2. Move the alternator on the adjusting arm slots on page 98).
to adjust the belt to 67 on the belt tension 1. Loosen the idler assembly pivot bolts and the
gauge. idler adjusting arm bolts.
3. Tighten the adjusting arm bolt and alternator 2. Push in or pull out on the idler adjusting arm
pivot bolt. to “center” the idler assembly between the
belts and balance the tension equally between
the upper and lower belts.
2
3
4
13
7
12
8
9
11 9
10
1. Upper Fan Belt 8. Lower Fan Belt

2. Condenser Fan Pulley 9. Engine Pulley
3. Condenser Fan 10. Idler Adjusting Arm Bolt
4. Condenser Inlet Ring 11. Idler Adjusting Arm
5. Idler Assembly Pivot Bolt 12. Alternator Belt
6. Idler Assembly 13 Idler Adjusting Arm Pivot Bolt
7. Belt Guide
Figure 90: Model 30 Belt Arrangement
97
Engine Maintenance
3. Tighten both idler adjusting arm bolts and 3. Pull the idler adjusting arm OUT. The upper
both idler assembly pivot bolts. fan belt should slip off the idler pulley as the
idler pulley hub clears the curbside idler
NOTE: If the idler assembly binds when
mounting bracket.
moving for belt adjustment, loosen the upper
idler support bracket mounting bolts to free 4. Loosen the two condenser fan hub to the shaft
up the assembly. Check the main idler clamping bolts.
retainer nut assembly for proper alignment
5. Tap the blower wheel with a soft hammer to
between the nut and the support bracket
drive the blower wheel up the fan shaft to
slots.
provide 1/2 in. (13 mm) clearance between the
blower wheel and the inlet ring.
Model 30 Fan Belt Replacement
NOTE: If the condenser fan does not slide
NOTE: Do not attempt to remove or install the
on the fan shaft with light tapping, remove
belts without loosening the adjustments. Belts
the small access panel located on the
that are installed by prying over pulleys will fail
condenser coil header above the radiator
prematurely due to internal cord damage.
tank. Thread a 1/4-20 x 1 in. diameter bolt
into the end of the fan shaft. Tighten the bolt
Lower Fan Belt
and washer down on the condenser fan hub
Removal to loosen the blower wheel. Drive the blower
1. Loosen both idler adjusting arm bolts and both wheel back to provide 1/2 in. (13 mm)
idler pulley assembly bolts. clearance between the blower wheel and
condenser fan inlet ring.
2. Push the idler adjusting arm IN. The lower fan
belt will come off the engine pulley. Move the 6. Lift the belt up over the condenser blower
arm OUT far enough to clear the roadside wheel and remove it from the unit.
idler mounting bracket. Installation
Installation 1. Slip the belt over the condenser blower wheel
1. Slip the belt into the groove of the idler pulley. and place it in the condenser fan pulley.
2. Push the idler adjusting arm back in toward 2. Drive the condenser blower wheel out toward
the unit. the condenser fan inlet ring using a soft
hammer.
3. Slip the belt onto the pulley groove on the
engine. 3. Position the blower wheel so the edge of the
inlet ring lines up with the alignment mark on
4. Pull the idler adjusting arm back OUT and the blower wheel.
adjust the belts to the proper tension.
4. Check the radial clearance between the blower
5. Tighten the idler assembly pivot bolts and the wheel and inlet ring with a gauge wire. Check
idler adjusting arm bolts. around the entire circumference to the inlet
ring and blower wheel (see “Condenser and
Upper Fan Belt Evaporator Fan Location” on page 137).
Removal 5. Torque the blower hub clamping bolts to
1. Loosen the idler adjusting arm bolts and 18 ft-lb (24 N•m).
remove the lower fan belt (see “Lower Fan 6. Seat the upper belt in the blower wheel pulley
Belt” above). groove.
2. Push the idler adjusting arm in and the idler 7. Push inward on the idler adjusting arm and
assembly up. The upper belt should become slip the belt into the idler pulley groove.
slack and slip down out of the idler pulley
groove.
98
Engine Maintenance
8. Pull the idler adjusting arm forward and install Compressor Belt Adjustment
the lower fan belt.
The compressor drive belts should read 79 on the
1 2
belt tension gauge.
1. Loosen the back-up hex nut on the belt
tensioner compression spring adjustment
3 screw.
2. Move the hex nuts on the compression spring
adjustment screw to adjust the belt tension to
79 on the belt tension gauge.
4 3. With the proper belt tension adjustment,
tighten the back-up hex nut to the adjustment
hex nut on the compression spring adjustment
screw.
Water Pump Belt Adjustment

The water pump belt tension should be 35 on the
belt tension gauge.
AEA749
1. Remove the bolts from the water pump pulley.
1. Blower Wheel 2. Remove the pulley sliding section and add or
2. Inlet Ring remove shims to adjusting the belt tension
3. Alignment Mark
gauge.
4. Edge of Inlet Ring 3. Reinstall the belt on the pulley and replace the
Figure 91: Condenser Blower Alignment sliding pulley section on the pulley.
4. Tighten the mounting belts on the water pump
Model 50 Belt Adjustments pulley.
Alternator Belt Adjustment 5. The belt tension should read 35 on the belt
tension gauge.
The alternator belt tension should read 29 on the
belt tension gauge. Fan Belt Adjustment
1. Loosen the alternator pivot bolt and the The fan belt tension should read 74 on the belt
adjusting arm bolt. tension gauge.
2. Move the alternator on the adjusting arm slot 1. Loosen the idler pulley mounting bolts.
to adjust the belt to 29 on the belt tension
gauge. 2. Move the idler pulley assembly to adjust the
belt tension to 74 on the belt tension gauge.
3. Tighten the adjusting arm bolt and alternator
pivot bolt. 3. Tighten the idler pulley mounting bolt.
99
Engine Maintenance
1 2
3
12
11
10
6
8
AGA223
1. Condenser Fan Pulley 7. Electric Motor

2. Condenser Fan 8. Compressor Pulley
3. Condenser Inlet Ring 9. Compressor Belts
4. Idler Pulley 10. Belt Tension Adjustment Idler
5. Fan Belt 11. Alternator Belt
6. Water Pump Belt 12. Alternator
Figure 92: Model 50 Belt Arrangement
Model 50 Compressor Belt Installation

Replacement 1. Install the belts on the clutch pulley through
the gap between the clutch and the flywheel.
Removal
2. Place the compressor in position and install
1. Loosen the back-up hex on the belt tensioner
the mounting bolts.
compression spring adjustment screw.
3. Adjust the hex nuts on the compression spring
2. Move the hex nuts on the compression spring
adjustment to tighten the belts to 79 on the
adjustment screw to relieve belt tension.
belt tension gauge.
3. Support the compressor and unbolt the
4. Tighten the back-up hex nut on the belt
compressor form the flywheel housing (leave
tension compression spring adjustment screw.
the refrigeration lines connected).
4. Swing the compressor assembly away from
the flywheel housing.
5. Remove the belts through the gap between the
clutch and the flywheel.
100
Engine Maintenance
Model 50 Fan Belt Replacement 4. Check the radial clearance between the blower
NOTE: Do not attempt to remove or install the wheel and inlet ring with a gauge wire. Check
belts without loosening the adjustments. Belts around the entire circumference to the inlet
that are installed by prying over pulleys will fail ring and blower wheel (see “Condenser and
prematurely due to internal cord damage. Evaporator Fan Location” on page 137).
5. Torque the blower hub clamping bolts to
Removal 24 N•m (18 ft-lb).
1. Loosen the idler pulley mounting bolts. 6. Seat the upper belt in the blower wheel pulley
2. Move the idler pulley assembly to obtain groove.
enough slack to remove the belt from the idler 7. Place the belt in the idler and electric motor
and the electric motor. pulleys.
3. Loosen the two condenser fan hub to the shaft 8. Move the idler pulley assembly to adjust the
clamping bolts. belt tension to 74 on the belt tension gauge.
4. Tap the blower wheel with a soft hammer to 9. Tighten the idler pulley mounting bolt.
drive the blower wheel up the fan shaft to
provide 13 mm (1/2 in.) clearance between the Clutch (Model 50)
blower wheel and the inlet ring.
Periodically inspect the clutch for worn bearings,
NOTE: If the condenser fan does not slide worn friction shoes and for broken springs. To
on the fan shaft with light tapping, remove inspect the clutch:
the small access panel located on the
condenser coil header above the radiator 1. Loosen the back-up hex nut and move the hex
tank. Thread a 1/4-20 x 1 in. diameter bolt nuts on the compression spring adjustment
into the end of the fan shaft. Tighten the bolt screw to relieve the tension on the compressor
and washer down on the condenser fan hub belts.
to loosen the blower wheel. Drive the blower 2. Support the compressor and unbolt the
wheel back to provide 1/2 in. (13 mm) compressor from the bell housing studs.
clearance between the blower wheel and
condenser fan inlet ring. 3. Remove the compressor from the bell housing
and turn the compressor to provide better
5. Lift the belt up over the condenser blower access to the clutch.
wheel and remove it from the unit.
NOTE: The refrigeration lines may be
Installation removed from the compressor to allow more
movement of the compressor for better access
1. Slip the belt over the condenser blower wheel to the clutch.
and place it in the condenser fan pulley.
4. Remove the compressor belts.
2. Drive the condenser blower wheel out toward
the condenser fan inlet ring using a soft 5. Remove the clutch mounting bolt and special
hammer. washer.
3. Position the blower wheel so the edge of the 6. Remove the clutch with a clutch puller.
inlet ring lines up with the alignment mark on 7. Remove the key from the compressor
the blower wheel (see Figure 91 on page 99). crankshaft and inspect the key and the
crankshaft for wear, burrs, or damage.
101
Engine Maintenance
8. To disassemble the clutch, press the pulley out c. Use a soft hammer to tap the friction shoe
of the bearing. mounting bolts out of the hub and remove
them from the friction shoes.
9. Inspect the friction shoes and springs.
d. Attach the new friction shoes to the hub
a. Replace the friction shoes if the linings are
with the mounting bolt plate, the mounting
worn to a thickness of less than 1/16 to
bolts, and the lock nuts. Torque the lock
3/32 in. (1.6 to 2.4 mm).
nuts to 30 to 35 ft-lb (41 to 47 N•m).
b. Replace the springs if they are worn or
11. To replace the bearing:
broken.
a. Remove the snap ring and press the
10. To replace the friction shoes:
bearing out of the hub.
a. Remove the springs from the friction
b. Press the new bearing into the hub and
shoes.
install the snap ring.
b. Remove the lock nuts from the friction
12. To assemble the clutch, press the pulley into
shoe mounting bolts.
the bearing.
11
10
8
7
AGA338
6
5
4
3
2
1
1. Clutch Mounting Bolt 7. Spring

2. Special Washer 8. Friction Shoe
3. Snap Ring 9. Mounting Bolt Plate
4. Bearing 10. Friction Shoe Mounting Bolt
5. Lock Nut 11. Pulley
6. Hub
Figure 93: Clutch
102
Engine Maintenance
13. Place the clutch on the compressor crankshaft,

align the keyways (use Keyway Tool 1
204-972), and insert the key to be flush with
the end of the crankshaft.
CAUTION: Do not place the key on the 2
compressor crankshaft before installing
the clutch because the key might be
pushed out of place behind the clutch
when the clutch is installed.
1. Elastomer
14. Install the special washer and the clutch
mounting bolt. Torque the clutch mounting 2. Outer Steel Sleeve
bolt to 90 ft-lb (122 N•m). Figure 95: Old Style Drive Bushing
15. Reinstall the compressor drive belts. The new style drive bushings and dowel pins
16. Reinstall the compressor on the bell housing should be used to replace the old style drive
studs. bushings and dowel pins. Use 8-Pin and Bushing
Replacement Kit 70-208.
17. Install and tighten the flatwashers, lock
washers and nuts on the studs. NOTE: The new bushing must be mated with a
newly designed, heat-treated dowel pin. It is
18. Readjust the compressor drive belts. imperative the old style dowel pins are replaced
with the new heat-treated dowel pins. See
Drive Bushing Replacement “Dowel Pin Replacement” on page 105.
A new style, bonded drive bushing was The design of the new style drive bushing requires
introduced in July 2004 in model 50 trailer units that the following procedure be used to replace the
with 8-pin clutches. drive bushings.
1. Loosen the compressor drive belt(s).
1
2. Remove the compressor, or pull the
compressor away from the bell housing and
turn the compressor to access the clutch.
2 Support the compressor so it is not hanging
from the vibrasorbers if you are not removing
it.
3. Remove the clutch mounting bolt and special
1. Elastomer washer, and remove the clutch.
2. Inner Fiber Sleeve 4. Remove the clutch pulley by pressing it out of
the bearing. It is not necessary to remove the
Figure 94: New Style, Bonded Drive Bushing
bearing to replace the drive bushings.
5. Remove the friction shoes.
a. Remove the springs from the friction
shoes.
b. Remove the lock nuts from the friction
shoe mounting bolts.
c. Use a soft hammer to tap the friction shoe
mounting bolts out of the hub, and remove
the mounting bolts and the friction shoes.
103
Engine Maintenance
6. Use the straight pin end of the Clutch Bushing 9. Put a thick ring of Loctite adhesive 203-535
Removal/Installation Tool 204-1116 to press around the bottom of the new bushing before
the old bushings out of the clutch hub (see pressing it into place. The adhesive will
Figure 96). squeegee up the entire length of bushing as it
is pressed into the hole.
7. Clean the holes from which the bushings were
removed. WARNING: If a thin coating of adhesive
8. “Start fit” the bushing in the clutch is applied all over the bushing before it is
hub/coupling about 1/8 in. (3 mm) to make started in the hole, the adhesive will begin
sure it fits in the hole and does not hang up on to cure before the bushing can be pressed
something. “Start fit” the bushing in the side completely into place.
of the hub/coupling that faces the flywheel. 10. Use the cupped end of the Clutch Bushing
NOTE: The Loctite adhesive has a working Removal/Installation Tool 204-1116 to press
time of 2 minutes so the bushing must be the new bushing into the hub until the cup
installed within 2 minutes of when the contacts the hub. Press the new bushing into
adhesive was applied. Apply the adhesive and the hub from side of the hub that faces the
install the bushings one at a time to avoid flywheel (see Figure 97).
exceeding the time limit. NOTE: Let the Loctite adhesive cure for at
least 1 hour at 70 F (21 C) before running
the unit. The components can be
reassembled immediately.
1. Straight Pin End

2. Cupped End
Figure 96: Press Old Bushings Out Of Hub With Tool 204-1116
104
Engine Maintenance
1 2
1. Clean Holes
2. Cupped End
Figure 97: Press New Bushing Into Hub With Tool 204-1116
11. Inspect the clutch components before 20. Install the compressor on the bell housing
reassembling the clutch and replace them if studs.
necessary.
NOTE: Do not place any kind of lubricant
12. Install the friction shoes, mounting bolt plate, on the outside of the dowel pins or on the
and friction shoe mounting bolts. inside of the drive bushings. Lubricant
between the dowel pins and drive bushings
13. Torque the lock nuts on the friction shoe
will cause premature wear.
mounting bolts to 35 ft-lb (47 N•m).
21. Install and tighten the flatwashers,
14. Install the springs on the friction shoes.
lockwashers, and nuts on the studs.
15. Press the clutch pulley into the bearing.
22. Adjust the compressor drive belts.
16. Place the clutch on the compressor crankshaft,
align the keyways (use Keyway Tool Dowel Pin Replacement
204-972), and insert the key to be flush with
1. Remove the flywheel.
the end of the crankshaft.
2. Press the old dowel pins out of the flywheel.
CAUTION: Do not place the key on the
compressor crankshaft before installing 3. Use the Manual Pin Tool 204-1117 or the
the clutch because the key might be Impact Pin Tool 204-1118 to press or drive the
pushed out of place behind the clutch new dowel pins into the flywheel. The end of
when the clutch is installed. each dowel pin should be 1.15 in. (29.2 mm)
from the outer face of the flywheel.
17. Install the special washer and the clutch
mounting bolt. Torque the clutch mounting
bolt to 90 ft-lb (122 N•m).
18. If the clutch had old style drive bushings,
replace the dowel pins in the flywheel with
new, hardened (black) dowel pins. See
“Dowel Pin Replacement” on page 105.
19. Install the compressor drive belts.
105
Engine Maintenance
5. Install the flywheel mounting bolts. Torque

1
2 the flywheel mounting bolts to 65 ft-lb (88
N•m).
3
1.15 in. (29.2 mm) 6. Install the compressor and adjust the drive
belts.
1. Press Dowel Pin In Until Flush With

Tool 204-1117
2. Dowel Pin
3. Outer Face Of Flywheel
Figure 98: Pressing New Dowel Pin Into Flywheel

Using Manual Pin Tool 204-1117
3
1
1. Drive Dowel Pin In Until Tool

204-1118 Hits Flywheel
2. Dowel Pin
3. Outer Face Of Flywheel
Figure 99: Driving New Dowel Pin Into Flywheel

With Impact Pin Tool 204-1118
4. Install the flywheel and align it with the dowel

pin in the end of the crankshaft.
106
Refrigeration Maintenance
NOTE: The following procedures involve Testing the Refrigerant Charge with
servicing the refrigeration system. Some of these a Loaded Trailer
service procedures are regulated by Federal, and
NOTE: This test determines if there is enough
in some cases, by State and Local laws.
refrigerant for the current temperatures, not if
In the USA all regulated refrigeration service there is a full charge of refrigerant.
procedures must be performed by an EPA
1. Install a gauge manifold.
certified technician, using approved equipment
and complying with all Federal, State and Local 2. Run all the evaporators on cool.
laws.
3. Build up and maintain 325 to 400 psig (2241
to 2758 kPa) of discharge pressure. If the
Refrigerant Charge pressure is below this, it can be raised by
covering the roadside condenser grille with a
Testing the Refrigerant Charge with piece of cardboard to block condenser air
an Empty Trailer flow.
If the unit has an insufficient charge of refrigerant, 4. Cool the compartments to lowest temperatures
the evaporators will be “starved” and the box required.
temperatures will rise even though the unit is
operating. The suction pressure will drop as the 5. Check suction pressure. It should be 13 to
refrigerant charge decreases. If the unit has an 22 psig (90 to 152 kPa).
overcharge of refrigerant, the unit may not cool 6. Under these conditions, the ball should be
properly and the suction and discharge pressure floating in the receiver tank sight glass. If
may be high. The charge may be determined by refrigerant is not visible in the sight glass, the
inspection of the refrigerant through the receiver unit is low on refrigerant.
tank sight glass with the following conditions
established: Testing for an Overcharge
1. Place a test box over each evaporator. Use the following procedure to identify a unit
2. Install a gauge manifold. with an excessive refrigerant charge:
3. Run all the evaporators on cool until the return 1. Install a gauge manifold on the compressor.
air temperature in each box is at 0 F (-18 C). 2. Operate the host unit in high speed with all the
By allowing a box to leak a small amount, you evaporators in cool to stabilize system
will be able to maintain 0 F (-18 C). pressures and reduce the compartment
4. The suction pressure should be 13 to 18 psig temperatures to approximately 60 F (16 C) or
(90 to 124 kPa). colder.
5. The discharge pressure should be 325 to 3. Observe discharge pressure and cover the
400 psig (2241 to 2758 kPa). If the pressure is condenser to increase the discharge pressure
below this, it can be raised by covering a approximately 50 psig (345 kPa) above the
portion of the roadside condenser grille with a observed pressure. Do not allow the discharge
piece of cardboard to block condenser airflow. pressure to go above 350 psig (2413 kPa).
6. Under these conditions, the ball should be NOTE: If the ball and liquid level in the
floating in the receiver tank sight glass. If receiver sight glass drops during step 3, the
refrigerant is not visible in the receiver tank unit is not overcharged and it is not
sight glass, the unit is low on refrigerant. necessary to complete the procedure.
4. Remove the condenser cover to rapidly reduce
discharge pressure.
107
5. Observe the receiver tank sight glass and the 5. Remove the gauge manifold set and cap all
unit’s discharge pressure. service ports and valve stems when the
refrigerant level is correct.
6. By the time the discharge pressure drops
approximately 50 psig (345 kPa) the ball in
the receiver tank sight glass should begin to Moisture Indicating Sight Glass
move and the liquid level should drop. The receiver tank is equipped with a moisture
a. When discharge pressure stabilizes, the indicating sight glass. The outer edge of the sight
ball and liquid level will rise. glass has a colored ring approximately 0.1 in.
(2.5 mm) thick. The color of the ring indicates the
b. If the ball will not begin to move or the moisture content of the refrigerant, but it may not
liquid level will not drop, the unit most be completely reliable.
likely has an overcharge of refrigerant.
The refrigerant level should be adjusted. • Green = Dry
• Chartreuse = Caution
Adjusting Refrigerant Level
• Yellow = Wet
1. Stop the unit and remove some refrigerant
with an approved refrigerant recovery device.
1
2. Perform a refrigerant level check and repeat
the overcharge test.
3. If the liquid level is low, add refrigerant as
follows: 2
AEA672
a. Connect a refrigerant tank to the gauge

manifold service line and purge the line. 1. Floating Ball
2. Colored Ring
b. Mid seat the suction service valve. Figure 100: Moisture Indicating Sight Glass
c. Set the refrigerant tank for liquid removal A system has to run for at least 15 minutes to
and open the hand valve. change the color of the indicator ring after the
d. Operate the unit in high speed with all moisture content of the system has been changed.
evaporators in cool. For example, evacuating a system to remove the
moisture will not change the color of the indicator
e. Observe the suction pressure and slowly ring until the system has been recharged and then
open the gauge manifold low pressure operated for at least 15 minutes.
hand valve to allow liquid refrigerant to
flow into the suction service valve.
Refrigerant Leaks
f. Control the liquid flow so the suction
pressure increases approximately 20 psig Use a reliable leak detector that is suitable for
(138 kPa). R-404A to leak test the refrigeration system.
Inspect for signs of oil leakage which is the first
g. Maintain a discharge pressure of at least sign of a leak in the refrigeration system.
325 to 400 psig (2241 to 2758 kPa) while
adding refrigerant.
h. Close the hand valve on the refrigerant
tank when liquid appears in the receiver
sight glass.
4. Repeat the overcharge test.
108
Compressor Sump Sizes

Units built before mid-February 2003 are
sump.
Units built after mid-February 2003 are equipped
with compressors that have a 7-quart sump.
Identification
The 4-quart sump measures 2.67 in. (68 mm)
from the bottom of the sump to the top of its
gasket surface.
1
The 7-quart sump measures 5.35 in. (136 mm)
from the bottom of the sump to the top of its
gasket surface.
1. Sight Glass
2. Sump Height 5.35 in. (136 mm)
Figure 102: Compressor with 7-Quart Sump
1
Compressor Oil Level
The recommended compressor oil level is the
same for both compressors. The sight glass should
be 1/4 to 1/2 full. See “Checking Compressor Oil”
on page 110. See the Specifications Chapter for
the total quantity of compressor oil.
2
Compatibility
1. Sight Glass The 7-quart sump compressor and the 4-quart
2. Sump Height 2.67 in. (68 mm) sump compressor are interchangeable. However,
the increased oil capacity of the 7-quart sump
Figure 101: Compressor with 4-Quart Sump
improves long-term reliability.
109
Compressor Removal and Installation To check compressor oil level with an

ambient air temperature above 50 F (10 C):
The 7-quart sump extends below the top of the
lower frame rails. Therefore, a flat board cannot Install a gauge manifold on the compressor.
be used as a support when removing or installing
Operate all the evaporators on cool with a 20 psig
a compressor with a 7-quart sump. A Compressor
(138 kPa) minimum suction pressure and a
Installation Tool P/N 204-1087 (two pieces) has
185 psig (1275 kPa) minimum discharge pressure
been developed to aid in the removal and
for 15 minutes or more.
installation of the 7-quart sump compressor. See
Compressor Removal and Installation on pages After the unit has maintained the above conditions
117 and 118 for more information. for 15 minutes, observe the oil level. The oil
should be 1/4 to 1/2 up in the sight glass.
Compressor Disassembly and Assembly
To check compressor oil level with an
All compressor repair procedures and torque
ambient air temperature below 50 F (10 C):
specifications are the same for the 7-quart sump
compressor as for the 4-quart sump compressor. Run all the evaporators through a complete
See the X214, X418, X426 & X430 Compressor defrost cycle. After completing the defrost cycles,
Overhaul Manual TK 6875 for complete details. run all the evaporators on cool for ten minutes.
Observe the oil level. The oil should be 1/4 to 1/2
Compressor Conversion up in the sight glass.
A 4-quart sump compressor can be converted to a If the compartment is empty, you can run the
7-quart sump compressor. The following parts evaporator on the heat cycle instead of the defrost
must be replaced: cycle.
Description P/N Qty NOTE: Use refrigeration compressor oil ONLY.

Polyol Ester type (P/N 203-513) is required on
Sump Oil Machined 7 Quart 22-1181 1
R-404A systems.
Tube/Screen Oil Pickup 7 Quart 22-1182 1
Bracket Pickup Tube 92-2921 1
Gasket Sump 7 Quart 33-3797 1
High Pressure Cutout Switch
(HPCO)
Screw HH 3/8-16 x 5.5 Inch SZN 51-0575 16
The HPCO is located on the compressor discharge
IMPORTANT: The sump gasket for the 4-quart manifold. If the discharge pressure rises above
sump is different and must not be used with the 470 psig (3241 kPa), the HPCO opens. This opens
7-quart sump. the 8P-8D circuit, which de-energizes the fuel
solenoid and shuts down the unit. The
Checking Compressor Oil microprocessor then records Alarm Code 10. To
test the HPCO; rework a gauge manifold. See
The compressor oil should be checked when there Figure 103 on page 111.
is evidence of oil loss (oil leaks) or when
components in the refrigeration system have been 1. Connect the gauge manifold to the compressor
removed for service or replacement. Use the discharge service valve with a heavy duty,
compressor sight glass to check the oil level. See black jacketed thick wall #HCA 144 hose with
Figure 101 or Figure 102 on page 109. a 900 psig (6204 kPa) working pressure
rating.
2. Use the Service Test mode to run the host unit
in High Speed Cool. Refer to the appropriate
Diagnosis Manual for specific information
about the Service Test Mode.
110
3. Raise the discharge pressure of the High Pressure Switch (HPSW)

compressor first by blocking the condenser Test
coil air flow by covering the roadside
condenser grille with apiece of cardboard. If The high pressure switch (HPSW) is located on
this does not raise the discharge pressure to the compressor discharge manifold. This switch is
the cutout level of the HPCO, increase the used by the microprocessor to confirm the
engine speed by overriding the throttle operation of the receiver tank pressure solenoid
solenoid. This should increase the discharge and the purge valve. It is connected to the 7K1
pressure enough to cause the HPCO to cut out. and HP wires in the main wire harness. The
The cut out pressure should be HPSW opens when the discharge pressure rises
470 +7/-35 psig (3241 +48/-241 kPa). above 300 psig (2068 kPa). The HPSW closes
when the discharge pressure drops below 200 psig
CAUTION: If the discharge pressure (1379 kPa).
reaches 477 psig (3289 kPa), shut the unit
off immediately. Do not allow the Use the following procedure to test the HPSW:
discharge pressure to exceed 477 psig 1. Install a gauge manifold on the compressor.
(3289 kPa).
2. Disconnect the HPSW from the 7K1 and HP
4. If the HPCO does not open to de-energize the wires in the main wire harness.
fuel solenoid and stop the engine, it must be
3. Check the HPSW for continuity. It should be
replaced.
closed when the unit is not running.
4. Use the Service Test mode to run the host unit
in High Speed Cool. Refer to the appropriate
Diagnosis Manual for specific information
about the Service Test Mode.
5. Cover the condenser to raise the discharge
pressure.
6. Monitor the discharge pressure. When the
discharge pressure reaches 300 +25/-0 psig
(2068 +172/-0 kPa), the HPCI should open.
7. Uncover the condenser to lower the discharge
pressure.
8. Monitor the discharge and suction pressures.
When the discharge pressure reaches 200 ±
20 psig (1379 ± 138 kPa), the HPSW should
close.
9. Replace the HSW if it does not function
properly.
10. Reconnect the HPSW to the main wire harness
1. Relief Valve (66-6543) and remove the gauge manifold.
2. O-Ring (33-1015)
3. Adapter Tee Weather Head (No. 552X3)
Figure 103: High Pressure Cutout Manifold
111
Evacuating and Charging 7. Press the SELECT key. If [OFF] and [PRNT]
Smart Reefer Multi-Temp appear on the display, press the SELECT key
again. The letters [REV] should appear in the
Systems lower display and the revision number should
appear in the upper display.
Set-up Unit
The Smart Reefer Multi-Temp µP-IV 8. With the revision screen on the display, press
microprocessor must be placed in the Evacuation both the TK key and the CLEAR key and hold
them down (for 3 to 5 seconds) until [TEST]
Mode to evacuate and charge the unit. When the
and [VAC] appears on the display.
microprocessor is in the Evacuation Mode it
opens all the normally closed solenoid valves in 9. Press the ENTER key to load the Evacuation
the refrigeration system. This allows the Mode [VAC]. All normally closed valves will
refrigeration system to be evacuated properly. be energized.
Refer to the appropriate Diagnosis Manual for
complete information about the microprocessor. The display should show [TEST] and [VAC].
Use the following procedure to set-up the unit and If the display shows [SET] and [VAC], a
place the microprocessor in the Evacuation mode: higher rate of battery charge is required.
1. Connect a battery charger to the unit battery. Alarm Code 109 will be generated. This is
The battery charge must have an output of at normal.
least 15 amperes. This will maintain the 10. The microprocessor is now in the Evacuation
charge level of the battery during the time Mode. The refrigeration system is set-up for
required to evacuate and charge the unit. The evacuation and charging.
microprocessor's Service Test mode is used to
open unit valves as required for evacuation. Evacuating the System
Failure to connect a battery charger may result
in the battery voltage falling too low to CAUTION: Do not evacuate the system
reliably operate the microprocessor and until it is leak free. A unit with less than
valves. full refrigerant charge should be leak
checked and all leaks must be repaired
2. Use the CYCLE-SENTRY Selection screen to
select Continuous Run operation if 1. Be sure all refrigerant has been recovered
Continuous Run operation is not already from the unit.
selected. 2. Connect a vacuum pump and gauge manifold
3. Place the Zone 1/Host On/Off switch in the for three-point evacuation to the suction
Off position. service valve, discharge service valve, and
receiver tank outlet valve.
4. Place the Zone 1/Host, Zone 2, and Zone 3
On/Off switches in the On position. Do not NOTE: The use of the Thermo King
allow the unit to start. Evacuation Station P/N 204-725 or 204-744
is recommended.
5. Clear any alarm codes using the CODE and
CLEAR keys. 3. Verify proper operation of the Evacuation
Station as shown in the Evacuation Station
6. With the standard screen on the display and Operation Manual TK 40612.
before the engine starts, press the TK key and
hold it down (for 3 to 5 seconds) until [PrE] 4. Start the vacuum pump and mid-seat the
[TRIP] appears on the display. suction service valve, discharge service valve,
and receiver tank outlet valve.
5. Install service valve stem caps with seals and
tighten them. The valve stems should remain
capped while evacuating the unit.
112
6. Evacuate the unit to 500 microns, or the 1,000 microns. This insures complete
lowest achievable level between 500 and evacuation of the remote evaporators and
1,000 microns. lines.
7. Continue to evacuate the unit for one 8. Close the Evacuation Station valve nearest the
additional hour after reaching 500 microns, or vacuum pump (V1) to isolate the vacuum
the lowest achievable level between 500 and pump from the system. Turn the vacuum
pump off.
8
2
7
3
1. V-4 6. To AC Power
2. V-3 7. Vacuum or Micron Gauge
3. V-2 8. Thermistor
4. V-1 9. Correct Refrigerant Level
5. Two Stage Vacuum Pump
Figure 104: Multi-Temp Evacuation and Charging (Two Zone Unit Shown Other Units Similar)
113
9. Observe the micron gauge. 4. Close the gauge manifold hand valve.
The system pressure should remain below 5. Back seat (close) the receiver tank outlet valve
2000 microns for 5 minutes. and discharge service valve.
If the pressure does not hold, check for leaks 6. Exit the Evacuation Mode by turning the
(if a leak is suspected) or continue evacuation Zone1/Host On/Off switch Off, and then back
(if system is not dry). On.
10. Restart the vacuum pump, open the 7. Turn all zones On and set all zone setpoints
Evacuation Station valve nearest the vacuum for the lowest possible temperature to insure
pump (V1) and repeat steps 6, 8, and 9 as that all zones run in Cool mode. Allow the
required until system pressure remains below unit to start.
2000 microns for 5 minutes.
8. Front seat the suction service valve and allow
11. When system pressure remains below 2000 the compressor to pump down to 1 to 3 psi (7
microns for 5 minutes, restart the vacuum to 21 kPa). Stop the unit.
pump and open the Evacuation Station valve
9. Remove the evacuation manifold hoses from
nearest the vacuum pump (V1).
the receiver tank outlet valve, the discharge
12. With the vacuum pump running, back seat the service valve, and the suction service valve.
suction service valve. Replace the valve cap, Replace and tighten the service port and valve
re-close the Evacuation Station valve nearest stem caps on the receiver tank outlet valve.
the vacuum pump (V1), and stop the vacuum
10. Attach the gauge manifold (with the
pump.
refrigerant supply bottle still connected) to the
13. Close valve V4. The unit is ready to charge. compressor. Attach the low side gauge to the
NOTE: Do not exercise the service valves with suction service valve. Mid-seat the suction
the unit in a deep vacuum unless the vacuum service valve. Attach the high pressure gauge
pump is operating. on to the discharge service valve. Open the
discharge service valve to monitor the
discharge pressure.
Charging the System
NOTE: The unit must be left in the Evacuation 11. Turn all zones On (with all zone setpoints set
Mode. to the lowest possible temperature) and allow
the unit to start.
1. Insure that all compartment bulkheads are
open. Ceiling mounted bulkheads should not 12. Observe the suction pressure and slowly open
be stored close to the evaporator outlets as this the gauge manifold hand valve to allow liquid
will restrict airflow. refrigerant to flow into the suction service
valve. Control the liquid flow so the suction
2. Before charging system, make sure the pressure increases 20 to 25 psi (138 to
refrigerant lines from the gauge manifold to 172 kPa). Maintain a discharge pressure of
the refrigerant supply bottle have been 325 to 400 psi (2241 to 2758 kPa).
evacuated or purged, the suction service valve
is back seated, and the discharge service valve 13. Add refrigerant until the ball in the receiver
and receiver tank outlet valve are still open. tank sight glass rises to the middle of the sight
glass, then close the gauge manifold hand
3. Set the refrigerant supply bottle for liquid. valve. Make sure the liquid level does not rise
Open the gauge manifold hand valve and add above the top of the sight glass.
a partial charge of R-404A. Add 14 lb (6.4 kg)
to a unit with one remote evaporator. 14. Continue to operate the unit and monitor the
Add 15 lb (6.8 kg) to a unit with two remote sight glass until all compartment temperatures
evaporators. Do not add more than this. The are at or below 0 F (-18 C).
remainder of charge will be added through
suction service valve while unit is running.
114
15. Check the position of the ball in the receiver

tank sight glass. If the liquid level has
dropped, add liquid refrigerant until the level
stabilizes near the middle of the sight glass.
Do not exceed the recommended refrigerant
charge for the unit model.
16. Close the hand valve on the refrigerant supply
bottle.
17. Back seat the discharge service valve.
18. Open both hand valves on the gauge manifold.
19. Front seat the suction service valve and allow
the compressor to pump down to 1 to 3 psi
(7 to 21 kPa). Stop the unit.
20. Remove the gauge line from the suction
service valve and cap the service port.
21. Remove the gauge line from the discharge
service valve and cap the service port.
22. Back seat the suction service valve and cap the
valve stem.
23. Cap the valve stem on the discharge service
valve.
24. Secure all the gauge lines to the gauge line
anchors.
115
116
Refrigeration Service Operations
NOTE: It is generally good practice to replace NOTE: Repeat the pump down procedure
the filter drier whenever the high side is opened if the pressures equalize above 20 psi
or when the low side is opened for an extended (138 kPa). If suitably low pressures cannot
period of time. be achieved after the third pump down, the
refrigerant must be recovered to perform
Low Side Pump Down service on the low side.
NOTE: Operate all the evaporators in Cool for c. If the reading on the gauge manifold’s
2 to 5 minutes with the service valves in their high pressure gauge increases after the
normal operating positions before performing high and low side pressures have been
the low side pump down. Install a gauge equalized, the condenser inlet check valve
manifold at the compressor. is leaking.
1. Run all the evaporators in cool, front seat the d. Remember to reconnect the purge valve
receiver tank outlet valve and the bypass hand solenoid wires to the main wire harness
valve, and pump down the low side to 20 to when the service procedures have been
25 in. Hg vacuum (-68 to -85 kPa). Turn the completed.
Zone 1/Host On/Off switch Off.
If the unit pumps down acceptably and then Compressor
holds at least 15 in. Hg vacuum (-51 kPa) for The 7-quart sump extends below the top of the
2 minutes or more, it can be assumed that the lower frame rails. Therefore, a flat board cannot
receiver tank outlet valve, the compressor be used as a support when removing or installing
discharge valve plates, the HGS solenoid, the a compressor with a 7-quart sump. A Compressor
HGS2 solenoid, the HGS3 solenoid, and the Installation Tool P/N 204-1087 (two pieces) has
purge valve solenoid are sealing acceptably. been developed to aid in the removal and
installation of the 7-quart sump compressors.
2. Prepare to perform service on the unit’s low
side by equalizing the high side and low side
Removal
pressures.
1. Pump down the low side and equalize the
a. Disconnect the purge valve solenoid wires
pressure to slightly positive.
from the main wire harness.
NOTE: If the purge valve solenoid wires are 2. Loosen the compressor belts on Model 50
not disconnected from the main wire units.
harness, the purge valve is energized when 3. Front seat the discharge and suction service
the unit is placed in the Evacuation mode. valves. Remove the remaining refrigerant
This allows the refrigerant in the condenser pressure from the compressor.
to flow into the accumulator, undoing the
low side pump down. 4. Unbolt the discharge and suction service
valves from the compressor.
b. Place the unit in the Evacuation mode.
Refer to the Service Test mode in the 5. Remove the compressor oil filter and its lines.
appropriate Microprocessor Diagnosis 6. Disconnect the HPCO wires and the HPSW
Manual. The high and low side pressures wires.
should equalize in the Evacuation mode.
117
7. Support the compressor and remove the 5. Pressurize the compressor and test for
compressor mounting bolts from the flywheel refrigerant leaks.
housing. For a compressor with a 7-quart
6. If no leaks are found, evacuate the
sump use The Compressor Installation Tool
compressor.
(P/N 204-1087) to support the compressor as
follows: 7. Back seat the suction and discharge service
valves.
a. Identify the four machined feet on the base
of the compressor sump. The Compressor 8. Tighten the compressor belts on Model 50
Installation Tools bridge the lower frame units.
rails and support the compressor directly
9. Operate the unit at least 30 minutes and then
under these feet.
inspect the oil level in the compressor. Add or
b. Position the Compressor Installation Tools remove oil if necessary.
by inserting them from the end of the
10. Check the refrigerant charge and add
compressor and sliding them into place on
refrigerant if needed.
the lower frame rails. Alternatively,
position the Compressor Installation Tools
by inserting them on a diagonal from Compressor Coupling Removal
below the compressor and twisting them 1. After the compressor has been removed from
into position over the lower frame rails. the unit, use the appropriate Allen tool
provided with removal tool P/N 204-991 (see
8. Lift the service valves out of the way.
Figure 105 on page 119) to loosen the center
9. Slide the compressor to the left until the bolt, which holds the coupling to the
coupling pins are clear, and remove the compressor shaft.
compressor belts from Model 50 units.
2. Attach the tool to the coupling with the
10. Remove the compressor from the front of the provided socket head screws and spacers. Two
unit. Keep the compressor ports covered to sets of spacers are provided with the tool, use
prevent dust, dirt, etc., from falling into the the short spacers with shallow compressor
compressor. mounting flanges and the longer set for deeper
flanges. The side with the countersunk holes
NOTE: When the compressor is removed
should be toward the coupling.
from the unit, the oil level should be noted,
or the oil removed from the compressor 3. To prevent the tool and crankshaft from
should be measured so that the same amount rotating, use one of the compressor to engine
of oil can be added before placing the mounting screws to pin the tool to the flange.
replacement compressor in the unit. If a nut is used to prevent the bolt from falling
out, the nut should not be tightened.
Installation
4. Use the appropriate Allen tool to loosen the
1. If installing a 7-quart sump compressor, place coupling mounting screw.
the Compressor Installation Tools on the
5. Once the center screw has been loosened,
lower frame rails to support the compressor.
back the head against the tool and it should
2. Slide the compressor into the unit. push the coupling off the crankshaft as you
3. Place the compressor in position, install the continuing turning the center screw in a
compressor belts on Model 50 units, and counter-clockwise direction. Using this tool
install the mounting bolts. will prevent the coupling from popping off
because the center bolt and flatwasher will
4. Install the service valves using new gaskets hold it in place.
soaked in compressor oil. Connect the HPCO
wires, the HPSW wires, and install the
compressor oil filter.
118
Compressor Coupling Installation Use the following procedure to install a

compressor coupling on the compressor
In a tapered fit joint the entire twisting load
crankshaft.
should be handled by the friction fit between the
two tapered parts. The key is only a backup and is 1. Clean the compressor shaft taper and coupling
used to index the parts correctly. When a taper fit bore taper with a solvent that leaves no oily
is machined and assembled properly a key is not residue (such as naphtha, lacquer thinner,
needed. In fact, if the key is not installed correctly brake cleaner or the like).
it may be worse than no key at all! If the key does
2. Inspect both mating surfaces for burrs,
not fit easily into the keyway, it will push the
oxidation and other surface imperfections.
tapered components apart and the reduced friction
Dress with crocus cloth if necessary and
could lead to slippage and premature failure.
re-clean as required.
The following procedure requires the key to be
fitted after the tapers are pulled together with
20 ft-lb (27 N•m) torque. This insures that the key
cannot hold the tapers apart when the final bolt
torque is applied.
1
2
3
8
7
6
AGA1059
1. Coupling 5. 10 mm Allen Tool (for large shaft compressor)

2. Long Spacers (supplied with tool) 6. 5/16 Allen Tool (for small shaft compressors)
3. Short Spacers (supplied with tool) 7. Coupling Removal Tool (P/N 204-991)
4. Socket Head Bolts (supplied with Tool) 8. Engine Mounting Flange
Figure 105: Compressor Coupling Removal Tool
119
3. Using no lubricants, set the coupling on the 8. Install the key in the keyway. As above, it
crankshaft and align the keyways using the should fit with a light press fit requiring only a
Keyway Tool (P/N 204-972). Insert the minimum of light tapping. Do not install the
tapered end of the tool into the keyway and key into the keyway beyond the front face
gently move the coupling on the shaft while of the coupling. If tapped in farther it may
pressing the tool into the keyway. This will cause the coupling to move off center on the
align the keyway in the crankshaft with the shaft.
keyway in the coupler.
1
2
3
AGA333
Figure 106: Keyway Tool P/N 204-972
CAUTION: If you are assembling a used

coupler or crankshaft and the tool does 5 4
AGA1254
not fit easily there is a problem with one of
the keyways! Do not remove the coupler
and place the key in the crankshaft 1. Compressor Coupling or Clutch
keyway and then drop the coupler on. If Key tapped flush with outside face of coupling.
2.
the tool does not fit, the key will not fit, Do not tap key any farther into keyway.
and it will hold the taper in the coupler off 3. Torque bolt to 90 ft-lb (122 N•m)
the taper on the shaft. Check both keyways 4. Washer
for burrs or corrosion. A key can be Spray this area with corrosion inhibitor after
5.
coated with fine lapping compound and assembling.
used as a lapping tool to clean the Figure 107: Compressor Coupling Installation
keyways.
9. Re-install the bolt and heavy flat washer and
4. Remove the Keyway Tool and check the fit of snug the bolt down by hand. Torque the bolt to
the key (P/N 55-9024). It should fit into the 90 ft-lb (122 N•m).
keyway with a light press fit requiring only a
minimum of light tapping. If the key does not 10. Spray a corrosion inhibitor (such as spray
fit properly, remove the coupler and inspect paint) on the exposed part of the shaft and the
the keyways and key for burrs or other joint between the shaft and the coupling. This
problems. Recheck the fit as shown above. prevents moisture from wicking into the joint
and causing corrosion.
5. When the key fits properly, remove the
coupling and key from the shaft.
Condenser Coil
6. Re-install the coupling and align the keyways
with the Keyway Tool. Removal
7. Do not install the key at this time. Install the 1. Recover the refrigerant charge.
flat washer and bolt and pre-torque to 20 ft-lb 2. Drain engine coolant from the expansion tank.
(27 N•m). Remove the bolt and washer. Unbolt and remove the coolant expansion tank
from the condenser coil frame. Unsolder the
tank breather tube.
120
3. Remove the condenser coil mounting bolts. In-Line Check Valves

Remove the mounting clamps from the
condenser inlet line. This unit uses some in-line check valves. An
in-line check valve is not repairable and must be
4. Unsolder the inlet line and liquid line replaced if it fails. A heat sink must be used on the
connections. Lift the coil from the unit. in-line check valve when it is being soldered in
place to prevent damage to the neoprene seal.
Installation
1. Clean the fittings for soldering.
2. Place the coil in the unit and install the
mounting bolts.
3. Solder the inlet line and liquid line
connections.
4. Pressurize the refrigeration system and test for
leaks. If no leaks are found, evacuate the
system.
5. Install the clamps on the condenser inlet line. 1. Valve
6. Install the engine coolant expansion tank and 2. Neoprene Seal
refill half way with engine coolant. 3. Valve Seat
4. Spring
7. Recharge the unit with proper refrigerant and
check the compressor oil. Figure 108: Cross Section of In-line Check Valve
Removal
Discharge Vibrasorber
1. Recover the refrigerant charge.
Removal 2. Place a heat sink on the check valve.
1. Recover the refrigerant charge. 3. Unsolder the lines and remove the check
2. Heat the connections on the vibrasorber until valve.
the vibrasorber can be removed.
Installation
CAUTION: Use a heat sink, P/N 204-584
or wrap the vibrasorber with wet rags to NOTE: A heat sink must be used on the in-line
prevent damaging the vibrasorber. check valve when it is being soldered in place to
prevent damage to the neoprene seal.
Installation 1. Clean the tubes for soldering.
1. Prepare the vibrasorber and tubing fittings by 2. Place the check valve in position. The arrow
cleaning thoroughly. on the valve body indicates the direction of
2. Solder the vibrasorber connections. refrigerant flow through the valve.
3. Place a heat sink on the check valve.
CAUTION: Use a heat sink, (P/N 204-584
or wrap the vibrasorber with wet rags to 4. Solder the inlet and outlet connections.
prevent damaging the vibrasorber.
3. Pressurize the system and test for leaks. If no leaks.
leaks are found, evacuate the system. 6. If no leaks are found, evacuate the system.
4. Charge the unit with the proper refrigerant and 7. Recharge the unit with proper refrigerant and
check the compressor oil level. check the compressor oil.
121
Receiver Tank 2. Install the new drier and tighten the mounting
screws and nuts.
Removal 3. Install and tighten the inlet ORS nut. Hold the
1. Recover the refrigerant charge. drier with a back-up wrench on the hex behind
the ORS fitting.
2. Unsolder the refrigeration lines from the
receiver tank. 4. Release a small amount of refrigerant to purge
the air through the drier. Then tighten the
3. Unbolt the mounting brackets and remove the outlet ORS nut.
receiver tank from the unit.
5. Pressurize the system and inspect for leaks. If
4. Remove the high pressure relief valve from no leaks are found, open the refrigeration
the receiver tank. It will be installed on the valves and place the unit in operation.
new receiver tank.
Installation Expansion Valve Assembly

1. Install the high pressure relief valve on the NOTE: This procedure applies to the
new receiver tank. Make sure to use a new Zone 1/Host unit expansion valve.
O-ring and coated with refrigerant oil.
Removal
2. Place the receiver tank in the unit and install
the mounting bolts and nuts loosely. Position
the receiver tank so that the sight glass is pressure to slightly positive.
clearly visible. 2. Remove the evaporator access panels.
3. Solder the refrigeration lines to the receiver 3. Remove the feeler bulb from the clamp. Note
tank. the position of the feeler bulb on the suction
line.
4. Tighten the receiver tank mounting hardware
securely. 4. Disconnect the equalizer line from the suction
line.
5. Pressurize the refrigeration system and check
for leaks. If no leaks are found, evacuate the 5. Disconnect the inlet liquid line and unsolder
system. the distributor from the expansion valve.
6. Recharge the unit with proper refrigerant. 6. Remove the expansion valve mounting bolt
and remove the expansion valve from the unit.
Filter Drier
Installation
Removal 1. Install and bolt the expansion valve assembly
1. Pump down the low side and equalize the in the unit.
pressure to slightly positive. 2. Connect the inlet liquid line and solder the
2. Disconnect the ORS nuts at the ends of the distributor to the expansion valve.
drier. 3. Connect the equalizer line to the suction line.
3. Loosen the mounting hardware and remove 4. Clean the suction line to a bright polished
the drier. condition. Install the feeler bulb clamps and
the feeler bulb on the side of the suction line
Installation in its former position. The feeler bulb must
1. Place the new O-rings in the ORS fittings on make good contact with the suction line or
the ends of the drier. operation will be faulty. Wrap with insulating
tape.
122
5. Pressurize the low side and test for leaks. If no 2. Place the heat exchanger assembly in the
leaks are found, evacuate the low side. evaporator housing and install the mounting
hardware loosely.
6. Replace the access panels.
3. Solder the liquid inlet and the suction outlet
7. Open the refrigeration valves and place the
line connections on the condenser side of the
unit in operation.
bulkhead. Seal the openings through the
8. Test the unit to see that the expansion valve is bulkhead with putty when the refrigerant lines
properly installed. have cooled off.
4. Solder the suction inlet line connection.
5. Solder the liquid outlet line connection.
6. Pressurize the low side and test for leaks. If no
leaks are found, evacuate the low side.
7. Tighten the heat exchanger mounting
hardware securely.
8. Replace the evaporator access panels.
unit in operation.
AEA713
Evaporator Coil
1. End View
2. Side View
NOTE: This procedure applies to the
Zone 1/Host unit evaporator coil.
Figure 109: Location of Expansion Valve Bulb
Removal
Heat Exchanger 1. Pump down the low side and equalize the
Removal
2. Remove the evaporator access panels and
damper assembly.
3. Disconnect and remove the sensors.
2. Remove the evaporator access panels.
4. Remove the feeler bulb from the suction line
3. Remove the hardware that holds the heat
clamp. Note the position of the feeler bulb on
exchanger on the bulkhead.
the suction line.
4. Unsolder the liquid outlet line.
5. Unsolder the distributor from the expansion
5. Unsolder the suction inlet line. valve.
6. Unsolder the remaining outlet suction line and 6. Unsolder the hot gas line and the suction line
inlet liquid line connections from the from the evaporator coil.
condenser side of the bulkhead. Remove any
7. Remove the mounting bolts, lift and slide the
putty from around the lines before unsoldering
coil from the housing.
the connections.
7. Slide the heat exchanger assembly out of the Installation
evaporator housing.
1. Place the evaporator coil in the evaporator
housing and install the mounting bolts.
Installation
1. Clean the tubes for soldering.
123
2. Solder the hot gas line and suction line 4. Open the refrigeration valves and place the
connections to the evaporator coil. unit in operation. Check the refrigerant charge
and the compressor oil, and add as required.
3. Solder the distributor to the expansion valve.
4. Replace and connect the sensors. Suction Vibrasorber
leaks are found, evacuate the low side. Removal
6. Clean the suction line to a bright polished 1. Pump down the low side and equalize the
condition. Install the feeler bulb on the side of pressure to slightly positive.
the suction line in its former position. The 2. Unsolder the suction vibrasorber from the
feeler bulb must make good contact with the suction service valve.
suction line or operation will be faulty. Wrap
with insulating tape. 3. Unsolder the connection to the accumulator
and remove the vibrasorber from the unit.
7. Replace the upper and lower evaporator
access panels. CAUTION: Use a heat sink or wrap the
vibrasorber with wet rags to prevent
damaging the vibrasorber.
unit in operation. Check the refrigerant charge
and compressor oil. Add as required.
Installation
Accumulator 1. Prepare the suction vibrasorber and tube

fittings for soldering by cleaning thoroughly.
Removal 2. Solder the vibrasorber to the suction service
1. Pump down the low side and equalize the valve.
pressure to slightly positive. CAUTION: Use a heat sink or wrap the
2. Unsolder the inlet and outlet suction lines vibrasorber with wet rags to prevent
from the accumulator. damaging the vibrasorber.
CAUTION: Use a heat sink or wrap 3. Solder the suction hose connection to the
vibrasorber with wet rags to prevent accumulator.
damaging the vibrasorber. 4. Pressurize the low side and check for leaks. If
3. Unbolt and remove the accumulator from the no leaks are found, evacuate the system.
unit. 5. Open the refrigeration valves and place the
Installation and the compressor oil, and add as required.
1. Place the accumulator in the unit and tighten
the mounting bolts and nuts. High Pressure Cutout Switch
2. Solder the inlet and outlet suction lines to the and High Pressure Switch
accumulator.
Removal
CAUTION: Use a heat sink or wrap
vibrasorber with wet rags to prevent
damaging the vibrasorber.
2. Front seat the discharge and suction service
3. Pressurize the low side and test for refrigerant valves. Remove the remaining refrigerant
leaks. If no leaks are found, evacuate the low from the compressor.
side.
124
3. Disconnect the wires and remove the switch High Pressure Relief Valve
from the compressor discharge manifold.
Removal
Installation
1. Apply a refrigerant Loctite to the threads of
the switch. 2. Unscrew and remove the high pressure relief
valve. It is located near the top of the receiver
2. Install and tighten the switch and reconnect tank.
the wires.
3. Pressurize the compressor and test for leaks. Installation
4. If no leaks are found, open the refrigeration 1. Apply a refrigerant oil to the O-ring of the
service valves and place the unit in operation. high pressure relief valve.
Check the refrigerant charge and the 2. Install and tighten the high pressure relief
compressor oil, and add as required. valve.
Discharge Pressure Sensor leaks. If no leaks are found, evacuate the
system.
Removal
4. Recharge the unit with the proper refrigerant
1. Recover the refrigerant charge. and check the compressor coil.
2. Disconnect the wire connector from the
discharge pressure sensor. Throttling Valve
3. Remove the mounting clamp (if used) from See Figure 110 on page 126 for an illustration of
the discharge pressure sensor. the throttling valve assembly.
4. Unscrew the discharge pressure sensor from
the adapter on the end of the tube. Use a Removal
backup wrench to hold the adapter. 1. Pump down the low side and equalize the
5. Remove the discharge pressure sensor. pressure to slightly positive.
2. Front seat the discharge and suction service
Installation valves. Recover the refrigerant remaining in
1. Apply refrigerant Loctite to the threads on the the compressor.
discharge pressure sensor. 3. Remove the suction service valve.
2. Screw the discharge pressure sensor into the 4. Unbolt and remove the throttling valve from
adapter on the end of the tube. Use a backup the unit.
wrench to hold the adapter.
3. Install the mounting clamp (if used) for the
discharge pressure sensor.
4. Recharge the unit with the proper refrigerant
and check the compressor oil.
125
aea717
1. Screw - mtg plate 10. Gasket - piston housing

2. Flatwasher 11. Piston
3. Plate - bellows end 12. Spring - piston
4. Gasket - end plate 13. Nut - adjusting
5. Shim - adjusting 14. Pin - cotter
6. Spring - bellows 15. Housing - piston
7. Bellows & Shaft - assy 16. O-ring - valve to compressor
8. O-ring 17. Cap - rubber
9. Housing
Figure 110: Throttling Valve Assembly
126
Disassembly
1. Remove the piston end cap (round end).
2. Remove the cotter pin from the castle nut and
remove the nut.
3. Remove the spring and piston.
4. Loosen all the bolts on the bellows end cap.
CAUTION: This end cap is under slight
spring pressure.
1. Inspect for Wear
5. Break the gasket free and remove the end cap.
Figure 112: Inspect for Wear
6. Note the number of shims next to the cap.
These can be reused.
1. Inspect for Damage

Figure 113: Inspect for Damage
1. Inspect Cap
2. Inspect Spring 9. Clean the parts that will be reused.
3. Shims
Reassembly
Figure 111: Inspect the Parts
1. Install the bellows with the O-ring in the
7. Remove the bellows.
housing.
8. Inspect all the parts.
2. Center the spring on the bellows shoulder.
a. Piston and cap for wear (scuff marks).
3. Oil the gasket, install it on the housing, and
b. Body for stripped threads. place the shims in the end cap (use same
number as removed). Tighten the end cap in
c. Bellows end cap for damage in the pilot
place with the vent hole closest to the outlet
hole.
opening of the valve housing.
NOTE: The bellows is normally replaced.
4. Install the piston, spring and tighten the castle
nut until it is firmly seated against the bottom
of the piston.
127
5. Back off the castle nut, one full turn only. Liquid Line Solenoid Valve
6. Insert the cotter pin. (LLS)
NOTE: Valves that have nylon seats must be
disassembled before soldering.
Removal
1. Pump down the low side and equalize pressure
to slightly positive.
3. Remove the coil and disassemble the valve.
4. Unsolder the liquid lines from the valve, and
remove the valve from the unit.
CAUTION: Use a heat sink to prevent
damage.
1. Tighten castle nut to bottom, then back
off 1 turn only. Insert cotter pin Installation
Figure 114: Throttling Valve Reassembly 1. Clean the tubes for soldering.
7. Oil the gasket and install the end cap. 2. Remove the coil, disassemble the valve, and
8. The throttling valve will have to be place the valve in position.
recalibrated on operating unit. (See the 3. Solder the inlet and outlet connections. After
Specifications Chapter for the setting.) the valve cools, assemble the valve and install
9. Adjust by adding or removing shims under the the coil.
spring.
damage.
Installation
1. Install the throttling valve using a new O-ring 4. Pressurize the refrigeration system and test for
soaked in compressor oil. Bolt the throttling leaks.
valve to the compressor. 5. If no leaks are found, evacuate the system.
2. Install the suction valve. 6. Install the evaporator access panels.
3. Pressurize the compressor and check for leaks. 7. Open the refrigeration valves and run the unit.
If no leaks are found, evacuate the Check the refrigerant charge and compressor
compressor. oil.
unit in operation.
128
Hot Gas Solenoid Valve (HGS) Suction Line Solenoid Valve

NOTE: Valves that have nylon seats must be (SLS)
disassembled before soldering. NOTE: Valves that have nylon seats must be
Removal
1. Pump down the low side and equalize the Removal
pressure in the high side to slightly positive. 1. Pump down the low side and equalize the
2. Remove the evaporator access panels. pressure in the high side to slightly positive.
3. Remove the coil and disassemble the valve. 2. Remove the evaporator access panels.
4. Unsolder the hot gas lines from the valve, and 3. Remove the coil and disassemble the valve.
remove the valve from the unit. 4. Unsolder the suction lines from the valve, and
remove the valve from the unit.
damage. CAUTION: Use a heat sink to prevent
damage.
Installation
1. Clean the tubes for soldering. Installation
2. Remove the coil, disassemble the valve, and 1. Clean the tubes for soldering.
place the valve in position. 2. Remove the coil, disassemble the valve, and
3. Solder the inlet and outlet connections. After place the valve in position.
the valve cools, assemble the valve and install 3. Solder the inlet and outlet connections. After
the coil. the valve cools, assemble the valve and install
the coil.
damage. CAUTION: Use a heat sink to prevent
damage.
leaks. 4. Pressurize the refrigeration system and test for
5. If no leaks are found, evacuate the system. leaks.
6. Install the evaporator access panels. 5. If no leaks are found, evacuate the system.
7. Open the refrigeration valves and run the unit. 6. Install the evaporator access panels.
Check the refrigerant charge and compressor 7. Open the refrigeration valves and run the unit.
oil. Check the refrigerant charge and compressor
oil.
129
Check Valve Repair (SLCV,

SLCV2, SLCV3, LRCV, and 1
PVC)
Removal 2
1. Pump down the low side and equalize pressure

3
to slightly positive.
4
3. Remove the cap nut, or the four cap mounting
screws and the cap, from the check valve and 5
remove the spring and seat.
AGA173
1
1. Cap
4 2. Gasket
3. Spring
2 4. Seat
5. Body
3
Figure 116: Check Valve with Cap Nut
Installation
1. Inspect the inside of the check valve body for
damage or foreign particles that might adhere
5
to the seat and damage the new seat. If the
body is damaged, replace the check valve.
6 2. Install the new seat and spring. Place a new

AGA172 gasket on the cap and tighten the cap.
3. Pressurize the low side and test for leaks.
1. Cap Mounting Screw
2. Cap 4. If no leaks are found, evacuate the system.
3. Gasket 5. Install the evaporator access panels.
4. Spring
6. Open the refrigeration valves and run the unit.
5. Seat
Check the refrigerant charge and compressor
6. Body oil.
Figure 115: Suction Line Check Valve
130
Check Valve Replacement Installation

(SLCV, SLCV2, SLCV3, LRCV, 1. Clean the tubes for soldering.
and PVC) 2. Remove the coil, disassemble the valve, and
place the valve in position.
Removal
3. Solder the inlet and outlet connections. After
the valve cools, assemble the valve and install
the coil.
CAUTION: Use a heat sink or wrap the
3. Unsolder the lines and remove the check valve with wet rags to prevent damaging
valve. the valve.
NOTE: Disassemble the valve before 4. Pressurize the refrigeration system and test for
unsoldering. leaks.
Installation 5. If no leaks are found, evacuate the system.
1. Clean the tubes for soldering. 6. Recharge the unit with proper refrigerant and
check the compressor oil.
2. Place the disassembled check valve in
position. The arrow on the valve body
indicates the direction of refrigerant flow Condenser Inlet Check Valve
through the valve. (CICV) Repair
3. Solder the inlet and outlet connections. After Removal
the valve cools, reassemble the valve.
2. Remove the cap nut from the check valve, and
5. If no leaks are found, evacuate the system. remove the spring and seat.
6. Install the evaporator access panels.
Installation
Check the refrigerant charge and compressor 1. Inspect the inside of the check valve body for
oil. damage or foreign particles which might
adhere to the seat and damage the new seat. If
the body is damaged, replace the check valve.
Condenser Inlet Solenoid Valve
(CIS) 2. Install the new seat and spring. Place the new
gasket on cap and torque to 45 ft-lb (61 N•m).
Removal 3. Pressurize the refrigeration system and test for
1. Recover the refrigerant charge. leaks.
2. Remove the coil and disassemble the valve. 4. If no leaks are found, evacuate the system.
3. Unsolder the hot gas lines from the valve, and 5. Recharge the unit with proper refrigerant and
remove the valve from the unit. check the compressor oil.

valve with wet rags to prevent damaging
the valve.
131
Condenser Inlet Check Valve 2. Remove the coil from the valve, and place the
(CICV) Replacement valve in position.
Removal the valve cools, install the coil on the valve.
1. Recover the refrigerant charge. CAUTION: Use a heat sink or wrap the
2. Unsolder the lines and remove the check valve with wet rags to prevent damage.
valve.
NOTE: Disassemble the valve before leaks.
unsoldering.
5. If no leaks are found, evacuate the system.
Installation 6. Recharge the unit with proper refrigerant and
1. Clean the tubes for soldering. check the compressor oil.
2. Place the disassembled check valve in
position. The arrow on the valve body Purge Valve (PV)
indicates the direction of refrigerant flow
through the valve. Removal
3. Solder the inlet and outlet connections. After 1. Recover the refrigerant charge.
the valve cools, reassemble it. 2. Remove the coil from the valve.
4. Pressurize the refrigeration system and test for 3. Unsolder the refrigeration lines from the
leaks. valve, and remove the valve from the unit.
5. If no leaks are found, evacuate the system. CAUTION: Use a heat sink to prevent
6. Recharge the unit with proper refrigerant and damaging the valve.
check the compressor oil.
Installation
Receiver Tank Pressure 1. Clean the tubes for soldering.
Solenoid Valve (RTPS)
2. Remove the coil from the valve, and place the
Removal valve in position.
1. Recover the refrigerant charge. 3. Solder the inlet and outlet connections. After
the valve cools, assemble the valve and install
2. Remove the coil from the valve. the coil.
3. Unsolder the hot gas lines from the valve, and CAUTION: Use a heat sink to prevent
remove the valve from the unit. damaging the valve.
valve with wet rags to prevent damage. 4. Pressurize the refrigeration system and test for
leaks.
Installation 5. If no leaks are found, evacuate the system.
1. Clean the tubes for soldering. 6. Recharge the unit with the proper refrigerant.
132
Compressor Oil Filter Use the following procedure to change the

compressor oil filter.
This unit is equipped with a compressor oil filter.
The compressor oil filter should be changed when 1. Pump down the low side and equalize the
the drier is replaced. pressure to slightly positive.
The outlet fitting is larger than the inlet fitting, so 2. Front seat the discharge and suction service
the compressor oil filter cannot be put on valves. Remove the remaining refrigerant
backwards. There are two fittings on the inlet end from the compressor.
of the compressor oil filter. The inlet fitting 3. Disconnect the oil lines from the compressor
contains a check valve that prevents reverse flow oil filter. Hold the oil filter with back-up
through the compressor oil filter. The capped wrench on the hex behind the ORS fitting.
fitting is called the oil pressure access port and is
used to check the compressor oil pressure (see 4. Remove the clamp and the compressor oil
“Checking Compressor Oil Pressure” on filter.
page 133). 5. Coat the new O-rings with clean compressor
oil and place them in the ORS fittings on the
ends of the new compressor oil filter.
6. Fasten the new compressor oil filter in place
with the clamp.
7. Attach and tighten the oil lines to the
compressor oil filter. Hold the oil filter with a
back-up wrench on the hex behind the ORS
fitting.
8. Evacuate the compressor and filter to a
maximum of 500 microns to remove trapped
air.
9. Open the service valves, operate the system,
and check the compressor oil filter for leaks.
1 Checking Compressor Oil

Pressure
The oil pressure at the oil pressure access port
3 varies with the suction pressure in the compressor.
Therefore, we need to calculate the “net oil
pressure” to determine the actual compressor oil
2 pressure. The net oil pressure is the pressure at the
AEA718
oil pressure access port minus the suction pressure
1. Oil Pressure Access Port
below the throttling valve. Use the following
procedure to check the compressor oil pressure.
2. Inlet Fitting
3. Outlet Fitting 1. Attach a suitable oil pressure gauge to the oil
pressure access port on the compressor oil
Figure 117: Compressor Oil Filter
filter.
133
2. Attach the low pressure gauge of a gauge NOTE: The microprocessor will probably
manifold to the fitting on the side of the record some alarm codes because the
throttling valve. This fitting allows you to solenoids are disconnected and the engine
monitor the suction pressure in the compressor does not start. Clear these alarm codes as
below the throttling valve. necessary.
3. Start the unit and note the pressure at the oil 5. Turn the unit on and let the engine crank (or
pressure access port and the suction pressure crank the engine) for 30 seconds, but do not
below the throttling valve. crank the engine for more than 30 seconds.
4. Subtract the suction pressure below the a. Note the pressure at the oil pressure access
throttling valve from the pressure at the oil port and the suction pressure below the
pressure access port to get the net oil pressure. throttling valve while the engine is
cranking. Subtract the suction pressure
Pressure at Oil Pressure Access Port
below the throttling valve from the
– Suction Pressure Below Throttling Valve
pressure at the oil pressure access port to
= Net Oil Pressure
get the net oil pressure.
5. The net oil pressure should be at least 20 psi b. If the compressor does not develop at least
(138 kPa). If the net oil pressure is low, first 10 psi (96 kPa) of net oil pressure in the
check the compressor oil level, then check the first 30 seconds, allow the starter to cool
compressor oil pump and relief valve. for a few minutes and the crank the engine
again for 30 seconds. If 10 psi (96 kPa) of
Priming New Compressor net oil pressure still does not develop, first
Installations check the compressor oil level, then check
the compressor oil pump and relief valve.
Thermo King remanufactured compressors have
had a special break in process to assure that the oil 6. As soon as the compressor develops 10 psi
pump is primed, functioning, and broken in. The (96 kPa) of net oil pressure, re-connected the
following procedure is recommended, but not fuel solenoid wires, but do not re-connect the
required for factory-remanufactured compressors. high speed solenoid wires.
This procedure must be followed to prevent 7. Start unit and run the engine on low speed for
premature pump failure in any compressor that at least five minutes. If the net oil pressure is
has had an oil pump installed, especially a above 20 psi (138 kPa) for this period, stop the
compressor that has been stored for any length of unit and re-connect the high speed solenoid
time. wires.
1. Attach a suitable oil pressure gauge to the oil 8. Run the engine on high speed for at least five
pressure access port on the compressor oil more minutes. The compressor oil pump is
filter. now primed and broken in.
2. Attach the low pressure gauge of a gauge
manifold to the fitting on the side of the
throttling valve. This fitting allows you to
monitor the suction pressure in the compressor
below the throttling valve.
3. Disconnect the wires to the fuel solenoid.
4. Disconnect the wires to the high speed
solenoid.
134
Structural Maintenance
Unit and Engine Mounting Bolts

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

Radiator Coils
Clean the coils during scheduled maintenance
inspections. Remove any debris (e.g., leaves or ARA104
plastic wrap) that reduces the air flow. Clean dirty 1
coils with compressed air or a pressure washer. Be
careful not to bend the fins when cleaning a coil.
If possible, blow the air or water through the coil
in the direction opposite the normal airflow.
Repair bent fins and any other noticeable damage.
Defrost Drains
Clean the defrost drains during scheduled
maintenance inspections to be sure the lines
remain open.
ARA106
Unit Installation
1. Check Bolts for Tightness
All nuts that hold the unit to the trailer are
accessible using an impact wrench with a 10 in. Figure 118: Unit and Engine Mounting Bolts
extension, ball-type swivel and a deep-well
socket.
NOTE: The nuts for mounting the unit should
be elastic stop nuts (Nylock type).
135
Defrost Damper 4. If necessary, adjust Distance A to the proper

dimension by loosening the locknut on the end
Check the damper during scheduled maintenance of the solenoid plunger and turning the eye
inspections for shaft wear, end play, and the bolt. Tighten the locknut when Distance A is
ability to stop the air flow. correct.
Position the damper so that air flow is stopped on 5. Connect the damper link to the eye bolt.
the top and bottom edges with the solenoid
plunger bottomed out. 6. Energize the solenoid (apply 12 volts dc) and
check the damper blade to make sure that both
To adjust the damper: edges contact the damper housing. If
1. Remove the damper assembly from the necessary, adjust this by loosening the
evaporator. solenoid mounting bolts and moving the
solenoid. Tighten the solenoid mounting bolts
2. Disconnect the damper link from the eye bolt. when both edges of the damper blade contact
3. Check Distance A, the distance from the the damper housing.
shoulder on the solenoid to the center of the 7. Adjust the damper blade stops so they contact
hole in the eye bolt. Distance A should be the edges of the damper blade. This keeps the
2.75 in. (69.85 mm) with the solenoid damper from sticking closed.
de-energized.
1 2
3 6
5
7
9
AEA719
8
1
1. Stop 6. Eye Bolt

2. Mounting Bolts 7. Round Stop
3. Closed Position 8. Distance A 2.75 in. (69.85 mm)
4. Open Position 9. Solenoid
5. Damper Link
Figure 119: Defrost Damper Adjustment
136
8. De-energize and energize the damper several 5. Pass a gauge wire completely around the
times to make sure that the damper operates blower orifice to check for uniform clearance.
correctly and seals properly.
6. Spin the blower by hand to check for blower
9. Make sure the damper blade rests on the round distortion.
stops when the damper is open. Adjust the
7. Position the blower so the edge of the inlet
round stops if necessary.
ring lines up with the alignment mark on the
10. Install the damper assembly in the evaporator. blower.
8. Torque blower hub bolts to 18 ft-lb (24 N•m).
Condenser and Evaporator Fan
Location Evaporator Fan Blower
When mounting the condenser or evaporator fan 1. Loosen the inlet rings on the sides of the
and hub assembly on the fanshaft, the blowers and blower housing.
inlet orifices must be properly aligned for proper
2. Center the blower wheel in the blower housing
air flow and to prevent damage to the blower.
with equal overlap on both inlet rings. The
overlap on each ring should be approximately
Condenser Fan Blower 0.15 in. (3.8 mm).
1. Loosen the condenser inlet ring (spinning) on
3. Tighten the hub bolts that hold the blower
the condenser coil bulkhead.
wheel on the fanshaft.
2. Slide the blower towards the inlet ring until it
4. Center the inlet rings in the blower orifices.
contacts the inlet ring. This centers the inlet
Tighten the inlet rings securely.
ring in the blower orifice.
5. Check the radial clearance by passing a wire
3. Tighten the inlet ring securely.
completely around the circumference of the
4. Slide the blower away from the inlet ring. inlet rings and the blower wheel.
1 6. Torque the blower hub bolts to 18 ft-lb
2
(24 N•m).
AEA720
1. Check Clearance with a Wire

2. Blower Housing Sides
AEA749
3. Inlet Rings
4. Evaporator Blower
1. Blower Wheel 3. Alignment Mark
5. Radial Clearance
2. Inlet Ring 4. Edge of Inlet Ring
6. Equalize Blower Inlet Overlap
Figure 120: Condenser Blower Alignment
Figure 121: Evaporator Fan Location
137
Fan Shaft Assembly 2. After draining the oil from the housing,
remove the four retaining bolts from the
The unit is equipped with a one-piece fan shaft condenser end of the assembly.
assembly that contains tapered roller bearings in a
sealed oil reservoir. 3. To remove the shaft from the assembly, tap the
opposite end of the shaft with a soft hammer.
This assembly does not require any maintenance. After the shaft has been removed, clean all
There is a level plug and a fill plug, but they are parts in clean solvent.
not normally used except after removal and repair
of the fan shaft assembly. The condenser and 4. Using a punch, remove the oil seal from the
evaporator end oil seals should be checked during evaporator end of the assembly. With the seal
the pretrip inspection for oil leakage. If there is removed, clean the housing in clean solvent.
any sign of leakage, the fan shaft assembly should 5. Check the condition of the vent. If it is loose
be removed and repaired. or damaged, it must be repaired or replaced.
NOTE: The fan shaft assembly requires a
6. After all the parts are cleaned, inspect the
special lubricant, Thermo King P/N 203-278.
bearings and bearing races for wear or
damage.
Fan Shaft Assembly Overhaul
7. If necessary, remove the bearings by tapping
Disassembly them off the shaft with a hammer and a punch.
Be careful not to damage the shaft with the
1. Remove the fan shaft assembly from the unit.
punch.
Remove both oil plugs and drain the oil from
the housing. 8. The bearing races can now be driven out with
a punch and replaced in the same manner.
AEA721
1. Cap and Shims 6. Oil Seal

2. Oil Plug Screw (Use Oil P/N 203-278) 7. Shaft
3. Breather Vent 8. Sleeve
4. Housing 9. Pin
5. Roller Bearing 10. O-ring
Figure 122: Fan Shaft Assembly
138
Reassembly Idler Assembly

1. Tap the new bearings on the shaft with a pipe. The unit is equipped with a one-piece idler
2. Install new oil seals after replacing the bearing assembly that contains tapered roller bearings in a
races. sealed oil reservoir. This assembly does not
require any maintenance. There is a level plug and
3. Replace the shaft in the housing. Install a new a fill plug, but they are not normally used except
seal in the retainer cap. Use the original shims after removal and repair of the idler assembly. The
and replace the O-ring if needed. roadside end oil seal and the curbside end oil seal
4. Install the retainer cap assembly over the should be checked during the pretrip inspection
shaft, then install the bolts. for oil leakage. If there is any sign of leakage, the
idler assembly should be removed and repaired.
5. Torque the bolts in a criss-cross pattern in
equal steps to 80 in-lb (9.04 N•m). Idler Assembly Overhaul
6. Lock the assembly in a vise and set up a dial
indicator to read end-play. To measure the Disassembly
end-play, rotate the shaft while pushing in one 1. Remove the idler assembly from the unit.
direction and set the dial indicator to ‘0’. Now Remove both oil plugs and drain the oil from
rotate the shaft and pull in the opposite the housing.
direction while reading the dial indicator.
End-play should be 0.001 to 0.005 in. (0.025 2. After draining the oil from the housing,
to 0.127 mm). If end-play is incorrect, use remove the four retaining bolts from the
different shims to obtain correct end-play. curbside end of the assembly.
3. To remove the shaft from the assembly, tap the
Shims available from the Service Parts
opposite end of the shaft with a soft hammer.
Department
After the shaft has been removed, clean all the
0.020 in. (0.500 mm) Thermo King P/N 99-4231
parts in clean solvent.
4. Using a punch, remove the oil seal from the
curbside end of the assembly. With the seal
7. After correct end-play is obtained, add oil for removed, clean the housing in solvent.
the bearings.
5. Check the condition of the vent. If it is loose
8. Lock the assembly in a vise with the vent or damaged, it must be repaired or replaced.
facing up. Pour the oil (P/N 203-278) through
the top plug until it runs out of the side hole. 6. After all the parts are cleaned, inspect the
The assembly holds 2.5 oz (74 ml). Check the bearings and bearing races for wear or
condition of the O-ring used on the plugs and damage.
replace if necessary. Install the top and side 7. To replace the bearings, first drive bearing off
plugs. Clean up any spillage. shaft with a punch at notch in the base of the
9. Place the assembly on the workbench with the shaft.
vent up. Rotate the shaft by hand. The shaft
should be free enough to rotate without having Reassembly
to hold the housing. 1. Install the new bearings on the shaft with a
pipe. Place the pipe over the shaft and drive
CAUTION: When installing the fan shaft bearing down. Turn the shaft upside down,
assembly, make sure that the vent is and use the pipe to drive the other bearing
mounted facing up. down.
2. Install a new oil seal on the curbside end of
the assembly after replacing the bearing race
and splash guard.
139
3. Replace the shaft in the housing. Install a new 7. After the correct end-play is obtained, add
seal in the retainer cap. Use the original shims approximately 1.1 oz (33 ml) of oil
and replace the O-ring if needed. (P/N 203-278) for the bearings.
4. Install the retainer cap assembly over the 8. Lock the assembly in a vise with the vent
shaft, then install the bolts. facing up. Pour the oil through the top plug
until it runs out of the side hole. Check the
5. Torque the bolts in a criss-cross pattern in
condition of the O-ring used on the plugs and
equal steps to 80 in-lb (9.04 N•m).
replace if necessary. Install the top and side
6. Lock the assembly in a vise and set up a dial plugs. Clean up any spillage.
indicator to read end-play. To measure the
9. Place the assembly on the workbench with the
end-play, rotate the shaft while pushing in one
vent up. Rotate the shaft by hand. The shaft
direction, and set the dial indicator to ‘0’.
should be free enough to rotate without having
Now rotate the shaft and pull in the opposite
to hold the housing.
direction while reading the dial indicator.
End-play should be 0.001 to 0.005 in. (0.025 CAUTION: Reinstall the assembly into
to 0.127 mm). If end-play is incorrect, use the unit, making sure the vent is mounted
different shims to obtain correct end-play. facing up.
Shims available from the Service Parts
Department
AEA722
1. Oil Seal 6. Shaft

2. Cap and Shims 7. Housing
3. O-ring 8. Breather Vent
4. Roller Bearing 9. Oil Plug Screw (Use Oil P/N 203-278)
5. Splash Guard Tube
Figure 123: Idler Assembly
140
Mechanical Diagnosis
Condition Possible Cause Remedy

Engine will not crank Electrical problem Check and repair electrical system
Defective starter solenoid Replace solenoid
Defective starter Repair starter
Water in cylinders Check for hydrostatic lock. Remove
injectors and turn engine slowly
Starter motor turns but engine Starter clutch defective Replace
does not crank
Engine cranks but fails to start Fuel solenoid not energized Check 8D and 8DP circuits and fuel
solenoid relay. Check that YAN =
YES in Super Guarded Access.
Refer to appropriate Microprocessor
Diagnostic Manual.
Fuel solenoid defective or stuck Replace
Fuel injection pump defective Replace pump
Air heater defective Replace
No fuel or wrong fuel Fill with proper fuel
Fuel transfer pump defective Replace transfer pump
Air in fuel system Bleed air
Compression low Overhaul engine
Injection nozzles defective Replace nozzles
Incorrect timing Adjust timing
Air cleaner clogged Replace air filter
Exhaust plugged Clean exhaust
Defective HPCO Replace HPCO
Engine stops after starting Air in injection pump Bleed fuel system
Fuel filter obstructed Replace filter element
High head pressure Eliminate cause of high head
pressure
Vent of fuel tank obstructed Unclog vent
Clogged fuel tank or fuel lines Clean fuel tank and fuel lines
Engine does not develop full Air intake system clogged Clean air intake system
power Fuel tank vent clogged Unclog vent
Clogged fuel tank or fuel lines Clean fuel tank and fuel lines
Speed adjustment wrong Adjust speed
Insufficient fuel volume leaving filter Check for dirty filter or air in system
Air cleaner clogged Replace air filter
Delivery of fuel pump insufficient Repair pump
Injection pump timing off Adjusting timing
Injection nozzles defective Repair or replace nozzles
Compression low or unbalanced Overhaul engine
Worn injection pump plungers, Repair or replace pump
delivery valve defective, injection
rate too low, gum formations
141

Engine speed too high Misadjusted high speed solenoid Adjust high speed solenoid
Defective injection pump Repair injection pump
Engine fails to stop when unit is Fuel solenoid defective Replace
Off Injection pump defective Replace pump
Engine knocks heavily Air in system Bleed fuel system
Injection pump not timed Retime injection pump
Wrong fuel Change fuel
Compression too low Overhaul engine
Injection nozzles fouled or opening Clean, repair or replace injection
pressure too low nozzles
Delivery valve spring broken Replace spring or repair injection
pump
Valve out of adjustment Adjust valves
Fuel return line plugged Remove return line restriction
Rod or main bearing worn Replace rod or main bearings
Engine runs hot Dirty radiator Wash radiator
Coolant level is low Add coolant
Cooling system heavily scaled Cleaning cooling system
Cylinder head gasket leaks Replace cylinder head gasket. Use
correct gasket
Faulty thermostat Check or replace thermostat
Loose or worn water pump belt Replace belt
Oil pressure low Insufficient oil in pan Add oil
Faulty oil pressure switch Check oil pressure switch. Replace if
necessary
Oil control valve defective Check oil pressure control valve
Worn oil pump, camshaft, main or Repair engine
connecting rod bearings, loose oil
gallery plug
High oil consumption Oil leakage Check and eliminate possible
causes at rocker arm cover, oil lines,
oil filter, front timing cover or
crankshaft seals
Damaged valve seals Replace seals on valve stem
Worn valve stem Replace valves
Broken piston rings or cylinder bore Have engine repaired and rebored.
worn or scored Replace broken piston rings
Clogged air cleaner system Unclog air cleaner
142
Engine Emits Excessive Smoke

White Smoke Black Smoke Blue Smoke
Fuel is not burning Excessive Fuel to Air Ratio Oil Consumption
• Air or water in fuel • Type of fuel used • Poor compression
• Incorrect timing • Cold engine • Defective valve seals
• Poor compression • Excessive load
• Faulty injectors • Clogged air intake system
• Faulty nozzles
• Poor compression
• Restricted exhaust
• Faulty injection pump
143
144
Electric Standby Diagnosis

Unit switch Off—LCD Blank Battery discharged Charge or replace battery
Faulty battery cable connections Clean battery cables
Check for short circuit and replace
Fuse link blown
fuse link
Fuse F10 blown Check for short circuits and replace
fuse
Open circuit Check 2, 2P, and 2PA circuits
Unit switch On—LCD backlight Faulty Zone 1/Host On/Off switch Check Zone 1/Host On/Off switch
does not come on Fuse F20 or F22 blown Check for short circuit and replace
fuse
Open circuit Check 2AA, 8A, and 8 circuits
Unit switch On and LCD backlight Diesel/Electric switch on Diesel Place switch on Electric
On but motor will not start and run Unit in NULL Check setpoint and box temperature
Faulty Diesel/Electric switch Check switch
Faulty K7 relay Check K7 relay
Check for short circuit and replace
Fuse F6 or F2 blown
fuse
Faulty HPCO Check HPCO
Open or faulty overload relay Determine cause and rest or replace
overload relay
Faulty PSM Check PSM
Faulty motor contactor Check motor contactors
Open circuit Check 8E, 7K, 7K1, 7E, 7EA, 7EHA,
7EH, 7EB, 7EC, CH, L1, L2, and L3
circuits
Faulty drive motor Check drive motor
Faulty electric standby power source Check electric standby power source
Evaporator heaters do not heat Check for short circuit and replace
Fuse F1 or F14 blown
fuse
Faulty heater contactor Check heater contactor
Check 7EH, 26E, 26E2, 26E3, L1,
Open circuit
L2, L3, BRN, BLU and BLK circuits
Faulty heaters Check heaters
145
Electric Standby Diagnosis
146
Refrigeration Diagnosis
Rapid cycling between Cool and Heat
Unit cools in Heat and Defrost cycle
Unable to hold vacuum in low side

Unable to pull vacuum in low side
Unit heats in Refrigeration cycle
Unable to pump down system
Unit not heating or defrosting

Receiver sight glass empty
Unit operating in a vacuum
Suction line frosting back
Symptom
High suction pressure
Low suction pressure
Unit not refrigerating

No suction pressure
High head pressure
Low head pressure
Noisy compressor
No head pressure
Possible Causes
• • • • Overcharge of refrigerant
• • • • • • Shortage of refrigerant
• • • • • No refrigerant
• Air through condenser too hot (ambient)
• Air flow through condenser restricted
• • • Air through condenser too cold (ambient)
• • • Air in refrigerant system
• Condenser fan blades bent or broken
• Air short cycling around evaporator coil
• Air through evaporator restricted
• • • • Evaporator needs defrosting
• • Compressor discharge valves leaking
• • Compressor suction valves leaking
• Too much compressor oil in system
• Faulty oil pump in compressor
• Faulty compressor drive coupling
• Compressor bearing loose or burned out
• • • • • Broken valve plate in compressor
• • Expansion valve power element lost its charge
• • Expansion valve feeler bulb improperly mounted
• • • Expansion valve feeler bulb making poor contact
• • Expansion valve open too much
• • Expansion valve closed too much
• • Expansion valve needle eroded or leaking
• • • Expansion valve partially closed by ice, dirt or wax
• • • Liquid refrigerant entering compressor
• • Restricted line on the low side
• • • • Restricted line on the high side
• • • • Restricted drier
• Damper open
• • • Damper stuck closed
• Discharge service valve back seated
147
Refrigeration Diagnosis
Rapid cycling between Cool and Heat

Unit cools in Heat and Defrost cycle
Unable to hold vacuum in low side

Unable to pull vacuum in low side
Unit heats in Refrigeration cycle
Unable to pump down system
Unit not heating or defrosting

Receiver sight glass empty
Unit operating in a vacuum
Suction line frosting back
Symptom
High suction pressure
Low suction pressure
Unit not refrigerating

No suction pressure
High head pressure
Low head pressure
Noisy compressor
No head pressure
Possible Causes
• Suction service valve back seated

• • • • • • • Faulty CIS
• • • • • Faulty HGS
• • Loose or broken electrical connections
• • • • • Sensor out of calibration
• • • • Compound pressure gauge out of calibration
• Leaky receiver tank outlet valve
• • • • • Leaky check valve
• • • • Faulty check valve
• Leaky receiver tank pressure solenoid (RTPS)
• • Closed receiver tank pressure solenoid (RTPS)
• • • • Leaky hot gas solenoid (HGS)
• • Closed hot gas solenoid (HGS)
• • • Leaky liquid line solenoid (LLS)
• • • • • • Closed liquid line solenoid (LLS)
• Leaky liquid return check vale (LRCV)
• • Leaky suction line solenoid (SLS)
• • • Leaky suction line check valve (SLCV)
• • Leaky Zone 2 or 3 hot gas solenoid (HGS2 or 3)
• • • • Closed Zone 2 or 3 hot gas solenoid (HGS2 or 3)
• • Leaky Zone 2 or 3 liquid line solenoid (LLS2 or 3)
• • • Closed Zone 2 or 3 liquid line solenoid (LLS2 or 3)
• Leaky Zone 2 or 3 liquid return check valve
(LRCV2 or 3)
• • Leaky Zone 2 or 3 suction line solenoid (SLS2 or 3)
• • • Leaky Zone 2 or 3 suction line check valve
(SLCV2 or 3)
• • • • Leaky purge valve (PV)
148
Remote Evaporator Specifications
Refrigeration System
Evaporator Coil Type Direct Expansion
Refrigerant Type R-404A
Heat/Defrost Method Hot Gas
Electrical
Control System Voltage 12.5 Vdc
Fan Motors (each):
Power Rating 0.13 hp (100 Watts)
rpm 2390
Full Load Amps 7 amps (per motor)
Remote Liquid Line Solenoid:
Current Draw 1.3 amps
Resistance 9.6 ohms
Remote Hot Gas Solenoid:
Resistance 8.3 ohms
Remote Suction Line Solenoid:
Resistance 8.3 ohms
149
Remote Evaporator Specifications
150
Remote Evaporator Maintenance Inspection
Schedule
Every Every Annual/

Hours Hours* Hours
Electrical
• • • Inspect/replace DC fan motors.
Structural
• • • • Visually inspect unit for damaged, loose, or broken parts.
• • • Clean entire unit including evaporator coils and defrost drains.
• Check all unit mounting bolts, brackets, lines, hoses, etc.
151
Remote Evaporator Maintenance Inspection Schedule
152
Remote Evaporator Unit Description
1. Coil Temperature Sensor (Ungraded) 5. Return Air Sensor (Graded) 9. Terminal Board Bracket
2. Hot Gas Solenoid 6. Variable Blower (12 V) 10. Terminal Board
3. Liquid Solenoid 7. Blower Housing 11. Terminal Board Markstrip
4. Suction Line Solenoid 8. Blower Cover 12. Resistance Wire
Figure 124: Spectrum S-3 Evaporator Components
153
AJA984
Figure 125: Spectrum S-3 Evaporator - Front View
AJA985
Figure 126: Spectrum S-3 Evaporator - Back View
154
The Spectrum SB multi-temperature refrigeration Defrost

system provides heavy duty temperature control
for multiple compartment trailers. The system The Defrost mode can be initiated any time the
provides direct expansion cooling in all trailer evaporator coil temperature is below 45 F (7 C).
compartments. Non-contaminating refrigerant Defrost is initiated automatically by the controller
tap-ins in the host unit evaporator provide or manually by selecting defrost from the Defrost
convenient refrigerant piping connections for the Prompt Screen for the desired zone.
remote evaporator(s). The evaporator fan stops during defrost. The
The host unit mounts on the front of the trailer Defrost mode will continue until the evaporator
with the evaporator protruding into the trailer. The coil temperature rises to 58 F (14 C), causing the
remote evaporator(s) is a ceiling mounted controller to terminate defrost. After Defrost, the
Spectrum unit. evaporator may shift back to Cool, Null or Heat.
Heat and defrost is provided in all compartments

by circulating hot refrigerant gas through the
Operating Modes
evaporators. Remote evaporator operating modes are:
Controls for the remote evaporator(s) are located • Cool
on the host unit (and in the optional remote • Null
control box if so equipped).
• Heat
Unit Operation • Defrost
The remote evaporator cycles between cool, null NOTE: The controller locks out heat at setpoints
and heat to maintain the trailer’s compartment(s) below 15 F (-9.5 C).
at the setpoint. The operating modes include Cool,
Null, Heat, and Defrost. Unit Features
Power to run the direct current fan motors is • Direct Expansion Evaporator Coil
supplied by the alternator in the host unit.
• Smart Reefer Multi-Temp µP-IV
When cooling is required, the Smart Reefer Microprocessor
Multi-Temp µP-IV microprocessor energizes the
remote liquid line solenoid valve. Refrigerant • 12 Vdc Fan Motor
flows through the evaporator coil to provide • Aluminum Housing
cooling.
• Liquid Line Solenoid
When the compartment temperature is near
setpoint, the Smart Reefer Multi-Temp µP-IV • Hot Gas Solenoid
microprocessor de-energizes the remote liquid • Suction Line Solenoid
line solenoid valve and switches the remote
evaporator to null. • Liquid Return Check Valve
The Smart Reefer Multi-Temp µP-IV
microprocessor energizes the remote hot gas
solenoid when the remote compartment requires
heat or defrost.
155
Unit Protection Devices

• Circuit Breakers in Host Unit (located inside
the control box)
• Fuses in Host Unit (located on the relay
board)
Serial Number Location

Unit: Nameplate on the right end of the unit frame.
AJA985
1. Nameplate on Right End of Unit Frame

Figure 127: Serial Number Location
156
Remote Evaporator Electrical Maintenance
Smart Reefer Multi-Temp µP-IV

Microprocessor Controlled
Components
Refer to the appropriate Microprocessor
Diagnosis Manual for information about
maintenance of the microprocessor controlled
components.
Unit Wiring
Inspect the unit wiring and wire harnesses during
scheduled maintenance inspections for loose,
chaffed or broken wires to protect against unit
malfunction due to opens or shorts.
157
Remote Evaporator Electrical Maintenance
158
Remote Evaporator Refrigeration Service
Operations
NOTE: It is generally good practice to replace Evaporator Coil
the filter drier whenever the high side is opened
or when the low side is opened for an extended Removal
period of time.
Expansion Valve Assembly
2. Disconnect the distributor from the expansion
Removal valve.
1. Pump down the low side and equalize the 3. Remove the insulating tape and feeler bulb
pressure to slightly positive. Remove the from the suction line. Note the position of the
evaporator access panels. feeler bulb on the suction line. Disconnect the
equalizer line from the suction line.
2. Disconnect the liquid inlet line and distributor
from the expansion valve. 4. Heat and unsolder the suction line connection
to the evaporator coil.
3. Remove the feeler bulb from the clamp. Note
the position of the feeler bulb on the suction 5. Remove the mounting bolts and slide the coil
line. from the housing.
4. Disconnect the equalizer line. Installation
5. Remove the expansion valve assembly from 1. Place the evaporator coil in the evaporator
the unit. housing and install the mounting bolts.
Installation 2. Clean and solder the suction line connections
to the evaporator coil.
1. Place the expansion valve in the unit.
3. Connect the distributor to the expansion valve.
2. Connect the equalizer line to the expansion
valve. 4. Clean the suction line to a bright polished
condition. Install the feeler bulb clamps and
3. Connect the liquid inlet line and distributor to the feeler bulb on the suction line. Locate the
the expansion valve. bulb on the side of the suction line in its
4. Clean the suction line to a bright polished former position. The feeler bulb must make
condition. Install the feeler bulb clamps and good contact with the suction line or the
feeler bulb on the side of the suction line in its operation will be faulty. Wrap it with
former position. The feeler bulb must make insulating tape.
good contact with the suction line or the 5. Connect the equalizer line to the suction line.
operation will be faulty. Wrap it with
insulating tape. 6. Pressurize the low side and test for leaks. If no
leaks are found, evacuate the low side.
leaks are found, evacuate the low side. 7. Install the access panels.
6. Install the access panels. 8. Open the refrigeration valves and place the
7. Open the refrigeration valves and place the and compressor oil. Add as required.
unit in operation.
8. Test the unit to see that the expansion valve is
properly installed.
159
Remote Evaporator Refrigeration Service Operations
Solenoid Valves Liquid Return Check Valve

NOTE: Valves that have nylon seats must be Repair
Removal
Removal 1. Pump down the low side and equalize pressure
1. Pump down the low side and equalize the to slightly positive.
pressure to slightly positive. For the hot gas 2. Remove the access panels.
valve, recover the refrigerant charge.
3. Remove the cap nut from the check valve and
2. Remove the access panels. remove the spring and seat.
3. Remove the coil and disassemble the valve.
4. Unsolder the refrigeration lines from the 1
valve, and remove the valve from the unit.
CAUTION: Use a heat sink to prevent 2
damaging the valve.
3
Installation
1. Clean the tubes for soldering. 4
2. Remove the coil, disassemble the valve, and 5

place the valve in position.
the valve cools, assemble the vale and install
AGA173
the coil.
CAUTION: Use a heat sink to prevent 1. Cap
damaging the valve. 2. Gasket
3. Spring
4. Pressurize the low side and test for leaks. If no 4. Seat
leaks are found, evacuate the low side. For the
5. Body
hot gas valve, pressurize the refrigeration
system and test for leaks If no leaks are found, Figure 128: Check Valve with Cap Nut
evacuate the system.
Installation
5. Install the access panels.
1. Inspect the inside of the check valve body for
6. Open the refrigeration valves and run the unit. damage or foreign particles that might adhere
Check the refrigerant charge and compressor to the seat and damage the new seat. If the
oil. Add as required. For the hot gas valve, body is damaged, replace the check valve.
recharge the unit with proper refrigerant.
2. Install the new seat and spring. Place a new
gasket on the cap and tighten the cap nut.
4. If no leaks are found, evacuate the low side.
oil.
160
Liquid Return Valve Installation

Replacement 1. Clean the tubes for soldering.
Removal 2. Position the tubes in the proper ports on the

heat exchanger.
pressure to slightly positive. 3. Reinstall the mounting hardware used to
mount heat exchanger to the panel.
2. Remove the access panels.
4. Solder the refrigeration lines from the heat
3. Unsolder the lines and remove the check exchanger ports to the tubes.
valve.
NOTE: Disassemble the valve before
damage to nearby valves.
unsoldering.
Installation leaks.
1. Clean the tubes for soldering. 6. If no leaks are found, evacuate the low side.
2. Place the disassembled check valve in 7. Install the access panels.
position. The arrow on the valve body
indicates the direction of refrigerant flow 8. Open the refrigeration valves and run the unit.
through the valve. Check the refrigerant charge and compressor
oil. Add as required.
the valve cools, reassemble the valve.
5. If no leaks are found, evacuate the low side.
oil.
Heat Exchanger
Removal
2. Remove the access panels.
3. Remove the mounting hardware used to
mount heat exchanger to the panel.
4. Unsolder the refrigeration lines from the heat
exchanger ports and remove it from the unit.
damage to nearby valves.
161
162
Remote Evaporator Structural Maintenance
Unit Inspection
Inspect the unit during the unit pretrip inspection
and scheduled maintenance inspections for loose
or broken wires or hardware, compressor oil
leaks, or other physical damage which might
affect unit performance and require repair or
replacement of parts.
Defrost Drains
Clean the defrost drains during scheduled
maintenance inspections to make sure the lines
remain open.
Evaporator Coil
Clean the evaporator coil during scheduled
maintenance inspections by blowing compressed
air from the top side of the coil down toward the
bottom (the direction opposite the normal air
flow). Inspect the coil and fins for damage, and
repair if necessary.
CAUTION: Air pressure should not be
high enough to damage the coil fins.
163
Remote Evaporator Structural Maintenance
164
Remote Evaporator System Diagnosis

Load temperature too high Refrigerant shortage Repair leak and recharge
Setpoint too high Adjust setpoint
Expansion valve plugged Clean or replace
Partial obstruction in low side of Locate obstruction and repair
refrigeration system
Iced or dirty evaporator coil Defrost or clean evaporator coil
Expansion valve open too much Replace or adjust valve
Poor fitting trailer door Repair or replace doors
Liquid line solenoid partially closed Repair or replace
or defective
Evaporator fan not operating Check and correct evaporator fan
Evaporator fan motor does not Fuse F12 or F15 blown Check for short circuit in unit wiring
run and replace fuse
Open in FM circuit Locate open and repair
Defective fan relay Replace fan relay
Defective fan motor Replace fan motor
165
Remote Evaporator System Diagnosis
166
Index
A compressor oil filter, replacement 133
AC components 60 compressor oil pressure, checking 133
accumulator, replacement 124 compressor oil sight glass 47
after start inspection 51 computer port 47
air cleaner 94 condenser coil, replacement 120
air cleaner, EMI 3000 94 condenser inlet check valve
air heater 59 repair 131
air restriction indicator 47, 95 replacement 132
alternator condenser inlet solenoid valve, replacement 131
Australian Bosch 53 control panel 45
field current test, Australian Bosch alternator 55 cooling system, engine 68
Prestolite 56 bleeding air from 70
antifreeze crankcase breather, Tier 1 engine 94
changing 70
checking 70 D
maintenance procedure 69 DAS (Data Acquisition System) 29
auto phase system 60 defrost 30
remote evaporator 155
B defrost damper, adjustment 136
battery 58 defrost drains 135
battery cables 58 defrost drains, remote evaporator 163
belt adjustments, model 30 97 diagnosis
alternator belt 97 electric standby 145
upper and lower fan belts 97 mechanical 141
belt adjustments, model 50 99 refrigeration 147
alternator belt 99 remote evaporator system 165
compressor belts 99 diagrams
fan belt 99 fuel line routing 171
water pump belt 99 refrigeration system 31
belt replacement, model 30 wiring 171
lower fan belt 98 discharge pressure sensor, replacement 125
upper fan belt 98 discharge vibrasorber, replacement 121
belt replacement, model 50 display, microprocessor 46
compressor 100
fan 101 E
belts 96 ELC (Extended Life Coolant) 68
electrical contactors 60
C EMI 3000 66
charging refrigeration system 114 engine change 65
charging system diagnostic procedures engine speed adjustments 76
105 amp Prestolite alternator 56 high speed 76
120 amp Australian Bosch alternator 53 low speed 76
check valve evacuating and charging multi-temp systems 112
repair 130 evacuating refrigeration system 112
replacement 131 evaporator coil, replacement 123
clutch 101 evaporator heaters 60
dowel pin replacement 105 expansion valve, replacement 122
drive bushing replacement 103
cold start device 90 F
compressor fan alignment
priming new compressor installations 134 condenser blower 137
replacement 117 evaporator blower 137
X430L 28 fan shaft assembly 138
compressor coupling overhaul 138
installation 119 filter drier, replacement 122
removal 118 first aid 18
compressor oil electrical shock 18
checking 110 engine coolant 18
167
Index
refrigerant 18 O
refrigerant oil 18 oil change, engine 66
fuel filter/water separator, replacement 75 oil filter change, engine 66
fuel line routing 71 opening front doors 37
fuel return line replacement 74 operating instructions 45
fuel solenoid replacement 88 operating modes, remote evaporator 155
fuel solenoid system 85
troubleshooting 86 P
fuel solenoid timer 85 PCV, positive crankcase ventilation 93
fuel system 71 positive crankcase ventilation, Tier 2 engine 93
bleeding 74 post load procedure 52
maintenance 71 post trip checks 52
fuel tank, draining water from 75 priming new compressor installations 134
fuse link 59 printer port 47
fuses 58 purge valve, replacement 132
G R
general description 27 receiver tank pressure solenoid valve, replacement
132
H receiver tank sight glass 47
high pressure cutout switch (HPCO) receiver tank, replacement 122
replacement 124 refrigerant charge 107
testing 110 adjusting refrigerant level 108
high pressure relief valve, replacement 125 testing for an overcharge 107
high pressure switch (HPSW) testing with a loaded trailer 107
replacement 124 testing with an empty trailer 107
testing 111 refrigerant leaks 108
host unit 27 remote control box 29
hot gas solenoid valve, replacement 129 remote evaporator coil
cleaning 163
I replacement 159
idler assembly 139 remote evaporators 27
overhaul 139 remote expansion valve, replacement 159
injection pump remote heat exchanger, replacement 161
reinstallation 83 remote liquid return check valve
removal 82 repair 160
timing, Tier 1 engine 77 replacement 161
timing, Tier 2 engine 79 remote solenoid valves, replacement 160
in-line check valves, replacement 121 remote status light 47
inspection, unit 135 restarting unit 50
installation, unit 135 routing
wire harness 60
K routing, fuel line routing 71
keypad 46
S
L safety precautions 15
liquid line solenoid valve, replacement 128 battery removal 16
loading procedure 51 electrical hazards 17
low oil pressure 66 general practices 15
low side pump down 117 microprocessor service precautions 17
lubrication system, engine 66 refrigerant hazards 16
refrigerant oil hazards 16
M welding precautions 18
manual pretrip inspection 48 selection of operating modes 49
microprocessor, Multi-Temp µP-IV 29, 59 serial number locations 38
moisture indicating sight glass 108 remote evaporator 156
mounting bolts, unit and engine 135 single temperature loading procedures 51
specifications
belt tension 20
168
Index
electric standby 23
electrical components 22
electrical control system 21
engine 19
microprocessor 22
refrigeration system 21
remote evaporator electrical 149
remote evaporator refrigeration system 149
starters 95
suction line solenoid valve, replacement 129
suction vibrasorber, replacement 124
system operation 30
T
thermostat, engine 71
throttling valve 125
installation 128
reassembly 127
removal 125
trochoid feed pump 89
U
unit description 27
unit features, remote evaporator 155
unit inspection, remote evaporator 163
unit operation 48
unit protection devices 47
unit wiring 60
V
valve clearance adjustment, engine 91
W
wire harness routing 60
Z
Zone 1/Host On/Off Switch 45
Zone 2 On/Off Switch 46
Zone 3 On/Off Switch 46
169
Index
170
Diagrams Index
Drawing No. Drawing Title Page
5D55924 Model 30 with Tier 1 Engine Schematic Diagram 173-174
5D55923 Model 30 with Tier 1 Engine Wiring Diagram 175-178
1E29283 Model 30 with Tier 2 Engine Schematic Diagram 179-180
1E29284 Model 30 with Tier 2 Engine Wiring Diagram 181-184
5D56152 Model 50 Schematic Diagram 185-186
5D56153 Model 50 Wiring Diagram 187-191
Model 30 with Tier 1 Engine Fuel Line Routing Diagram 192-194
171
Model 30 with Tier 1 Engine Schematic Diagram - Page 1 of 2
173
174
Model 30 with Tier 1 Engine Wiring Diagram - Page 1 of 4
175
176
177
178
179
180
181
182
183
184
Model 50 Schematic Diagram - Page 1 of 2
185
Model 50 Schematic Diagram - Page 2 of 2
186
Model 50 Wiring Diagram - Page 1 of 5
187
188
189
190
191
Model 30 with Tier 1 Engine Fuel Line Routing Diagram - Page 1 of 3
1. Screw 1/4-20 X 1.0 in. 55-101

2. Flatwasher 1/4 in. (2) 55-411
3. Nylock Nut 1/4 in. 55-4118
4. Clamp 5/8 in. Diameter 55-4203
5. 3/8 in. Inlet Line from Fuel Tank
6. 1/4 in. Return Line to Fuel Tank
192
1. Fuel Filter 11-9342

2. Return to Fuel Tank
3. Return from Injection Pump
4. Inlet from Fuel Transfer Pump
5. Outlet to Injection Pump
6. Band Wrap 4.0 in. Diameter (2) 56-2331
8. Band Wrap 1.75 in. Diameter (5) 56-2330
9. Clamp 1.0 in. Diameter 55-3644
10. Screw M8 X 85 55-7394
11. Flatwasher M8 55-4613
12. Lockwasher M8 55-4614
193
1. Return from Injection Pump to Fuel Filter

2. Outlet from Fuel Filter to Injection Pump
3. Injection Pump
5. Inlet from Fuel Tank to Fuel Transfer Pump
6. Outlet from Fuel Transfer Pump to Fuel Filter
7. Return from Fuel Filter to Fuel Tank
194
1. Screw 1/4-20 X 0.75 in. 55-145

2. Flatwasher 1/4 in. (2) 55-411
3. Nylock Nut 1/4 in. 55-4118
5. Band Wrap 1.75 Diameter (4) 56-2330
195
1. Fuel Filter 11-9342 9. Lockwasher 1/4 in. (2) 55-366

2. Return to Fuel Tank 10. Grommet 33-316
3. Return from Injection Pump 11. Clamp 1.0 in. Diameter 55-3644
4. Inlet from Fuel Transfer Pump 12. Flatwasher M8 55-7069
5. Outlet to Injection Pump 13. Lockwasher M8 55-7727
6. Clamp 5/8 in. Diameter (2) 55-3026 14. Screw M8 X 110 55-5424
7. Screw 1/4-20 X 0.75 in. (2) 55-145 15. Clamp 5/8 in. Diameter 55-4203
8. Flatwasher 1/4 in. (2) 55-411 16. Band Wrap 1.75 Diameter (4) 56-2330
196

3. Injection Pump
197

2. Screw 1/4-20 X 1.0 in. 55-101
3. Flatwasher 1/4 in. (2) 55-411
4. Nylock Nut 1/4 in. 55-4118
198
1. Inlet to Fuel Transfer Pump

7. Clamp 1-1/4 in. Diameter 55-5274
9. Band Wrap 4.00 Diameter 56-2331
10. Clamp 1.0 in. Diameter 55-3644
11. Screw M8 X 85 55-7394
199

3. Injection Pump
200

2. Screw 1/4-20 X 0.75 in. 55-145
3. Flatwasher 1/4 in. (2) 55-411
4. Nylock Nut 1/4 in. 55-4118
201
1. Inlet to Fuel Transfer Pump

7. Clamp 1-1/4 in. Diameter 55-5274
12. Screw M8 X 110 55-5424
202

3. Injection Pump
203

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Spectrum SB

TK 51296-2-MM (Rev. 4, 04/05)

Copyright© 2001 Thermo King Corp., Minneapolis, MN, U.S.A. Printed in

For further information, refer to:

No warranties, express or implied, including warranties of fitness for a particular

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

In addition, service personnel must be aware of Federal regulations

Draining Water from Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

Refrigeration Service Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117

Mechanical Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141

Figure 51:Injection Angle Sticker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

Figure 101:Compressor with 4-Quart Sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109

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

NOTE: In the USA, EPA Section 608

Battery Removal CAUTION: When transferring

Electrical Hazards WARNING: Do not wear jewelry, watches

Welding Precautions INHALATION: Move victim to fresh air and use

Electrical Control System

Smart Reefer Multi-Temp µP-IV Microprocessor Temperature

Electric Standby (Model 50 Units Only)

Electric Heater Strips

Standby Power Requirements

Host Unit (Continued)

In the second quarter of 2005 the engines in these

Smart Reefer Multi-Temp µP-IV Features of the CYCLE-SENTRY system are:

• Null • The condenser inlet solenoid and the suction

• During engine operation when all zones are in

Zone 1 Cool, Zone 2 Cool, and Zone 2 Evaporator

Host Unit and Zone 1 Evaporator

Figure 5: Zone 1 Cool, Zone 2 Cool, and Zone 3 Cool

Zone 1 Cool, Zone 2 Cool, and Zone 2 Evaporator

Host Unit and Zone 1 Evaporator

Figure 6: Zone 1 Cool, Zone 2 Cool, and Zone 3 Heat

Opening the Front Doors

Opening the Secondary Door Latch

Serial Number Locations

Engine: Stamped on an nameplate on the valve

1. Serial Number Location

1. Serial Number Location

Figure 12: Laminated Serial Number Plate

1. Serial Number Location

Figure 13: Front View

1. Discharge Service Valve 9. Filter-Drier

1. Microprocessor Control Panel

1. DAS Module (Optional)

Control Panel Zone 1/Host On/Off Switch

1. Display 5. Zone 3 On/Off Switch (Three Temperature Units Only)

Zone 2 On/Off Switch Icons

Diesel/Electric Switch (Model 50 Keypad

THERMO KING LOGO Key: Used to initiate a Printer Port

High Pressure Cutout: The high pressure cutout is Unit Operation

After Start Inspection Loading Procedure

If all compartments are to be maintained at the

Figure 20: Same Temperatures in each

Post Load Procedure

Post Trip Checks

Australian Bosch Alternator - CAUTION: The F7 fuse must be removed

Field Current Test a. No field current or a low field current

Prestolite Alternator - Model 50 NOTE: The F7 fuse must be installed in the

1. EXC Terminal 5. NEG—B- Terminal