SPECTRUM DE SR-2

TK 53496-2-MM (Rev. 0, 01/07)

Copyright 2007 Thermo King Corp., Minneapolis, MN, U.S.A. Printed in

U.S.A.
The maintenance information in this manual covers unit models:
SPECTRUM DE SR-2 30-2 (002231) System SPECTRUM DE SR-2 30-2 (900227)
SPECTRUM DE SR-2 30-3 (002232) System SPECTRUM DE SR-2 30-3 (900228)

For further information, refer to:

SPECTRUM DE SR-2 Operators Manual TK 53519
SPECTRUM DE 30 SR-2 Parts Manual TK 53456
SR-2 Multi-Temp Microprocessor Controller Diagnostic Manual TK 53080
TK482 and TK486 Engine Overhaul Manual TK 50136
X214, X418, X426, and X430 Compressor Overhaul Manual TK 6875
Diagnosing TK Refrigeration System TK 5984
Tool Catalog TK 5955
Evacuation Station Operation and Field Application TK 40612
ElectroStatic Discharge (ESD) Training Guide TK 40282
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 Kings terms and conditions
including, but not limited to, the Thermo King Limited Express Warranty. Such terms and
conditions are available upon request. Thermo Kings warranty will not apply to any
equipment which has been so repaired or altered outside the manufacturers plants as,
in the manufacturers 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.

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 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 properlyDO 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.

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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
Low Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Microprocessor Service Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Welding Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
First Aid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
First Aid, Refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
First Aid, Refrigerant Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
First Aid, Engine Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Belt Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Refrigeration System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Electrical Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Electrical Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Maintenance Inspection Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Unit Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Unit Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Design Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Host Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
SPECTRUM Remote Evaporators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Diesel Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Thermo King X430L Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
SMART REEFER 2 Multi-Temp (SR-2 MT) Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
CYCLE-SENTRY Start-Stop Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Data Logging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
OptiSet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Remote Control Panel (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Sequence of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Defrost . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
System Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Refrigeration System Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Zone 1 Cool, Zone 2 Cool, and Zone 3 Cool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Zone 1 Cool, Zone 2 Cool, and Zone 3 Heat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Opening the Front Doors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Opening the Secondary Door Latch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Engine Compartment Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Unit Protection Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Serial Number Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
SMART REEFER 2 Multi-Temp (SR-2 MT) Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Microprocessor On/Off Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
HMI Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Unit Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Manual Pretrip Inspection (Before Starting Unit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Turning Unit On . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Turning Unit Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Standard Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Operating The Unit In Single Zone Control Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Standard Display Variations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Alarm Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

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Table of Contents

Temperature Watch Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

Starting the Diesel Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
After Start Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Changing the Setpoint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Turning a Zone On and Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Selection of Operating Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Selecting CYCLE-SENTRY or Continuous Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Initiating a Manual Defrost Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Terminating a Defrost Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Menu Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Navigating the Main Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Language Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Alarms Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Gauges Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Sensors Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Datalogger Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Hourmeters Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Mode Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Pretrip Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Adjust Brightness Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Time Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Loading Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Single Temperature Loading Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Post Load Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Post Trip Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Electrical Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Alternator Charging System Diagnostic Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Alternator Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Interface Board Fuse F4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Test Equipment for Checking Voltage and Current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Alternator Load Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
General Diagnostic and Warranty Evaluation Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Field Current Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Battery Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Unit Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Wire Harness Routing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Interface Board LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Smart FETs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Expansion Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Expansion Module LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
SMART REEFER 2 Multi-Temp (SR-2 MT) Microprocessor Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Fuse Link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Air Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Engine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
EMI 3000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Engine Lubrication System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Engine Oil Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Oil Filter Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Low Oil Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Engine Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
ELC (Extended Life Coolant) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Antifreeze Maintenance Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Bleeding Air from the Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Engine Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Coolant Level Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96

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 Table of Contents

Engine Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Fuel Line Routing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Fuel Return Line Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Bleeding the Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Draining Water from Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Fuel Filter/Water Separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Fuel Filter/Water Separator Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Engine Speed Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Injection Pump Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Injection Pump Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Injection Pump Reinstallation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Fuel Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Trochoid Feed Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Cold Start Device Tier 2 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Engine Valve Clearance Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Crankcase Breather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
EMI 3000 Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Air Restriction Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
Belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
Belt Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Fan Belt Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
Refrigeration Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Refrigerant Charge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Testing the Refrigerant Charge with an Empty Trailer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Testing the Refrigerant Charge with a Loaded Trailer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Testing for an Overcharge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Adjusting Refrigerant Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Moisture Indicating Sight Glass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Refrigerant Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Checking Compressor Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
High Pressure Cutout Switch (HPCO) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
High Pressure Switch (HPCS) Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
Pressure Transducers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
Evacuating and Charging Smart Reefer Multi-Temp Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
Set-up Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
Evacuating the System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
Charging the System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
Refrigeration Service Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
Low Side Pump Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
Compressor Coupling Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
Compressor Coupling Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
Condenser Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
Discharge Vibrasorber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
In-Line Check Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
Receiver Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
Filter Drier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
Expansion Valve Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
Heat Exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
Evaporator Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
Accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
Suction Vibrasorber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
High Pressure Cutout Switch and High Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
Discharge Pressure Transducer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
Suction Pressure Transducer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
High Pressure Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137

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Table of Contents

Throttling Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
Liquid Line Solenoid Valves (LLS and LLS2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
Hot Gas Solenoid Valves (HGS and HGS2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
Suction Line Solenoid Valves (SLS and SLS2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
Check Valve Repair (SLCV, SLCV2, SLCV3, LRCV, and PVC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
Check Valve Replacement (SLCV, SLCV2, SLCV3, LRCV, and PVC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
Condenser Inlet Solenoid Valve (CIS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
Condenser Inlet Check Valve (CICV) Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
Condenser Inlet Check Valve (CICV) Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
Receiver Tank Pressure Solenoid Valve (RTPS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
Purge Valve (PV) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
Compressor Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
Checking Compressor Oil Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
Priming New Compressor Installations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
Structural Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
Unit and Engine Mounting Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
Unit Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
Condenser, Evaporator, and Radiator Coils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
Defrost Drains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
Unit Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
DE Defrost Dampers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
Condenser and Evaporator Fan Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
Condenser Fan Blower Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
Evaporator Fan Blower Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
DE Evaporator Fan Blower Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
Fan Shaft Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
Fan Shaft Assembly Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
Idler Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
Idler Assembly Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
Mechanical Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
Refrigeration Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
Remote Evaporator Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
Refrigeration System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
Remote Evaporator Maintenance Inspection Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
Remote Evaporator Unit Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
Unit Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
Defrost . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
Operating Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
Unit Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
Unit Protection Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
Serial Number Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
Remote Evaporator Electrical Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
SR-2 Multi-Temp Microprocessor Controlled Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
Unit Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171

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 Table of Contents

Remote Evaporator Refrigeration Service Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173

Expansion Valve Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
Evaporator Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
Solenoid Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
Liquid Return Check Valve Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
Liquid Return Valve Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
Heat Exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
Remote Evaporator Structural Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
Unit Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
Defrost Drains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
Evaporator Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
Remote Evaporator System Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
Diagrams Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185

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Table of Contents

10
List of Figures
Figure 1:Front View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Figure 2:S-3 SPECTRUM Remote Evaporator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Figure 3:HMI Controller and Data Ports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Figure 4:Zone 1 Cool, Zone 2 Cool, and Zone 3 Cool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Figure 5:Zone 1 Heat, Zone 2 Cool, and Zone 3 Cool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Figure 6:Door Latch Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Figure 7:Opening Secondary Door Latch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Figure 8:Engine Compartment Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Figure 9:Compressor Serial Number Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Figure 10:Engine Serial Number Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Figure 11:Unit Serial Number Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Figure 12:Laminated Serial Number Plate (Located Where Shown Above) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Figure 13:Front View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Figure 14:Back View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Figure 15:Typical Components Inside Control Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Figure 16:Control Box With Service Door Open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Figure 17:HMI Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Figure 18:Display and Keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Figure 19:Press On Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Figure 20:Turning Unit On Screen Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Figure 21:Press Off Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Figure 22:Turning Unit Off Screen Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Figure 23:Two Zone Standard Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Figure 24:Three Zone Standard Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Figure 25:Single Zone Standard Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Figure 26: Standard Display Variations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Figure 27:Alarm Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Figure 28:Zone Alarm Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Figure 29:Two Zone Temperature Watch Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Figure 30:Three Zone Temperature Watch Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Figure 31:Starting Diesel Engine Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Figure 32:Press Zone Soft Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Figure 33:Changing the Setpoint Screen Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Figure 34:Press Zone Soft Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Figure 35:Zone 2 Setpoint Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Figure 36:Turning Zone On/Off Screen Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Figure 37:Changing Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Figure 38:Screen Sequence for Changing from Continuous Mode to CYCLE-SENTRY Mode . . . . . . . . . . . . . 53
Figure 39:Screen Sequence for Changing from CYCLE-SENTRY Mode to Continuous Mode . . . . . . . . . . . . . 53
Figure 40:Initiating a Manual Defrost Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Figure 41:Defrost Zone Select Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Figure 42:Initiating Manual Defrost Screen Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Figure 43:Menu Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Figure 44:Accessing Main Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Figure 45:Using Main Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Figure 46:Main Menu Choices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Figure 47:Standard Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Figure 48:Standard Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Figure 49:Change Language Screen Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Figure 50:Standard Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Figure 51:Viewing and Clearing Alarms Screen Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Figure 52:Standard Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Figure 53:Viewing Gauges Screen Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Figure 54:Standard Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Figure 55:Sensors Menu Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Figure 56:Soft Keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Figure 57:Standard Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Figure 58:Start of Trip Screen Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

11
List of Figures

Figure 59:Printer Port Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

Figure 60:Standard Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Figure 61:Print Report Screen Sequence. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Figure 62:Standard Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Figure 63:Hourmeters Menu Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Figure 64:Soft Keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Figure 65:Standard Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Figure 66:Selecting Mode Screen Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Figure 67:Standard Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Figure 68:Mode Menu Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Figure 69:Single Zone Control On/Off Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Figure 70:Standard Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Figure 71:Mode Menu Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Figure 72:Keypad Lockout Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Figure 73:Standard Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Figure 74:Selecting Sleep Mode Screen Sequence. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Figure 75:Standard Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Figure 76:No Pretrip Alarm Active Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Figure 77:Pretrip Test Screen Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Figure 78:Standard Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Figure 79:Adjusting Display Brightness Screen Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Figure 80:Time and Date Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Figure 81:Two Compartments, Same Setpoint Temperature, Bulkheads In Place . . . . . . . . . . . . . . . . . . . . . . . 81
Figure 82:Two Compartments, Same Setpoint Temperature, Bulkhead(s) Removed . . . . . . . . . . . . . . . . . . . . 81
Figure 83:Thermo King Alternator Terminal and Component Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Figure 84:Wire Harness Routing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Figure 85:Interface Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Figure 86:Expansion Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Figure 87:Expansion Module LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Figure 88:Air Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Figure 89:ELC Nameplate Located On Expansion Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Figure 90:Engine Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Figure 91:Plastic Expansion Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Figure 92:Removing Coolant Level Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Figure 93:Coolant Level Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Figure 94:Expansion Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Figure 95:Expansion Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Figure 96:Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Figure 97:Fuel Return Line Replacement Decal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Figure 98:Fuel Return Line Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Figure 99:Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Figure 100:Injection Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Figure 101:Filling Fuel Filter/Water Separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Figure 102:Engine Speed Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Figure 103:Index Mark Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Figure 104:Index Mark Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Figure 105:Marking Gear Case . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Figure 106:Place Injection Angle Sticker on Gear Case . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Figure 107:Injection Angle Sticker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Figure 108:Removing Injection Pump Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Figure 109:Injection Angle Mark Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Figure 110:Injection Angle Mark . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Figure 111:Injection Pump Serial Number Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Figure 112:Examples of Injection Pump Index Mark Alignment with Injection Angle Sticker . . . . . . . . . . . . . . 105
Figure 113:Timing Mark Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Figure 114:Align Flat Sides of Crankshaft Gear with Flat Sides of Inner Rotor in Timing Gear Cover . . . . . . . 105
Figure 115:Index Mark Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Figure 116:Index Mark Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Figure 117:Injection Pump Gear Tool. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Figure 118:Fuel Solenoid Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108

12
 List of Figures

Figure 119:Fuel Solenoid Connector Pin Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108

Figure 120:Fuel Solenoid Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Figure 121:Trochoid Feed Pump Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Figure 122:Trochoid Feed Pump Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Figure 123:Trochoid Feed Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Figure 124:Cold Start Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Figure 125:Remove Engine Coolant Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Figure 126:Remove Cold Start Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Figure 127:Clean Piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Figure 128:Top Dead Center One and Four . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Figure 129:Adjusting the Valve Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Figure 130:Crankcase Breather Tier 2 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Figure 131:EMI 3000 Air Cleaner Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Figure 132:EMI 3000 Air Filter Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Figure 133:EMI 3000 Air Cleaner System Model 30 Shown Model 50 Similar . . . . . . . . . . . . . . . . . . . . . . . . . 115
Figure 134:Air Restriction Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
Figure 135:Model 30 Belt Arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Figure 136:Condenser Blower Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Figure 137:Moisture Indicating Sight Glass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Figure 138:Compressor Sight Glass Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
Figure 139:High Pressure Cutout Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
Figure 140:Multi-Temp Evacuation and Charging (Two Zone Unit Shown Other Units Similar) . . . . . . . . . . . 126
Figure 141:Compressor Coupling Removal Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
Figure 142:Keyway Tool P/N 204-972 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
Figure 143:Compressor Coupling Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
Figure 144:Cross Section of In-line Check Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
Figure 145:Location of Expansion Valve Bulb . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
Figure 146:Throttling Valve Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
Figure 147:Inspect the Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
Figure 148:Inspect for Wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
Figure 149:Inspect for Damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
Figure 150:Throttling Valve Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
Figure 151:Check Valve with Cap Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
Figure 152:Compressor Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
Figure 153:Unit and Engine Mounting Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
Figure 154:Rear View of DE Damper Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
Figure 155:Compressor Side Damper Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
Figure 156:Control Box Side Damper Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
Figure 157:Damper Adjustment (Control Box Side Shown Compressor Side Similar) . . . . . . . . . . . . . . . . . . 149
Figure 158:Condenser Blower Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
Figure 159:Evaporator Fan Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
Figure 160:DE Evaporator Blower Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
Figure 161:Fan Shaft Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
Figure 162:Idler Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
Figure 163:SPECTRUM S-3 Evaporator Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
Figure 164:SPECTRUM S-3 Evaporator - Front View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
Figure 165:SPECTRUM S-3 Evaporator - Back View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
Figure 166:Serial Number Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
Figure 167:Check Valve with Cap Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174

13
List of Figures

14
Safety Precautions
Thermo King recommends that all service be
performed by a Thermo King dealer. However,
you should be aware of several general safety
practices:
The symbol appears next to a point that is
particularly important
DANGER: Denotes the possibility of
serious injury or death.
WARNING: Denotes the possibility of
serious equipment damage or serious
personal injury.
CAUTION: Denotes the possibility of
minor to severe equipment damage or
personal injury.
General Practices
DANGER: Do not operate the compressor
with the discharge service valve closed.
This condition increases internal pressure,
which can cause an explosion.
DANGER: Never apply heat to a sealed
refrigeration system or container. Heat
increases internal pressure, which might
cause an explosion.
DANGER: Refrigerant in the presence of
an open flame, spark or electrical short
produces toxic gases that are severe
respiratory irritants.
DANGER: Keep your hands, clothing and
tools clear of fans when working on a unit
that is running. Loose clothing might
entangle moving pulleys or belts, causing
serious injury or possible death.
DANGER: Do not inhale refrigerant. Use
caution when working with refrigerant or
a refrigeration system in any confined
area with a limited air supply, such as a
cargo area or garage. Refrigerant
displaces air and can cause oxygen
depletion, resulting in suffocation and
possible death.
DANGER: Avoid engine operation in
confined spaces and areas or
circumstances where fumes from the
engine could become trapped and cause
serious injury or death.
WARNING: Make sure your gauge
manifold hoses are in good condition
before using them. Never let them come in
contact with moving belts, fans, pulleys or
hot surfaces. Defective gauge equipment
can damage components or cause serious
injury.
WARNING: Always wear goggles or safety
glasses when working on a unit.
Refrigerant liquid, oil and battery acid can
permanently damage your eyes. See First
Aid on page 18.
WARNING: Use extreme caution when
drilling holes in a unit. Holes might
weaken structural components. Holes
drilled into electrical wiring can cause a
fire or explosion.
WARNING: Exposed coil fins can cause
lacerations. Service work on the
evaporator or condenser coils is best left to
a certified Thermo King technician.
WARNING: Do not apply heat to a closed
cooling system. Before applying heat to a
cooling system, drain it. Then flush it with
water and drain the water. Antifreeze
contains water and ethylene glycol. The
ethylene glycol is flammable and can
ignite if the antifreeze is heated enough to
boil off the water.
WARNING: Be careful when using
ladders or scaffolding to install or service
a unit. Observe the manufactures safety
labels and warnings.
CAUTION: Make sure all mounting bolts
are tight and are the correct length for
their applications. Improper torque and
incorrect bolt lengths can damage
equipment.
15
Safety Precautions
NOTE: In the USA, EPA Section 608
Certification is required to work on refrigeration
systems.
Battery Removal
DANGER: Disconnect the negative
battery terminal (-) first when removing a
battery. Connect the positive terminal (+)
first when installing a battery.
This order is important because the frame is
grounded to the negative battery terminal. If the
negative terminal is still connected, a complete
circuit exists from the positive terminal of the
battery to the frame. Metal objects contacting the
positive side and the frame simultaneously will
cause sparks or arcing. If there are sufficient
hydrogen gases emitted from the battery, an
explosion might occur, causing equipment
damage, serious injury, even death.
Refrigerant Hazards
DANGER: Do not use a Halide torch.
When a flame comes in contact with
refrigerant, toxic gases are produced.
These gases can cause suffocation, even
death.
DANGER: Store refrigerant in proper
containers, out of direct sunlight and away
from intense heat. Heat increases pressure
inside storage containers, which can cause
them to burst.
DANGER: Do not use oxygen (O2 ) or
compressed air for leak testing. Oxygen
mixed with refrigerant is combustible.
WARNING: Wear butyl lined gloves when
handling refrigerant to help prevent
frostbite.
CAUTION: Refrigerant in a liquid state
evaporates rapidly when exposed to the
atmosphere, freezing anything it contacts.
Be careful when handling refrigerant to
protect your skin from frostbite.
16
CAUTION: When being transferred,
refrigerant must be in liquid state to avoid
possible equipment damage.
CAUTION: When transferring
refrigerant, use a process that prevents or
greatly restricts refrigerant from escaping
into the atmosphere. Refrigerant damages
the earths upper ozone layer.
Refrigerant Oil Hazards
WARNING: Protect your eyes from
contact with refrigerant oil. The oil can
cause serious eye injuries. Avoid
prolonged or repeated contact with
refrigerant oil. To prevent irritation, wash
your hands and clothing thoroughly after
handling the oil.
CAUTION: Use the correct oil in Thermo
King systems to avoid damaging
equipment and invalidating its warranty.
CAUTION: Do not mix refrigerant oils
because that can cause system damage.
CAUTION: Use dedicated equipment to
prevent contaminating systems with the
wrong type of oil.
CAUTION: Store refrigerant oil in an
approved sealed container to avoid
moisture contamination.
CAUTION: Do not expose the refrigerant
oil to the air any longer than necessary.
The oil will absorb moisture, which results
in much longer evacuation times and
possible system contamination.
CAUTION: Wipe up spills immediately.
Refrigerant oil can damage paints and
rubber materials.

Electrical Hazards
Low Voltage
WARNING: Control circuits used in
refrigeration units are low voltage (12 to
24 volts dc). This voltage is not dangerous,
but the large amount of amperage
available from the alternator can cause
severe burns if accidentally shorted to
ground with metal objects, such as tools.
WARNING: Do not wear jewelry, watches
or rings because they increase the risk of
shorting out electrical circuits and
damaging equipment or causing severe
burns.
Microprocessor Service
Precautions
Take precautions to prevent electrostatic
discharge when servicing the microprocessor and
its related components. Even tiny amounts of
current can severely damage or destroy electronic
components.
Observe the following precautions when servicing
a microprocessor control system to avoid
damaging electronic components. Refer to the
appropriate microprocessor diagnosis manual and
the Electrostatic Discharge Training Guide (TK
40282) for more information.
If the microprocessor has a power switch, turn
it OFF before connecting or disconnecting the
battery.
Disconnect power to the unit.
Avoid wearing clothing that generates static
electricity (wool, nylon, polyester, etc.).
Wear a wrist strap (P/N 204-622 or its
equivalent) with the lead end connected to the
microprocessors ground terminal. These
straps are available from most electronic
equipment distributors. DO NOT wear these
straps with power applied to the unit.
Safety Precautions
Avoid unnecessary contact with the electronic
components.
Store and ship electronic components in
antistatic bags and protective packaging.
Leave electronic components in their antistatic
packing materials until youre ready to use
them.
After servicing any electronic components,
check the wiring for possible errors before
restoring power to the unit.
Never use a battery and a light bulb to test
circuits on any microprocessor-based
equipment.
Welding Precautions
Take precautions before electrically welding any
portion of the unit or the vehicle to which it is
attached. Ensure that welding currents are not
allowed to flow through the units electronic
circuits.
Observe the following precautions when welding
to avoid damaging electronic components.
If the microprocessor has a power switch, turn
it OFF before connecting or disconnecting the
battery.
Disconnect power to the unit.
Disconnect all wire harnesses from the
microprocessor.
If there are any electrical circuit breakers in
the control box, switch them OFF.
Close the control box.
Components that could be damaged by
welding sparks should be removed from the
unit.
Use normal welding procedures, but keep the
ground return electrode as close to the area
being welded as practical. This will reduce the
likelihood of stray welding currents passing
through any electronic circuits.
17
Safety Precautions
First Aid
First Aid, Refrigerant
In the event of frostbite, protect the frozen area
from further injury, warm the area rapidly and
maintain respiration.
EYES : For contact with liquid, immediately flush
eyes with large amounts of water. CALL A
PHYSICIAN.
SKIN: Flush area with large amounts of warm
water. Do not apply heat. Remove contaminated
clothing and shoes. Wrap burns with dry, sterile,
bulky dressing to protect from infection. CALL A
PHYSICIAN. Wash contaminated clothing before
reuse.
INHALATION: Move victim to fresh air and use
CPR (cardio pulmonary resuscitation) or
mouth-to-mouth resuscitation to restore breathing,
if necessary. Stay with victim until emergency
personnel arrive.
18
First Aid, Refrigerant Oil
EYES : Immediately flush with water for at least
15 minutes. CALL A PHYSICIAN. Wash skin
with soap and water.
INGESTION: Do not induce vomiting.
Immediately contact local poison control center or
physician.
First Aid, Engine Coolant
EYES : Immediately flush with water for at least
15 minutes. CALL A PHYSICIAN. Wash skin
with soap and water.
INGESTION: Do not induce vomiting.
Immediately contact local poison control center or
physician.
Specifications

Engine
Model TK486V (Tier 2)
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 (-15 to 50 C): SAE 15W-40
-13 to 104 F (-25 to 40 C): SAE 10W-40
-13 to 86 F (-25 to 30 C): SAE 10W-30
-22 to 32 F (-30 to 0 C): SAE 5W-30
Engine rpm: Low Speed Operation 1450 25 rpm
High Speed Operation 2200 25 rpm
Engine Oil Pressure 18 psi (127 kPa) minimum in low speed
45 to 57 psi (310 to 390 kPa) in high speed
Intake Valve Clearance 0.006 to 0.010 in. (0.15 to 0.25 mm)
Exhaust Valve Clearance 0.006 to 0.010 in. (0.15 to 0.25 mm)
Valve Setting Temperature 70 F (21 C)
Fuel Injection Timing See Injection Pump Timing on page 103
Fuel Injection Nozzle Opening Pressure 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 160 F (71 C)
Coolant System Capacity 7.5 qt (7.1 liters)
Expansion Tank Cap Pressure 7 psi (48 kPa)
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 Direct to compressor; belts to fans, alternator, and water
pump

19
Specifications

Belt Tension
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
NOTE: These are the field reset settings. Because it is sometimes difficult to use the TK Gauge 204-427 in
the field, adjust each belt to allow 1/2 inch (13mm) deflection at the center of the longest span.

Refrigeration System
Compressor Thermo King X430L
Refrigerant Type R-404A
Compressor Oil Charge 6.9 qt (6.6 liters)*
Compressor Oil Type Polyol Ester type P/N 203-513
Throttling Valve Setting 27 to 29 psi (186 to 200 kPa)
Heat/Defrost Method Hot gas
High Pressure Cutout 470 +7/-35 psi (3241 +48/-241 kPa)
Automatic reset @ 375 38 psi (2586 262 kPa)
High Pressure Switch: Opens 300 +25/-0 psi (2068 +172/-0 kPa)
Closes 200 20 psi (1379 138 kPa)
* When the compressor is removed from the unit, oil level should be noted or the oil removed from the compressor should be
measured so that the same amount of oil can be added before placing the replacement compressor in the unit.

Electrical Control System

Voltage 12.5 Vdc
Battery One, group C31, 12 volt battery (950 CCA recommended for
operation below -15 F [-26C])
Fuses See Fuses on page 87.
Battery Charging 12 volt, 65 amp, brush type, Thermo King Alternator
Voltage Regulator Setting 13.8 to 14.3 volts @ 77 F (25 C)
NOTE: Fuse F4 (Bypass resistor for Prestolite Alternator) must be removed for the Thermo King
Alternator. Thermo King Alternators are painted black (see Figure 83 on page 83).

20
 Specifications

Electrical Components
NOTE: Disconnect components from unit circuit to check resistance.
Current Draw (Amps) ResistanceCold
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 Solenoids (Each) 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 350-475*
*On-the-engine cranking check. Bench test is approximately 140 amps.

21
Specifications

22
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 (see Pretrip Tests on page 75).
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 engine coolant level and antifreeze protection (-30 F [-40 C]).
Check air cleaner restriction indicator (change filter when indicator
reaches 25 in.). Replace EMI 3000 air cleaner element (seeEMI
3000 Air Cleaner on page 115) 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 fuel filter/water separator.
Change engine oil and filter (hot). Requires oil with API Rating CI-4
or better (ACEA Rating E3 for Europe).
Change ELC (red) engine coolant every 5 years or 12,000 hours.
Units equipped with ELC have an ELC nameplate on the expansion
tank (see page 93).
Test fuel injection nozzles at least every 10,000 hours.
Replace fuel return lines between fuel injection nozzles every 10,000
hours.
Electrical
Inspect battery terminals and electrolyte level.
Inspect wire harness for damaged wires or connections.
Check operation of damper door (closes on defrost initiation and
opens on defrost termination).
Inspect alternator wire connections for tightness.
* 3,000 hours or two years, whichever occurs first.

23
Maintenance Inspection Schedule

Host Unit (Continued)

Every Every Annual/
Pretrip 1,500 3,000 4,500 Inspect/Service These Items
Hours Hours* 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 (If Used)

Every Every Annual/
Pretrip 1,500 3,000 4,500 Inspect/Service These Items
Hours Hours* Hours
Electrical
Inspect wire harness for damaged wires or connections.
Inspect/replace DC fan motors.
Structural
Visually inspect unit for fluid leaks.
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.

24
Unit Description

Unit Overview Key Features & Options Model Model

The SPECTRUM DE SR-2 is a diesel powered, 30-2 30-3
multi-temperature refrigeration system. The unit SMART REEFER SR-2
provides heavy duty temperature control for Multi-Temp Controller
multiple compartment trailers. The SPECTRUM OptiSet Programmable Modes
DE SR-2 30-2 unit is equipped with a dual ServiceWatch
evaporator. The unit mounts on front of the trailer. CargoWatch
Two separate temperature controlled trailer EMI-3000
compartments can be used without the need for a
High-Capacity Condenser Coil
remote evaporator. Each side of the dual
Dual Evaporator
evaporator serves one side of the trailer, which is
split longitudinally. The compartment to the Remote Evaporator
control box side of the unit is called Zone 1. The Whisper Quiet Technology
compartment to the compressor side of the unit is Easy-Access Door Design
called Zone 2. The compartments can carry fresh, Composite Exterior Panels
frozen, and/or dry products. Each compartment Long-Life Coolant/Silicone
can be quickly changed to carry any type of Hoses
product. Remote Status Light
In the SPECTRUM DE SR-2 30-3 a remote Standard Unit Color White
SPECTRUM Evaporator is added to provide a Standard Grille Color Black
third compartment (Zone 3). Directional Air Delivery
Vibration Isolation System
Aluminum Undermount Fuel
Tank 50 Gal. (186 Liter)
Alternator, 65 Amp, 12V dc
Fuel Heater
Frost Plug Heater
Special Color Grills
Fresh Air Exchange
i-Box Interface / /
R:COM Automatic Data / /
Transmission System
FleetWatch Data Manager
TracKing Satellite / /
Communications Kit
Figure 1: Front View TracKing Cellular TBA TBA
Communications Kit
Design Features Rear Remote Control
The following chart lists key design features and ServiceWatch/CargoWatch
options. Accessories:
Door Switches / /
Standard Features
Temperature Sensor Kits / /
Option/Factory Installed Fuel Level Sensor Kits / /
Option/Dealer Installed Megatech Battery, 12V

25
Unit Description
Host Unit
The host unit contains the diesel engine, the
compressor, the condenser, the dual evaporator
and the control box. The unit is equipped with an
SR-2 Multi-Temp Microprocessor, which controls
the operation of the host unit, the dual
evaporators, and remote evaporator (where used).
Refrigeration lines and wire harness connect the
host unit to the remote evaporator (where used).
The host unit mounts on the front of the trailer
with the dual evaporator extending through a hole
in the front wall into separate compartments
inside the trailer.
SPECTRUM Remote Evaporators
A SPECTRUM Remote Evaporator is mounted on
the ceiling of the remote compartment to provide
temperature control Zone 3 (if used). A
SPECTRUM Remote Evaporator with two fans is
called an S-2. A SPECTRUM Remote Evaporator
with three fans is called an S-3.
AJA984
Figure 2: S-3 SPECTRUM Remote Evaporator
Diesel Engine
The unit uses a quiet running TK486V (Tier 2),
which is a 4-cylinder, water cooled, direct
injection diesel engine. The engine is connected
directly to the compressor. Belts transmit power to
the fans, alternator, and water pump.
Thermo King X430L Compressor
The unit is equipped with a Thermo King X430L,
four-cylinder compressor with 30 cu. in.
(492 cm3) displacement. The unit is also equipped
with a compressor oil filter.
26
SMART REEFER 2 Multi-Temp (SR-2
MT) Control System
WARNING: Do not operate the unit until
you are completely familiar with the
location and function of each control.
The SR-2 MT is a microprocessor control system
designed for a transport refrigeration system. The
SR-2 MT Control System consists of the
following main components:
Base Controller
Interface Board
Multi-Temp Expansion Module
HMI (Human Machine Interface) Control
Panel
Microprocessor (Base Controller) On/Off
Switch
Unit Sensors
Refrigeration Control Components
Engine Control Components
Communication Ports
Optional Electric Standby
The heart of the control system is the
microprocessor based controller. The interface
board is mounted on the base controller and is
connected to it by means of connectors J1 and J2.
When connected, the base controller and interface
board form a one-piece base controller/interface
board, (C/IB) assembly. The base
controller/interface board controls most host unit
functions.

For multi-temp applications an expansion module
is connected to the base controller/interface board
via a controller area network (CAN) connection.
The expansion module provides the inputs and
outputs necessary to control the remote zone
evaporators. The expansion module is a slave
controller. The slave designation indicates that
the expansion module supports inputs and
outputs, but it only executes instructions from the
base controller. The expansion module must be
connected to the controller/interface board, it is
not capable of stand-alone operation.
System conditions are displayed and operator
instructions are sent using the HMI (Human
Machine Interface) Control Panel.
The base controller/interface board and the
expansion module are located inside the control
box, which is located inside the lower roadside
service door. The microprocessor is connected to
the HMI Control Panel via a CAN connection.
The HMI Control Panel is mounted on the face of
the control box. It is clearly visible through an
opening in the lower roadside service door.
Refer to the SR-2 Multi-Temp Microprocessor
Controller Diagnostic Manual TK 53080 for more
information about the SR-2 MT Control System.
See the Operating Instructions Chapter for
information about operating the SR-2 MT
controller.
CYCLE-SENTRY Start-Stop Controls
The CYCLE-SENTRY Start-Stop fuel saving
system provides optimum operating economy.
WARNING: The unit can start at any time
without warning. Press the OFF key on the
HMI control panel and place the
microprocessor On/Off switch in the Off
position before inspecting or servicing any
part of the unit.
The CYCLE-SENTRY system automatically
starts the unit on microprocessor demand, and
shuts down the unit after those conditions are
satisfied.
Unit Description
NOTE: The SR-2 MT controller provides a wide
range of control and programming flexibility.
However, pre-programming of the unit
controller may prohibit operation in certain
temperature ranges within some modes and may
also prohibit certain modes of operation. Refer
to TK 53080 the SR-2 Multi-Temp
Microprocessor Controller Diagnostic Manual
for information about controller programming.
The system automatically monitors and maintains
the compartment temperature, engine block
temperature, and battery charge levels at a
condition where quick, easy starts are possible.
If the block temperature falls below 30 F (-1 C),
the engine will start and run until the block
temperature is above 90 F (32 C). If the battery
voltage falls to the programmed limit selected by
CYCLE-SENTRY Battery Voltage (typically 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).
Features of the CYCLE-SENTRY system are:
Offers either CYCLE-SENTRY or
Continuous Run operation.
Controller regulated all season temperature
control.
Maintains minimum engine temperature in
low ambient conditions.
Battery Sentry keeps batteries fully charged
during unit operation.
Variable preheat time.
Preheat indicator buzzer.
27
Unit Description
Data Logging
There are two separate data loggers. The data is
downloaded through the data ports on the front of
the control box using an IBM PC compatible
laptop or desktop computer and Thermo King
WinTrac 4.6 (or higher) software.
1 2
1. CargoWatch Port
2. ServiceWatch Port
Figure 3: HMI Controller and Data Ports
ServiceWatch: ServiceWatch is standard
equipment in the SR-2 base controller. It records
operating events, alarm codes and compartment
temperatures as they occur and at preset intervals.
This information is typically used to analyze unit
performance. Use the ServiceWatch Port to
downloaded the ServiceWatch data.
CargoWatch: CargoWatch data logging is
standard equipment in the HIM, but requires the
installation of optional sensors. Up to six
temperature sensor/probes and three digital inputs
(typically used for door switches) can be installed.
CargoWatch also logs the setpoint. Use the
CargoWatch Port to downloaded the CargoWatch
data. If optional temperature sensors are installed,
their readings are displayed as Datalogger Sensor
(1-6) Temperature in the sensor readings. See
Sensors Menu on page 64.
A printer can also be used to print a report of the
optional sensor readings. See Printing a Trip
Report on page 66.
28
OptiSet
Optiset is a group of programmable functions
that control how the unit will operate with specific
setpoints. This assures that when a particular
setpoint is selected, the unit will always operate
the same way. Optiset can be programmed for up
to ten setpoints or setpoint ranges. This allows an
entire fleet to be configured to match customers
needs (up to 10 preset conditions). OptiSet is
standard equipment. Refer to TK 53080 the SR-2
Multi-Temp Microprocessor Controller
Diagnostic Manual for configuration instructions.
Remote Control Panel (Optional)
The remote control panel is mounted in a remote
location (such as inside the trailer) and is used to
operate the unit. Each zone can be turned on and
off and the setpoints can be changed. Refer to the
SPECTRUM DE SR-2 Operators Manual TK
53519 or the SR-2 Multi-Temp Microprocessor
Controller Diagnostic Manual TK 53080 for
information about the operation of the remote
control panel.
Sequence of Operation
When the Microprocessor On/Off switch is turned
on and HMI ON key is pressed, the LCD display is
illuminated and shows the setpoint and the return
air temperature for all zones. If the
CYCLE-SENTRY mode has been selected, the
unit will start and stop automatically. If the
Continuous mode has been selected, the unit will
start and run automatically.
The microprocessor uses a complex program to
determine which operating mode each zone
should be in. Therefore, it is difficult to predict
which operating mode an evaporator should be in
by comparing its setpoint to the compartment
temperature. Also, the different versions of
software that are used have some operational
differences.

Each zone that is turned on will operate in one of
the following modes:
Cool
Heat
Defrost
Null
During engine operation, engine speed is
determined by a combination of the requirements
of each zone and the discharge pressure. The
diesel engine will operate in High or Low Speed
accordingly.
Defrost
Defrost is initiated in each zone automatically or
manually.
Automatic Defrost: The controller is programmed
to automatically initiate timed or demand defrost
cycles. The controller can be programmed to
initiate timed defrost cycles at intervals of 2, 4, 6,
8, or 12 hours. Demand defrost cycles occur if the
differences between the return air temperature,
discharge air temperature, and coil temperature
exceed certain limits. The unit can enter defrost
cycles as often as every 30 minutes if required.
Manual Defrost: In Manual Defrost Mode, the
operator initiates a defrost cycle. See Initiating a
Manual Defrost Cycle on page 54.
The evaporator coil temperature in the selected
zone must be below 45 F (7 C) to allow defrost. If
the unit is in CYCLE-SENTRY Null mode, the
engine will start when defrost is initiated.
The zone will stay in defrost until the evaporator
coil temperature rises to 58 F (14.5 C).
System Operation
Several operating characteristics of the unit are:
All zones can cool at the same time.
All zones can heat at the same time.
Any zone can cool while any other zone heats.
When the host zone is in defrost, it may delay
cool or heat in the other zone(s).
When a zone is in null, the blowers may run
but the zone does not cool or heat.
Unit Description
When a zone is in heat while another zone is
in cool, the evaporator in the zone that is in
heat acts as the condenser.
The condenser inlet solenoid and the suction
line solenoids are normally open solenoid
valves that close when energized.
The liquid line solenoids, the hot gas
solenoids, the receiver tank pressure solenoid
and the purge valve are normally closed
solenoid valves that open when energized.
The flow of refrigerant through the system is
controlled by the solenoid valves and the
check valves.
If the condenser inlet solenoid is energized
(closed) because a zone is in heat or defrost,
and if the discharge pressure exceeds 400 psi
(2758 kPa), the condenser inlet solenoid is
de-energized until the discharge pressure
drops below 250 psi (1724 kPa).
The receiver tank pressure solenoid and the
purge valve are energized (open) when any
zone is in heat or defrost. If the discharge
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).
During engine operation when all zones are in
cool, the microprocessor will shift the engine
to low speed if the discharge pressure exceeds
425 psi (2930 kPa). High speed is enabled, if
required, when the discharge pressure drops
below 375 psi (2586 kPa).
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).
Refrigeration System Diagrams
The following pages show examples of the
refrigerant flow through a three zone system. The
two zone system is similar, except the Zone 3
evaporator and its components are removed.
29
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
through the Zone 2 expansion valve into the
3R. Zone 3 Suction Line Check Valve
Zone 2 evaporator. There the liquid refrigerant
(SLCV3) Open
cools the Zone 2 evaporator as it evaporates into
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
through the Zone 3 expansion valve into the
Zone 3 evaporator. There the liquid refrigerant
cools the Zone 3 evaporator as it evaporates into
low pressure vapor. The refrigerant returns to the
compressor through the SLS3, the suction line, the
SLCV3, and the accumulator.

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

30
 Unit Description

3
2

AGA211

1. Zone 1Control Box Side Evaporator

2. Zone 2Compressor Side Evaporator
3. Zone 1Remote Evaporator
Figure 4: Zone 1 Cool, Zone 2 Cool, and Zone 3 Cool

31
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
through the Zone 1 expansion valve into the
Zone 1 evaporator. There the liquid refrigerant 1R. Zone 3 Liquid Line Solenoid (LLS3)Open
cools the Zone 1 evaporator as it evaporates into
2R. Zone 3 Liquid Return Check Valve
low pressure vapor. The refrigerant returns to the
(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
cools the Zone 2 evaporator as it evaporates into
5R. Zone 3 Hot Gas Solenoid (HGS3)Open
low pressure vapor. The refrigerant returns to the
compressor through the SLS2, the suction line, the
SLCV2, and the accumulator.

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.

32
 Unit Description

3
2

AGA212

1. Zone 1Control Box Side Evaporator

2. Zone 2Compressor Side Evaporator
3. Zone 1Remote Evaporator
Figure 5: Zone 1 Heat, Zone 2 Cool, and Zone 3 Cool

33
Unit Description

Opening the Front Doors Opening the Secondary Door Latch

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.
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

2
2

1. Spring Latch
1. Door Latch
2. Spring Catch
2. Secondary Door Latch Nameplate
Figure 7: Opening Secondary Door Latch
Figure 6: Door Latch Location

34
 Unit Description

Engine Compartment Compressor Oil Sight Glass: Use this sight glass
Components to check the compressor oil level. See the
Refrigeration Maintenance Chapter for the correct
The following maintenance items can be checked procedure.
visually.
Engine Oil Dipstick: Use the engine oil dipstick to
WARNING: The unit can start at any time check the engine oil level.
without warning. Press the Off key on the
CAUTION: Make sure the engine is
HMI control panel and place the
turned off before attempting to check the
microprocessor On/Off switch in the Off
engine oil.
position before inspecting any part of the
unit. Receiver Tank Sight Glass: Use this sight glass to
check the level of refrigerant in the receiver tank.
Air Filter Restriction Indicator: The air filter
See the Refrigeration Maintenance Chapter for the
restriction indicator is attached to the engine
correct procedure.
intake manifold. When the diaphragm indicates
25, service the air filter. Press the button on the
bottom of the restriction indicator to reset after
servicing the air cleaner.

9
1
2
10
3

4
11

5
6
12
7
13
14
8
15

1. Air Filter Restriction Indicator 9. Alternator

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

35
Unit Description

Unit Protection Devices Low Oil Level Switch: The low oil level switch
closes if the oil drops below an acceptable level. If
Coolant Level Switch: The coolant level switch it stays closed for a specified time, the
closes if the coolant level drops below an microprocessor shuts the unit down and records
acceptable level. If it stays closed for a specified alarm code 66.
time, the microprocessor records alarm code 37.
Low Oil Pressure Switch: The low oil pressure
Engine Coolant Temperature Sensor: The switch closes if the oil pressure drops below an
microprocessor uses the engine coolant acceptable level. If it stays closed for a specified
temperature sensor to monitor the engine coolant time, the microprocessor shuts the unit down and
temperature. If the engine coolant temperature records alarm code 19.
rises above an acceptable level, the
microprocessor records alarm code 41 and Preheat Buzzer: The preheat buzzer sounds when
possibly 18. The the microprocessor might also the controller energizes the preheat relay. This
shut the unit down. warns anyone near the unit that the controller is
about to start the engine.
Fuse Link (Current Limiter): The fuse link is
located in the positive battery cable. The fuse link
protects the electric system from a short. If the
fuse link burns out, replace it by replacing the
positive battery cable.
Fuses: Various fuses are located on the controller
interface board to protect circuits and
components. See Fuses on page 87 for more
information.
Smart FETs: Smart FETs in the controller
interface board and expansion module protect
circuits and components. See Smart FETs on
page 88 for more information.
High Pressure Cutout Switch: The high pressure
cutout switch is located on the compressor
discharge manifold. If the compressor discharge
pressure becomes excessive, the switch opens the
circuit to the run relay to stop the unit. The
microprocessor will record Alarm Code 10.
High Pressure Relief Valve: This valve is designed
to relieve excessive pressure in the refrigeration
system. It is located on the receiver tank. The
valve is a spring-loaded piston that lifts off its seat
when refrigerant pressure exceeds 500 psi (3447
kPa). The valve will reseat when the pressure
drops to 400 psi (2758 kPa). The valve could
possibly leak refrigerant after it has relieved
excess pressure. Tapping the valve lightly may
help the valve reseat and seal properly. The valve
is non-repairable and requires no adjustment. If
the valve fails to reseat properly, recover the
refrigerant charge and replace the valve.

36
 Unit Description

Serial Number Locations

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

1
1

1. Serial Number Location

Figure 11: Unit Serial Number Locations

1. Serial Number Location

Figure 9: Compressor Serial Number Location

1 Figure 12: Laminated Serial Number Plate

(Located Where Shown Above)

1. Serial Number Location

Figure 10: Engine Serial Number Location

37
Unit Description

Figure 13: Front View

38
 Unit Description

1. Access Panels
2. Defrost Dampers
Figure 14: Back View

39
Unit Description

1. Expansion Module
2. HMI Control Panel
3. Base Controller/Interface Board Assembly
Figure 15: Typical Components Inside Control Box

40
Operating Instructions

SMART REEFER 2 Multi-Temp HMI Control Panel

(SR-2 MT) Control System
The microprocessor control system components
are located inside the control box, which is
located inside the lower roadside service door.
The microprocessor is connected to an HMI
(Human Machine Interface) Control Panel, which
is used to operate the unit. The CargoWatch and
ServiceWatch ports are used to retrieve data from
the data logging system.
1
2 touch sensitive keys.
Use the HMI control panel to operate the unit.
Refer to the SPECTRUM DE SR-2 Operators
Manual TK 53519 and the SR-2 Multi-Temp
Microprocessor Controller Diagnostic Manual TK
53080 for more information.
The HMI (Human/Machine Interface) Control
Panel is connected to the microprocessor and is
used to operate the unit and display unit
information. The HMI communicates with the
controller via a controller area network (CAN)
bus.
The HMI control panel has a display and eight

3 The display is capable of showing both text and

graphics.
4
The keys on the left and right sides of the display
are dedicated or single function keys. These are
5 termed hard keys.
The four keys under the display are termed soft
keys. The functions of these keys change
depending on the operation being performed. If a
soft key is active the current key function is
1. Control Box 4. CargoWatch Port shown in the display directly above the key.
2. Microprocessor 5. HMI Control Panel
On/Off Switch
3. ServiceWatch Port
Figure 16: Control Box With Service Door Open CONTINUOUS

-8.2 35.8 48.8

ON TEMP F

Microprocessor On/Off Switch OFF

-10 35 50
SET
POINT

ZONE 1 ZONE 2 ZONE 3 MENU

This switch supplies or removes electrical power
to the microprocessor. It is located on the left side
of the control box.
CAUTION: The unit can start at any time SmartRReefer22
without warning. Press the OFF key on the
HMI control panel and place the ARA794

microprocessor On/Off switch in the Off Figure 17: HMI Control Panel
position before inspecting or servicing any
part of the unit.

41
Operating Instructions

Display NOTE: Zone 1 is always on when the control

The display presents information to the operator.
This information can include setpoint and
temperature for each zone, unit or zone operating
information, gauge readings, temperatures and
other information as selected by the operator.
The default display is called the Standard Display.
See page 45 for more information about Standard
Displays.
The Standard Display of box temperature and
setpoint for 3 zones is shown in Figure 18. The
unit is running in Continuous Mode. Zone 1 has a
setpoint of -10 F, and a return air temperature of
-8.2 F. The downward pointing arrow shows this
zone is cooling. Zone 2 has a setpoint of 35 F, and
a return air box temperature of -35.8 F. The
absence of an arrow indicates that this zone is in
null. Zone 3 has a setpoint of 50 F, and a return air
temperature of 48.8 F. The upward pointing arrow
shows this zone is heating.
NOTE: The zone temperature shown is always
return air temperature.
Pressing the soft key under each zone allows the
setpoint for that zone to be changed. In addition,
the soft keys under Zone 2 and Zone 3 are used to
turn those zones on and off. Pressing the soft key
under MENU accesses the MAIN MENU.
3
CONTINUOUS
2 4
2
35 .8 48 .8
ON
-8 .
1 -10 35 50
OFF
system is powered up. Zone 1 cannot be turned
off using the HMI control panel menu.
Control Panel Keys
The keys on either side of the display (see Figure
18) are dedicated or hard keys. Their function
always remains the same. They are described
below.
On Key: Press this key to turn the host
unit and Zone 1 on. First the display
will briefly show the Thermo King
Logo, and then the statement
Configuring System - Please Wait.
When the power-up sequence is
complete, the display shows the
Standard Display of box temperature
and setpoint. For more information see
Turning Unit On on page 43.
Off Key: Press this key to turn the host
unit and Zone 1 off. First the display
will briefly show System is Powering
Down - Please Wait. Press On to
Resume, and then Off will appear
momentarily. When the power-down
sequence is complete the display will
be blank. For more information see
Turning Unit Off on page 44.
Defrost Key: Press this key to initiate a
Manual Defrost cycle. For more
information see Initiating a Manual
Defrost Cycle on page 54.
TEMP F
SET
POINT 5 Mode Key: Press this key to select

ZONE 1 ZONE 2 ZONE 3 MENU

CYCLE-SENTRY Mode or
Continuous Mode operation if allowed
by OptiSet. For more information see
ARA907 Selecting CYCLE-SENTRY or
Continuous Mode on page 53.
6

1. Off Key (Hard Key)

2. On Key (Hard Key)
3. Display
4. Defrost Key (Hard Key)
5. CYCLE-SENTRY/Continuous Mode Key
(Hard Key)
6. Soft Keys
Figure 18: Display and Keys

42

The four soft keys under the display
(see Figure 18) are multi-purpose keys.
Their function changes depending on
the operation being performed. If a soft
key is active, the key function is shown
in the display directly above the key.
The keys are numbered from left to
right, with Key 1 on the far left and
Key 4 on the far right.
Typical soft key functions:
Zone On/Off and Setpoint Change
Menu
Next/Back
Yes/No
+/
Select/Exit
Clear/Help
Hour Meters/Sensors
Gauges
Unit Operation
Manual Pretrip Inspection (Before
Starting Unit)
The following Manual Pretrip Inspection should
be completed before starting the unit and loading
the trailer. While the pretrip inspection is not a
substitute for regularly scheduled maintenance
inspections, it is an important part of the
preventive maintenance program designed to head
off operating problems and breakdowns before
they happen.
Fuel: The dieselfuel supply must be adequate to
guarantee engine operation to the next check
point.
Engine Oil: The engine oil level should be at the
FULL mark with the dipstick turned (threaded)
into oil pan. Never overfill.
Coolant: The engine coolant must have antifreeze
protection to -30 F (-34 C). Alarm Code 37
indicates low coolant. Add coolant in the
expansion tank.
Operating Instructions
CAUTION: Do not remove expansion
tank cap while coolant is hot.
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.
Battery: The terminals must be clean and tight.
Belts: The belts must be in good condition and
adjusted to the proper tensions.
Electrical: The electrical connections should be
securely fastened. The wires and terminals should
be free of corrosion, cracks or moisture.
Structural: Visually inspect the unit for leaks,
loose or broken parts and other damage. The
condenser and evaporator coils should be clean
and free of debris. Check the defrost drain hoses
and fittings to make sure they are open. Make sure
all the doors are latched securely.
Turning Unit On
Complete the following steps to turn on the unit:
1. Press the ON hard key.
NOTE: With SPECTRUM Multi-Temp
applications, Zone 1 is turned on any time
the host unit is turned on. Zone 1 is turned
off when the host unit is turned off.
2
1
1. On Key
2. Display
Figure 19: Press On Key
2. The display briefly shows a Thermo King
Logo as the display initializes.
43
Operating Instructions

NOTE: With extremely cold ambient Turning Unit Off

temperatures it may take up to 15 seconds for
Complete the following steps to turn unit off:
the first display to appear.
1. Press the OFF hard key.
2
CONTINUOUS

ON
TEMP F
-8 .2 35 .8
1 SET

OFF -10 35 POINT

ZONE 1 ZONE 2 MENU

ARA798

1. Off Key
2. Display
CONTINUOUS

TEMP F Figure 21: Press Off Key

-8 .2 35 .8 SET
-10 35 POINT
2. The controller shuts down immediately.
ZONE 1 ZONE 2 MENU

ARA796 3. The System is Powering Down Screen will

briefly appear.
DIESEL ENGINE STARTING

ARA797

CONTINUOUS

TEMP F
-8 .2 35 .8 SET
-10 35 POINT

ZONE 1 ZONE 2 MENU

ARA796
Figure 20: Turning Unit On Screen Sequence

3. The Configuring System Screen briefly

appears while communications are established
and the unit prepares for operation.
4. The Standard Display showing box
Figure 22: Turning Unit Off Screen Sequence
temperatures and setpoints briefly appears.
5. The Diesel Engine Starting Screen briefly 4. The Off Screen will briefly appear.
appears as the engine preheats and starts. On 5. The screen then goes blank. To start the unit
Model 50 units the electric standby run screen again, press the ON hard key.
will appear instead if the unit is connected to
standby power.
6. The Standard Display showing box
temperatures and setpoints reappears when the
unit is running.

44
 Operating Instructions

Standard Display Three Zone Standard Display

The Standard Display is the default display that The Three Zone Standard Display adds the third
appears if no other display function is selected. zone for units equipped with three zones. The
Three Zone Standard Display is shown in Figure
Two Zone Standard Display 24. It functions the same way as the Two Zone
Standard Display, but with a third zone. The top of
A Two Zone Standard Display is shown in Figure
the display shows that the unit is operating in
23. It shows the return air temperature and
Continuous mode. The return air temperature for
setpoint for two zones. The top of the display
Zone 1 is -8.2 F with a -10 F setpoint. The
shows that the unit is operating in Continuous
down-pointing arrow indicates that Zone 1 is
mode. The return air temperature for Zone 1 is
cooling. The return air temperature for Zone 2 is
-8.2 F with a -10 F setpoint. The down-pointing
35.8 F with a 35 F setpoint. The down-pointing
arrow indicates that Zone 1 is cooling. The return
arrow indicates that Zone 2 is also cooling. The
air temperature for Zone 2 is 35.8 F with a 35 F
return air temperature for Zone 3 is 48.8 F with a
setpoint. The down-pointing arrow indicates that
50 F setpoint. The up-pointing arrow indicates
Zone 2 is also cooling. The soft key under each
that Zone 3 is heating. The soft key under each
zone allows the Setpoint for that zone to be
zone allows the Setpoint for that zone to be
changed. In addition, the soft key under Zone 2 is
changed. In addition, the soft keys under Zone 2
used to turn that zone on and off. The soft key
and Zone 3 are used to turn those zones on and
labeled MENU allows the Main Menu to be
off. The soft key labeled MENU allows the Main
selected.
Menu to be selected.
2 1 8
CONTINUOUS

CONTINUOUS
TEMP F
3 ON

-8 . 2
35 . 8 TEMP F

SET
-8 .2 35 .8 48 .8 SET
-10 35
-10 35 50
POINT
OFF POINT
ZONE 1 ZONE 2 MENU

4 ZONE 1 ZONE 2 ZONE 3 MENU

ARA799
ARA798
Figure 24: Three Zone Standard Display
5 6 7

1. Continuous Mode 5. Zone 1 Soft Key

2. Box Temperature 6. Zone 2 Soft Key
(Zone 1)
3. Setpoint (Zone 1) 7. Menu Soft Key
4. Cooling (Zone 1) 8. Zone 2 Display
Figure 23: Two Zone Standard Display

45
Operating Instructions

Single Zone Control Standard Display Method 2:

This feature, if enabled in Guarded Access, allows
Single Zone Control operation to be selected by
choosing the Main Menu and then selecting
Single Zone Control from the Mode submenu (see
Selecting Single Zone Control or Multi Zone
Control on page 71). When this feature is
selected, all zones will be forced on and will
control to the same selected setpoint. The Single
Zone Control Standard Display is shown in Figure
25. It functions the same way as the other
Standard Displays. The top of the display shows
that the unit is operating in Continuous mode. The
box temperature for all zones is 35.8 F and all
zones are controlling to a 35 F setpoint. The
down-pointing arrow indicates that all zones are
cooling. The soft key labeled Setpoint allows the
setpoint for all zones to be changed. The soft key
labeled Menu allows the Main Menu to be
selected.
CONTINUOUS
SETPOINT
F when in this mode. Unit control is based on
If Single Zone Control Mode has been has been
enabled in the Guarded Access/Main Menu
Configuration menu, the following will apply.
Single Zone Control Mode will appear in the
Mode Menu only if the Single Zone Control
feature has been enabled in the Guarded
Access/Main Menu Configuration menu. IF
the feature is enabled then Single Zone
Control will appear in the Main Menu/Mode
Menu.
If Single Zone Control operation is selected
then all zones will be forced on and will
control to the same setpoint. The Zone 1
sensors are used to determine box
temperature.
NOTE: Using Method 2, it is recommended
that all bulkheads should be taken down to
create one large compartment.
With the exception of defrost, the operating
mode of each zone evaporator(s) will be same

35 .8
SETPOINT
35
MENU

the temperature sensors of Zone 1.
If Single Zone Control operation is selected
the Single Zone Standard Display provides
ARA902 one soft key labeled Setpoint as shown in
Figure 25: Single Zone Standard Display Figure 25. This allows the setpoint for all
zones to be changed simultaneously.
Operating The Unit In Single Zone If Single Zone Control operation is selected
Control Mode the individual zones cannot be turned off. The
There are two methods of operating the unit in unit and all zones are turned On and Off
Single Zone Control. simultaneously using the On and Off hard
keys at the left side of the display.
Method 1:
NOTE: If Single Zone Control Mode has been
The unit may be operated with each Zone
enabled in the Guarded Access/Main Menu
individually set to the same setpoint temperature.
Configuration menu, either Single Zone or
For example, each Zone could be individually set
Multi Zone control can be selected in the Main
to 35 F. The evaporator in each compartment will
Menu/Mode menu. For example, to return to
then control the temperature in that compartment
Multi Zone Control from Single Zone Control,
to the same 35 F setpoint.
select Multi Zone Control in the Main
NOTE: Using Method 1, it is recommended that Menu/Mode menu.
the bulkheads that separate each compartment
be in place to isolate the compartments.

46
 Operating Instructions

Standard Display Variations If an alarm specific to a zone occurs, then a small

zone alarm icon will appear next to the affected
The Standard Display has variations. A display
zone as well. Both Alarm Icons will be present.
showing any of the following variations is still
Below in Figure 28 the small zone Alarm Icon
considered a Standard Display.
indicates that an alarm exists specific to Zone 2.
The top of the display will show that the unit is
1
operating in either CYCLE-SENTRY or
Continuous Mode. The temperature can be CONTINUOUS
displayed in degrees Fahrenheit (F) or degrees
Celsius (C). See Figure 26. -8 .2 35 .8
1 2 0 35
CYCLE SENTRY
ZONE 1 ZONE 2 MENU
TEMP C
-8 .2 0 .8 SET 1. Zone Alarm Icon
ARA822

-18 OFF POINT

Figure 28: Zone Alarm Display
ZONE 1 ZONE 2 MENU
NOTE: Zone specific alarm codes use the
ARA803
standard Thermo King alarm code numbers. If
1. CYCLE-SENTRY or Continuous an alarm is specific to a zone then both the
2. Degrees Celsius or Fahrenheit alarm code number and affected zone number
are displayed.
Figure 26: Standard Display Variations
NOTE: If the large alarm icon only appears,
Alarm Display then the active alarm(s) are unit level alarm(s).
If a unit alarm condition occurs the large Alarm If a zone alarm icon and the large alarm icon
Icon will appear on the Standard Display as are displayed there is a zone level alarm or a
shown below in Figure 27. combination of zone level and unit level alarms
present.
1
See Alarms Menu on page 60 for information
CONTINUOUS about displaying and clearing alarms.

-8 .2 35 .8
0 35
ZONE 1 ZONE 2 MENU

ARA821

1. Alarm Icon
Figure 27: Alarm Display

47
Operating Instructions

Temperature Watch Display If an alarm condition (other than a log alarm) is

If there is no key activity and no check, prevent,
or shutdown alarms are present the Temperature
Watch Display appears 2-1/2 minutes after the last
key entry from the Standard Display. The
Temperature Watch screen will remain on until
any key is pressed or a check, prevent, or
shutdown alarm occurs. The Temperature Watch
Display shows the return air temperature and
setpoint for each zone. Tenths of a degree are not
shown by the Temperature Watch display. The
large numbers allow unit conditions to be checked
from a distance.
A Two Zone Temperature Watch Display is shown
in Figure 29. The box temperature for Zone 1 is
-8.2 F with a -10 F setpoint. The down-pointing
arrow indicates that Zone 1 is cooling. The box
temperature for Zone 2 is 35.8 F with a 35 F
setpoint. The down-pointing arrow indicates that
Zone 2 is also cooling. Pressing any soft key
returns the display to the Standard Display.
ON
-8 36
present the Temperature Watch Display will not
appear. If an alarm condition occurs while the
Temperature Watch Display is present the display
will return to the Standard Display. If the Defrost
or Cycle Sentry keys are pressed the display will
return to the Temperature Watch Display after
defrost is initiated or the operating mode is
changed.
In the Three Zone Temperature Watch Display the
Menu soft key label covers the Zone 3 label as
shown below in Figure 30.
If the unit is operating in Cycle-Sentry Mode, the
Cycle-Sentry icon will appear near Zone 2 as
shown below in Figure 30. If the unit is operating
in Continuous Mode the Cycle-Sentry icon will
not be present.
1 2
ON
-8 36 48
OFF
-10 35 50
ZONE 1 F ZONE 2 MENU

OFF
-10 35
ZONE 1 F ZONE 2 MENU

ARA908

1. Cycle-Sentry Icon
ARA801 2. Menu Soft Key Label
Figure 29: Two Zone Temperature Watch Display Figure 30: Three Zone Temperature Watch Display

48

Starting the Diesel Engine
Diesel engine preheating and starting is automatic
in both Continuous Mode and CYCLE-SENTRY
Mode. The engine will preheat and start as
required when the unit is turned on. If any keys
are being pressed on the HMI control panel prior
to the engine start, the engine preheat and start
will be delayed until 10 seconds after the last key
is pressed.
See Turning Unit On on page 43.
CAUTION: The engine may start
automatically any time the unit is turned
on.
WARNING: Never use starting fluid.
When the engine is preparing to start the HMI
control panel will display the engine start screen,
as shown below. The preheat buzzer sounds
during the engine preheat and crank sequence.
ON
DIESEL ENGINE STARTING
OFF
ARA840
Figure 31: Starting Diesel Engine Display
After the engine is started the display returns to
the Standard Display of temperature and setpoint.
NOTE: Run a pretrip test if the unit has not been
used recently. See Pretrip Tests on page 75.
Unit Fails To Start
If the engine does not start and the Alarm Icon
appears on the display, take the following steps.
1. Check for and correct any alarm conditions.
See Viewing and Clearing Alarms Screen
Sequence on page 61.
2. Clear all alarms. See Viewing and Clearing
Alarms Screen Sequence on page 61.
3. Press the OFF key to tun the unit off.
4. Press the ON key to turn the unit on.
Operating Instructions
5. The controller will go through the start up
screens and then after a 10 second delay the
unit will start automatically.
6. If the engine will still not start, turn the unit
off. Determine and correct the cause for not
starting.
7. Repeat the procedure.
After Start Inspection
After the unit is running, check the following
items to confirm that the unit is running properly.
Oil Pressure: Checkthe engine oil pressure by
using the Gauges Menu. See Gauges Menu on
page 62. The Engine Oil Pressure Display should
indicate OK not LOW.
Ammeter: Check the ammeter reading by using
the Gauges Menu. See Gauges Menu on page
62. The Amps Display should indicate a positive
charge amperage rate to the battery. A negative (-)
number indicates a discharge condition.
Compressor Oil: The compressor oil level should
be visible in the compressor sight glass after 15
minutes of operation. If not, check the compressor
oil level using the procedure in the Refrigeration
Maintenance Chapter.
Pre-Cooling: Make sure that the setpoints are at
the desired temperatures. See Changing the
Setpoint on page 50. Allow the unit to run for a
minimum of 30 minutes (longer if possible)
before loading the trailer.
This provides a good test of the refrigeration
system while removing residual heat and the
moisture from the trailer interior to prepare it for a
refrigerated load.
Defrost: When the unit has finished pre-cooling
the trailer interior, manually initiate a Defrost
cycle. See Initiating a Manual Defrost Cycle on
page 54. This will remove the frost that builds up
while running the unit to pre-cool the trailer.
49
Operating Instructions

Changing the Setpoint If the NO key is pressed the setpoint change

made with the + or - soft keys will not be
To change the setpoint complete the following
accepted. The display will briefly show
steps.
SETPOINT NOT CHANGED and return to
1. Begin at the Standard Display. the Standard Display. The Standard Display
If the Temperature Watch display is showing, will show the old setpoint.
press any soft key to return to the Standard
NOTE: If the YES or NO key is not pressed
Display.
within 5 seconds of making a change with
2. Press the ZONE soft key for the desired zone. the + or - key, a warning beep will sound
Zone 1 is shown below in Figure 32. as a reminder. If the YES or NO key is not
pressed within 10 seconds of making a
1 change with the + or - key, the setpoint
CONTINUOUS

ON
2 TEMP F is not changed and the display returns to the
-8 . 35 .8
OFF -10 35
SET
POINT
Setpoint Display. The display briefly shows
ZONE 1 ZONE 2 MENU [SETPOINT NOT CHANGED] and Alarm
2 Code 127 Setpoint Not Entered is set, to
indicate that the setpoint change was started
ARA798
but not completed.

1. Standard Display If the YES soft key was pressed, the setpoint
2. Press Zone 1 Soft Key
change made with the + or - soft keys will
be accepted, and the following screens will
Figure 32: Press Zone Soft Key appear.
3. The setpoint display appears as shown in 6. The Programming New Setpoint Screen will
Figure 33. appear. See Figure 33.
4. Press the + or - soft keys to increase or 7. The New Setpoint Is XX Screen briefly
decrease the setpoint until the desired setpoint appears. See Figure 33.
is shown. The setpoint has been changed to
8. The Standard Display appears with setpoint
0 F using the + soft key in Figure 33.
changed to the new setpoint. Notice that the
5. Press the YES OR NO soft key accordingly as Zone 1 arrow now points up, to indicate that
described below. See Figure 33. Zone 1 is heating. See Figure 33.

If YES Key was pressed If NO Key was pressed

CONTINUOUS

TEMP F
-8 .2 35 .8 SET
-10 35 POINT

ZONE 1 ZONE 2 MENU

ARA805
ZONE 1 Key

CURRENT ZONE 1 SETPOINT

NEW SETPOINT IS

-10 F 0F
+/- TO CHANGE
- + EXIT

ARA806 ARA808
+ or Key

NEW SETPOINT WILL BE CONTINUOUS CONTINUOUS

TEMP F
-8 .2 35 .8
TEMP F

0F SET
-8 .2 35 .8 SET
0 35 POINT
-10 35 POINT
+/- TO CHANGE OK?
- + YES NO ZONE 1 ZONE 2 MENU ZONE 1 ZONE 2 MENU

ARA809
YES or NARA807
O Key
ARA805

Figure 33: Changing the Setpoint Screen Sequence

50
 Operating Instructions

Turning a Zone On and Off 3. Press the TURN ZONE OFF soft key to turn the
zone off.
Zone 1 will always be turned on any time the unit
is turned on. Zone 2 and Zone 3 (if present) can be
turned on and off as desired. ON
CURRENT ZONE 2 SETPOINT

The state of each zone is retained when the unit is 35 F

OFF
+/- TO CHANGE
turned off and on. For example, on a three zone - + TURN
ZONE OFF
EXIT

unit if zone 2 is turned off and Zone 3 is turned on 1

and the unit is turned off, the zone states remain as
they were. When the unit is turned back on Zone 2 ARA810
will still be off and Zone 3 will still be on.
1. Press Turn Zone Off Soft Key
NOTE: Units equipped with a remote control
Figure 35: Zone 2 Setpoint Display
may operate in a slightly different manner. Refer
to the SPECTRUM DE SR-2 Operators Manual 4. The display briefly shows PROGRAMMING
TK 53519 or the SR-2 Multi-Temp ZONE ON/OFF - PLEASE WAIT. See Figure
Microprocessor Controller Diagnostic Manual 36.
TK 53080 for information about the operation of
the remote control panel. 5. The display then confirms the new Zone 2
setting for several seconds. See Figure 36.
To turn Zone 2 or Zone 3 on or off complete the
following steps. 6. The display then returns to the Standard
Display showing Zone 2 is off. The setpoint
1. Begin at the Standard Display. for Zone 2 has been replaced with OFF to
If the Temperature Watch display is showing, indicate that the zone is now off. See Figure
press any soft key to return to the Standard 36.
Display.
1. Press the ZONE soft key under the desired zone. PROGRAMMING ZONE ON/OFF
Zone 2 is selected here (see Figure 34).
PLEASE WAIT

1
CONTINUOUS
ARA811
ON
TEMP F
-8 .2 35 .8 SET

OFF -10 35 POINT

ZONE 2 IS
ZONE 1 ZONE 2 MENU

2
OFF

ARA798 ARA812

1. Standard Display
CONTINUOUS
2. Press Zone Soft Key TEMP F
-8 .2 35 .8
Figure 34: Press Zone Soft Key SET
0 OFF POINT

ZONE 1 ZONE 2 MENU

2. The setpoint display appears as shown in ARA813

Figure 35. If the zone is turned on, the third

Figure 36: Turning Zone On/Off Screen Sequence
soft key will be labeled Turn Zone Off. If the
zone is turned off, the third soft key will be
labeled Turn Zone On. In this case Turn Zone
Off is shown.

51
Operating Instructions

Selection of Operating Modes

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

52
 Operating Instructions

Selecting CYCLE-SENTRY or NOTE: CYCLE-SENTRY or Continuous mode

Continuous Mode may be disabled by OptiSet.
When CYCLE-SENTRY Mode is selected the
unit will start and stop automatically to maintain CONTINUOUS

TEMP F
2
setpoint, keep the engine warm and the battery -8 . 35 .8 SET

charged. When Continuous Mode is selected, the -10 35 POINT

ZONE 1 ZONE 2 MENU

unit starts automatically and runs continuously to ARA805

maintain setpoint and provide constant airflow.

CYCLE-SENTRY or Continuous may not be
available from the Mode menu if OptiSet is in use.
The CYCLE-SENTRY/Continuous selection
affects all zones.
If allowed by OptiSet, complete the following
steps to change modes:
NOTE: The mode can also be changed using the
Mode Menu Screen in the Main Menu. See CYCLE SENTRY

Turning CYCLE-SENTRY On or Off on page -8 . 2

35 .8
TEMP F

SET
70. -10 35 POINT

ZONE 1 ZONE 2 MENU

1. Press the MODE key. See Figure 37. ARA814

Figure 38: Screen Sequence for Changing from

1 Continuous Mode to CYCLE-SENTRY Mode
CONTINUOUS

ON
TEMP F
-8 .2 35 .8
-10 35
SET
POINT 2
OFF

ZONE 1 ZONE 2 MENU CYCLE SENTRY

TEMP F
-8 .2 35 .8 SET
-10 35 POINT

ZONE 1 ZONE 2 MENU

ARA798 ARA814

1. Shows Mode Selected

2. Press Mode Key
Figure 37: Changing Mode

2. The Programming CYCLE-SENTRY Mode

or Programming Continuous Mode Screen
briefly appears. See Figure 38 and Figure 39.
3. The New System Mode CYCLE-SENTRY
or New System Mode is Continuous Screen CONTINUOUS

briefly appears. See Figure 38 and Figure 39. -8 . 2

35 .8
TEMP F

SET
-10 35 POINT

4. The Standard Display appears and the new ZONE 1 ZONE 2 MENU

mode is shown at the top of the display. See ARA805

Figure 38 and Figure 39. Figure 39: Screen Sequence for Changing from
CYCLE-SENTRY Mode to Continuous Mode
5. Press the MODE key again to change the unit
back to the previous mode.
IMPORTANT: If the unit is in CYCLE-SENTRY
null and the mode is switched to Continuous
Mode, the unit will start automatically.

53
Operating Instructions

Initiating a Manual Defrost Cycle 5. The Defrost Started Screen briefly appears.
See Figure 42.
Defrost cycles are usually initiated automatically
based on time or demand. Manual defrost is also 6. The display then shows the Defrost display.
available The bar indicator shows approximately the
percentage of time remaining to complete the
Manual defrost is only available if the zone is
defrost cycle. The bar indicator below (see
running and the zone evaporator coil temperature
Figure 42) shows that the Zone 1 defrost cycle
is less than or equal to 45 F (7 C). Other features
is approximately 25% complete.
such as door switch settings may not allow
manual defrost under some conditions. If the unit is prevented from going into a
Manual Defrost (IE: Coil temperature more
NOTE: If the Rail Alternate feature is set
than 45 F [7 C]. A Defrost Not Available
ENABLED then a manual defrost cycle is
Screen briefly appears. The display returns to
available with temperatures less than or equal to
the Standard Display. See Figure 42.
55 F (13 C).
Use the following steps to initiate a Manual
Defrost:
1. Press the DEFROST key. See Figure 40.
1
CONTINUOUS

ON
2
TEMP F
2
-8 . 35 .8 SET

OFF -10 35 POINT

ZONE 1 ZONE 2 MENU

or
ARA798

1. Standard Display
2. Press Defrost Key
CONTINUOUS
Figure 40: Initiating a Manual Defrost Cycle CONTINUOUS

TEMP F
2
35 .8
TEMP F

SET
-8 . 35 .8 SET

2. The display will briefly show [DEFROST]. 35 POINT -10 35 POINT

ZONE 1 ZONE 2 MENU ZONE 1 ZONE 2 MENU

Then the Zone Select display will appear. ARA816 ARA805

Press the ZONE soft key under the desired zone. Figure 42: Initiating Manual Defrost
Zone 1 has been selected here (see Figure 41). Screen Sequence

Terminating a Defrost Cycle

ON
SELECT ZONE TO DEFROST
The Defrost cycle will terminate automatically
OFF

EXIT ZONE 1 ZONE 2

when the coil temperature reaches 58 F (14.5 C)
1 or when the defrost timer expires. Defrost can also
be terminated by turning the unit off.
ARA815 NOTE: If the Rail Alternate feature is set
ENABLED then a defrost cycle will terminate
1. Press Zone Soft Key
with temperatures greater than or equal to 70 F
Figure 41: Defrost Zone Select Display (21 C).
3. The Defrost Screen briefly appears. See NOTE: If the defrost timer consistently
Figure 42. terminates Defrost because the evaporator coil
temperature fails to reach 58 F (14.5 C), check
4. The Programming Defrost Screen briefly
the unit to see if it is working properly.
appears. See Figure 42.

54
 Operating Instructions

Menu Overview Refer to the SR-2 Multi-Temp Microprocessor

Controller Diagnostic Manual TK 53080 for
The diagram below shows an overview of the
information about the Maintenance Menu and the
menus. See the following pages for information
Guarded Access Menu.
about using the Main Menu.

Not all menu features Temp Watch

may appear Display
Press Any
2.5 Minute Soft Key
Time-out
Zone 1 Soft Key
Zone 1 Setpoint Change

Zone 2 On/Off and Zone 2 Soft Key

Setpoint Change 1, 2 or 3 Zone
Standard
Zone 3 On/Off and Zone 3 Soft Key Display
Setpoint Change

Main Menu Soft Key

Menu
Language (If enabled)
Alarms
Gauges
Sensors
Datalogger Guarded Access Menu
Hourmeters (Not Available if Running)
Mode
Pretrip
Diesel Mode/Electric Standby Security Code (If required)
Adjust Brightness Programmable Features
Time Main Menu Configuration
Alarms
Controlled Access Hourmeter Setup
Sensor Calibration
Maintenance
Cycle Sentry Setup
Menu Defrost Setup
Hourmeters Language Setup
Gauges Access Code Setup
Sensors OptiSet
Alarms (CargoWatch) Sensor Configuration
Service Test Unit Configuration
Interface Board Test ARA912
Display Self Test
Evacuation Test
Software Revision Not all menu features
Set Time and Date may appear

Controlled Access

Figure 43: Menu Overview

55
Operating Instructions

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

operation. Use the following steps to access these

menu areas: GAUGES

1. Begin at the Standard Display. SENSORS

If the Temperature Watch Display is showing,
press any soft key once to return to the DATALOGGER

Standard Display.
HOURMETERS
2. Press the MENU soft key. See Figure 44.
MODE

CONTINUOUS

ON
TEMP F PRETRIP
2
-8 . 35 .8 SET

OFF -10 35 POINT

ADJUST BRIGHTNESS
ZONE 1 ZONE 2 MENU

1
TIME

ARA798 Figure 46: Main Menu Choices

1. Press Menu Soft Key
Main Menu Choices
Figure 44: Accessing Main Menu
Language Menu: This menu only appears if the
3. The first Main Menu choice will appear. Press controller is programmed to activate more than
the NEXT and BACK soft keys to scroll through one language. It allows the operator to select
the menu choices. See Figure 45. which language is used. All other subsequent
displays are shown in the selected language.
4. When the desired selection is shown on the English is the default language. See page 58.
display, press the SELECT soft key to access it.
Alarms Menu: Allows the operator to view any
The Pretrip selection is shown here in Figure
45. active alarms, and allows most alarms to be
cleared. If only one language is enabled this will
be the first menu item to appear. See page 60.
MAIN MENU
ON
PRETRIP Gauges Menu: Allows the operator to view the
unit gauges and the state of the Inputs and Outputs
OFF

EXIT SELECT BACK NEXT

on both the Interface Board and Expansion
Module. See page 62.
Sensors Menu: Allows the operator to view the
ARA818 unit temperature sensors. If CargoWatch sensors
1 2 3 4 are installed they can be viewed as well. See
1. Exit Soft Key 3. Back Soft Key
page 64.
2. Select Soft Key 4. Next Soft Key Datalogger Menu: Allows the operator to set a
Start of Trip marker or print the contents of the
Figure 45: Using Main Menu
CargoWatch datalogger. See page 65.
5. To return to the Standard Display press the Hourmeters Menu: Allows the operator to view
EXIT soft key. The Main Menu choices are the unit hourmeters that have the view feature
shown in Figure 46. For detailed information enabled in the Guarded Access Menu. If the view
on each submenu, see the individual feature for a particular hourmeter is not enabled,
explanations of each submenu item on the then that hourmeter cannot be viewed. See
following pages of this manual. page 67.

56
 Operating Instructions

Mode Menu: Allows the operator to change the

following unit operating modes if allowed. Not all
modes may appear depending on the settings
selected from the Guarded Access Menu. See
page 69.
Turn Off CYCLE-SENTRY Mode/Turn On
CYCLE-SENTRY Mode (If CYCLE-
SENTRY is Off unit runs in Continuous)
Allow Single Zone Control or Multi Zone
Control to be selected
Allow Keypad Lockout to be selected
Start Sleep Mode
Pretrip: Allows the operator to start a Pretrip Test.
If an alarm is active, the Pretrip Test is not
allowed and the operator is prompted to clear the
alarm(s) See page 75.
Adjust Brightness: Allows the operator to adjust
the HMI control panel display backlight intensity
as required by conditions. See page 79.
Time: Allows the operator to view the unit time
and date. The time and date cannot be changed
from this menu. The Time is displayed in 24 hour
military time. See page 80.

57
Operating Instructions
Language Menu
If the Language feature is enabled, an alternate
language can be selected from the Language
Menu. After a new language is chosen all displays
will appear in that language. If the language
feature is not enabled this menu does not appear.
The default language is English. Only languages
that have been enabled in Guarded Access will
appear. Refer to the SR-2 Multi-Temp
Microprocessor Controller Diagnostic Manual
TK 53080 for information about programming the
controller.
The languages available are dependant on the
HMI control panel software revision. Languages
currently supported by software revision 65xx are
English, Spanish, French, German, Italian, Dutch,
Portuguese, Greek, Turkish, Hebrew and Arabic.
Languages currently supported by software
revision 66xx are English, Russian, Polish,
Hungarian, Romanian, Bulgarian, Czech, Danish,
Swedish, Norwegian and Finnish. Languages
currently supported by software revision 67xx are
English and Japanese. Other than the languages
supported, software revisions 65xx, 66xx and
67xx are identical.
To select an alternate language:
1. Begin at the Standard Display.
If the Temperature Watch Display is showing,
press any soft key to return to the Standard
Display.
2. Press the MENU soft key on the Standard
Display.
ON
CONTINUOUS
-8 .2 35 .8
OFF -10 35
ZONE 1 ZONE 2
1. Press Menu Soft Key
Figure 47: Standard Display
58
3. If enabled, the Language Menu is the first
menu item to appear. Press the SELECT soft key
to choose the Language Menu. See Figure 49.
4. The NEW LANGUAGE WILL BE Screen
will appear. See Figure 49.
5. Press the + or - soft keys to select the desired
language. German is shown in Figure 49.
6. When the desired language is shown, press the
YES soft key to confirm the choice.
7. The PROGRAMMING
LANGUAGE-PLEASE WAIT Screen briefly
appears in the new language.
8. The display will then return to the Language
Menu, but will show the new language.
German is shown below in Figure 49.
NOTE: Exercise care when changing
languages, as once changed all HMI Control
panel displays will be in the new language. If
the user is not familiar with the new
language, problems may be experienced
returning to the default language.
9. Repeat the process to select a different
language. Press the NEXT soft key to select a
different Main Menu item. Press the EXIT soft
key to return to the Standard Display.
NOTE: English and all other enabled languages
may be accessed from the Standard Display.
When the Standard Display is shown press and
hold the first and last soft key for 5 seconds as
shown below in Figure 48.
CONTINUOUS
ON
TEMP F
2
-8 . 35 .8 SET
TEMP F
OFF -10 35 POINT
SET
POINT ZONE 1 ZONE 2 MENU
MENU
1
ARA798
1
ARA798
1. Press These Soft Keys
Figure 48: Standard Display
 Operating Instructions

SELECT Key

HAUPTMENU

SPRACHE

BEENDEN AUSWHAL WEITER

ARA820

+ or - Key

NEW LANGUAGE WILL BE

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

Figure 49: Change Language Screen Sequence

59
Operating Instructions

Alarms Menu Important Alarm Notes

If an alarm condition occurs the large Alarm Icon If an alarm will not clear, it may still exist. If
will appear on the Standard Display. See Alarm the alarm is not corrected, it will not clear.
Display on page 47.
If an alarm cannot be cleared from the Main
Alarms are displayed and cleared using the Alarm menu, the Clear key will not appear. These
Menu as follows: alarms must be cleared from the Guarded
Access Menus.
1. Begin at the Standard Display.
If the Temperature Watch Display is showing, All alarms must be viewed before any of the
press any soft key to return to the Standard alarms can be cleared.
Display.
Refer to the SR-2 Multi-Temp Microprocessor
2. Press the MENU soft key on the Standard Controller Diagnostic Manual TK 53080 for
Display. more information about alarm codes and their
diagnosis.
CONTINUOUS

ON
TEMP F
2
-8 . 35 .8 SET

OFF -10 35 POINT

ZONE 1 ZONE 2 MENU

ARA798

1. Press Menu Soft Key

Figure 50: Standard Display

3. The Language Menu or Alarm Menu will

appear. If the Language Menu appears, press
the NEXT key to display the Alarm Menu.
4. Press the SELECT soft key. The Alarm Display
will appear. See Figure 51.
5. If no alarms are present, the No Alarm
Screen will be shown on the display. See
Figure 51. Press the EXIT soft key to return to
the Standard Display.
6. If alarms are present, the quantity of alarms (if
more than one), the alarm code number and
alarm description will be shown on the
display. In the example below (see Figure 51),
there are two alarms present. The most recent
is Alarm Code 6. This alarm code indicates a
problem with the coolant temperature sensor.
7. After the alarm situation is resolved press the
CLEAR key to clear the alarm. To display the
next alarm, press the NEXT key (see Figure 51).
NOTE: For additional information
regarding the alarm shown on the display
press the HELP soft key. A help message will
appear.

60
 Operating Instructions

ALARM 6

2 OF 2 ALARMS
SELECT Key COOLANT TEMP SENSOR

EXIT CLEAR HELP NEXT

ARA823
SELECT Key
NEXT Key

ALARM 5

1 OF 2 ALARMS
AMBIENT TEMP SENSOR

EXIT CLEAR HELP NEXT

ARA824

CLEAR Key

Figure 51: Viewing and Clearing Alarms Screen Sequence

61
Operating Instructions

Gauges Menu 5. Press the BACK or NEXT soft keys to scroll

through the following gauges (see Figure 53):
Unit Gauges and I/O (Input/Output) State are
viewed using the Gauges Menu as follows: Coolant Temperature
1. Begin at the Standard Display. Coolant Level
If the Temperature Watch Display is showing,
Amps
press any soft key to return to the Standard
Display. Battery Voltage
2. Press the MENU soft key on the Standard Engine RPM
Display.
Fuel Level Sensor
CONTINUOUS
Discharge Pressure
ON
TEMP F
-8 .2 35 .8 SET
Suction Pressure
OFF -10 35 POINT

ZONE 1 ZONE 2 MENU I/O (Input/Output State) - Displays the

1 current state of the input/output devices.
NOTE: Selecting I/O (Input/Output State)
ARA798 enters a group of screens that show the
1. Press Menu Soft Key current state of the input/output devices. See
I/O (Input/Output State) on page 63.
Figure 52: Standard Display
6. Press the LOCK soft key to display any Gauge
3. Press the NEXT soft key until the Gauges Menu Screen for 15 minutes. Press the key again to
appears. See Figure 53. unlock the screen.
4. Press the SELECT soft key to enter the Gauges 7. Press the EXIT soft key to return to the Standard
Menu. Display. If no keys are pressed within 30
seconds, the screen will return to the Standard
Display.

BACK Key BACK Key

SELECT Key BACK Key NEXT Key

BACK Key NEXT Key

BACK Key NEXT Key SELECT Key

BACK Key NEXT Key

To I/O States Displays

See Next Page

BACK Key NEXT Key

BACK Key NEXT Key

NEXT Key NEXT Key

Figure 53: Viewing Gauges Screen Sequence

62
 Operating Instructions

I/O (Input/Output State)

The I/O Screens display the current state of the
input/output devices listed below. Press the BACK
or NEXT soft keys to scroll through the I/O Screens.
Press the EXIT soft key to return to the Gauges
Menu.
High Speed Relay
Run Relay
Defrost Damper
Oil Pressure
Oil Level
Run Relay Feedback
Fuel Pressure
Alternator Frequency
Diesel/Electric Relay
Electric Ready Input
Electric Overload
Variable Speed Fan Current Pos Z2
Variable Speed Fan Desired Pos Z2
Variable Speed Fan Current Pos Z3
Variable Speed Fan Desired Pos Z3
Condenser Inlet Solenoid
Receiver Tank Inlet Pressure Solenoid
Purge Valve
Liquid Line Solenoid Zone 1
Liquid Line Solenoid Zone 2
Liquid Line Solenoid Zone 3
Hot Gas Solenoid Zone 1
Hot Gas Solenoid Zone 2
Hot Gas Solenoid Zone 3
Suction Line Solenoid Zone 1
Suction Line Solenoid Zone 2
Suction Line Solenoid Zone 3
NOTE: Not all menu items may appear.

63
Operating Instructions

Sensors Menu Zone 1 Evaporator Coil Temperature

Use the following steps to view the sensor Zone 2 Return Air Temperature
readings.
Zone 2 Discharge Air Temperature
1. Begin at the Standard Display.
Zone 2 Temperature Differential
If the Temperature Watch Display is showing,
press any soft key to return to the Standard Zone 2 Evaporator Coil Temperature
Display.
Zone 3 Return Air Temperature
2. Press the MENU soft key on the Standard
Zone 3 Discharge Air Temperature
Display.
Zone 3 Temperature Differential
CONTINUOUS

ON

-8 .2 35 .8
TEMP F Zone 3 Evaporator Coil Temperature
SET
-10 35 POINT
OFF

ZONE 1 ZONE 2 MENU Ambient Air Temperature

1
Spare 1 Temperature
ARA798
Spare 2 Temperature
1. Press Menu Soft Key
Spare 3 Temperature
Figure 54: Standard Display
Optional CargoWatch Datalogger Sensor
3. Press the NEXT soft key until the Sensors Menu 1-6 Temperatures
appears. Board Temperature Sensor The Board
4. Press the SELECT soft key to enter the Sensors Temperature Sensor displays the
Menu. temperature of the PC board inside the
HMI control panel. The controller will
MAIN MENU turn the HMI display heater on if this
ON

SENSORS temperature goes below a certain point in

OFF

EXIT SELECT BACK NEXT extremely cold ambient temperatures.

1

ZONE 2 RETURN AIR TEMPERATURE

ARA828 ON

35. 8 F
1. Press Select Soft Key OFF

EXIT LOCK BACK NEXT

Figure 55: Sensors Menu Display

5. Press the BACK or NEXT soft keys to scroll

ARA827
through the following sensor screens. Only 1 2 3 4
configured and enabled sensors are shown.
For example, if the unit is configured as a two 1. Exit Soft Key 3. Back Soft Key
zone unit, then Zone 3 sensors are not shown. 2. Lock Soft Key 4. Next Soft Key
If the CargoWatch sensors are not enabled,
Figure 56: Soft Keys
they will not be shown.
Zone 1 Return Air Temperature 6. Press the LOCK soft key to display any sensor
screen for an indefinite period. Press the key
Zone 1 Discharge Air Temperature again to unlock the screen.
Zone 1 Temperature Differential 7. Press the EXIT soft key to return to the Standard
NOTE: The Temperature Differential is Display. If no keys are pressed within 30
the difference between the Return Air seconds, the screen will return to the Standard
Temperature and the Discharge Air Display.
Temperature.

64
 Operating Instructions

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

Display.
The CargoWatch Datalogger is physically located
in the HMI Control Panel. It can support up to six
optional temperature sensors. ON
CONTINUOUS

TEMP F
2
-8 . 35 .8
The Datalogger Menu is used to initiate a start of OFF -10 35
SET
POINT

trip, or to print a trip report with a hand-held ZONE 1 ZONE 2 MENU

printer. 1

Initiating a Start of Trip ARA798

A Start Of Trip places a marker in the memory
of both the ServiceWatch and CargoWatch
Dataloggers. It is typically initiated when the
cargo is being loaded. The Start Of Trip marker
then shows when the trip started in the data that is
downloaded or printed from the datalogger. A
Start Of Trip can be initiated through the use of
WinTrac datalogging software, or manually in the
field. The following procedure covers manual
initiation. For more information on datalogging,
see the WinTrac User Manual included with the
WinTrac software. The WinTrac User Manual is
also available on the Internet at
HTTP://WWW.BLUETREE.IE.
1. Begin at the Standard Display.
If the Temperature Watch Display is showing,
press any soft key to return to the Standard
Display.
1. Press Menu Soft Key
Figure 57: Standard Display
3. Press the NEXT soft key until the Datalogger
Menu appears. See Figure 58.
4. Press the SELECT soft key on the Datalogger
Menu. The Start Trip Screen will appear.
5. Press the SELECT soft key. The Start Of Trip
Screen will appear.
6. Press the SELECT soft key to initiate a start of
trip.
7. A Start Of Trip Marker has been inserted into
the datalogger memory.
NOTE: The Start Of Trip Marker is sent to both
the CargoWatch and ServiceWatch dataloggers.

SELECT Key

SELECT Key

SELECT Key

Figure 58: Start of Trip Screen Sequence

65
Operating Instructions

Printing a Trip Report 2. Begin at the Standard Display.

If the Temperature Watch Display is showing,
This procedure prints the CargoWatch Datalogger
press any soft key to return to the Standard
record directly to a hand-held printer. The printed
Display.
record shows things such as the unit and
controller identification numbers, dates and times, 3. Press the MENU soft key on the Standard
the setpoints, and data from the optional sensors Display.
connected to the CargoWatch datalogger. If no
sensors are connected, the printed record shows CONTINUOUS

the same things without the sensor data. ON

-8 . 2
35 .8
TEMP F

SET

OFF -10 35 POINT

ZONE 1 ZONE 2 MENU

ARA798

1. Press Menu Soft Key

Figure 60: Standard Display

1 4. Press the NEXT soft key until the Datalogger

Menu appears. See Figure 61.
5. Press the SELECT soft key on the Datalogger
3 Menu. The Start Trip Screen will appear.
2
6. Press the NEXT soft key. The Print/View
Screen will appear.
7. Press the SELECT soft key. The Delivery
1. ServiceWatch Port
Ticket Screen will appear. Press the SELECT
2. CargoWatch Port soft key to print a Delivery Ticket, which is a
3. Printer Port short ticket that shows delivery specific details
Figure 59: Printer Port Location including the current temperature.

1. Connect the printer to the 6-pin printer port
located inside the control box.
NOTE: The printer port can be mounted so it
is accessible without opening the control box.
It is typically mounted between the
CargoWatch Port and the ServiceWatch Port.
8. Press the NEXT soft key to go to the Trip
Ticket Screen. Press the SELECT soft key to
print a Trip Ticket, which is a long ticket that
shows details for the current trip including a
temperature history. The Trip Ticket is also
called a Journey Ticket.

SELECT Key

SELECT Key

NEXT Key NEXT Key

SELECT Key SELECT Key

Figure 61: Print Report Screen Sequence

66
 Operating Instructions

Hourmeters Menu 5. Press the NEXT and BACK soft keys to view the
hourmeter displays. The Hourmeter names
The Hourmeters are programmable to be visible
and definitions are shown in the table on
or hidden in Guarded Access. Hourmeters that are
page 68 in the order they appear. Only
visible are displayed. Hourmeters that are hidden
configured hourmeters that have been enabled
are not displayed, but they do count hours. The
for viewing in Guarded Access will be shown.
default setting is to display only the Engine
Hours. The Hourmeters Menu will not appear if
all hourmeters are hidden. Refer to the SR-2 ON
TOTAL RUN TIME HOURS

Multi-Temp Microprocessor Controller 138

Diagnostic Manual TK 53080 for information OFF

EXIT LOCK BACK NEXT

about programming the controller.
Hourmeters can be viewed in the Hourmeters
Menu as follows: ARA831

1. Begin at the Standard Display. 1 2 3 4

If the Temperature Watch Display is showing,
1. Exit Soft Key 3. Back Soft Key
press any soft key to return to the Standard
Display. 2. Lock Soft Key 4. Next Soft Key
Figure 64: Soft Keys
2. Press the MENU soft key on the Standard
Display. 6. Press the LOCK soft key to lock the hourmeter
on the display. Press the key again to unlock
CONTINUOUS the display.
ON
TEMP F
-8 .2 35 .8 SET 7. Press the Exit soft key to return to the
OFF -10 35 POINT
Standard Display. If no keys are pressed
ZONE 1 ZONE 2 MENU

within 30 seconds, the screen will return to the

1
Standard Display.
ARA798

1. Press Menu Soft Key

Figure 62: Standard Display

3. Press the NEXT soft key until the Hourmeters

Menu appears.
4. Press the SELECT soft key to enter the
Hourmeters Menu.

MAIN MENU
ON

HOURMETERS

OFF

EXIT SELECT BACK NEXT

1

ARA830

1. Press Select Soft Key

Figure 63: Hourmeters Menu Display

67
Operating Instructions

Hourmeter Name Definition

Total Hours Total number of hours the unit has been turned on (protection hours).
Total Run Time Hours Total number of hours the unit has run in both diesel and electric mode.
Engine Hours Total number of hours the unit has run in diesel mode.
Electric Run Hours Total number of hours the unit has run in electric mode.
Zone 1 Run Time Hours Total number of hours Zone 1 has run in both diesel and electric mode.
Zone 2 Run Time Hours Total number of hours Zone 2 has run in both diesel and electric mode.
Zone 3 Run Time Hours Total number of hours Zone 3 has run in both diesel and electric mode.
Total Run Reminder 1 Hours User Programmable The number of hours before a Total Unit Run Time
Maintenance Reminder 1 occurs.
Total Run Reminder 2 Hours User Programmable The number of hours before a Total Unit Run Time
Maintenance Reminder 2 occurs.
Controller Power On Hours Total hours the controller and HMI control panel have been turned on.
Pretrip Reminder Hours User Programmable number of hours before a Pretrip Reminder occurs.
Engine Reminder 1 Hours User Programmable The number of hours before an Engine Run Time
Maintenance Reminder 1 occurs.
Engine Reminder 2 Hours User Programmable The number of hours before an Engine Run Time
Maintenance Reminder 2 occurs.
Electric Reminder 1 Hours User Programmable The number of hours before an Electric Run Time
Maintenance Reminder 1 occurs.
Electric Reminder 2 Hours User Programmable The number of hours before an Electric Run Time
Maintenance Reminder 2 occurs.
Only configured hourmeters that have been enabled in Viewable Hourmeter Setup Menu will be shown.

68

Mode Menu
Various operating modes can be selected using the
Mode menu. Not all modes may be available,
depending on OptiSet usage and settings of other
programmable features. The following modes
may be available.
Turn CYCLE-SENTRY On or Off
The CYCLE-SENTRY Mode can be turned On or
Off. If CYCLE-SENTRY is turned off the unit
runs in Continuous mode. Either
CYCLE-SENTRY or Continuous operation may
be disabled via OptiSet. See Turning
CYCLE-SENTRY On or Off on page 70.
Single Zone Control - Multi Zone Control
If enabled in Guarded Access, Single Zone
Control allows single temperature operation. If
Single Zone Control operation is selected then all
zones will be forced on and will control to the
same setpoint. All bulkheads should be removed
to create one large compartment. Multi Zone
Control allows separate control for each
configured zone. See Operating The Unit In
Single Zone Control Mode on page 46 and
Selecting Single Zone Control or Multi Zone
Control on page 71 for more information.
Keypad Lockout
If enabled in Guarded Access, the keypad can be
locked to prevent unauthorized use. If the keypad
is locked only the On and Off keys function. The
keypad will remain locked even if the unit is
turned off and back on. If Keypad Lockout is
active, press and hold any soft key for 5 seconds
to deactivate the feature. See Selecting Keypad
Lockout on page 72.
Operating Instructions
Sleep Mode
If enabled in Guarded Access, Sleep Mode is used
to keep the engine warm and the battery charged
when the unit is not in use. When the unit is in
Sleep Mode the display will show SLEEP and
the current time. See Selecting Sleep Mode on
page 73.
Program Wakeup Time: This feature allows a
wakeup time to be specified. When the
selected time is reached the unit will start and
resume normal operation.
If Wakeup Time is selected:
Day to Wake Up: This feature allows the
day the unit is to wake up to be specified.
Hour to Wake Up: This feature allows the
hour the unit is to wake up to be specified.
Minute to Wake Up: This feature allows
the minute the unit is to wake up to be
specified.
Run Pretrip on Wake Up: This feature
allows a Pretrip Test to be automatically
run when the unit wakes up.
69
Operating Instructions

Turning CYCLE-SENTRY On or Off 3. Press the NEXT soft key until the Mode Menu
appears.
The easiest way to switch between
CYCLE-SENTRY and Continuous Run is to press 4. Press SELECT soft key to enter the Mode Menu.
the Mode key (see page 53). But, you can also The CYCLE-SENTRY On/Off Screen will
switch modes in the Mode Menu as follows: appear (see Figure 66).
1. Begin at the Standard Display. 5. Press the SELECT soft key, to switch between
If the Temperature Watch Display is showing, CYCLE-SENTRY Mode and Continuous
press any soft key to return to the Standard Mode.
Display.
6. The new mode is then confirmed for 10
2. Press the MENU soft key on the Standard seconds.
Display.
7. The display then returns to the Mode Menu.
1 Press the SELECT soft key again to change the
ON
CYCLE SENTRY
mode again.
TEMP F
-8 .2 35 .8
OFF -10 35
SET
POINT 2 CAUTION: If the unit is in
ZONE 1 ZONE 2 MENU CYCLE-SENTRY null and the mode is
3 switched to Continuous mode, the unit will
start automatically.
ARA841

1. Shows Current Mode

2. Mode Key
3. Press Menu Soft Key
Figure 65: Standard Display

SELECT Key

SELECT Key SELECT Key

Figure 66: Selecting Mode Screen Sequence

70
 Operating Instructions

Selecting Single Zone Control or Multi 5. Press the NEXT soft key to display the Single
Zone Control Zone Control On/Off Display.
This feature must be enabled in Guarded Access 6. Press the SELECT soft key to turn Single Zone
to be available. See Operating The Unit In Single Control On or Off.
Zone Control Mode on page 46 and Single
Zone Control - Multi Zone Control on page 69 CHANGE MODE
for more information about Single Zone Control. ON

TURN ON SINGLE ZONE CONTROL

Use the following steps to select Single Zone OFF

Control or Multi Zone Control: EXIT SELECT BACK NEXT

1
1. Begin at the Standard Display.
If the Temperature Watch Display is showing,
press any soft key to return to the Standard ARA833

Display. 1. Press Select Soft Key

2. Press the MENU soft key on the Standard Figure 69: Single Zone Control On/Off Display
Display.
7. The new mode is then confirmed for 10
CONTINUOUS
seconds.
ON

-8 .2 35 .8
TEMP F
8. The display then returns to the Mode Menu.
SET
-10 35 POINT
OFF

ZONE 1 ZONE 2 MENU

9. Press the Exit soft key to return to the
1
Standard Display. If no keys are pressed
within 30 seconds, the screen will return to the
Standard Display.
ARA798

1. Press Menu Soft Key

Figure 67: Standard Display

3. Press the NEXT soft key until the Mode Menu

appears.
4. Press the SELECT soft key to enter the Mode
Menu. The Turn CYCLE-SENTRY On/Off
Screen will appear.

MAIN MENU
ON

MODE

OFF

EXIT SELECT BACK NEXT

1

ARA832

1. Press Select Soft Key

Figure 68: Mode Menu Display

71
Operating Instructions

Selecting Keypad Lockout 5. Press the NEXT soft key until the Keypad
Lockout Display appears.
This feature must be enabled in Guarded Access
to be available. See Keypad Lockout on page 69 6. Press the SELECT soft key to select Keypad
for more information about Keypad Lockout. Use Lockout.
the following steps to select Keypad Lockout:
1. Begin at the Standard Display. ON
CHANGE MODE

If the Temperature Watch Display is showing, KEYPAD LOCKOUT

press any soft key to return to the Standard OFF

Display. 1
EXIT SELECT BACK NEXT

2. Press the MENU soft key on the Standard

Display. ARA834

1. Press Select Soft Key

CONTINUOUS

ON
TEMP F Figure 72: Keypad Lockout Display
-8 .2 35 .8 SET
-10 35 POINT
OFF

ZONE 1 ZONE 2 MENU

7. The new mode is then confirmed for 10
1
seconds.
8. The display then returns to the Mode Menu.
ARA798
9. Press the Exit soft key to return to the
1. Press Menu Soft Key Standard Display. If no keys are pressed
Figure 70: Standard Display within 30 seconds, the screen will return to the
Standard Display.
3. Press the NEXT soft key until the Mode Menu
NOTE: If Keypad Lockout is active, press and
appears.
hold any soft key for 5 seconds to deactivate the
4. Press the SELECT soft key to enter the Mode feature.
Menu. The Turn CYCLE-SENTRY On/Off
Screen will appear.

MAIN MENU
ON

MODE

OFF

EXIT SELECT BACK NEXT

1

ARA832

1. Press Select Soft Key

Figure 71: Mode Menu Display

72

Selecting Sleep Mode
This feature must be enabled in Guarded Access
to be available. Sleep mode starts and stops the
unit as required to keep the unit battery in a
charged condition and keep the unit engine warm
in cold ambient conditions. Sleep mode does not
maintain setpoint, it keeps the compartment
temperature near the ambient temperature when
the unit is running. This is useful in extremely
cold weather or when the unit is to be out of
service for an extended time.
Sleep mode operates in both Diesel mode and
Electric mode. In Diesel mode the unit will start
and stop as required to maintain engine
temperature and battery charge. In Electric mode
the unit starts and stops as necessary to maintain
battery charge only.
When Sleep mode is entered, the operator can
program an automatic Wake-up Time up to a week
away. Using this feature, the unit will
automatically restart and run normally at the
determined time. If a Wake-up Time is
programmed, the operator can also program an
automatic Pretrip Test when the unit restarts.
Select Sleep Mode as follows:
1. Begin at the Standard Display.
If the Temperature Watch Display is showing,
press any soft key to return to the Standard
Display.
2. Press the MENU soft key on the Standard
Display.
CONTINUOUS
ON
2 TEMP F
-8 . 35 .8
OFF -10 35
ZONE 1 ZONE 2
1. Press Menu Soft Key
Figure 73: Standard Display
3. Press the NEXT soft key until the Mode Menu
appears. See Figure 74.
4. Press SELECT soft key to enter the Mode Menu.
Operating Instructions
5. Press the NEXT soft key as required to display
the Sleep Mode Screen.
6. Press the SELECT soft key to start the Sleep
mode.
7. You now choose to program a Sleep mode
Wake-up Time or simply enter Sleep mode
immediately. Press the NO soft key to
immediately enter Sleep mode.
a. The display will show SLEEP and the
unit will start and stop as required to keep
engine warm and/or the battery charged.
Sleep mode does not maintain the
compartment temperature.
b. Press the EXIT soft key to exit Sleep mode
or turn the unit off and back on. The unit
will resume normal operation and control
to setpoint.
8. To enter a Wake-up Time verify that the unit
clock is set properly (see Time Display on
page 80). Then press the YES soft key at the
Program A Wake-Up Time? Screen.
9. Press the + or - soft keys to select the day the
unit is to restart in normal operation. In this
example Monday has been chosen. Press the
YES soft key to confirm the day.
10. The display will now prompt you for the hour
the unit is to restart in normal operation. In
this example 18:00 hours has been chosen.
Note that 24 hour military time is used.
Press the YES soft key to confirm the hour.
11. The display will now prompt you for the
minute the unit is to restart in normal
operation. In this example 18:37 hours has
SET
POINT been chosen. Press the YES soft key to confirm
MENU the minute.
1 12. The display will now prompt you to Run A
Pretrip On Wake-Up? Press YES soft key or
ARA798 the NO soft key accordingly and the display
will show the unit is programming the Sleep
mode.
13. The display will show SLEEP and the unit
will start and stop as required to keep the
engine warm and/or the battery charged. Sleep
mode does not maintain setpoint.
73
Operating Instructions

14. The unit will restart at the programmed time
(in this example 18:37 hours) and perform a
Pretrip (if selected). After the Pretrip is
complete the test results will be displayed and
the unit will resume normal operation and
control to setpoint.
15. To exit Sleep mode before the selected
Wake-up time press the EXIT soft key or turn
the unit off and back on. The unit will resume
normal operation and control to setpoint.

SELECT Key then NEXT Key YES Key

SELECT Key YES Key

CONTINUOUS

TEMP F
2
-8 . 35 .8 SET
-10 35 POINT

ZONE 1 ZONE 2 MENU

ARA805
YES Key YES Key or NO Key

YES Key

Figure 74: Selecting Sleep Mode Screen Sequence

74

Pretrip Tests
A Pretrip Test verifies unit operation. The Pretrip
Menu allows the operator to select and initiate a
Pretrip Test. There are two different Pretrip Tests,
the Full Pretrip and the Running Pretrip.
CAUTION: Monitor the return air
temperature when performing a Pretrip
Test on a loaded trailer. The controller
may not maintain setpoints during the
Pretrip Test.
Pretrip Test Conditions
Current unit settings such as zones on or off
and setpoints are saved and restored at the end
of the Pretrip Test or if the unit is turned off
and back on.
All zones are forced on.
A Pretrip Test can be run in either Diesel or
Electric Mode.
The unit will auto switch from Diesel Mode to
Electric Mode or from Electric Mode to Diesel
Mode during a Pretrip Test if these features
are enabled and the auto switch conditions
occur.
Conditions Where Pretrip Tests Are Not
Allowed
Any alarms are present.
The unit is in Sleep Mode.
Unit is in Service Test Mode, Interface Board
Test Mode, or Evacuation Mode.
Operating Instructions
Full Pretrip
A Full Pretrip occurs when Pretrip is initiated
before the engine or electric motor starts running.
The Full Pretrip test proceeds in the order shown
below:
Amp Checks Each electrical control
component is energized and the current drawn
is confirmed to be within specification.
Engine or Electric Motor Start The engine or
electric motor will start automatically.
Defrost If the coil temperature in a zone is
below 45 F (7 C), a Defrost cycle is initiated
for that zone.
RPM Check (Diesel Mode only) If the unit
is running in the Diesel Mode, the engine
RPM in high and low speed is checked.
Zone 1 Cool Check The ability of the zone
to cool in low speed is checked.
Zone 1 Heat Check The ability of the zone
to heat in low speed is checked.
Zone 1 Return to Cool Check The ability of
the zone to return to cool mode is checked.
Zone 2 Cool Check The ability of the zone
to cool in low speed is checked.
Zone 2 Heat Check The ability of the zone
to heat in low speed is checked.
Zone 2 Return to Cool Check The ability of
the zone to return to cool mode is checked.
Zone 3 Cool Check The ability of the zone
to cool in low speed is checked.
Zone 3 Heat Check The ability of the zone
to heat in low speed is checked.
Zone 3 Return to Cool Check The ability of
the zone to return to cool mode is checked.
Report Test Results The test results are
reported as PASS, CHECK or FAIL
when the Pretrip Test is completed. If test
results are CHECK or FAIL, alarm codes
will exist to direct the technician to the source
of the problem.
75
Operating Instructions

Running Pretrip Pretrip Test Issues

A Running Pretrip occurs when Pretrip is initiated When performing a Pretrip Test, the following
after the engine or electric motor is running. The issues should be considered.
Running Pretrip test proceeds in the order shown
If running a Pretrip Test on a trailer loaded
below:
with dry cargo, insure that proper airflow can
Defrost If the coil temperature in a zone is occur around the load. If the load restricts
below 45 F (7 C), a Defrost cycle is initiated airflow, false test results may occur. Also,
for that zone. SR-2 units have high refrigeration capacity
which results in rapid temperature changes.
RPM Check (Diesel Mode only) If the unit
Sensitive dry cargo may be damaged as a
is running in the Diesel Mode, the engine
result.
RPM in high and low speed is checked.
If running a Pretrip Test on a trailer that has
Zone 1 Cool Check The ability of the zone
just been washed down, the extremely high
to cool in low speed is checked.
humidity inside the trailer may result in false
Zone 1 Heat Check The ability of the zone test results.
to heat in low speed is checked.
If running a Pretrip Test on a trailer loaded
Zone 1 Return to Cool Check The ability of with sensitive cargo, monitor the load
the zone to return to cool mode is checked. temperature during the test as normal
temperature control is suspended during
Zone 2 Cool Check The ability of the zone
pre-trip operation.
to cool in low speed is checked.
Always perform Pretrip Tests with the trailer
Zone 2 Heat Check The ability of the zone
cargo doors closed to prevent false test
to heat in low speed is checked.
failures.
Zone 2 Return to Cool Check The ability of
the zone to return to cool mode is checked.
Zone 3 Cool Check The ability of the zone
to cool in low speed is checked.
Zone 3 Heat Check The ability of the zone
to heat in low speed is checked.
Zone 3 Return to Cool Check The ability of
the zone to return to cool mode is checked.
Report Test Results The test results are
reported as PASS, CHECK or FAIL
when the Pretrip Test is completed. If test
results are CHECK or FAIL, alarm codes
will exist to direct the technician to the source
of the problem.

76
 Operating Instructions

Initiating a Pretrip Test 6. The Pretrip display appears.

Before initiating a Pretrip Test, clear all alarm
codes.
To stop a Pretrip Test at any time, turn the unit off.
Use the following procedure to initiate a Full
Pretrip or a Running Pretrip. A Running Pretrip
can also be initiated by starting at step 3 with the
unit running.
1. If the unit is running, press the OFF key to stop
the unit.
2. Press the ON key to turn the unit on.
3. To initiate a Full Pretrip press the MENU soft
key as soon as the Standard Display appears
and before the unit starts.
To initiate a Running Pretrip let the unit start
before pressing the MENU soft key on the
Standard Display.
CONTINUOUS
ON
-8 .2 35 .8
OFF -10 35
ZONE 1 ZONE 2
1. Press Menu Soft Key
Figure 75: Standard Display
4. Press the NEXT soft key until the Pretrip Screen
appears. See Figure 77.
5. Press the SELECT soft key to start a Pretrip.
NOTE: If all alarms were not cleared a
prompt appears as shown below. Press the
EXIT key to exit the Pretrip Test, clear all
alarms and repeat the Pretrip Test.
ON
NO PRETRIP -- ALARM ACTIVE
OFF
The top line of the display indicates the
unit is performing the non-running (or
running) portion of the Pretrip Test.
The second line shows Test 1 of 55 is
being performed. Note that the tests may
not be performed in numerical order.
The soft keys may be used during the
Pretrip Test to select the Hourmeter,
Gauge, or Sensor menus.
To stop a Pretrip Test at any time, turn the
unit off. This will generate Alarm Code 28
Pretrip Abort. Other alarm codes may also
be generated. This is normal when the
Pretrip Test is halted before completion.
In a Full Pretrip, when the non-running tests
are complete the unit will start automatically
and continue with the running tests.
7. When all tests are complete, the results are
TEMP F reported as PASS, CHECK or FAIL. If
SET
POINT FAIL appears, the unit will shut down. If the
MENU results are CHECK or FAIL, the
1 accompanying alarm codes will direct the
technician to the cause of the problem.
ARA798 8. If the Pretrip Test results are CHECK or
FAIL, the problem should be diagnosed and
corrected and the Pretrip Test repeated and
passed before the unit is released for service.
The Pretrip Test result screen will exit to the
Main Menu Alarm Submenu for convenient
access to any alarms generated during the
Pretrip Test.
Stopping a Pretrip Test
Turn the unit off to stop a Pretrip Test at any time.
This will generate Alarm Code 28Pretrip Abort.
Other alarm codes may also be generated. This is
normal when the Pretrip test is stopped before
completion.

EXIT

ARA835

1. Press Exit Soft Key

Figure 76: No Pretrip Alarm Active Display

77
Operating Instructions

SELECT Key

RUNNING PRETRIP
TEST 3 OF 15

ZONE 1 COOL TEST

HOUR SENSORS GAUGES

METERS
ARA837

NON-RUNNING PRETRIP
TEST 1 OF 55

SENSOR CHECK

HOUR SENSORS GAUGES

METERS
ARA836

Figure 77: Pretrip Test Screen Sequence

78
 Operating Instructions

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

2. Press the MENU soft key on the Standard

Display.

CONTINUOUS

ON
TEMP F
-8 .2 35 .8 SET
YES Key
OFF -10 35 POINT

ZONE 1 ZONE 2 MENU

1 ADJUSTING BRIGHTNESS

PLEASE WAIT
ARA798

1. Press Menu Soft Key ARA903

Figure 78: Standard Display

3. Press the NEXT soft key until the Adjust

Brightness Menu appears. See Figure 79.
4. Press the SELECT soft key to enter the Adjust
Brightness Menu. See Figure 79.
5. Press the + or - soft keys to select the desired
backlight brightness. See Figure 79. This
example shows changing backlight brightness
from low to medium.
6. Press the YES soft key to enter the new
backlight brightness level. Figure 79: Adjusting Display Brightness
Screen Sequence
7. The ADJUSTING BRIGHTNESS - PLEASE
WAIT Screen briefly appears.
8. The selected level appears on the screen.
9. The Adjust Brightness Main Menu Screen
reappears.

79
Operating Instructions

Time Display Loading Procedure

The time and date held by the HMI Control Panel
real time clock can be checked. Time and Date
cannot be changed from the Main Menu. The time
and date are changed by programming the
controller. Refer to the SR-2 Multi-Temp
Microprocessor Controller Diagnostic Manual
TK 53080 for information about programming the
controller.
View the time and date as follows:
1. Begin at the Standard Display.
If the Temperature Watch Display is showing,
press any soft key to return to the Standard
Display.
2. Press the MENU soft key on the Standard
Display.
3. Press the NEXT soft key until the Time Display
appears.
4. Press the SELECT soft key to view the time and
date.
1
CONTINUOUS
1. Make sure the unit is turned off before
opening the doors to minimize frost
accumulation on the evaporator coil and heat
gain in the trailer. (Unit may be running when
loading the trailer from a warehouse with door
seals.)
2. Spot check and record load temperature while
loading. Especially note any off-temperature
product.
3. Load the product so that there is adequate
space for air circulation completely around the
load. DO NOT block the evaporator inlets or
outlets.
4. Products should be pre-cooled before loading.
Thermo King transport refrigeration units are
designed to maintain loads at the temperature
at which they were loaded. Transport
refrigeration units are not designed to pull hot
loads down to temperature. Verify that the
setpoint temperatures are correct for your
cargo. Pre-cool the trailer as required.

ON
TEMP F
CAUTION: Cargo must be pre-cooled to
-8 .2 35 .8 SET the proper temperature before loading.
OFF -10 35 POINT
The unit is designed to maintain
ZONE 1 ZONE 2 MENU
temperature, not to bring a product to
2
temperature.
ARA798
MENU Key then NEXT Key Single Temperature Loading
Procedure
Additional steps must be taken to insure load
temperature requirements are implemented and
maintained when a multi-temp unit is used to
SELECT Key
refrigerate a single-temperature load. Trailer
loading procedures will be different depending on
how temperature control is established for each
trailer compartment Zone. See Operating The
Unit In Single Zone Control Mode on page 46
and the two methods of controlling to a single
1. Standard Display temperature in the trailer.
2. Menu Soft Key
Using Method 1 on page 46, the unit is operated
Figure 80: Time and Date Screens with each Zone individually set to the same
setpoint temperature. With this method, bulkheads
that separate compartments must be in place.

80
 Operating Instructions

Figure 81 shows two Zones that have the same
setpoint. The bulkhead separating the
compartments is in place. Each Zone evaporator
senses temperature and controls to the
temperature setpoint in that Zone.
Figure 81: Two Compartments, Same Setpoint
Temperature, Bulkheads In Place
In this example, each Zone could be individually
set to 35 F. The evaporator in each compartment
will then control the temperature in that
compartment to the same 35 F setpoint.
NOTE: Using the above method, it is
recommended that the bulkheads that separate
each compartment be in place to isolate the
compartments.
Using Method 2 on page 46, Single Zone
Control Mode has been enabled in the Guarded
Access/Main Menu Configuration menu.
Figure 82 shows two Zones that have the same
setpoint. The bulkhead separating the
compartments has been removed. The Zone 1
evaporator senses temperature and controls both
evaporators to the temperature setpoint.
Post Load Procedure
1. Make sure all the doors are closed and locked.
2. Start the unit if it was shut off to load (see
Turning Unit On on page 43).
3. Make sure the setpoints are at the desired
settings.
4. One-half hour after loading, manually initiate
a Defrost cycle. If the evaporator coil sensor
temperature is below 45 F (7 C), the unit will
Defrost. The microprocessor will terminate
Defrost automatically when the evaporator
coil temperature reaches 58 F (14.5 C) or the
unit has been in the Defrost mode for 30 or 45
minutes (depending on setting).
Post Trip Checks
1. Wash the unit.
2. Check for leaks.
3. Check for loose or missing hardware.
4. Check for physical damage to the unit.

Figure 82: Two Compartments, Same Setpoint

Temperature, Bulkhead(s) Removed

NOTE: Using Method 2, it is recommended that

all bulkheads be removed to create one large
compartment.

81
Operating Instructions

82
Electrical Maintenance
Alternator Charging System
Diagnostic Procedures
General Information
Poor charging performance may not be caused by
a bad alternator. The following conditions can
cause improper battery charging, even with a
good alternator. (See Service Bulletin T&T 388
for more information.)
A problem may exist in the 2A output circuit
from the alternator to the battery. Check for an
open 2A circuit, loose connections, defective
battery cables or dirty battery terminals.
The battery must be in good condition and
capable of accepting a charge. Check for a
damaged battery, correct electrolyte level, and
loose or corroded connections.
1 2
7
1. B+ Terminal (Positive Output - 2A Wire)
2. B- Terminal (Negative Ground - CH Wire)
3. S Terminal (Regulator Sense - 2 Wire)
4. L Terminal (Regulator Excite - 7K Wire)
Figure 83: Thermo King Alternator Terminal and Component Locations
The alternator charging output will be low if
the alternator belt or pulleys are defective or
the belt is not properly adjusted. Be sure the
belt is not loose or cracked and the pulleys are
the correct size and in good condition.
The excitation circuit (EXC circuit) must
supply voltage to the excite terminal of the
alternator.
The sense circuit (2 circuit) must supply
voltage to the sense terminal of the alternator.
The alternator must be properly grounded.
The unit control circuits or installed
accessories may be drawing excessive current.
An overcharged battery is usually caused by a
defective voltage regulator.
Alternator Identification
These units use Thermo King Alternators (see
Figure 83), which are painted black.
3
4
5
6
5. F2 Terminal (Do Not Ground)
6. Voltage Regulator and Brush Assembly
7. W Terminal (AC Output)
83
Electrical Maintenance
Interface Board Fuse F4
The interface board has a 300 ohm resistor and a
resistor bypass fuse (F4) in the alternator
excitation circuit. The fuse and resistor are
connected in parallel and are located on the
interface board. Removing the resistor bypass
fuse places the 300 ohm resistor in the excitation
circuit as required for Thermo King alternators
(and Australian Bosch alternators). Installing the
resistor bypass fuse removes the 300 ohm resistor
from the excitation circuit as required for
Prestolite alternators. See the specific unit wiring
diagram for exact details.
NOTE: The F4 fuse must be removed from the
interface board on units equipped with Thermo
King alternators. The voltage regulator on the
Thermo King alternators will be damaged if the
unit is turned On with the F4 fuse in place on
the interface board.
Test Equipment for Checking
Voltage and Current
Always use accurate test equipment such as the
Fluke 23 Digital Multi-Meter and the Fluke
Clamp-On Ammeter accessory when checking
alternator circuit voltage and amperage. See the
table below for Thermo King service parts
numbers. Be sure voltages are measured from the
designated terminal to the alternator chassis
ground. All voltages are DC voltages unless
otherwise noted.
Service
Meter Part
Number
Fluke 23 Digital Multi-Meter 204-1079
Clamp-On Ammeter for above Meter 204-947
Alternator Load Test
Thermo King no longer recommends a full field
test for determining the alternator current output.
Full fielding an alternator can cause increases in
alternator output voltage that may damage internal
alternator or unit components. This damage may
not be readily apparent.
To test the alternator under load, Thermo King
recommends the use of a clamp-on ammeter to
monitor output current, both on initial startup and
84
under full unit load conditions. For example, on
multi-temp units, all remote evaporators should be
turned on.
General Diagnostic and Warranty
Evaluation Procedure
Complete the following diagnostic procedures
before replacing an alternator or the voltage
regulator.
1. When testing an alternator, use accurate
equipment such as a Thermo King P/N
204-1079 digital multimeter and a Thermo
King P/N 204-947 amp clamp or an
equivalent.
2. Make sure the drive belts and pulleys of the
charging system are in good condition and are
adjusted properly before testing the alternator.
Be sure the pulleys are the correct size. Worn
belts, loose belts and worn or improperly sized
pulleys will lower the output of the alternator.
3. The battery must be charged and in good
condition, the battery cable connections must
be clean and tight, and the 2A, 2 (sense), and
EXC (excitation) circuits must be connected
properly. All charging circuit connections
must be clean and secure. If the unit battery is
questionable, a known good jumper battery
should be substituted for alternator testing.
NOTE: If the unit battery is questionable, a
known good jumper battery should be
substituted for alternator testing.
NOTE: Do not perform this test with a
battery charger connected to the unit battery.
NOTE: All voltage readings should be taken
between the chassis ground on the alternator
and the terminals indicated, unless stated
otherwise.
4. Check that the resistor bypass fuse (F4) has
been removed. Units with Thermo King
alternators must have the resistor bypass fuse
(F4) removed.
CAUTION: Energizing the circuit with
the resistor bypass fuse installed will
damage Thermo King alternators. Be sure
the resistor bypass fuse is removed for
Thermo King alternators.

5. Check and note the battery voltage at the
battery with the unit turned off.
6. With the unit off, check the voltage at the B+
terminal on the alternator. Battery voltage
must be present. If not, check the 2A circuit.
7. Disconnect the alternator harness from the
voltage regulator by carefully pushing on the
spring clip to release the plug lock.
8. Turn the unit on and enter Non-Running
Service Test Mode. Place the unit in Zone 1
Cool. Refer to the appropriate Diagnostic
Manual for information about the Service Test
Mode.
9. Check the voltage at the sense circuit (2
circuit). Battery voltage should be present. If
not, check the sense circuit (2 circuit) in the
alternator harness and in the main wire
harness.
10. Check the voltage at the excitation circuit
(EXC circuit). 10 Vdc or more should be
present. If not, check the excitation circuit
(EXC circuit) in the alternator harness and in
the main wire harness.
11. Turn the unit off and reconnect the alternator
harness.
12. Attach a clamp-on ammeter around the 2A
wire connected to the B+ terminal on the
alternator. All wires connected to the B+
terminal must pass through the clamp-on
ammeter.
13. Connect a digital multi-meter between the B+
terminal at the alternator and chassis ground.
14. Turn the unit on and allow it to start. Using the
clamp-on ammeter, check the current flow in
the 2A wire.
A positive reading indicates the alternator is
charging. On unit startup, the current flow
should momentarily increase to allow for
battery current used during preheat and
cranking. Within a short time the current
should fall to normal unit load plus charge
current to the unit battery (typically 5-10
amps).
Electrical Maintenance
A reading on the clamp-on ammeter at or near
0 amps indicates the alternator is not charging.
Checking the unit ammeter will show a
discharge condition. The alternator is
defective if there are no problems in the
wiring. Recheck the wiring before assuming
the alternator is defective.
15. Check the voltage at the B+ terminal. The
voltage should increase until it reaches the
anticipated voltage regulator setting as shown
in the table below. Record the voltage.
The voltage regulator setting varies inversely
with the temperature as shown below.
Regulator voltage can vary from
approximately 15.2 Vdc at -40 F (-40 C) to
approximately 13.2 Vdc at 176 F (80 C).
Temperature Anticipated Regulator Voltage
-40 F (-40 C) From 15.2 Vdc to 14.0 Vdc
77 F (25 C) From 14.4 Vdc to 13.6 Vdc
176 F (80 C) From 14.2 Vdc to 13.2 Vdc
If the voltage does not increase to the
anticipated voltage regulator setting, the
alternator is defective if there are no problems
in the wiring. Recheck the wiring before
replacing the alternator.
16. If the voltage does increase until it reaches the
anticipated voltage regulator setting, compare
the voltage at the B+ terminal to the voltage
between the battery terminals. The voltage at
the B+ terminal should be no more than 1.0
Vdc higher than the voltage between the
battery terminals.
If the voltage at the B+ terminal is no more
than 1.0 Vdc higher than the voltage between
the battery terminals, continue with Step 17.
If the voltage at the B+ (POS) terminal is
more than 1.0 Vdc higher than the voltage
between the battery terminals, clean and check
the wires and connections in the 2A and 2
circuits and repeat this check.
17. Increase the charging system load as much as
possible by running all zones.
18. Monitor the alternator output voltage.
85
Electrical Maintenance

With the increased load, the alternator output Battery

voltage should decrease no more than 0.5 Vdc.
The voltage may increase as much as 1.0 Vdc.
If the alternator output voltage decreases no
more than 0.5 Vdc the alternator is good.
If the alternator output voltage decreases more
than 0.5 Vdc, the alternator is defective if
there are no problems in the wiring. Recheck
the wiring before replacing the alternator.
Alternator Diode Quick Check:
Inspect/clean the battery terminals and check the
electrolyte level during scheduled maintenance
inspections. A dead or low battery can be the
cause of an ammeter indicating discharge due to
lack of initial excitation of the alternator even
after the unit has been boosted for starting. The
minimum specific gravity should be 1.235. Add
distilled water as necessary to maintain the proper
water level.

This check confirms proper diode function.

Battery Cables
19. With the unit still running, set the digital
Units with Tier 2 engines use 0-gauge battery
multi-meter connected from the alternator B+
cables to ensure reliable starting in extremely cold
output to chassis ground for AC volts. No
weather. Make sure to use the 0-gauge battery
more than 1.0 Vac should be present. A
cables when replacing the battery cables for a Tier
reading of more than 1.0 Vac indicates
2 engine. Refer to the unit Parts Manual for the
damaged alternator diodes.
correct part numbers.
20. Turn the unit off.
Unit Wiring
Field Current Test
Inspect the unit wiring and the wire harnesses
Use this test to determine if the alternator can be during scheduled maintenance inspections for
repaired. Perform this test with the unit turned off. loose, chaffed or broken wires to protect against
1. Attach a clamp-on ammeter to the 2A wire unit malfunctions due to open or short circuits.
near the B+ terminal on the alternator.
2. Energize the field on the Thermo King Wire Harness Routing
alternator by connecting a jumper wire The wire harness is routed in front of the starter
between the F2 terminal and the B+ terminal. on the TK486V (Tier 2) engine. The wire harness
Do not connect the F2 terminal to ground or is attached to a harness routing bracket, which is
the alternator will be damaged. attached to the starter.
3. Note the ammeter reading. The ammeter
reading indicates the field current, which 1 2
should be 2.0 to 6.0 amps at 12 volts.
No field current or a low field current
indicates an open circuit or excessive
resistance in the field circuit. Remove the
voltage regulator and brush assembly and
inspect the slip rings. If the slip rings and
are acceptable, install a new voltage
regulator and brush assembly and repeat
the test. If the brushes are not the problem,
replace the alternator.
High field current indicates a short in the 1. Wire Harness In Front Of Starter
field circuit. Replace the rotor or the
2. Harness Routing Bracket
alternator.
Figure 84: Wire Harness Routing

86
 Electrical Maintenance

Fuses
A number of fuses, located on the interface board,
protect various circuits and components. The
interface board is located inside the control box.
Refer to the SR-2 Microprocessor Controller
Diagnostic Manual TK 53080 for a complete list
of the size and function of the fuses.

Fuse Size Function

F2 15A Power to On/Off Switch
F3 40A Fuel Sol Pull-In/Starter Circuit
None No Fuse - All Bosch and Thermo
F4 King Alternators
2A 2A Fuse - All Prestolite Alternators
F5 60A Preheat Circuit
F6 15A Damper and High Speed Circuits
8XP Circuit - Controller On Feedback
F7 2A
to HMI
F8 5A CAN Connector J12
F9 5A CAN Connector J14
8X Power (Install fuse in upper
F10 10A
position) Figure 85: Interface Board
F11 10A Zone 1 LLS
F12 5A CAN Connector J13 Interface Board LEDs
F13 2A 8FC Circuit (Remote Lights) The interface board has LEDs that indicate which
F15 P/S On/Off Relay outputs are energized. The LED is illuminated
F20 2A Alternator Sense when the associated circuit output is energized.
F22 Not Used
Interface Board LED Functions
F23 Not Used
LED # Function
F25 7.5A HPCO/Run Circuit
LED 3 K2 Preheat Circuit
F4 Remove fuse F4 for Model 30 units with Australian
Bosch or Thermo King Alternators. Install fuse F4 for LED 4 K4 Damper Circuit
Model 50 units with Prestolite Alternator. LED 5 K3 High Speed Circuit
F5 The F5 preheat fuse is a slow blow type. It is LED 6 K1 Run Relay Circuit
designed for use with the Yanmar engine air heater. LED 7 K5 Diesel/Electric Relay
Always replace the fuse with the TK specified fuse.
LED 8 Condenser Inlet Solenoid Circuit
F10 When fuse F10 is installed in the upper position
the On/Off keys on the HMI turn the unit on and off. LED 9 Receiver Tank Pressure Solenoid Circuit
When fuse F10 is installed in the lower position the Hot Gas Bypass Valve Circuit / Loader
LED 10
unit will start and run without the HMI control panel. Valve 2 (Not Used)
F15 The device identified as F15 is a poly switch. LED 11 Purge Valve Solenoid Circuit
These over-current devices reset automatically and LED 17 Loader Valve 1 (Not Used)
are not replaceable.
LED 18 Alternator Excite
LED 19 Liquid Injection Valve Circuit (Not Used)
LED 20 Water Valve (Not Used)

87
Electrical Maintenance

Interface Board LED Functions (Continued) Expansion Module

LED # Function The expansion module allows the addition of up
Status Flashes once per second when to two additional temperature controlled zones.
the base controller is powered and The module provides the interface between the
operating normally. Flashes several times
per second when flash loading. Is on
base controller and the Zone 1, Zone 2, and Zone
LED 21 3 (if used) multi-temperature components such as
without flashing during reboot and when
under test. Flashes twice within 1 second sensors, solenoids, valves, and fan motors. It also
followed by 1 second off if a CAN uses Smart FETs to provide overcurrent and short
communication error is present. circuit protection for the associated circuits.
LED 22 Zone 1 Liquid Line Solenoid
All engine functions and host unit valves are
LED 23 K9 On/Off Circuit
controlled by the base controller. This includes the
LED 24 K6 Fuel Solenoid Pull-In Circuit receiver tank pressure solenoid (RTPS), purge
LED 25 K7 Starter Circuit valve (PV) and condenser inlet solenoid (CIS). In
LED 26 Future Use addition the liquid line solenoid for Zone 1 (LLS)
LED 27 ETV (Not Used)* is controlled directly from the base controller. All
LED 28 ETV (Not Used)* other Zone 1 devices and all remote evaporators
are controlled by the expansion module.
LED 29 ETV (Not Used)*
LED 30 ETV (Not Used)* Load power is supplied by the 2A wires to the
* May be illuminated even though the ETV outputs expansion module via two terminal studs. Power
are not used. from the 8X circuit in the base controller is
supplied to the expansion module via the YEL
Smart FETs wire in the 8 pin connector. The expansion
module communicates with the base controller via
A Smart FET (Field Effect Transistor) is a self a CAN bus connection. All remote zone input and
protecting device. Smart FETs halt current flow if solenoid output functions are connected via the
an overcurrent condition exists, and resume expansion module 35 pin connector harness.
normal operation when current flow is within Remote evaporator fan motor outputs are
limits. Smart FETs are not field repairable. Refer provided for 6 variable speed remote fan motors.
to the SR-2 Microprocessor Controller Diagnostic Each output is capable of operating two fans.
Manual TK 53080 for more information about the
Smart FETs. There are no user replaceable components on the
expansion module. Refer to the SR-2
Smart FETs are used to protect the circuits in the Microprocessor Controller Diagnostic Manual TK
expansion module. 53080 for more information about the Expansion
Smart FETs are also used to protect the interface module.
board outputs listed in the following table.

Interface Board Outputs With Smart FETs

Output Function
ALPC Alarm Light
ALM Alarm Light
EXC Alternator Excite
CIS Condenser Inlet Solenoid
Receiver Tank Pressure
RTPS
Solenoid
PV Purge Valve

88
 Electrical Maintenance

Expansion Module LED Functions (Continued)

1
LED # Function
LED 13 Zone 1 Suction Line Solenoid
LED 14 Zone 2 Suction Line Solenoid
LED 15 Zone 3 Suction Line Solenoid
Status Flashes once per second when
the base controller is powered and
operating normally. Flashes several time
per second when flash loading. Is on
LED 16 without flashing during reboot and when
under test.
Flashes twice within one second followed
by one second off if a CAN
communication error is present
LED 17 Zone 2 Liquid Line Solenoid
LED 18 Zone 3 Liquid Line Solenoid

1. Expansion Module LEDs

Figure 86: Expansion Module

Expansion Module LEDs

The expansion module has LEDs that indicate
which outputs are energized. These LEDs are
located in the corner of the expansion module
body and are defined in the following table. An
LED is illuminated when its associated circuit
output is energized. The circuit outputs are
protected by Smart FETs. All the LEDs are red,
except LED 16, which is green. 1

Expansion Module LED Functions

LED # Function
Fan 1 (Zone 2 Damper Solenoid on DE
LED 01
Units) 1. Green Status LED (All other LEDs are Red)
LED 02 Fan 3
Figure 87: Expansion Module LEDs
LED 03 Fan 5
LED 04 Fan 2
SMART REEFER 2 Multi-Temp
LED 05 Fan 4
(SR-2 MT) Microprocessor
LED 06 Fan 6
Controller
LED 07 Zone 1 Drain Tube Heater (Not Used)
See the SR-2 Multi-Temp Microprocessor
LED 08 Zone 2 Drain Tube Heater
Controller Diagnostic Manual TK 53080 for
LED 09 Zone 3 Drain Tube Heater
complete service information about the
LED 10 Zone 1 Hot Gas Solenoid Microprocessor Controller and the related
LED 11 Zone 2 Hot Gas Solenoid components.
LED 12 Zone 3 Hot Gas Solenoid

89
Electrical Maintenance

Fuse Link
The fuse link is located in the positive battery
cable. The fuse link protects the electric system
from a short in the 2 circuit. If the fuse link burns
out, check for a grounded 2 wire before replacing
the fuse link. Replace the fuse link by replacing
the positive battery cable.

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.

1
AEA693

1. M6 Terminal
Figure 88: Air Heater

90
Engine Maintenance
EMI 3000
EMI 3000 is an extended maintenance interval
package. The EMI 3000 package consists of the
following key components:
New EMI 3000-Hour Cyclonic Air Cleaner
Assembly and Air Cleaner Element
New EMI 3000-Hour Fuel Filter (black with
gold lettering)
New EMI 3000-Hour Dual Element Oil Filter
(black with gold lettering)
API Rating CI-4 Mineral Oil (ACEA Rating
E3 for Europe)
Five Year or 12,000 Hour ELC (Extended Life
Coolant).
The EMI package allows standard maintenance
intervals to be extended to 3,000 hours, or 2 years,
whichever occurs first.
NOTE: Units equipped with the EMI 3000
package do require regular inspection in
accordance with Thermo King's maintenance
recommendations.
NOTE: The new EMI 3000 oil filters and new
EMI 3000 air cleaners are NOT interchangeable
with the oil filters and air cleaners previously
used in trailer units.
Engine Lubrication System
The TK486 family of engines use a pressure
lubrication system. Refer to the TK482 and
TK486 Engine Overhaul Manual TK 50136 for a
detailed description of the engine lubrication
system.
Engine Oil Change
The engine oil should be changed according to the
Maintenance Inspection Schedule. Drain the oil
only when the engine is hot to ensure that all the
oil drains out. When changing oil, keep unit and
trailer level so all the oil can flow from the oil
pan. It is important to get as much of the oil out as
possible because most of the dirt particles are
contained in the last few quarts of oil that drain
out of the pan. Refill the pan with 13 quarts
(12.3 liters) and check the dipstick level. Run the
unit, and then recheck the oil level. The engine oil
level should be at the FULL mark with the
dipstick turned (threaded) into the oil pan. Never
overfill. See Specifications Chapter for correct
type of oil.
Oil Filter Change
The oil filter should be changed along with the
engine oil. Use a genuine Thermo King extended
maintenance oil filter.
1. Remove the filter.
2. Apply oil to the rubber ring of the new filter
and install the filter.
3. Tighten the filter until the rubber ring makes
contact, then tighten 1/2 turn more.
4. Start the unit and check for leaks.
Low Oil Pressure
Oil pressure is affected by oil temperature, oil
viscosity, and engine speed. Low oil pressure can
usually be traced to the lack of oil, a faulty oil
pressure regulating valve, or worn bearings. Low
oil pressure is not normally caused by a faulty oil
pump. Use the Low Oil Pressure Flow Chart on
the following page to help diagnose low oil
pressure.
91
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

92
 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 89: 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.
ELC (Extended Life Coolant)
ELC has been phased into all trailer units
equipped with engines from the TK486 engine
family. A nameplate on the coolant expansion
tank identifies units with ELC.
NOTE: The new engine coolant, Texaco
Extended Life Coolant, is RED in color instead
of the current GREEN or BLUE-GREEN
colored coolants.
Havoline Dex-Cool (nitrite free)
Shell Dexcool
Shell Rotella
Havoline XLC (Europe)
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.

93
Engine Maintenance

NOTE: The use of 50/50 percent pre-mixed
Extended Life Coolant (ELC) is recommended to
assure that de-ionized water is being used. If 100
percent full strength concentrate is used,
de-ionized or distilled water is recommended
over tap water to insure the integrity of the
cooling system is maintained.
Antifreeze Maintenance Procedure
As with all equipment containing antifreeze,
periodic inspection on a regular basis is required
to verify the condition of the antifreeze. Inhibitors
become worn out and must be replaced by
changing the antifreeze. Change ELC (red) engine
coolant every five years or 12,000 hours
(whichever occurs first).
Do not mix green or blue-green engine coolant
with ELC (red) engine coolant. See ELC
(Extended Life Coolant) on page 93 for more
information about ELC.
The factory recommends the use of a 50/50
antifreeze mixture in all units even if they are not
exposed to freezing temperatures. This antifreeze
mixture will provide the required corrosion
protection and lubrication for the water pump.
1 2

4
3

6 7

1. Expansion Tank 5. Water Pump

2. Expansion Tank Cap 6. Coolant Hoses to Cold Start Device on Injection Pump
3. Coolant Level Switch 7. Thermostat
4. Radiator 8. Thermostat Housing
Figure 90: Engine Cooling System

94

Checking the Antifreeze
Check the solution concentration by using a
temperature compensated antifreeze hydrometer
or a refractometer (P/N 204-754) designed for
testing antifreeze. Maintain a minimum of
50 percent permanent type antifreeze concentrate
and 50 percent water solution to provide
protection to -30 F (-34 C). Do not mix antifreeze
stronger than 68 percent permanent type coolant
concentrate and 32 percent water for use in
extreme temperatures.
Changing the Antifreeze
1. Run the engine until it is up to its normal
operating temperature. Stop the unit.
2. Open the engine block drain (located behind
the starter) and completely drain the coolant.
Observe the coolant color. If the coolant is
dirty, proceed with a, b, and c. Otherwise go
to 3.
CAUTION: Avoid direct contact with hot
coolant.
a. Run clear water into the radiator and allow
it to drain out of the block until it is clear.
b. Close the block drain and install a
commercially available radiator and block
flushing agent, and operate the unit in
accordance with instructions of the
flushing agent manufacturer.
c. Open the engine block drain to drain the
water and flushing solution.
CAUTION: Avoid direct contact with hot
coolant.
3. Run clear water into the radiator, and allow it
to drain out of the block until it is clear.
4. Inspect all hoses for deterioration and hose
clamp tightness. Replace if necessary.
5. Loosen the water pump belt. Check the water
pump bearing for looseness.
6. Inspect the radiator cap. Replace the cap if the
gasket shows any signs of deterioration.
Engine Maintenance
7. If using ELC concentrate, mix one gallon of
ELC concentrate and one gallon of de-ionized
or distilled water in a container to make a
50/50 mixture. (Do not add antifreeze and
then add water to the unit. This procedure may
not give a true 50/50 mixture because the
exact cooling system capacity may not always
be known.)
8. Refill the radiator with the 50/50 antifreeze
mixture and make sure to bleed the air from
the cooling system as needed.
Bleeding Air from the Cooling
System
Jiggle pin thermostats are original equipment on
units that have engines from the TK486 engine
family. Jiggle pin thermostats make it unnecessary
to bleed the air out of the engine block because
they keep air from being trapped in the engine
block. Normally, all but about 1.5 qt (1.4 liters) of
coolant drain out of the cooling system when it is
drained. If approximately half of the Cooling
System Capacity (see Specifications Chapter)
seems to fill the cooling system after it has been
drained, air has been trapped in the block. Bleed
the air out of the block using the following
procedure:
CAUTION: If you suspect that air is
trapped in the block, do not start the
engine without bleeding the air out of the
block.
NOTE: If an engine runs with air trapped in the
block, the engine may be damaged. The high
water temperature switch may not protect an
engine that has air trapped in the block, because
the high water temperature switch is designed to
protect an engine from overheating due to
failures in the cooling system.
1. Loosen the plug on the back of the water
pump below the thermostat cover until coolant
comes out of the plug fitting.
2. Tighten the plug.
3. Pour coolant into the system until it appears to
be full.
95
Engine Maintenance
4. Make sure that the amount of coolant that
goes back into the system is approximately
equal to the amount of coolant that came out
of the system.
5. Start the unit on low speed heat, let it run for
two minutes, and then shut it off.
6. Check the coolant level and add coolant if
necessary.
7. Repeat steps 5 and 6 until the coolant level
stabilizes.
Engine Thermostat
For the best engine operation, use a 160 F (71 C)
thermostat year-round.
Coolant Level Switch
The plastic expansion tank uses a reed type
coolant level switch. The coolant level switch
senses the position of the magnetic float inside the
expansion tank. When the coolant level is above
the switch, the float is in the upper position and
the switch is closed. When the coolant level is
below the switch, the float is in the lower position
and the switch is open.
1 2
1. Coolant Level Switch
2. Float
Figure 91: Plastic Expansion Tank
96
NOTE: Figure 91 shows the expansion tank in
two pieces. The two pieces are bonded together
when the tank is assembled, so it cannot be
disassembled, but the coolant level switch can be
replaced.
Testing the Coolant Level Switch
You can test the switch in the unit by adjusting the
coolant level. You can also remove the expansion
tank from the unit and test the switch by flipping
the expansion tank upside down and right side up.
1. Remove the wire harness connector from the
coolant level switch.
2. Use an ohmmeter to check the continuity of
the switch at the connection pins.
3. Make sure the coolant level is above the
switch and check the continuity of the switch.
The switch should be closed. If you removed
the tank from the unit, do this check with the
tank upside down.
4. Drain coolant from the expansion tank until
the coolant level is well below the switch and
check continuity of the switch. The switch
should be open. If you removed the tank from
the unit, do this check with the tank right side
up.
5. Replace the switch if it is does not closed in
step 3 and does not open in step 4.
Checking the Float
The float is made of polypropylene foam. It is
unlikely that the float would fail unless it sticks
inside the tank so it cannot move.
1. Make sure the coolant level is above the float.
2. Slowly drain coolant from the expansion tank
and watch the float. The float should drop
with the coolant level.
3. If the float did not drop with the coolant level,
remove the expansion tank from the unit.
4. Flip the expansion tank upside down and right
side up to see if the float moves inside the
expansion tank. Replace the expansion tank
with a new one if the float is stuck or does not
move with the coolant level.
 Engine Maintenance

Replacing the Coolant Level Switch 4. Look at the hole in the expansion tank from
which the coolant level switch was removed.
It makes it easier to remove and install the switch
Notice that there is a tab in the top of the hole.
if you use a blow drier or heat gun to warm the
The slot in the switch must fit around this tab
expansion tank in the area around the switch. Do
when the switch is installed.
not overheat the expansion tank. Warm it to about
the temperature of hot bath water.
1. Warm the area around the coolant level
switch, but do not overheat it.
2. Use a wide, flat screwdriver to pry the switch
out of the expansion tank.
1

1. Tab
Figure 94: Expansion Tank
5. Warm the expansion tank in the area around
2 the hole for the coolant level switch, but do
not overheat it.

1. Warm Here 6. Place the coolant level switch in the expansion

tank. Make sure that the slot in the switch is
2. Pry Here
aligned with the tab in the expansion tank.
Figure 92: Removing Coolant Level Switch
7. Press the coolant level switch into the
3. Look at the new coolant level switch. Notice expansion tank. It should click when it snaps
that the switch has a raised ring around it. This into place. It may be helpful to use a wide
ring snaps into a grove in the expansion tank. bladed screwdriver to press on the switch
Also, notice that there is a slot in the top of the where shown in the following photograph.
switch. This slot fits around a tab in the
expansion tank.

1 2

1. Tab
1. Raised Ring
2. Slot Figure 95: Expansion Tank

Figure 93: Coolant Level Switch

97
Engine Maintenance
8. Refill the expansion tank with coolant (after
installing the expansion tank if it was
removed).
9. Connect the wire harness connector to the
coolant level switch.
Engine Fuel System
TK486V engines use a mono-plunger and
distributor injection pump.
The components of the fuel system are:
Fuel tank
Inlet strainer (prefilter)
Priming pump
Fuel transfer pump
Fuel filter/water separator
Injection pump
Trochoid feed pump
Injection nozzles
The priming pump is used to manually draw fuel
from the tank up to the fuel pump if the unit
should run out of fuel.
Operation
Fuel is drawn from the fuel tank and through the
prefilter by the fuel transfer pump. The fuel
transfer pump delivers fuel to the fuel filter/water
separator. Two orifices in the filter head control
the pressure in the fuel system by allowing a
certain amount of fuel to return to the tank. One
orifice is located in the center of the filter head. It
bleeds off water. The other orifice is located
off-center on the filter head. It bleeds off air.
Filtered fuel passes through a line from the outlet
fitting on the filter base to the injection pump.
The injection pump forces the fuel, at a very high
pressure, through the injection nozzles. The
injection nozzles atomize the fuel as it is injected
directly into the combustion chambers.
98
Injection pump leakage, injection nozzle overflow
and excess fuel from the fuel filter orifice are then
all sent back to the fuel tank in the return line.
Fuel Line Routing
The fuel lines inside the unit are installed and
routed at the factory. The fuel lines from the fuel
tank connect to the fittings on the bottom of the
unit frame. Do not change the factory routing of
the fuel lines inside the unit. See the fuel line
routing diagrams in the Diagrams Chapter.
Maintenance
The injection pump and fuel transfer pump are
relatively trouble-free and if properly maintained
will usually not require major service repairs
between engine overhauls.
Contamination is the most common cause of fuel
system problems. Therefore, to ensure best
operating results, the fuel must be clean and fuel
tanks must be free of contaminants. Change the
fuel filter/water separator regularly and clean the
prefilter on the inlet side of the fuel transfer pump.
NOTE: The injection nozzles should be tested
(and repaired if necessary) at 10,000 hour
intervals when used in normal conditions.
Normal conditions are considered to be the use
of clean high quality fuel, no used oil blending,
and regular maintenance of the fuel system
according to the Maintenance Inspection
Schedule. Refer to the TK482 and TK486
Overhaul Manual TK 50136 for injection nozzle
testing and repair procedures.
Whenever the fuel system is opened, take the
following precautions to prevent dirt from
entering the system:
1. Cap all fuel lines.
2. Work in a relatively clean area whenever
possible.
3. Complete the work in the shortest possible
time.
 Engine Maintenance

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

1 2

1. Relief Valve (Keeps air from entering fuel

5. Fuel Transfer Pump
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 96: Fuel System

99
Engine Maintenance

Fuel Return Line Replacement
The fuel return lines (hoses) and end cap on the
fuel injection nozzles should be changed every
10,000 engine operating hours. The return line kit
(P/N 10-368) contains new return lines, clamps,
an end cap, and a decal like the one shown below.
The decal is located near the unit serial plate. The
date and engine hours must be entered on the
decal when the fuel return lines are changed.
Figure 97: Fuel Return Line Replacement Decal
Use the following procedure to replace the fuel
return lines and end cap.
1. Remove the clamps, the end cap, the short fuel
return lines between the injection nozzles, and
the long fuel return line from the injection
nozzle to the banjo fitting on the injection
pump.
1 the tendency for air to enter the system.
2. Discard the old clamps, end cap, and fuel
return lines.
3. Install the end cap and clamp. Note that the
end cap has a larger OD than the other hoses
and requires the larger clamp.
4. Install the fuel return lines and clamps. It may
be necessary to adjust the banjo fitting slightly
to obtain the straightest routing for the long
return line.
5. Be sure all the fittings are tight and check for
leaks.
6. Write the date and engine hours on the decal.
Bleeding the Fuel System
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
fuel system.
NOTE: MAKE SURE the fuel tank vent is kept
open. If the vent becomes clogged, a partial
vacuum develops in the tank, and this increases

2 3
1 2

4 5

4
3
aea751 3

5
1. Stand Pipes 4. Drain Plug
2. Anti-Siphon Screen (Optional) 5. Vent
3 3. Fuel Gauge
Figure 99: Fuel Tank
1. End Cap 4. Short Fuel Return Lines
To bleed air from the fuel system:
2. Larger Clamp 5. Long Fuel Return Lines
3. Smaller Clamps 1. Loosen the bleed screw about one turn.
Figure 98: Fuel Return Line Replacement

100
 Engine Maintenance

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

2
Fuel Filter/Water Separator
The fuel filter/water separator removes water
1. Bleed Screw 2. Priming Pump from the fuel and returns it to the fuel tank.
Figure 100: Injection Pump
Fuel Filter/Water Separator
2. Unscrew the priming pump handle and Replacement
manually prime the fuel system until air
bubbles are no longer visible in the fuel Replace the fuel filter/water separator at intervals
coming out of the bleed screw. according to the Maintenance Inspection
Schedule.
3. Tighten the bleed screw and screw the priming
pump handle back in. 1. Unscrew the fuel filter/water separator
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
nozzles. 3. Lubricate the canister seal with clean fuel.

6. Tighten the injection lines. 4. Through one of the small openings in the top
of the canister, fill the new fuel filter/water
7. Start the engine and observe the engine run for separator canister with clean fuel. This will
a few minutes. If the engine fails to start, or purge the air from the canister. Do not fill
starts but stops in a few minutes, repeat the canister through the center hole.
procedure.
1 2
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
ARA160
breakdowns. Drain the water off after the fuel
tank and unit have remained idle for an hour. 1. Fill Through Small Openings
1. Place a container under the fuel tank to catch 2. Do Not Fill Through Center Hole
the draining water and fuel. Figure 101: Filling Fuel Filter/Water Separator

101
Engine Maintenance

5. Screw the new canister on hand-tight. Using a Low Speed

strap wrench, tighten another 1/4 turn.
1. Loosen the jam nut on the low speed
adjustment screw.
Engine Speed Adjustments
2. Use the Service Test Mode to run the unit in
When the diesel engine fails to maintain the
low speed. Adjust the screw to obtain the
correct engine speed, check the following before
correct speed. It should be 1450 25 rpm.
adjusting the speed:
3. Tighten the jam nut and recheck the speed.
1. Check the fuel inlet screen. Check the speed.
2. Bleed the air out of the fuel system. Check the 1 2 3 4 5
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
1. Use the Service Test Mode to run the unit in
high speed and check the high speed rpm. It
should be 2200 25 rpm.
2. Shut the unit off. 1. High Speed Solenoid

3. Remove the ball joint from the eye bolt in the 2. Boot
high speed solenoid. 3. Ball Joint
4. Remove the boot from the high speed 4. Speed Control Rod
solenoid. 5. Low Speed Adjustment Screw
5. Pull the plunger out of the solenoid enough to Figure 102: Engine Speed Adjustments
loosen the jam nut. An Allen wrench placed in
the hex opening in the face of the plunger will
keep the plunger from turning. Turn the
plunger eye bolt clockwise to increase the
speed and counterclockwise to decrease the
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.

102
 Engine Maintenance

Injection Pump Timing

Use this timing procedure when installing a new
injection pump. It is not necessary to use this
timing procedure when removing and reinstalling
the original injection pump. In that case, align the
index marks on the 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
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
105).
2
1
3
1. Index Mark on Injection Pump
2. Existing Index Mark on Gear Case
3. Make New Mark on Gear Case If Needed
Figure 105: Marking Gear Case
2. Clean the area with brake cleaner or
something similar. Place an injection angle
sticker on the gear case so the center line on
the sticker is aligned with the index mark on
the injection pump. An injection angle sticker
is provided with the new injection pump.

1 2
1
1. Index Mark on Injection Pump
1. Index Marks 2. Injection Angle Sticker
Figure 103: Index Mark Location Figure 106: Place Injection
Angle Sticker on Gear Case

0.5 Degrees
1
2

1 2
1. 1.0 Degrees Mark
1. Index Mark on Injection Pump 2. Center Line (0 Degrees Mark)
2. Index Mark on Gear Case 3. +1.0 Degrees Mark
Figure 104: Index Mark Alignment Figure 107: Injection Angle Sticker

103
Engine Maintenance

3. Remove the old injection pump. Use the

1
injection pump gear tool P/N 204-1011 to
remove the injection pump gear without
removing the timing gear cover (see Injection
Pump Removal on page 106).
NOTE: Remove the injection pump gear by
removing the nut and lock washer that
secure the injection pump gear assembly to
the injection pump shaft. The injection pump
gear assembly is made of three pieces; the
flange, the gear, and the transfer pump cam.
Do not loosen or remove the four bolts that
fasten the gear to the flange because that
changes the factory-set timing. The EPA 1. Injection Angle Mark
certification is based on the factory-set Figure 109: Injection Angle Mark Location
timing. If the factory-set timing is changed,
the EPA certification is void.
1

1
2

1
1
1 1. Injection Angle Mark
Figure 110: Injection Angle Mark

1. Do Not Loosen or Remove These Four Bolts
2. Remove Nut and Lock Washer
Figure 108: Removing Injection Pump Gear
4. Record the injection angle marked on the old
injection pump (see the following
photographs). The injection angle mark is
located on the side of the pump facing the
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
angle mark to get the injection angle. The
injection angle mark in the following
photographs is 67. That equals an injection
angle of 6.7 degrees.
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
hisashi_hamada@yanmar.co.jp) with the
injection pump serial number or the engine
serial number and they will provide the injection
angle. The injection pump serial number is
located on the bottom of the sticker on the
injection pump.
1

Examples
Injection Angle Mark Injection Angle
67 6.7 Degrees
85 8.5 Degrees 1. Injection Pump Serial Number
Figure 111: Injection Pump Serial Number Location

104
 Engine Maintenance

5. Record the injection angle marked on the side

1 3
of the new injection pump.
2
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 4
6.7 6.7
Injection Pump (Degrees)
= Injection Angle Difference
= +1.8 = 0.6 1. Fuel Injection Pump Gear
(Degrees)
2. Idler Gear
7. Install the new injection pump on the gear 3. Camshaft Gear
case and position it so the index mark on the 4. Crankshaft Gear
injection pump is aligned with the mark equal Figure 113: Timing Mark Alignment
to the injection angle difference on the
injection angle sticker (see the following NOTE: The oil pump is located in the timing
examples). Tighten the injection pump gear cover on TK486V engines. The inner rotor
mounting nuts when the index mark is aligned of the oil pump fits around the crankshaft gear.
as necessary with the injection angle sticker. 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 1
2
5
3
4

6
1. Injection Pump Index Mark at 0.6 Degrees
2. Injection Pump Index Mark at +1.8 Degrees
Figure 112: Examples of Injection Pump Index
Mark Alignment with Injection Angle Sticker
1. Crankshaft Gear
8. Install the injection pump gear, lock washer, 2. Oil Pump Cover
and nut. Torque the nut to 58 to 65 ft-lb (78 to 3. Outer Rotor
88 Nm). 4. Inner Rotor
NOTE: If the timing gear cover was removed to 5. Timing Gear Cover
remove the injection pump gear, make sure the 6. Flat Sides on Inner Rotor
timing marks on the timing gears are aligned as 7. Flat Side on Crankshaft Gear
shown below. It helps to install the idler gear last
Figure 114: Align Flat Sides of Crankshaft Gear
when aligning the timing marks. with Flat Sides of Inner Rotor in Timing Gear Cover

105
Engine Maintenance
Injection Pump Removal
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 117 Injection
Pump Gear Tool on page 107.
1. Note the alignment of the index marks on the
injection pump and the gear case. The index
mark on the injection pump is usually aligned
with the single index mark on the gear case. If
not, mark it so the injection pump can be
returned to the same position when it is
reinstalled.
1 the gear. Caution should be made to align the
1. Index Marks
Figure 115: Index Mark Location
1 2
1. Index Mark on Injection Pump
2. Index Mark on Gear Case
Figure 116: Index Mark Alignment
106
2. Remove the starter for clearance, remove
throttle linkage, fuel lines, harness and
mounting hardware from injection pump.
3. Remove the cover plate from the gear case.
Remove the nut and lock washer which secure
the gear to the injection pump shaft. Use a
shop rag to prevent the lock washer or nut
from falling into the gear case.
NOTE: The injection pump gear assembly is
made of three pieces; the flange, the gear,
and the transfer pump cam. Do not loosen or
remove the four bolts that fasten the gear to
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.
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
screw over the center of the injection pump
shaft.
7. Remove the screw and adapter leaving the tool
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
and the gear case like they were in step 1 of
Injection Pump Removal.
NOTE: If a different injection pump is being
installed, see Injection Pump Timing on
page 103 to set the timing.
 Engine Maintenance

3. Remove hardware holding gear to tool plate, 5. Fasten cover plate to gear case and reinstall all
then remove tool plate. components removed previously to facilitate
injection pump removal.
4. Secure the gear to the injection pump shaft
with the lock washer and nut. Use a shop rag,
as before, to prevent the lock washer or nut
from falling into the gear case. Torque the nut
to 58 to 65 ft-lb (78 to 88 Nm).

8 7 6

1. Injection Pump 5. Adapter (Tool)

2. Gear Case 6. Tool Long Screw (Tool)
3. Cover Plate 7. Tool Short Screw (Tool)
4. Cover Plate Bolt 8. Tool Plate (Tool)
Figure 117: Injection Pump Gear Tool

107
Engine Maintenance
Fuel Solenoid
The fuel solenoid is located on the end of the
injection pump. It contains two coils: the pull-in
coil, and the hold-in coil. The pull-in coil draws
approximately 35 to 45 amps at 12 volts. The
hold-in coil draws approximately 0.5 amps at
12 volts.
The pull-in coil must be energized to move the
injection pump governor linkage to the fuel on
position. Once the injection pump governor
linkage has been moved to the fuel on position,
the hold-in coil will keep it in fuel on position
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. The pull-in coil is
controlled by the microprocessor through the fuel
solenoid pull in relay (K6).
1
1. Fuel Solenoid
Figure 118: Fuel Solenoid Location
Testing the Fuel Solenoid
NOTE: The fuel solenoid pull-in coil will
require 35 to 45 amps to turn on the fuel. The
units battery must be in good condition. If the
battery has enough power to crank the engine
over, it has enough power to energize the fuel
solenoid pull-in coil.
If you suspect that the engine does not run
because the fuel solenoid is not operating
correctly, use the following procedure:
1. Use the microprocessor keypad to enter the
Interface Board Test Mode. Refer to the
appropriate Microprocessor Diagnostic
Manual for specific information about the
Interface Board Test Mode.
108
2. Energize the run relay with the Interface
Board Test Mode. The fuel solenoid relay is
momentarily energized when the run relay is
energized with the Interface Board Test Mode.
This energizes the fuel solenoid, which makes
a definite click when energized.
3. De-energize the run relay with the Interface
Board Test Mode. This de-energizes the fuel
solenoid, which makes a definite click when
de-energized.
4. Repeat steps 2 and 3 a few times to check the
operation of the fuel solenoid.
NOTE: The fuel solenoid may be removed
from the injection pump to visually check its
operation. The fuel solenoid must be
energized when it is re-installed in the
injection pump. If it is not, the plunger and
the linkage may not line up correctly and the
fuel solenoid will not function properly.
5. If the fuel solenoid is not operating properly,
check the run relay (K1), the fuel solenoid pull
in relay (K6), their fuses, and the associated
circuits. If the relays, fuses and circuits are
acceptable, use steps 6 through 9 to isolate and
check the fuel solenoid.
6. Disconnect the fuel solenoid wire connector
from the main wire harness.
AEA633
1. Red (8D)
2. White (8DP)
3. Black (CH)
Figure 119: Fuel Solenoid
Connector Pin Identification
7. Place a jumper wire between the black wire
(CHpin C) in the fuel solenoid connector
and a good chassis ground.
8. Test the pull-in coil by momentarily placing a
jumper between the white wire (8DPpin B)
in the fuel solenoid connector and the positive
 Engine Maintenance

battery terminal. The fuel solenoid should Fuel Solenoid Replacement

make a definite click when the pull-in coil is
1. Disconnect the fuel solenoid wire connector
energized and should click again when the
from the main wire harness and remove the
pull-in coil is de-energized.
old fuel solenoid.
NOTE: The pull-in coil will draw 35 to 45
2. Connect the new fuel solenoid wire connector
amps so do not leave the jumper connected to
to the main wire harness.
the white wire (8DPpin B) for more than a
few seconds. 3. Press the ON key to turn the unit on.
a. If the pull-in coil does not energize, check 4. Use the microprocessor keypad to enter the
the resistance of the pull-in coil by placing Interface Board Test Mode. Refer to the
an ohmmeter between the white wire appropriate Microprocessor Diagnostic
(8DPpin B) and the black wire (CH Manual for specific information about the
pin C) in the fuel solenoid connector. The Relay Test Mode.
resistance of the pull-in coil should be 0.2
5. Energize the fuel solenoid by energizing the
to 0.3 ohms. If the resistance of the pull-in
run relay with the Interface Board Test Mode.
coil is not in this range, replace the fuel
solenoid. NOTE: The fuel solenoid must be energized
when it is installed. If not, the plunger and
b. If the pull-in coil does energize, go to
the linkage may not line up correctly and the
step 9.
fuel solenoid will not function properly.
9. Test the hold-in coil.
6. Place the O-ring in the groove in the end of
a. Energize the hold-in coil by placing a the fuel injection pump. Make sure that the
jumper between the red wire (8Dpin A) O-ring is positioned correctly during
in the fuel solenoid connector and the installation to avoid damage and leaks.
positive battery terminal.
b. Momentarily energize the pull-in coil by
placing a jumper between the white wire
(8DPpin B) in the fuel solenoid
connector and the positive battery
terminal. The fuel solenoid should make a
definite click when the pull-in coil is
energized, but should not click when the
pull-in coil is de-energized.
AEA635
c. De-energize the hold-in coil by removing
the jumper from the red wire (8Dpin A) 1. Fuel Solenoid
and the positive battery terminal. The fuel
2. O-ring
solenoid should make a definite click
when the hold-in coil is de-energized. 3. Groove in Fuel Injection Pump

d. If the hold-in coil does not function Figure 120: Fuel Solenoid Components
properly, check the resistance of the
hold-in coil by placing an ohmmeter 7. Install the new fuel solenoid.
between the red wire (8Dpin A) and the 8. Press the OFF key to turn the unit off after
black wire (CHpin C) in the fuel installing the fuel solenoid.
solenoid connector. The resistance of the
hold-in coil should be 24 to 29 ohms. If
the resistance of the hold-in coil is not in
this range, replace the fuel solenoid.

109
Engine Maintenance

Trochoid Feed Pump

The TK486V 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 122: 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 121: 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 123: Trochoid Feed Pump
4. Place the new trochoid feed pump on the
injection pump.

110

5. Install and tighten four hex head screws that
attach the trochoid feed pump to the injection
pump. Torque the hex head screws to 6 to
7 ft-lb (8 to 10 Nm).
Cold Start Device Tier 2 Engine
The TK486V engine has a cold start device
located on the fuel injection pump. The cold start
device has a plunger that retracts at engine coolant
temperatures below 41 F (5 C) to advance the
injection timing approximately 2 degrees. The
plunger controls the position of a piston in the
injection pump to change the timing. The plunger
is extended and the injection timing is normal at
engine coolant temperatures above 41 F (5 C).
Check the operation of the cold start device if it is
difficult to start the engine in cold weather.
NOTE: Do not pull the plunger out of a cold
start device because that will damage it.
1. Plunger (Extended)
Figure 124: Cold Start Device
Checking Cold Start Device Operation
Use the following procedure to check the
operation of the cold start device. The engine
coolant temperature must be below 32 F (0 C) to
start the procedure.
1. Press the ON key to turn the unit on.
Engine Maintenance
2. Press the GAUGES key before the engine starts
(to enter the Gauges Menu) and check the
coolant temperature to make sure it is below
32 F (0 C).
3. Let the engine start, then check the engine rpm
in the Gauges Menu. The engine rpm should
be approximately 100 rpm higher than normal
(see Specifications).
4. Let the engine run to warm up and use the
Gauges Menu to check the coolant
temperature and engine rpm. When the
coolant temperature rises above 41 F (5 C),
the engine rpm should drop back to normal.
Replace the cold start device if the engine rpm
does not drop approximately 100 rpm when
the engine warms up.
Cold Start Device Replacement
1. Drain the engine coolant.
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.
3
1. Banjo Bolt
2. Engine Coolant Fitting
3. Coolant Hoses to Cold Start Device
Figure 125: Remove Engine Coolant Fitting
111
Engine Maintenance
3. Remove the cold start device from the
injection pump fitting. Use a backup wrench
on the injection pump fitting if necessary.
1 bell housing.
2 possibility of the engine firing while it is
1. Cold Start Device
2. Injection Pump Fitting
Figure 126: Remove Cold Start Device
4. Make sure the piston inside the injection
pump fitting is clean.
1
1. Piston
Figure 127: Clean Piston
5. Install the new cold start device with a new
O-ring in the injection pump fitting. Torque
the cold start device to 22 to 26 ft-lb (30 to 35
Nm).
6. Install the coolant fitting and banjo bolt on the
cold start device. Torque the banjo bolt to 16
to 18 ft-lb (22 to 25 Nm).
7. Refill the engine cooling system and make
sure to bleed the air from the cooling system.
112
Engine Valve Clearance
Adjustment
1. Remove the rocker arm cover.
2. Remove the round cover (plug) from the
timing mark access hole on the front of the
CAUTION: Loosen all of the injection
lines at the injection nozzles to prevent the
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 2
AEA701
1. Index Mark
2. Top Dead Center Mark for 1 and 4
Figure 128: Top Dead Center One and Four
a. Rotate the engine in the normal direction
of rotation (clockwise viewed from the
water pump end) until the 1-4 timing mark
on the flywheel lines up with the index
mark in the timing mark access hole.
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
stroke for the number one cylinder.
d. If the rocker arms are tight, the engine is at
top dead center of the exhaust stroke for
the number one cylinder. Rotate the engine
360 degrees to place the engine at top dead
center of the compression stroke for the
number one cylinder.
 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
until the valve clearance is correct.
6. Hold the adjustment screw in place and
tighten the locknut.
Figure 129: Adjusting the Valve Clearance
7. Recheck the valve clearance.
8. Rotate the engine one full turn (360 degrees)
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

113
Engine Maintenance

Crankcase Breather Normal crankcase pressures with a new air

cleaner are 2 to 12 in. (50 to 300 mm) H2O of
Gases formed in the crankcase are directed to the
vacuum. The vacuum will increase as the air
intake manifold. Harmful vapors that would
cleaner gets dirty and becomes more restrictive.
otherwise collect in the crankcase and
Check the air restriction indicator before checking
contaminate the oil, or escape to the outside, are
the crankcase pressure. Replace the air cleaner if
drawn back into the engine and burned.
the reading on the air restriction indicator exceeds
The crankcase breather is located in the valve 20 in. (508 mm) H2O of vacuum. A dirty air
cover. A restrictor is cast into the fitting for the cleaner may cause excessive vacuum, leading to
breather hose on the intake manifold. The oil carry over and high oil consumption.
restrictor limits the flow of gases from the
The crankcase breather and the breather hose
crankcase to the intake manifold and keeps the
should be inspected when the air cleaner element
crankcase pressure from getting too low in
is replaced to make sure they are not plugged or
vacuum. A breather hose connects the crankcase
damaged. Inspect the insulation to make sure it is
breather to the intake manifold.
in place and undamaged. The insulation is used to
3 prevent freezing in cold weather.

1 2 The following items can effect the crankcase

4 pressure readings.

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

1. Breather Hose 5. Baffle Breather

2. Insulation 6. Baffle Plate
3. Breather Cover 7. Intake Manifold
4. O-Ring 8. Restrictor Location
Figure 130: Crankcase Breather Tier 2 Engine

114
 Engine Maintenance

Air Cleaner
Before the first quarter of 2001, a heavy duty, dry
element air cleaner was used on this unit. Replace
this air cleaner when the air restriction indicator
reads 25 in. of vacuum.

EMI 3000 Air Cleaner

The EMI 3000 air cleaner is a dry element air
cleaner. It became standard equipment on this unit 1
in the first quarter of 2001. Replace the EMI 3000 2
air cleaner element when the air restriction
indicator reads 25 in. of vacuum, or at 3,000 hours
or 2 years, whichever occurs first. The EMI 3000 3
air cleaner element has a nameplate that reads
EMI 3000. It cannot be interchanged with air
cleaners used on previous units, however it can be
retrofit on previous units by using the EMI 3000
Air Cleaner Assembly and the related
components. 1. EMI 3000 Air Cleaner Assembly
2. EMI 3000 Air Filter Element
3. Air Restriction Indicator
Figure 133: EMI 3000 Air Cleaner System
Model 30 Shown Model 50 Similar

ARA189

Figure 131: EMI 3000 Air Cleaner Assembly

ARA190

1. Dust Ejector Must Point Down When Installed

Figure 132: EMI 3000 Air Filter Element

115
Engine Maintenance
Air Restriction Indicator
Excessive restriction of the air intake system
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.
AEA710
Figure 134: Air Restriction Indicator
116
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
motion and without pulling on the belt. Then read
the dial. Use an average of three readings.
NOTE: Do not attempt to remove or install belts
without loosening adjustments. Belts that are
installed by prying over pulleys will fail
prematurely due to internal cord damage.
CAUTION: Do not attempt to adjust belts
with the unit running.
CAUTION: Turn the unit off before
performing maintenance or repair
procedures. When the unit is turned on, it
can start at any time without warning.
 Engine Maintenance

Belt Adjustments Upper and Lower Fan Belt Adjustment

Alternator Belt Adjustment
The alternator belt tension should read 67 on the
belt tension gauge.
1. Loosen the alternator pivot bolt and the
adjusting arm bolt.
2. Move the alternator on the adjusting arm slots
to adjust the belt to 67 on the belt tension
gauge.
3. Tighten the adjusting arm bolt and alternator
pivot bolt.
The upper fan belt should read 74 and the lower
fan belt should read 67 on the belt tension gauge.
NOTE: Both the upper and lower fan belts are
adjusted at the same time in one procedure.
NOTE: If a fan belt is loose or damaged, replace
the belt (see Fan Belt Replacement on page
118).
1. Loosen the idler assembly pivot bolts and the
idler adjusting arm bolts.
2. Push in or pull out on the idler adjusting arm
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 135: Model 30 Belt Arrangement

117
Engine Maintenance
3. Tighten both idler adjusting arm bolts and
both idler assembly pivot bolts.
NOTE: If the idler assembly binds when
moving for belt adjustment, loosen the upper
idler support bracket mounting bolts to free
up the assembly. Check the main idler
retainer nut assembly for proper alignment
between the nut and the support bracket
slots.
Fan Belt Replacement
NOTE: Do not attempt to remove or install the
belts without loosening the adjustments. Belts
that are installed by prying over pulleys will fail
prematurely due to internal cord damage.
Lower Fan Belt
Removal
1. Loosen both idler adjusting arm bolts and both
idler pulley assembly bolts.
2. Push the idler adjusting arm IN. The lower fan
belt will come off the engine pulley. Move the
arm OUT far enough to clear the roadside
idler mounting bracket.
Installation
1. Slip the belt into the groove of the idler pulley.
2. Push the idler adjusting arm back in toward
the unit.
3. Slip the belt onto the pulley groove on the
engine.
4. Pull the idler adjusting arm back OUT and
adjust the belts to the proper tension.
5. Tighten the idler assembly pivot bolts and the
idler adjusting arm bolts.
Upper Fan Belt
Removal
1. Loosen the idler adjusting arm bolts and
remove the lower fan belt (see Lower Fan
Belt above).
2. Push the idler adjusting arm in and the idler
assembly up. The upper belt should become
slack and slip down out of the idler pulley
groove.
118
3. Pull the idler adjusting arm OUT. The upper
fan belt should slip off the idler pulley as the
idler pulley hub clears the curbside idler
mounting bracket.
4. Loosen the two condenser fan hub to the shaft
clamping bolts.
5. Tap the blower wheel with a soft hammer to
drive the blower wheel up the fan shaft to
provide 1/2 in. (13 mm) clearance between the
blower wheel and the inlet ring.
NOTE: If the condenser fan does not slide
on the fan shaft with light tapping, remove
the small access panel located on the
condenser coil header above the radiator
tank. Thread a 1/4-20 x 1 in. diameter bolt
into the end of the fan shaft. Tighten the bolt
and washer down on the condenser fan hub
to loosen the blower wheel. Drive the blower
wheel back to provide 1/2 in. (13 mm)
clearance between the blower wheel and
condenser fan inlet ring.
6. Lift the belt up over the condenser blower
wheel and remove it from the unit.
Installation
1. Slip the belt over the condenser blower wheel
and place it in the condenser fan pulley.
2. Drive the condenser blower wheel out toward
the condenser fan inlet ring using a soft
hammer.
3. Position the blower wheel so the edge of the
inlet ring lines up with the alignment mark on
the blower wheel.
4. Check the radial clearance between the blower
wheel and inlet ring with a gauge wire. Check
around the entire circumference to the inlet
ring and blower wheel (see Condenser and
Evaporator Fan Location on page 150).
5. Torque the blower hub clamping bolts to
18 ft-lb (24 Nm).
6. Seat the upper belt in the blower wheel pulley
groove.
7. Push inward on the idler adjusting arm and
slip the belt into the idler pulley groove.
 Engine Maintenance

8. Pull the idler adjusting arm forward and install

the lower fan belt.
1 2

AEA749

1. Blower Wheel
2. Inlet Ring
3. Alignment Mark
4. Edge of Inlet Ring
Figure 136: Condenser Blower Alignment

119
Engine Maintenance

120
Refrigeration Maintenance
NOTE: The following procedures involve
servicing the refrigeration system. Some of these
service procedures are regulated by Federal, and
in some cases, by State and Local laws.
In the USA all regulated refrigeration service
procedures must be performed by an EPA
certified technician, using approved equipment
and complying with all Federal, State and Local
laws.
Refrigerant Charge
Testing the Refrigerant Charge with
an Empty Trailer
If the unit has an insufficient charge of refrigerant,
the evaporators will be starved and the box
temperatures will rise even though the unit is
operating. The suction pressure will drop as the
refrigerant charge decreases. If the unit has an
overcharge of refrigerant, the unit may not cool
properly and the suction and discharge pressure
may be high. The charge may be determined by
inspection of the refrigerant through the receiver
tank sight glass with the following conditions
established:
1. Place a test box over each evaporator.
2. Install a gauge manifold.
3. Run all the evaporators on cool until the return
air temperature in each box is at 0 F (-18 C).
By allowing a box to leak a small amount, you
will be able to maintain 0 F (-18 C).
4. The suction pressure should be 13 to 18 psig
(90 to 124 kPa).
5. The discharge pressure should be 325 to
400 psig (2241 to 2758 kPa). If the pressure is
below this, it can be raised by covering a
portion of the roadside condenser grille with a
piece of cardboard to block condenser airflow.
6. Under these conditions, the ball should be
floating in the receiver tank sight glass. If
refrigerant is not visible in the receiver tank
sight glass, the unit is low on refrigerant.
Testing the Refrigerant Charge with
a Loaded Trailer
NOTE: This test determines if there is enough
refrigerant for the current temperatures, not if
there is a full charge of refrigerant.
1. Install a gauge manifold.
2. Run all the evaporators on cool.
3. Build up and maintain 325 to 400 psig (2241
to 2758 kPa) of discharge pressure. If the
pressure is below this, it can be raised by
covering the roadside condenser grille with a
piece of cardboard to block condenser air
flow.
4. Cool the compartments to lowest temperatures
required.
5. Check suction pressure. It should be 13 to
22 psig (90 to 152 kPa).
6. Under these conditions, the ball should be
floating in the receiver tank sight glass. If
refrigerant is not visible in the sight glass, the
unit is low on refrigerant.
Testing for an Overcharge
Use the following procedure to identify a unit
with an excessive refrigerant charge:
1. Install a gauge manifold on the compressor.
2. Operate the host unit in high speed with all the
evaporators in cool to stabilize system
pressures and reduce the compartment
temperatures to approximately 60 F (16 C) or
colder.
3. Observe discharge pressure and cover the
condenser to increase the discharge pressure
approximately 50 psig (345 kPa) above the
observed pressure. Do not allow the discharge
pressure to go above 350 psig (2413 kPa).
NOTE: If the ball and liquid level in the
receiver sight glass drops during step 3, the
unit is not overcharged and it is not
necessary to complete the procedure.
4. Remove the condenser cover to rapidly reduce
discharge pressure.
121
Refrigeration Maintenance
5. Observe the receiver tank sight glass and the
units discharge pressure.
6. By the time the discharge pressure drops
approximately 50 psig (345 kPa) the ball in
the receiver tank sight glass should begin to
move and the liquid level should drop.
a. When discharge pressure stabilizes, the
ball and liquid level will rise.
b. If the ball will not begin to move or the
liquid level will not drop, the unit most
likely has an overcharge of refrigerant.
The refrigerant level should be adjusted.
Adjusting Refrigerant Level
1. Stop the unit and remove some refrigerant
with an approved refrigerant recovery device.
2. Perform a refrigerant level check and repeat
the overcharge test.
3. If the liquid level is low, add refrigerant as
follows:
a. Connect a refrigerant tank to the gauge
manifold service line and purge the line.
b. Mid seat the suction service valve.
c. Set the refrigerant tank for liquid removal
and open the hand valve.
d. Operate the unit in high speed with all
evaporators in cool.
e. Observe the suction pressure and slowly
open the gauge manifold low pressure
hand valve to allow liquid refrigerant to
flow into the suction service valve.
f. Control the liquid flow so the suction
pressure increases approximately 20 psig
(138 kPa).
g. Maintain a discharge pressure of at least
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.
122
4. Repeat the overcharge test.
5. Remove the gauge manifold set and cap all
service ports and valve stems when the
refrigerant level is correct.
Moisture Indicating Sight Glass
The receiver tank is equipped with a moisture
indicating sight glass. The outer edge of the sight
glass has a colored ring approximately 0.1 in.
(2.5 mm) thick. The color of the ring indicates the
moisture content of the refrigerant, but it may not
be completely reliable.
Green = Dry
Chartreuse = Caution
Yellow = Wet
1
2
AEA672
1. Floating Ball
2. Colored Ring
Figure 137: Moisture Indicating Sight Glass
A system has to run for at least 15 minutes to
change the color of the indicator ring after the
moisture content of the system has been changed.
For example, evacuating a system to remove the
moisture will not change the color of the indicator
ring until the system has been recharged and then
operated for at least 15 minutes.
Refrigerant Leaks
Use a reliable leak detector that is suitable for
R-404A to leak test the refrigeration system.
Inspect for signs of oil leakage which is the first
sign of a leak in the refrigeration system.
 Refrigeration Maintenance

Checking Compressor Oil
The compressor oil should be checked when there
is evidence of oil loss (oil leaks) or when
components in the refrigeration system have been
removed for service or replacement. Use the
compressor sight glass to check the oil level.
If the compartment is empty, you can run the
evaporator on the heat cycle instead of the defrost
cycle.
NOTE: Use refrigeration compressor oil ONLY.
Polyol Ester type (P/N 203-513) is required on
R-404A systems.

High Pressure Cutout Switch

(HPCO)
The HPCO is located on the compressor discharge
manifold. If the discharge pressure rises above
470 psig (3241 kPa), the HPCO opens the HPCO
circuit to the run relay and stops the unit. To test
the HPCO; rework a gauge manifold. See Figure
1 139.
1. Connect the gauge manifold to the compressor
discharge service valve with a heavy duty,
black jacketed thick wall #HCA 144 hose with
a 900 psig (6204 kPa) working pressure
rating.

1. Compressor Sight Glass

Figure 138: Compressor Sight Glass Location

To check compressor oil level with an

ambient air temperature above 50 F (10 C):
Install a gauge manifold on the compressor.
Operate all the evaporators on cool with a 20 psig
(138 kPa) minimum suction pressure and a
185 psig (1275 kPa) minimum discharge pressure
for 15 minutes or more.
After the unit has maintained the above conditions
for 15 minutes, observe the oil level. The oil
should be 1/4 to 1/2 up in the sight glass.

To check compressor oil level with an

ambient air temperature below 50 F (10 C):
Run all the evaporators through a complete 1. Relief Valve (66-6543)
defrost cycle. After completing the defrost cycles, 2. O-Ring (33-1015)
run all the evaporators on cool for ten minutes. 3. Adapter Tee Weather Head (No. 552X3)
Observe the oil level. The oil should be 1/4 to 1/2
Figure 139: High Pressure Cutout Manifold
up in the sight glass.

123
Refrigeration Maintenance
2. Use the Service Test mode to run the host unit
in High Speed Cool. Refer to the appropriate
Diagnostic Manual for specific information
about the Service Test Mode.
3. Raise the discharge pressure of the
compressor first by blocking the condenser
coil air flow by covering the roadside
condenser grille with apiece of cardboard. If
this does not raise the discharge pressure to
the cutout level of the HPCO, increase the
engine speed by overriding the throttle
solenoid. This should increase the discharge
pressure enough to cause the HPCO to cut out.
CAUTION: If the discharge pressure
reaches 477 psig (3289 kPa), shut the unit
off immediately. Do not allow the
discharge pressure to exceed 477 psig
(3289 kPa).
4. If the HPCO does not open to de-energize the
fuel solenoid and stop the engine, it must be
replaced.
High Pressure Switch (HPCS)
Test
The high pressure switch (HPCS) is located on the
compressor discharge manifold. This switch is
used by the microprocessor to confirm the
operation of the discharge pressure transducer. It
is connected to the HPCS and CHHP wires in the
main wire harness. The HPCS opens when the
discharge pressure rises above 300 psig (2068
kPa). The HPSW closes when the discharge
pressure drops below 200 psig (1379 kPa).
Use the following procedure to test the HPCS:
1. Install a gauge manifold on the compressor.
2. Disconnect the HPCS from the HPCS and
CHHP wires in the main wire harness.
3. Check the HPCS for continuity. It should be
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
Diagnostic Manual for specific information
about the Service Test Mode.
5. Cover the condenser to raise the discharge
pressure.
124
6. Monitor the discharge pressure. When the
discharge pressure reaches 300 +25/-0 psig
(2068 +172/-0 kPa), the HPCS 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 HPCS should
close.
9. Replace the HPCS if it does not function
properly.
10. Reconnect the HPCS to the main wire harness
and remove the gauge manifold.
Pressure Transducers
The discharge pressure transducer and the suction
pressure transducer supply pressure information
to the microprocessor. These pressures can be
monitored with the GAUGES key. Check the
readings by comparing them to the readings on a
gauge manifold set attached to the compressor.
Refer to the SR-2 Multi-Temp Microprocessor
Controller Diagnostic Manual TK 53080 for more
information about the testing and operation of the
pressure transducers.
Evacuating and Charging
Smart Reefer Multi-Temp
Systems
Set-up Unit
The SR-2 Multi-Temp microprocessor must be
placed in the Evacuation Test to evacuate and
charge the unit. When the microprocessor is in the
Evacuation Test it opens all the normally closed
solenoid valves in the refrigeration system. This
allows the refrigeration system to be evacuated
properly. Refer to the appropriate Diagnostic
Manual for complete information about the
microprocessor. Use the following procedure to
set-up the unit and place the microprocessor in the
Evacuation Test:
1. Press the ON key to turn the unit on.
2. Before the unit starts, press the MENU key. The
first screen in the Main Menu (either the
Language or Alarms Display) will appear.

3. Press the EXIT key and the unlabeled soft key
at the same time, and hold them down for 5
seconds to enter the Maintenance Menu. The
first Maintenance Menu feature will appear.
4. Press the NEXT (or BACK) key to scroll through
the Maintenance Menu features until the
Evacuation Test appears.
5. Press the Select key to enter the Evacuation
Test.
6. Connect a battery charger to the unit battery.
The battery charge must have an output of at
least 15 amperes. This will maintain the
charge level of the battery during the time
required to evacuate and charge the unit. The
Evacuation Test is used to open unit valves as
required for evacuation. Failure to connect a
battery charger may result in the battery
voltage falling too low to reliably operate the
microprocessor and valves.
7. The microprocessor is now in the Evacuation
Test. The refrigeration system is set-up for
evacuation and charging.
Evacuating the System
CAUTION: Do not evacuate the system
until it is leak free. A unit with less than
full refrigerant charge should be leak
checked and all leaks must be repaired
1. Be sure all refrigerant has been recovered
from the unit.
2. Connect a vacuum pump and gauge manifold
for three-point evacuation to the suction
service valve, discharge service valve, and
receiver tank outlet valve (see Figure 140 on
page 126).
NOTE: The use of the Thermo King
Evacuation Station P/N 204-725 or 204-744
is recommended.
3. Verify proper operation of the Evacuation
Station as shown in the Evacuation Station
Operation Manual TK 40612.
4. Start the vacuum pump and mid-seat the
suction service valve, discharge service valve,
and receiver tank outlet valve.
Refrigeration Maintenance
5. Install service valve stem caps with seals and
tighten them. The valve stems should remain
capped while evacuating the unit.
6. Evacuate the unit to 500 microns, or the
lowest achievable level between 500 and
1,000 microns.
7. Continue to evacuate the unit for one
additional hour after reaching 500 microns, or
the lowest achievable level between 500 and
1,000 microns. This insures complete
evacuation of the remote evaporators and
lines.
8. Close the Evacuation Station valve nearest the
vacuum pump (V1) to isolate the vacuum
pump from the system. Turn the vacuum
pump off.
9. Observe the micron gauge.
The system pressure should remain below
2000 microns for 5 minutes.
If the pressure does not hold, check for leaks
(if a leak is suspected) or continue evacuation
(if system is not dry).
10. Restart the vacuum pump, open the
Evacuation Station valve nearest the vacuum
pump (V1) and repeat steps 6, 8, and 9 as
required until system pressure remains below
2000 microns for 5 minutes.
11. When system pressure remains below 2000
microns for 5 minutes, restart the vacuum
pump and open the Evacuation Station valve
nearest the vacuum pump (V1).
12. With the vacuum pump running, back seat the
suction service valve. Replace the valve cap,
re-close the Evacuation Station valve nearest
the vacuum pump (V1), and stop the vacuum
pump.
13. Close valve V4. The unit is ready to charge.
NOTE: Do not exercise the service valves with
the unit in a deep vacuum unless the vacuum
pump is operating.
125
Refrigeration Maintenance

Charging the System 2. Before charging system, make sure the

NOTE: The unit must be left in the Evacuation
Test.
1. Insure that all compartment bulkheads are
open. Ceiling mounted bulkheads should not
be stored close to the evaporator outlets as this
will restrict airflow.
refrigerant lines from the gauge manifold to
the refrigerant supply bottle have been
evacuated or purged, the suction service valve
is back seated, and the discharge service valve
and receiver tank outlet valve are still open.

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 140: Multi-Temp Evacuation and Charging (Two Zone Unit Shown Other Units Similar)

126

3. Set the refrigerant supply bottle for liquid.
Open the gauge manifold hand valve and add
a charge of 15.5 lb (7.0 kg) of R-404A.
For units without remote evaporators, this
is the total charge.
For units with remote evaporators, this is a
partial charge. Do not add more than this.
The remainder of charge will be added
through suction service valve while unit is
running.
4. Close the gauge manifold hand valve.
5. Back seat (close) the receiver tank outlet valve
and discharge service valve.
6. Exit the Evacuation Test by turning the unit
Off and then back On.
7. Turn all zones On and set all zone setpoints
for the lowest possible temperature to insure
that all zones run in Cool mode. Allow the
unit to start.
8. 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.
9. Remove the evacuation manifold hoses from
the receiver tank outlet valve, the discharge
service valve, and the suction service valve.
Replace and tighten the service port and valve
stem caps on the receiver tank outlet valve.
NOTE: For units without remote
evaporators, the unit is now charged. Cap the
suction and discharge service ports. Back
seat the suction service valve, and cap the
suction and discharge service valve stems.
10. Attach the gauge manifold (with the
refrigerant supply bottle still connected) to the
compressor. Attach the low side gauge to the
suction service valve. Mid-seat the suction
service valve. Attach the high pressure gauge
on to the discharge service valve. Open the
discharge service valve to monitor the
discharge pressure.
11. Turn the unit On, turn all zones On (with all
zone setpoints set to the lowest possible
temperature), and allow the unit to start.
Refrigeration Maintenance
12. Observe the suction pressure and slowly open
the gauge manifold hand valve to allow liquid
refrigerant to flow into the suction service
valve. Control the liquid flow so the suction
pressure increases 20 to 25 psi (138 to
172 kPa). Maintain a discharge pressure of
325 to 400 psi (2241 to 2758 kPa).
13. Add refrigerant until the ball in the receiver
tank sight glass rises to the middle of the sight
glass, then close the gauge manifold hand
valve. Make sure the liquid level does not rise
above the top of the sight glass.
14. Continue to operate the unit and monitor the
sight glass until all compartment temperatures
are at or below 0 F (-18 C).
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.
127
Refrigeration Maintenance

128
Refrigeration Service Operations
NOTE: It is generally good practice to replace
the filter drier whenever the high side is opened
or when the low side is opened for an extended
period of time.
Low Side Pump Down
NOTE: Operate all the evaporators in Cool for
2 to 5 minutes with the service valves in their
normal operating positions before performing
the low side pump down. Install a gauge
manifold at the compressor.
1. Run all the evaporators in cool, front seat the
receiver tank outlet valve and the bypass hand
valve, and pump down the low side to 20 to
25 in. Hg vacuum (-68 to -85 kPa). Turn the
unit Off.
If the unit pumps down acceptably and then
holds at least 15 in. Hg vacuum (-51 kPa) for
2 minutes or more, it can be assumed that the
receiver tank outlet valve, the compressor
discharge valve plates, the HGS solenoid, the
HGS2 solenoid, the HGS3 solenoid, and the
purge valve solenoid are sealing acceptably.
2. Prepare to perform service on the units low
side by equalizing the high side and low side
pressures.
a. Disconnect the purge valve solenoid wires
from the main wire harness.
NOTE: If the purge valve solenoid wires are
not disconnected from the main wire
harness, the purge valve is energized when
the unit is placed in the Evacuation Test.
This allows the refrigerant in the condenser
to flow into the accumulator, undoing the
low side pump down.
b. Place the unit in the Evacuation Test.
Refer to the appropriate Microprocessor
Diagnostic Manual. The high and low side
pressures should equalize in the
Evacuation Test.
NOTE: Repeat the pump down procedure
if the pressures equalize above 20 psi
(138 kPa). If suitably low pressures cannot
be achieved after the third pump down, the
refrigerant must be recovered to perform
service on the low side.
c. If the reading on the gauge manifolds
high pressure gauge increases after the
high and low side pressures have been
equalized, the condenser inlet check valve
is leaking.
d. Remember to reconnect the purge valve
solenoid wires to the main wire harness
when the service procedures have been
completed.
Compressor
The 7-quart sump extends below the top of the
lower frame rails. Therefore, a flat board cannot
be used as a support when removing or installing
a compressor with a 7-quart sump. A Compressor
Installation Tool P/N 204-1087 (two pieces) has
been developed to aid in the removal and
installation of the 7-quart sump compressors.
Removal
1. Pump down the low side and equalize the
pressure to slightly positive.
2. Front seat the discharge and suction service
valves. Remove the remaining refrigerant
pressure from the compressor.
3. Unbolt the discharge and suction service
valves from the compressor.
4. Remove the compressor oil filter and its lines.
5. Disconnect the HPCO wires and the HPCS
wires.
129
Refrigeration Service Operations
6. Support the compressor and remove the
compressor mounting bolts from the flywheel
housing. Use The Compressor Installation
Tool (P/N 204-1087) to support the
compressor as follows:
a. Identify the four machined feet on the base
of the compressor sump. The Compressor
Installation Tools bridge the lower frame
rails and support the compressor directly
under these feet.
b. Position the Compressor Installation Tools
by inserting them from the end of the
compressor and sliding them into place on
the lower frame rails. Alternatively,
position the Compressor Installation Tools
by inserting them on a diagonal from
below the compressor and twisting them
into position over the lower frame rails.
7. Lift the service valves out of the way.
8. Slide the compressor to the left until the
coupling pins are clear.
9. Remove the compressor from the front of the
unit. Keep the compressor ports covered to
prevent dust, dirt, etc., from falling into the
compressor.
NOTE: When the compressor is removed
from the unit, the 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.
Installation
1. Place the Compressor Installation Tools on the
lower frame rails to support the compressor.
2. Slide the compressor into the unit.
3. Place the compressor in position and install
the mounting bolts.
4. Install the service valves using new gaskets
soaked in compressor oil. Connect the HPCO
wires, the HPCS wires, and install the
compressor oil filter.
130
5. Pressurize the compressor and test for
refrigerant leaks.
6. If no leaks are found, evacuate the
compressor.
7. Back seat the suction and discharge service
valves.
8. Operate the unit at least 30 minutes and then
inspect the oil level in the compressor. Add or
remove oil if necessary.
9. Check the refrigerant charge and add
refrigerant if needed.
Compressor Coupling Removal
1. After the compressor has been removed from
the unit, use the appropriate Allen tool
provided with removal tool P/N 204-991 (see
Figure 141 on page 131) to loosen the center
bolt, which holds the coupling to the
compressor shaft.
2. Attach the tool to the coupling with the
provided socket head screws and spacers. Two
sets of spacers are provided with the tool, use
the short spacers with shallow compressor
mounting flanges and the longer set for deeper
flanges. The side with the countersunk holes
should be toward the coupling.
3. To prevent the tool and crankshaft from
rotating, use one of the compressor to engine
mounting screws to pin the tool to the flange.
If a nut is used to prevent the bolt from falling
out, the nut should not be tightened.
4. Use the appropriate Allen tool to loosen the
coupling mounting screw.
5. Once the center screw has been loosened,
back the head against the tool and it should
push the coupling off the crankshaft as you
continuing turning the center screw in a
counter-clockwise direction. Using this tool
will prevent the coupling from popping off
because the center bolt and flatwasher will
hold it in place.
 Refrigeration Service Operations

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 Nm) 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 141: Compressor Coupling Removal Tool

131
Refrigeration Service Operations
3. Using no lubricants, set the coupling on the
crankshaft and align the keyways using the
Keyway Tool (P/N 204-972). Insert the
tapered end of the tool into the keyway and
gently move the coupling on the shaft while
pressing the tool into the keyway. This will
align the keyway in the crankshaft with the
keyway in the coupler.
AGA333
Figure 142: Keyway Tool P/N 204-972
CAUTION: If you are assembling a used
coupler or crankshaft and the tool does
not fit easily there is a problem with one of
the keyways! Do not remove the coupler
and place the key in the crankshaft
keyway and then drop the coupler on. If
the tool does not fit, the key will not fit,
and it will hold the taper in the coupler off
the taper on the shaft. Check both keyways
for burrs or corrosion. A key can be
coated with fine lapping compound and
used as a lapping tool to clean the
keyways.
4. Remove the Keyway Tool and check the fit of
the key (P/N 55-9024). It should fit into the
keyway with a light press fit requiring only a
minimum of light tapping. If the key does not
fit properly, remove the coupler and inspect
the keyways and key for burrs or other
problems. Recheck the fit as shown above.
5. When the key fits properly, remove the
coupling and key from the shaft.
6. Re-install the coupling and align the keyways
with the Keyway Tool.
7. Do not install the key at this time. Install the
flat washer and bolt and pre-torque to 20 ft-lb
(27 Nm). Remove the bolt and washer.
132
8. Install the key in the keyway. As above, it
should fit with a light press fit requiring only a
minimum of light tapping. Do not install the
key into the keyway beyond the front face
of the coupling. If tapped in farther it may
cause the coupling to move off center on the
shaft.
1
2
3
5 4
AGA1254
1. Compressor Coupling or Clutch
Key tapped flush with outside face of coupling.
2.
Do not tap key any farther into keyway.
3. Torque bolt to 90 ft-lb (122 Nm)
4. Washer
Spray this area with corrosion inhibitor after
5.
assembling.
Figure 143: Compressor Coupling Installation
9. Re-install the bolt and heavy flat washer and
snug the bolt down by hand. Torque the bolt to
90 ft-lb (122 Nm).
10. Spray a corrosion inhibitor (such as spray
paint) on the exposed part of the shaft and the
joint between the shaft and the coupling. This
prevents moisture from wicking into the joint
and causing corrosion.
Condenser Coil
Removal
1. Recover the refrigerant charge.
2. Drain engine coolant from the expansion tank.
Unbolt and remove the coolant expansion tank
from the condenser coil frame. Unsolder the
tank breather tube.

3. Remove the condenser coil mounting bolts.
Remove the mounting clamps from the
condenser inlet line.
4. Unsolder the inlet line and liquid line
connections. Lift the coil from the unit.
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.
6. Install the engine coolant expansion tank and
refill half way with engine coolant.
7. Recharge the unit with proper refrigerant and
check the compressor oil.
Discharge Vibrasorber
Removal
1. Recover the refrigerant charge.
2. Heat the connections on the vibrasorber until
the vibrasorber can be removed.
CAUTION: Use a heat sink, P/N 204-584
or wrap the vibrasorber with wet rags to
prevent damaging the vibrasorber.
Installation
1. Prepare the vibrasorber and tubing fittings by
cleaning thoroughly.
2. Solder the vibrasorber connections.
CAUTION: Use a heat sink, (P/N 204-584
or wrap the vibrasorber with wet rags to
prevent damaging the vibrasorber.
3. Pressurize the system and test for leaks. If no
leaks are found, evacuate the system.
4. Charge the unit with the proper refrigerant and
check the compressor oil level.
Refrigeration Service Operations
In-Line Check Valves
This unit uses some in-line check valves. An
in-line check valve is not repairable and must be
replaced if it fails. A heat sink must be used on the
in-line check valve when it is being soldered in
place to prevent damage to the neoprene seal.
1. Valve
2. Neoprene Seal
3. Valve Seat
4. Spring
Figure 144: Cross Section of In-line Check Valve
Removal
1. Recover the refrigerant charge.
2. Place a heat sink on the check valve.
3. Unsolder the lines and remove the check
valve.
Installation
NOTE: A heat sink must be used on the in-line
check valve when it is being soldered in place to
prevent damage to the neoprene seal.
1. Clean the tubes for soldering.
2. Place the check valve in position. The arrow
on the valve body indicates the direction of
refrigerant flow through the valve.
3. Place a heat sink on the check valve.
4. Solder the inlet and outlet connections.
5. Pressurize the refrigeration system and test for
leaks.
6. If no leaks are found, evacuate the system.
7. Recharge the unit with proper refrigerant and
check the compressor oil.
133
Refrigeration Service Operations
Receiver Tank
Removal
1. Recover the refrigerant charge.
2. Unsolder the refrigeration lines from the
receiver tank.
3. Unbolt the mounting brackets and remove the
receiver tank from the unit.
4. Remove the high pressure relief valve from
the receiver tank. It will be installed on the
new receiver tank.
Installation
1. Install the high pressure relief valve on the
new receiver tank. Make sure to use a new
O-ring and coated with refrigerant oil.
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
clearly visible.
3. Solder the refrigeration lines to the receiver
tank.
4. Tighten the receiver tank mounting hardware
securely.
5. Pressurize the refrigeration system and check
for leaks. If no leaks are found, evacuate the
system.
6. Recharge the unit with proper refrigerant.
Filter Drier
Removal
1. Pump down the low side and equalize the
pressure to slightly positive.
2. Disconnect the ORS nuts at the ends of the
drier.
3. Loosen the mounting hardware and remove
the drier.
Installation
1. Place the new O-rings in the ORS fittings on
the ends of the drier.
134
2. Install the new drier and tighten the mounting
screws and nuts.
3. Install and tighten the ORS nuts. Hold the
drier with a back-up wrench on the hex behind
the ORS fitting.
4. Pressurize the low side and inspect for leaks.
If no leaks are found, evacuate the low side.
5. Open the refrigeration valves and place the
unit in operation.
Expansion Valve Assembly
NOTE: This procedure applies to the Zone 1 and
Zone 2 expansion valves.
Removal
1. Pump down the low side and equalize the
pressure to slightly positive.
2. Remove the evaporator access panels.
3. Remove the feeler bulb from the clamp. Note
the position of the feeler bulb on the suction
line.
4. Disconnect the equalizer line from the suction
line.
5. Disconnect the inlet liquid line and unsolder
the distributor from the expansion valve.
6. Remove the expansion valve mounting bolt
and remove the expansion valve from the unit.
Installation
1. Install and bolt the expansion valve assembly
in the unit.
2. Connect the inlet liquid line and solder the
distributor to the expansion valve.
3. Connect the equalizer line to the suction line.
4. Clean the suction line to a bright polished
condition. Install the feeler bulb clamps and
the feeler bulb on the side of the suction line
in its former position. The feeler bulb must
make good contact with the suction line or
operation will be faulty. Wrap with insulating
tape.
5. Pressurize the low side and test for leaks. If no
leaks are found, evacuate the low side.

6. Replace the access panels.
7. Open the refrigeration valves and place the
unit in operation.
8. Test the unit to see that the expansion valve is
properly installed.
AEA713
1. End View
2. Side View
Figure 145: Location of Expansion Valve Bulb
Heat Exchanger
Removal
1. Pump down the low side and equalize the
pressure to slightly positive.
2. Remove the evaporator access panels.
3. Remove the hardware that holds the heat
exchanger on the bulkhead.
4. Unsolder the liquid outlet line.
5. Unsolder the suction inlet line.
6. Unsolder the remaining outlet suction line and
inlet liquid line connections from the
condenser side of the bulkhead. Remove any
putty from around the lines before unsoldering
the connections.
7. Slide the heat exchanger assembly out of the
evaporator housing.
Installation
1. Clean the tubes for soldering.
Refrigeration Service Operations
2. Place the heat exchanger assembly in the
evaporator housing and install the mounting
hardware loosely.
3. Solder the liquid inlet and the suction outlet
line connections on the condenser side of the
bulkhead. Seal the openings through the
bulkhead with putty when the refrigerant lines
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.
9. Open the refrigeration valves and place the
unit in operation.
Evaporator Coil
NOTE: This procedure applies to the Zone 1 and
Zone 2 evaporator coils.
Removal
1. Pump down the low side and equalize the
pressure to slightly positive.
2. Remove the evaporator access panels and
damper assembly.
3. Disconnect and remove the sensors.
4. Remove the feeler bulb from the suction line
clamp. Note the position of the feeler bulb on
the suction line.
5. Unsolder the distributor from the expansion
valve.
6. Unsolder the hot gas line and the suction line
from the evaporator coil.
NOTE: It may be necessary to unsolder and
remove other refrigeration tubes to remove
the control box side DE evaporator coil.
7. Remove the mounting bolts, lift and slide the
coil from the housing.
135
Refrigeration Service Operations
Installation
1. Place the evaporator coil in the evaporator
housing and install the mounting bolts.
2. Solder the hot gas line and suction line
connections to the evaporator coil.
NOTE: Replace any other refrigeration tubes
that were removed.
3. Solder the distributor to the expansion valve.
4. Replace and connect the sensors.
5. Pressurize the low side and test for leaks. If no
leaks are found, evacuate the low side.
6. Clean the suction line to a bright polished
condition. Install the feeler bulb on the side of
the suction line in its former position. The
feeler bulb must make good contact with the
suction line or operation will be faulty. Wrap
with insulating tape.
7. Replace the upper and lower evaporator
access panels.
8. Open the refrigeration valves and place the
unit in operation. Check the refrigerant charge
and compressor oil. Add as required.
Accumulator
Removal
1. Pump down the low side and equalize the
pressure to slightly positive.
2. Unsolder the inlet and outlet suction lines
from the accumulator.
CAUTION: Use a heat sink or wrap
vibrasorber with wet rags to prevent
damaging the vibrasorber.
3. Unbolt and remove the accumulator from the
unit.
Installation
1. Place the accumulator in the unit and tighten
the mounting bolts and nuts.
2. Solder the inlet and outlet suction lines to the
accumulator.
136
CAUTION: Use a heat sink or wrap
vibrasorber with wet rags to prevent
damaging the vibrasorber.
3. Pressurize the low side and test for refrigerant
leaks. If no leaks are found, evacuate the low
side.
4. Open the refrigeration valves and place the
unit in operation. Check the refrigerant charge
and the compressor oil, and add as required.
Suction Vibrasorber
Removal
1. Pump down the low side and equalize the
pressure to slightly positive.
2. Unsolder the suction vibrasorber from the
suction service valve.
3. Unsolder the connection to the accumulator
and remove the vibrasorber from the unit.
CAUTION: Use a heat sink or wrap the
vibrasorber with wet rags to prevent
damaging the vibrasorber.
Installation
1. Prepare the suction vibrasorber and tube
fittings for soldering by cleaning thoroughly.
2. Solder the vibrasorber to the suction service
valve.
CAUTION: Use a heat sink or wrap the
vibrasorber with wet rags to prevent
damaging the vibrasorber.
3. Solder the suction hose connection to the
accumulator.
4. Pressurize the low side and check for leaks. If
no leaks are found, evacuate the system.
5. Open the refrigeration valves and place the
unit in operation. Check the refrigerant charge
and the compressor oil, and add as required.

High Pressure Cutout Switch
and High Pressure Switch
Removal
1. Pump down the low side and equalize the
pressure to slightly positive.
2. Front seat the discharge and suction service
valves. Remove the remaining refrigerant
from the compressor.
3. Disconnect the wires and remove the switch
from the compressor discharge manifold.
Installation
1. Apply a refrigerant Loctite to the threads of
the switch.
2. Install and tighten the switch and reconnect
the wires.
3. Pressurize the compressor and test for leaks.
4. If no leaks are found, open the refrigeration
service valves and place the unit in operation.
Check the refrigerant charge and the
compressor oil, and add as required.
Discharge Pressure Transducer
Removal
1. Recover the refrigerant charge.
2. Disconnect the wire connector from the
discharge pressure transducer.
3. Unscrew the discharge pressure transducer
from the adapter on the end of the tube. Use a
backup wrench to hold the adapter.
4. Remove the discharge pressure transducer.
Installation
1. Apply refrigerant Loctite to the threads on the
discharge pressure transducer.
2. Screw the discharge pressure transducer into
the adapter on the end of the tube. Use a
backup wrench to hold the adapter.
3. Recharge the unit with the proper refrigerant
and check the compressor oil.
Refrigeration Service Operations
Suction Pressure Transducer
Removal
1. Pump down the low side and equalize the
pressure to slightly positive.
2. Disconnect the wire connector from the
suction pressure transducer.
3. Unscrew the suction pressure transducer from
the adapter on the end of the tube. Use a
backup wrench to hold the adapter.
4. Remove the suction pressure transducer.
Installation
1. Apply refrigerant Loctite to the threads on the
suction pressure transducer.
2. Screw the suction pressure transducer into the
adapter on the end of the tube. Use a backup
wrench to hold the adapter.
3. Pressurize the low side and test for refrigerant
leaks. If no leaks are found, evacuate the low
side.
4. Open the refrigeration valves and place the
unit in operation. Check the refrigerant charge
and the compressor oil, and add as required.
High Pressure Relief Valve
Removal
1. Recover the refrigerant charge.
2. Unscrew and remove the high pressure relief
valve. It is located near the top of the receiver
tank.
Installation
1. Apply a refrigerant oil to the O-ring of the
high pressure relief valve.
2. Install and tighten the high pressure relief
valve.
3. Pressurize the refrigeration system and test for
leaks. If no leaks are found, evacuate the
system.
4. Recharge the unit with the proper refrigerant
and check the compressor coil.
137
Refrigeration Service Operations

Throttling Valve 2. Front seat the discharge and suction service

valves. Recover the refrigerant remaining in
See Figure 146 for an illustration of the throttling the compressor.
valve assembly.
3. Remove the suction service valve.
Removal 4. Unbolt and remove the throttling valve from
1. Pump down the low side and equalize the the unit.
pressure to slightly positive.

aea717

1. Screw - mtg plate 10. Gasket - piston housing

2. Flatwasher 11. Piston
3. Plate - bellows end 12. Spring - piston
4. Gasket - end plate 13. Nut - adjusting
5. Shim - adjusting 14. Pin - cotter
6. Spring - bellows 15. Housing - piston
7. Bellows & Shaft - assy 16. O-ring - valve to compressor
8. O-ring 17. Cap - rubber
9. Housing
Figure 146: Throttling Valve Assembly

138
 Refrigeration Service Operations

Disassembly
1. Remove the piston end cap (round end).
2. Remove the cotter pin from the castle nut and
remove the nut.
3. Remove the spring and piston.
4. Loosen all the bolts on the bellows end cap.
CAUTION: This end cap is under slight
spring pressure.
1. Inspect for Wear
5. Break the gasket free and remove the end cap.
Figure 148: Inspect for Wear
6. Note the number of shims next to the cap.
These can be reused.

1. Inspect for Damage

Figure 149: Inspect for Damage
1. Inspect Cap
2. Inspect Spring 9. Clean the parts that will be reused.
3. Shims
Reassembly
Figure 147: 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.

139
Refrigeration Service Operations
5. Back off the castle nut, one full turn only.
6. Insert the cotter pin.
1. Tighten castle nut to bottom, then back
off 1 turn only. Insert cotter pin
Figure 150: Throttling Valve Reassembly
7. Oil the gasket and install the end cap.
8. The throttling valve will have to be
recalibrated on operating unit. (See the
Specifications Chapter for the setting.)
9. Adjust by adding or removing shims under the
spring.
Installation
1. Install the throttling valve using a new O-ring
soaked in compressor oil. Bolt the throttling
valve to the compressor.
2. Install the suction valve.
3. Pressurize the compressor and check for leaks.
If no leaks are found, evacuate the
compressor.
4. Open the refrigeration valves and place the
unit in operation.
140
Liquid Line Solenoid Valves
(LLS and LLS2)
NOTE: Valves that have nylon seats must be
disassembled before soldering.
Removal
1. Pump down the low side and equalize pressure
to slightly positive.
2. Remove the evaporator access panels.
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.
Installation
1. Clean the tubes for soldering.
2. Remove the coil, disassemble the valve, and
place the valve in position.
3. Solder the inlet and outlet connections. After
the valve cools, assemble the valve and install
the coil.
CAUTION: Use a heat sink to prevent
damage.
4. Pressurize the refrigeration system and test for
leaks.
5. If no leaks are found, evacuate the system.
6. Install the evaporator access panels.
7. Open the refrigeration valves and run the unit.
Check the refrigerant charge and compressor
oil.

Hot Gas Solenoid Valves (HGS
and HGS2)
NOTE: Valves that have nylon seats must be
disassembled before soldering.
Removal
1. Pump down the low side and equalize the
pressure in the high side to slightly positive.
2. Remove the evaporator access panels.
3. Remove the coil and disassemble the valve.
4. Unsolder the hot gas lines from the valve, and
remove the valve from the unit.
CAUTION: Use a heat sink to prevent
damage.
Installation
1. Clean the tubes for soldering.
2. Remove the coil, disassemble the valve, and
place the valve in position.
3. Solder the inlet and outlet connections. After
the valve cools, assemble the valve and install
the coil.
CAUTION: Use a heat sink to prevent
damage.
4. Pressurize the refrigeration system and test for
leaks.
5. If no leaks are found, evacuate the system.
6. Install the evaporator access panels.
7. Open the refrigeration valves and run the unit.
Check the refrigerant charge and compressor
oil.
Refrigeration Service Operations
Suction Line Solenoid Valves
(SLS and SLS2)
NOTE: Valves that have nylon seats must be
disassembled before soldering.
Removal
1. Pump down the low side and equalize the
pressure in the high side to slightly positive.
2. Remove the evaporator access panels.
3. Remove the coil and disassemble the valve.
4. Unsolder the suction lines from the valve, and
remove the valve from the unit.
CAUTION: Use a heat sink to prevent
damage.
Installation
1. Clean the tubes for soldering.
2. Remove the coil, disassemble the valve, and
place the valve in position.
3. Solder the inlet and outlet connections. After
the valve cools, assemble the valve and install
the coil.
CAUTION: Use a heat sink to prevent
damage.
4. Pressurize the refrigeration system and test for
leaks.
5. If no leaks are found, evacuate the system.
6. Install the evaporator access panels.
7. Open the refrigeration valves and run the unit.
Check the refrigerant charge and compressor
oil.
141
Refrigeration Service Operations

Check Valve Repair (SLCV, 6. Open the refrigeration valves and run the unit.
SLCV2, SLCV3, LRCV, and Check the refrigerant charge and compressor
oil.
PVC)
Removal Check Valve Replacement
1. Pump down the low side and equalize pressure
(SLCV, SLCV2, SLCV3, LRCV,
to slightly positive. and PVC)
2. Remove the evaporator access panels. Removal
3. Remove the cap nut from the check valve and 1. Pump down the low side and equalize the
remove the spring and seat. pressure to slightly positive.
2. Remove the evaporator access panels.
1 3. Unsolder the lines and remove the check
valve.
2 NOTE: Disassemble the valve before
unsoldering.
3
Installation
4 1. Clean the tubes for soldering.
2. Place the disassembled check valve in
5 position. The arrow on the valve body
indicates the direction of refrigerant flow
through the valve.
AGA173
3. Solder the inlet and outlet connections. After
the valve cools, reassemble the valve.
1. Cap
2. Gasket
4. Pressurize the low side and test for leaks.
3. Spring 5. If no leaks are found, evacuate the system.
4. Seat 6. Install the evaporator access panels.
5. Body
7. Open the refrigeration valves and run the unit.
Figure 151: Check Valve with Cap Nut
Check the refrigerant charge and compressor
oil.
Installation
1. Inspect the inside of the check valve body for Condenser Inlet Solenoid Valve
damage or foreign particles that might adhere
to the seat and damage the new seat. If the
(CIS)
body is damaged, replace the check valve. Removal
2. Install the new seat and spring. Place a new 1. Recover the refrigerant charge.
gasket on the cap and tighten the cap.
2. Remove the coil and disassemble the valve.
3. Pressurize the low side and test for leaks.
3. Unsolder the hot gas lines from the valve, and
4. If no leaks are found, evacuate the system. remove the valve from the unit.
5. Install the evaporator access panels.

142

CAUTION: Use a heat sink or wrap the
valve with wet rags to prevent damaging
the valve.
Installation
1. Clean the tubes for soldering.
2. Remove the coil, disassemble the valve, and
place the valve in position.
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
valve with wet rags to prevent damaging
the valve.
4. Pressurize the refrigeration system and test for
leaks.
5. If no leaks are found, evacuate the system.
6. Recharge the unit with proper refrigerant and
check the compressor oil.
Condenser Inlet Check Valve
(CICV) Repair
Removal
1. Recover the refrigerant charge.
2. Remove the cap nut from the check valve, and
remove the spring and seat.
Installation
1. Inspect the inside of the check valve body for
damage or foreign particles which might
adhere to the seat and damage the new seat. If
the body is damaged, replace the check valve.
2. Install the new seat and spring. Place the new
gasket on cap and torque to 45 ft-lb (61 Nm).
3. Pressurize the refrigeration system and test for
leaks.
4. If no leaks are found, evacuate the system.
5. Recharge the unit with proper refrigerant and
check the compressor oil.
Refrigeration Service Operations
Condenser Inlet Check Valve
(CICV) Replacement
Removal
1. Recover the refrigerant charge.
2. Unsolder the lines and remove the check
valve.
NOTE: Disassemble the valve before
unsoldering.
Installation
1. Clean the tubes for soldering.
2. Place the disassembled check valve in
position. The arrow on the valve body
indicates the direction of refrigerant flow
through the valve.
3. Solder the inlet and outlet connections. After
the valve cools, reassemble it.
4. Pressurize the refrigeration system and test for
leaks.
5. If no leaks are found, evacuate the system.
6. Recharge the unit with proper refrigerant and
check the compressor oil.
Receiver Tank Pressure
Solenoid Valve (RTPS)
Removal
1. Recover the refrigerant charge.
2. Remove the coil from the valve.
3. Unsolder the hot gas lines from the valve, and
remove the valve from the unit.
CAUTION: Use a heat sink or wrap the
valve with wet rags to prevent damage.
Installation
1. Clean the tubes for soldering.
2. Remove the coil from the valve, and place the
valve in position.
3. Solder the inlet and outlet connections. After
the valve cools, install the coil on the valve.
143
Refrigeration Service Operations

CAUTION: Use a heat sink or wrap the Compressor Oil Filter

valve with wet rags to prevent damage.
4. Pressurize the refrigeration system and test for
leaks.
5. If no leaks are found, evacuate the system.
6. Recharge the unit with proper refrigerant and
check the compressor oil.
Purge Valve (PV)
Removal
1. Recover the refrigerant charge.
2. Remove the coil from the valve.
3. Unsolder the refrigeration lines from the
valve, and remove the valve from the unit.
CAUTION: Use a heat sink to prevent
damaging the valve.
This unit is equipped with a compressor oil filter.
The compressor oil filter should be changed when
the drier is replaced.
The outlet fitting is larger than the inlet fitting, so
the compressor oil filter cannot be put on
backwards. There are two fittings on the inlet end
of the compressor oil filter. The inlet fitting
contains a check valve that prevents reverse flow
through the compressor oil filter. The capped
fitting is called the oil pressure access port and is
used to check the compressor oil pressure (see
Checking Compressor Oil Pressure on
page 145).

Installation
1. Clean the tubes for soldering.
2. Remove the coil from the valve, and place the
valve in position.
3. Solder the inlet and outlet connections. After
the valve cools, assemble the valve and install
the coil.
1
CAUTION: Use a heat sink to prevent
damaging the valve.

4. Pressurize the refrigeration system and test for 3

leaks.
5. If no leaks are found, evacuate the system.
2
6. Recharge the unit with the proper refrigerant. AEA718

1. Oil Pressure Access Port

2. Inlet Fitting
3. Outlet Fitting
Figure 152: Compressor Oil Filter

144

Use the following procedure to change the
compressor oil filter.
1. Pump down the low side and equalize the
pressure to slightly positive.
2. Front seat the discharge and suction service
valves. Remove the remaining refrigerant
from the compressor.
3. Disconnect the oil lines from the compressor
oil filter. Hold the oil filter with back-up
wrench on the hex behind the ORS fitting.
4. Remove the clamp and the compressor oil
filter.
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.
Checking Compressor Oil
Pressure
The oil pressure at the oil pressure access port
varies with the suction pressure in the compressor.
Therefore, we need to calculate the net oil
pressure to determine the actual compressor oil
pressure. The net oil pressure is the pressure at the
oil pressure access port minus the suction pressure
below the throttling valve. Use the following
procedure to check the compressor oil pressure.
1. Attach a suitable oil pressure gauge to the oil
pressure access port on the compressor oil
filter.
Refrigeration Service Operations
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. Start the unit and note the pressure at the oil
pressure access port and the suction pressure
below the throttling valve.
4. Subtract the suction pressure below the
throttling valve from the pressure at the oil
pressure access port to get the net oil pressure.
Pressure at Oil Pressure Access Port
Suction Pressure Below Throttling Valve
= Net Oil Pressure
5. The net oil pressure should be at least 20 psi
(138 kPa). If the net oil pressure is low, first
check the compressor oil level, then check the
compressor oil pump and relief valve.
Priming New Compressor
Installations
Thermo King remanufactured compressors have
had a special break in process to assure that the oil
pump is primed, functioning, and broken in. The
following procedure is recommended, but not
required for factory-remanufactured compressors.
This procedure must be followed to prevent
premature pump failure in any compressor that
has had an oil pump installed, especially a
compressor that has been stored for any length of
time.
1. Attach a suitable oil pressure gauge to the oil
pressure access port on the compressor oil
filter.
2. Attach the low pressure gauge of a gauge
manifold to the fitting on the side of the
throttling valve. 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.
145
Refrigeration Service Operations

NOTE: The microprocessor will probably

record some alarm codes because the
solenoids are disconnected and the engine
does not start. Clear these alarm codes as
necessary.
5. Turn the unit on and let the engine crank (or
crank the engine) for 30 seconds, but do not
crank the engine for more than 30 seconds.
a. Note the pressure at the oil pressure access
port and the suction pressure below the
throttling valve while the engine is
cranking. Subtract the suction pressure
below the throttling valve from the
pressure at the oil pressure access port to
get the net oil pressure.
b. If the compressor does not develop at least
10 psi (96 kPa) of net oil pressure in the
first 30 seconds, allow the starter to cool
for a few minutes and the crank the engine
again for 30 seconds. If 10 psi (96 kPa) of
net oil pressure still does not develop, first
check the compressor oil level, then check
the compressor oil pump and relief valve.
6. As soon as the compressor develops 10 psi
(96 kPa) of net oil pressure, re-connected the
fuel solenoid wires, but do not re-connect the
high speed solenoid wires.
7. Start unit and run the engine on low speed for
at least five minutes. If the net oil pressure is
above 20 psi (138 kPa) for this period, stop the
unit and re-connect the high speed solenoid
wires.
8. Run the engine on high speed for at least five
more minutes. The compressor oil pump is
now primed and broken in.

146
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 Nm). Torque the engine mounting bolts to
150 ft-lb (203 Nm).

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
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.

Unit Installation
1. Check Bolts for Tightness
All nuts that hold the unit to the trailer are
Figure 153: Unit and Engine Mounting Bolts
accessible using an impact wrench with a 10 in.
extension, ball-type swivel and a deep-well
socket.
NOTE: The nuts for mounting the unit should
be elastic stop nuts (Nylock type).

147
Structural Maintenance

DE Defrost Dampers 2. Disconnect the solenoid rod from the damper

Check the dampers during scheduled maintenance
inspections for shaft wear, end play, and sealing
against air flow.
Position the damper so that air flow is stopped on
the top and bottom with the solenoid plunger
bottomed.
To adjust the damper:
1. Remove the damper assembly from the
evaporator.
shaft.
3. Energize the solenoid (apply 12 volts to the 29
or 29B circuit) and check Distance A, the
distance from the upper mounting hole to the
end of the solenoid rod when the solenoid is
energized.
Control Box SideDistance A = 3.36 in.
(85.3 mm)
Compressor SideDistance A = 2.09 in.
(53.1 mm)

1 1

2 2
4 3

AGA225

1. Damper Shaft 3. Control Box Side Damper Solenoid

2. Solenoid Rod 4. Compressor Side Damper Solenoid
Figure 154: Rear View of DE Damper Assembly

1
1

AGA227
AGA226

1. Distance A = 53.1 mm (2.09 in.)

1. Distance A = 85.3 mm (3.36 in.) Figure 156: Control Box Side Damper Solenoid
Figure 155: Compressor Side Damper Solenoid

148
 Structural Maintenance

1. If necessary, adjust Distance A to the proper 4. Adjust the damper blade stops so they contact
dimension by loosening the locknut on the end the edges of the damper blade. This keeps the
of the solenoid plunger and turning the damper from sticking closed.
plunger to move the solenoid rod. Tighten the
5. De-energize and energize the damper several
locknut when Distance A is correct.
times to make sure that the damper operates
2. De-energize the solenoid and connect the correctly and seals properly.
solenoid rod to the damper shaft.
6. Make sure that the damper blade rests on the
3. Energize the solenoid and check the damper round stops when the damper is open. Adjust
blade to make sure that both edges contact the the round stops if necessary.
damper housing. If necessary, adjust this by
7. Install the damper assembly in the evaporator.
loosening the solenoid mounting bolts and
moving the solenoid. Tighten the solenoid
mounting bolts when both damper blades
contact the damper housing.

3 2

AGA228

1. Closed Position 4. Round Stop

2. Stop 5. Open Position
3. Mounting Bolts
Figure 157: Damper Adjustment (Control Box Side Shown Compressor Side Similar)

149
Structural Maintenance
Condenser and Evaporator Fan
Location
When mounting the condenser or evaporator fan
and hub assembly on the fanshaft, the blowers and
inlet orifices must be properly aligned for proper
air flow and to prevent damage to the blower.
Condenser Fan Blower Alignment
1. Loosen the condenser inlet ring (spinning) on
the condenser coil bulkhead.
2. Slide the blower towards the inlet ring until it
contacts the inlet ring. This centers the inlet
ring in the blower orifice.
3. Tighten the inlet ring securely.
4. Slide the blower away from the inlet ring.
1
2 the seal is centered on the spacer and the
3
AEA749
1. Blower Wheel 3. Alignment Mark
2. Inlet Ring 4. Edge of Inlet Ring
Figure 158: Condenser Blower Alignment
5. Pass a gauge wire completely around the
blower orifice to check for uniform clearance.
6. Spin the blower by hand to check for blower
distortion.
7. Position the blower so the edge of the inlet
ring lines up with the alignment mark on the
blower.
8. Torque blower hub bolts to 18 ft-lb (24 Nm).
150
Evaporator Fan Blower Alignment
1. Loosen the inlet rings on the sides of the
blower housing.
2. Center the blower wheel in the blower housing
with equal overlap on both inlet rings. The
overlap on each ring should be approximately
0.15 in. (3.8 mm).
3. Tighten the hub bolts that hold the blower
wheel on the fanshaft. Torque the blower hub
bolts to 18 ft-lb (24 Nm).
4. Center the inlet rings in the blower orifices.
Tighten the inlet rings securely.
5. Check the radial clearance by passing a wire
completely around the circumference of the
inlet rings and the blower wheel.
6. Position the seal housing on the inner panel so
spacer spins freely in the seal.
AEA720
1. Check Clearance with a Wire
2. Blower Housing Sides
3. Inlet Rings
4. Evaporator Blower
5. Radial Clearance
6. Equalize Blower Inlet Overlap
Figure 159: Evaporator Fan Location
 Structural Maintenance

DE Evaporator Fan Blower 3. Remove the other two 5/16-18 x 3.0 in. bolts
Removal and Installation form the blower ring.
4. Remove the blower ring, the curbside blower,
Removal and the spacer.
NOTE: The blower assembly is balanced and 5. Remove the seal housing and the seal with the
permanent index marks are placed on the inner panel.
components. Pay attention to these index marks
when disassembling the blower. This will make it 6. Remove the roadside blower.
easier to correctly reassemble the blower. 7. Remove the hub from the fanshaft.
1. Remove the curbside panel and inlet ring. 8. If necessary, remove the blower housing and
2. Remove two of the 5/16-18 x 3.0 in. bolts the roadside inlet ring.
from the blower ring and replace them with
two 5/16-18 x 4.0 in. studs. The studs keep the
blower components aligned.
2
3
1
4
5

6
7

8
14
13
12
11
10
AGA229

1. Compressor Side Inlet Ring 8. Fan Shaft Assembly

2. Blower Ring 9. Blower Housing
3. Compressor Side Blower 10. Inner Panel
4. Spacer 11. Seal Ring
5. Control Box Side Blower 12. Seal
6. Hub 13. Seal Housing
7. Control Box Side Inlet Ring 14. Compressor Side Panel
Figure 160: DE Evaporator Blower Components

151
Structural Maintenance
Installation
NOTE: The blower assembly is balanced and
permanent index marks are placed on the
components. Make sure to align these index
marks when assembling the blower. This keeps
the blower balanced.
1. If necessary install the blower housing and the
roadside inlet ring.
2. Place two 5/16-18 x 4.0 in. studs in the hub.
These studs are used temporarily to keep the
blower components aligned.
3. Place the hub on the fanshaft.
4. Place the roadside blower on the hub.
5. Place the spacer on the hub.
6. Lubricate the spacer and seal with grease
P/N 204-475.
7. Install the inner panel.
8. Install the seal housing and seal.
9. Place the curbside blower on the hub.
10. Place the blower ring on the hub. Make sure
that the index marks on the components of
blower assembly are all correctly aligned.
11. Insert two 5/16-18 x 3.0 in. bolts into the
blower ring and blower assembly and thread
the bolts into the hub.
12. Remove the two 5/16-18 x 4.0 in. studs from
the hub and replace them with two 5/16-18 x
3.0 in. bolts.
13. Torque the four 5/16-18 x 3.0 in. bolts to 13 to
15 ft-lb (18 to 20 Nm).
14. Install the curbside panel and inlet ring.
15. Align the evaporator blower. See Evaporator
Fan Blower Alignment on page 150.
152
Fan Shaft Assembly
The unit is equipped with a one-piece fan shaft
assembly that contains tapered roller bearings in a
sealed oil reservoir.
This assembly does not require any maintenance.
There is a level plug and a fill plug, but they are
not normally used except after removal and repair
of the fan shaft assembly. The condenser and
evaporator end oil seals should be checked during
the pretrip inspection for oil leakage. If there is
any sign of leakage, the fan shaft assembly should
be removed and repaired.
NOTE: The fan shaft assembly requires a
special lubricant, Thermo King P/N 203-278.
Fan Shaft Assembly Overhaul
Disassembly
1. Remove the fan shaft assembly from the unit.
Remove both oil plugs and drain the oil from
the housing.
2. After draining the oil from the housing,
remove the four retaining bolts from the
condenser end of the assembly.
3. To remove the shaft from the assembly, tap the
opposite end of the shaft with a soft hammer.
After the shaft has been removed, clean all
parts in clean solvent.
4. Using a punch, remove the oil seal from the
evaporator end of the assembly. With the seal
removed, clean the housing in clean solvent.
5. Check the condition of the vent. If it is loose
or damaged, it must be repaired or replaced.
6. After all the parts are cleaned, inspect the
bearings and bearing races for wear or
damage.
7. If necessary, remove the bearings by tapping
them off the shaft with a hammer and a punch.
Be careful not to damage the shaft with the
punch.
8. The bearing races can now be driven out with
a punch and replaced in the same manner.

1. Cap and Shims 6.
2. Oil Plug Screw (Use Oil P/N 203-278) 7.
3. Breather Vent 8.
4. Housing 9.
5. Roller Bearing 10.
Figure 161: Fan Shaft Assembly
Reassembly
1. Tap the new bearings on the shaft with a pipe.
2. Install new oil seals after replacing the bearing
races.
3. Replace the shaft in the housing. Install a new
seal in the retainer cap. Use the original shims
and replace the O-ring if needed.
4. Install the retainer cap assembly over the
shaft, then install the bolts.
5. Torque the bolts in a criss-cross pattern in
equal steps to 80 in-lb (9.04 Nm).
6. Lock the assembly in a vise and set up a dial
indicator to read end-play. To measure the
end-play, rotate the shaft while pushing in one
direction and set the dial indicator to 0. Now
rotate the shaft and pull in the opposite
direction while reading the dial indicator.
End-play should be 0.001 to 0.005 in. (0.025
to 0.127 mm). If end-play is incorrect, use
different shims to obtain correct end-play.
Structural Maintenance
AEA721
Oil Seal
Shaft
Sleeve
Pin
O-ring
Shims available from the Service Parts
Department
0.020 in. (0.500 mm) Thermo King P/N 99-4231
0.007 in. (0.177 mm) Thermo King P/N 99-2902
0.005 in. (0.127 mm) Thermo King P/N 99-2901
7. After correct end-play is obtained, add oil for
the bearings.
8. Lock the assembly in a vise with the vent
facing up. Pour the oil (P/N 203-278) through
the top plug until it runs out of the side hole.
The assembly holds 2.5 oz (74 ml). Check the
condition of the O-ring used on the plugs and
replace if necessary. Install the top and side
plugs. Clean up any spillage.
9. Place the assembly on the workbench with the
vent up. Rotate the shaft by hand. The shaft
should be free enough to rotate without having
to hold the housing.
CAUTION: When installing the fan shaft
assembly, make sure that the vent is
mounted facing up.
153
Structural Maintenance
Idler Assembly
The unit is equipped with a one-piece idler
assembly that contains tapered roller bearings in a
sealed oil reservoir. This assembly does not
require any maintenance. There is a level plug and
a fill plug, but they are not normally used except
after removal and repair of the idler assembly. The
roadside end oil seal and the curbside end oil seal
should be checked during the pretrip inspection
for oil leakage. If there is any sign of leakage, the
idler assembly should be removed and repaired.
Idler Assembly Overhaul
Disassembly
1. Remove the idler assembly from the unit.
Remove both oil plugs and drain the oil from
the housing.
2. After draining the oil from the housing,
remove the four retaining bolts from the
curbside end of the assembly.
3. To remove the shaft from the assembly, tap the
opposite end of the shaft with a soft hammer.
After the shaft has been removed, clean all the
parts in clean solvent.
4. Using a punch, remove the oil seal from the
curbside end of the assembly. With the seal
removed, clean the housing in solvent.
5. Check the condition of the vent. If it is loose
or damaged, it must be repaired or replaced.
6. After all the parts are cleaned, inspect the
bearings and bearing races for wear or
damage.
7. To replace the bearings, first drive bearing off
shaft with a punch at notch in the base of the
shaft.
Reassembly
1. Install the new bearings on the shaft with a
pipe. Place the pipe over the shaft and drive
bearing down. Turn the shaft upside down,
and use the pipe to drive the other bearing
down.
2. Install a new oil seal on the curbside end of
the assembly after replacing the bearing race
and splash guard.
154
3. Replace the shaft in the housing. Install a new
seal in the retainer cap. Use the original shims
and replace the O-ring if needed.
4. Install the retainer cap assembly over the
shaft, then install the bolts.
5. Torque the bolts in a criss-cross pattern in
equal steps to 80 in-lb (9.04 Nm).
6. Lock the assembly in a vise and set up a dial
indicator to read end-play. To measure the
end-play, rotate the shaft while pushing in one
direction, and set the dial indicator to 0.
Now rotate the shaft and pull in the opposite
direction while reading the dial indicator.
End-play should be 0.001 to 0.005 in. (0.025
to 0.127 mm). If end-play is incorrect, use
different shims to obtain correct end-play.
Shims available from the Service Parts
Department
0.020 in. (0.500 mm) Thermo King P/N 99-4231
0.007 in. (0.177 mm) Thermo King P/N 99-2902
0.005 in. (0.127 mm) Thermo King P/N 99-2901
7. After the correct end-play is obtained, add
approximately 1.1 oz (33 ml) of oil
(P/N 203-278) for the bearings.
8. Lock the assembly in a vise with the vent
facing up. Pour the oil through the top plug
until it runs out of the side hole. Check the
condition of the O-ring used on the plugs and
replace if necessary. Install the top and side
plugs. Clean up any spillage.
9. Place the assembly on the workbench with the
vent up. Rotate the shaft by hand. The shaft
should be free enough to rotate without having
to hold the housing.
CAUTION: Reinstall the assembly into
the unit, making sure the vent is mounted
facing up.
 Structural Maintenance

AEA722

1. Oil Seal 6. Shaft

2. Cap and Shims 7. Housing
3. O-ring 8. Breather Vent
4. Roller Bearing 9. Oil Plug Screw (Use Oil P/N 203-278)
5. Splash Guard Tube
Figure 162: Idler Assembly

155
Structural Maintenance

156
Mechanical Diagnosis
Condition
Engine will not crank
Starter motor turns but engine
does not crank
Engine cranks but fails to start
Engine stops after starting
Engine does not develop full
power
Possible Cause Remedy
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 clutch defective Replace
Fuel solenoid not energized Check 8D and 8DP circuits and fuel
solenoid pull-in relay. 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
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
Air intake system clogged Clean air intake system
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
157
Mechanical Diagnosis

Condition Possible Cause Remedy

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

158
 Mechanical Diagnosis

Engine Emits Excessive Smoke

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

159
Mechanical Diagnosis

160
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

161
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)

162
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
Circuit Protection Smart FETs in the Expansion Module (see Smart FETs on
page 88 and Expansion Module on page 88)
Fan Motors (each): Power Rating 0.13 hp (100 Watts)
rpm 2500
Full Load Amps 8.0 amps (per motor)
Remote Liquid Line Solenoid: Current Draw 1.3 amps
Resistance 9.6 ohms
Remote Hot Gas Solenoid: Current Draw 1.5 amps
Resistance 8.3 ohms
Remote Suction Line Solenoid: Current Draw 1.5 amps
Resistance 8.3 ohms
Drain Heaters (each): Current Draw 2.0 amps
Resistance 6.1 ohms

163
Remote Evaporator Specifications

164
Remote Evaporator Maintenance Inspection
Schedule

Every Every Annual/

Pretrip 1,500 3,000 4,500 Inspect/Service These Items
Hours Hours* Hours
Electrical
Inspect wire harness for damaged wires or connections.
Inspect/replace DC fan motors.
Structural
Visually inspect unit for fluid leaks.
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.

165
Remote Evaporator Maintenance Inspection Schedule

166
Remote Evaporator Unit Description

1. Coil Temperature Sensor (Ungraded) 6. Variable Blower (12 V) 11. Terminal Board Markstrip
2. Hot Gas Solenoid 7. Blower Housing 12. Drain Heater (Resistance Wire)
3. Liquid Solenoid 8. Blower Cover 13. Return Air Sensor (Graded)
4. Suction Line Solenoid 9. Terminal Board Bracket 14. Sensor Clamp
5. Discharge Air Sensor (Graded) 10. Terminal Board 15. Coil Sensor Delay Pad
Figure 163: SPECTRUM S-3 Evaporator Components

167
Remote Evaporator Unit Description

AJA984

Figure 164: SPECTRUM S-3 Evaporator - Front View

AJA985

Figure 165: SPECTRUM S-3 Evaporator - Back View

168
 Remote Evaporator Unit Description

The SPECTRUM DE SR-2 multi-temperature Defrost

refrigeration system provides heavy duty
temperature control for multiple compartment The Defrost mode can be initiated any time the
trailers. The system provides direct expansion evaporator coil temperature is below 45 F (7 C).
cooling in all trailer compartments. Defrost is initiated automatically by the controller
Non-contaminating refrigerant tap-ins in the host or manually by selecting defrost from the Defrost
unit evaporator provide convenient refrigerant Prompt Screen for the desired zone.
piping connections for the remote evaporators. 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 (14.5 C), causing
remote evaporator is a ceiling mounted the controller to terminate defrost. After Defrost,
SPECTRUM unit. the evaporator may shift back to Cool, Null or
Heat.
Heat and defrost is provided in all compartments
by circulating hot refrigerant gas through the
evaporators.
Operating Modes
Remote evaporator operating modes are:
The remote evaporator is controlled by the SR-2
MT Control System through the expansion Cool
module. The SR-2 MT Control System is located
Null
in the host unit. The wire harnesses connect the
remote evaporator(s) to the expansion module. Heat
The expansion module is connected to the base
Defrost
controller/interface board assembly through the
CAN bus. See SMART REEFER 2 Multi-Temp NOTE: The controller locks out heat at setpoints
(SR-2 MT) Control System on page 26 and Refer below 15 F (-9.5 C).
to the SR-2 Multi-Temp Microprocessor
Controller Diagnostic Manual TK 53080 for more Unit Features
information about the SR-2 MT Control System.
Direct Expansion Evaporator Coil
Unit Operation SR-2 MT Control System with Expansion
Module
The remote evaporator cycles between cool, null
and heat to maintain the trailers compartment at 12 Vdc Fan Motor
the setpoint. The operating modes include Cool, Aluminum Housing
Null, Heat, and Defrost.
Liquid Line Solenoid
Power to run the direct current fan motors is
supplied by the alternator in the host unit. Hot Gas Solenoid
When cooling is required, the SR-2 MT Control Suction Line Solenoid
System energizes the remote liquid line solenoid Liquid Return Check Valve
valve. Refrigerant flows through the evaporator
coil to provide cooling.
When the compartment temperature is near
setpoint, the SR-2 MT Control System
de-energizes the remote liquid line solenoid valve
and switches the remote evaporator to null.
The SR-2 MT Control System energizes the
remote hot gas solenoid when the remote
compartment requires heat or defrost.

169
Remote Evaporator Unit Description

Unit Protection Devices

Smart FETs in the expansion module.

Serial Number Location

Unit: Nameplate on the right end of the unit frame.

AJA985

1. Nameplate on Right End of Unit Frame

Figure 166: Serial Number Location

170
Remote Evaporator Electrical Maintenance

SR-2 Multi-Temp
Microprocessor Controlled
Components
Refer to the SR-2 Multi-Temp Microprocessor
Controller Diagnostic Manual TK 53080 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.

171
Remote Evaporator Electrical Maintenance

172
Remote Evaporator Refrigeration Service
Operations
NOTE: It is generally good practice to replace
the filter drier whenever the high side is opened
or when the low side is opened for an extended
period of time.
Expansion Valve Assembly
Removal
1. Pump down the low side and equalize the
pressure to slightly positive. Remove the
evaporator access panels.
2. Disconnect the liquid inlet line and distributor
from the expansion valve.
3. Remove the feeler bulb from the clamp. Note
the position of the feeler bulb on the suction
line.
4. Disconnect the equalizer line.
5. Remove the expansion valve assembly from
the unit.
Installation
1. Place the expansion valve in the unit.
2. Connect the equalizer line to the expansion
valve.
3. Connect the liquid inlet line and distributor to
the expansion valve.
4. Clean the suction line to a bright polished
condition. Install the feeler bulb clamps and
feeler bulb on the side of the suction line in its
former position. The feeler bulb must make
good contact with the suction line or the
operation will be faulty. Wrap it with
insulating tape.
5. Pressurize the low side and test for leaks. If no
leaks are found, evacuate the low side.
6. Install the access panels.
7. Open the refrigeration valves and place the
unit in operation.
8. Test the unit to see that the expansion valve is
properly installed.
Evaporator Coil
Removal
1. Pump down the low side and equalize the
pressure to slightly positive.
2. Disconnect the distributor from the expansion
valve.
3. Remove the insulating tape and feeler bulb
from the suction line. Note the position of the
feeler bulb on the suction line. Disconnect the
equalizer line from the suction line.
4. Heat and unsolder the suction line connection
to the evaporator coil.
5. Remove the mounting bolts and slide the coil
from the housing.
Installation
1. Place the evaporator coil in the evaporator
housing and install the mounting bolts.
2. Clean and solder the suction line connections
to the evaporator coil.
3. Connect the distributor to the expansion valve.
4. Clean the suction line to a bright polished
condition. Install the feeler bulb clamps and
the feeler bulb on the suction line. Locate the
bulb on the side of the suction line in its
former position. The feeler bulb must make
good contact with the suction line or the
operation will be faulty. Wrap it with
insulating tape.
5. Connect the equalizer line to the suction line.
6. Pressurize the low side and test for leaks. If no
leaks are found, evacuate the low side.
7. Install the access panels.
8. Open the refrigeration valves and place the
unit in operation. Check the refrigerant charge
and compressor oil. Add as required.
173
Remote Evaporator Refrigeration Service Operations

Solenoid Valves Liquid Return Check Valve

NOTE: Valves that have nylon seats must be Repair
disassembled before soldering.
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.
3. Solder the inlet and outlet connections. After
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 167: 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.
3. Pressurize the low side and test for leaks.
4. If no leaks are found, evacuate the low side.
5. Install the access panels.
6. Open the refrigeration valves and run the unit.
Check the refrigerant charge and compressor
oil.

174
 Remote Evaporator Refrigeration Service Operations

Liquid Return Valve Installation

Replacement 1. Clean the tubes for soldering.

Removal 2. Position the tubes in the proper ports on the

heat exchanger.
1. Pump down the low side and equalize the
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.
CAUTION: Use a heat sink to prevent
NOTE: Disassemble the valve before
damage to nearby valves.
unsoldering.
5. Pressurize the refrigeration system and test for
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.
3. Solder the inlet and outlet connections. After
the valve cools, reassemble the valve.
4. Pressurize the low side and test for leaks.
5. If no leaks are found, evacuate the low side.
6. Install the access panels.
7. Open the refrigeration valves and run the unit.
Check the refrigerant charge and compressor
oil.

Heat Exchanger
Removal
1. Pump down the low side and equalize the
pressure to slightly positive.
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.
CAUTION: Use a heat sink to prevent
damage to nearby valves.

175
Remote Evaporator Refrigeration Service Operations

176
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.

177
Remote Evaporator Structural Maintenance

178
Remote Evaporator System Diagnosis
Condition
Load temperature too high
Evaporator fan motor does not
run
Possible Cause
Refrigerant shortage
Setpoint too high
Expansion valve plugged
Partial obstruction in low side of
refrigeration system
Iced or dirty evaporator coil
Expansion valve open too much
Poor fitting trailer door
Liquid line solenoid partially closed
or defective
Evaporator fan not operating
Open in 2A circuit
Open in FM circuit
Open circuit between interface board Locate open and repair
and expansion module
Defective fan motor
Defective expansion module
Remedy
Repair leak and recharge
Adjust setpoint
Clean or replace
Locate obstruction and repair
Defrost or clean evaporator coil
Replace or adjust valve
Repair or replace doors
Repair or replace
Check and correct evaporator fan
Locate open and repair
Locate open and repair
Replace fan motor
Replace expansion module
179
Remote Evaporator System Diagnosis

180
Index
A display 42
accumulator, replacement 136 keys 42
adjust brightness menu 79 coolant level switch 36, 96
air cleaner 115 checking the float 96
air cleaner restriction indicator 35 replacing 97
air cleaner, EMI 3000 115 testing 96
air heater 90 cooling system, engine 93
air restriction indicator 116 bleeding air from 95
alarms menu 60 crankcase breather
alternator 83 TK486V (Tier 2) 114
field current test 86 CYCLE-SENTRY
general diagnostic and warranty evaluation proce- operation 27
dure 84 selecting 53
identification 83 CYCLE-SENTRY start-stop controls 27
load test 84
antifreeze D
changing 95 data logging 28
checking 95 datalogger (CargoWatch) menu 65
maintenance procedure 94 defrost 29
remote evaporator 169
B defrost damper, adjustment 148
battery 86 defrost drains 147
battery cables 86 defrost drains, remote evaporator 177
belt adjustments 117 Defrost key 42
alternator belt 117 design features 25
upper and lower fan belts 117 diagnosis
belt replacement mechanical 157
lower fan belt 118 refrigeration 161
upper fan belt 118 remote evaporator system 179
belts 116 diagrams
fuel line routing 185
C refrigeration system 29
charging refrigeration system 126 wiring 185
charging system diagnostic procedures 83 discharge pressure transducer, replacement 137
check valve discharge vibrasorber, replacement 133
repair 142
replacement 142 E
cold start device 111 ELC (Extended Life Coolant) 93
compressor EMI 3000 91
priming new compressor installations 145 engine compartment components 35
replacement 129 engine coolant temperature sensor 36
X430L 26 engine speed adjustments 102
compressor coupling high speed 102
installation 131 low speed 102
removal 130 evacuating and charging multi-temp systems 124
compressor oil evacuating refrigeration system 125
checking 123 evaporator coil, replacement 135
compressor oil filter, replacement 144 evaporator fan blower
compressor oil pressure, checking 145 installation 152
compressor oil sight glass 35 removal 151
condenser coil, replacement 132 expansion module 88
condenser inlet check valve LEDs 89
repair 143 expansion valve, replacement 134
replacement 143
condenser inlet solenoid valve, replacement 142 F
continuous mode fan alignment
selecting 53 condenser blower 150
control panel 41 evaporator blower 150

181
Index

fan shaft assembly 152 liquid line solenoid valve, replacement 140
overhaul 152 loading procedure 80
filter drier, replacement 134 low oil level switch 36
first aid 18 low oil pressure 91
engine coolant 18 low oil pressure switch 36
refrigerant 18 low side pump down 129
refrigerant oil 18 lubrication system, engine 91
fuel filter/water separator, replacement 101
fuel line routing 98 M
fuel return line replacement 100 main menu
fuel solenoid 108 choices 56
replacement 109 navigating 56
testing 108 manual defrost cycle, initiating 54
fuel system 98 manual pretrip inspection 43
bleeding 100 microprocessor On/Off switch 41
maintenance 98 Mode key 42
fuel tank, draining water from 101 mode menu 69
fuse link 36, 90 moisture indicating sight glass 122
fuses 36, 87 mounting bolts, unit and engine 147

G O
gauges menu 62 Off key 42
general description 25 oil change, engine 91
oil filter change, engine 91
H On key 42
high pressure cutout 36 opening front doors 34
high pressure cutout switch (HPCO) operating modes, remote evaporator 169
replacement 137 OptiSet 28
testing 123
high pressure relief valve 36 P
replacement 137 post load procedure 81
high pressure switch (HPCS) post trip checks 81
replacement 137 preheat buzzer 36
testing 124 pretrip tests 75
high pressure switch (HPSW) priming new compressor installations 145
replacement 137 protection devices 35
HMI control panel 41 purge valve, replacement 144
host unit 26
hot gas solenoid valve, replacement 141 R
hourmeters menu 67 receiver tank pressure solenoid valve, replacement
143
I receiver tank sight glass 35
idler assembly 154 receiver tank, replacement 134
overhaul 154 refrigerant charge 121
injection pump adjusting refrigerant level 122
reinstallation 106 testing for an overcharge 121
removal 106 testing with a loaded trailer 121
timing 103 testing with an empty trailer 121
in-line check valves, replacement 133 refrigerant leaks 122
inspection, unit 147 remote control panel 28
installation, unit 147 remote evaporator coil
interface board LEDs 87 cleaning 177
replacement 173
K remote evaporators 26
keypad lockout 69 remote expansion valve, replacement 173
selecting 72 remote heat exchanger, replacement 175
remote liquid return check valve
L repair 174
language menu 58 replacement 175

182
 Index

remote solenoid valves, replacement 174 unit operation

routing remote evaporator 169
wire harness 86 unit overview 25
routing, fuel line routing 98 unit protection devices
remote evaporator 170
S unit wiring 86
safety precautions 15
battery removal 16 V
electrical hazards 17 valve clearance adjustment, engine 112
general practices 15
microprocessor service precautions 17 W
refrigerant hazards 16 wire harness routing 86
refrigerant oil hazards 16
welding precautions 17 Z
selection of operating modes 52 zone, turning on and off 51
sensors menu 64
serial number locations 37
remote evaporator 170
setpoint, changing 50
single temperature loading procedure 80
single zone control 46, 69
selecting 71
sleep mode 69
selecting 73
Smart FETs 36, 88
SMART REEFER 2 (SR-2) Control System 41
soft keys 43
specifications
belt tension 20
electrical components 21
electrical control system 20
engine 19
refrigeration system 20
remote evaporator electrical 163
remote evaporator refrigeration system 163
SR-2 Control System 41
standard display 45
start of trip, initiating 65
suction line solenoid valve, replacement 141
suction pressure transducer, replacement 137
suction vibrasorber, replacement 136
system operation 29

T
temperature watch display 48
thermostat, engine 96
throttling valve 138
installation 140
reassembly 139
removal 138
time display 80
trip report, printing 66
trochoid feed pump 110

U
unit description 25
remote evaporator 167
unit features, remote evaporator 169
unit inspection, remote evaporator 177

183
Index

184
Diagrams Index

Drawing No. Drawing Title Page

1E34219 Schematic Diagram 187-193

1E34218 Wiring Diagram 194-201

Fuel Line Routing Diagram 202-204

185
Schematic Diagram - Page 1 of 7

187
Schematic Diagram - Page 2 of 7

188
Schematic Diagram - Page 3 of 7

189
Schematic Diagram - Page 4 of 7

190
Schematic Diagram - Page 5 of 7

191
Schematic Diagram - Page 6 of 7

192
Schematic Diagram - Page 7 of 7

193
Wiring Diagram - Page 1 of 8

194
Wiring Diagram - Page 2 of 8

195
Wiring Diagram - Page 3 of 8

196
Wiring Diagram - Page 4 of 8

197
Wiring Diagram - Page 5 of 8

198
Wiring Diagram - Page 6 of 8

199
Wiring Diagram - Page 7 of 8

200
Wiring Diagram - Page 8 of 8

201
Model 30 Fuel Line Routing Diagram - Page 1 of 3

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

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

202
Model 30 Fuel Line Routing Diagram - Page 2 of 3

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

203
Model 30 Fuel Line Routing Diagram - Page 3 of 3

1. Outlet from Fuel Filter to Injection Pump

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

204
205