SPECTRUM SB 30 50 SR-2 (TK53087-2-MM Rev 0, 01-07)

SPECTRUM SB
30 & 50 SR-2
TK 53087-2-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 SB SR-2 30-2 (002227) System SPECTRUM SB SR-2 30-2 (900223)
For further information, refer to:

SPECTRUM SB 30 & 50 SR-2 Operators Manual TK 53084
SPECTRUM SB 30 & 50 SR-2 Parts Manual TK 53091
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.
2
Recover Refrigerant
At Thermo King, we recognize the need to preserve the environment
and limit the potential harm to the ozone layer that can result from
allowing refrigerant to escape into the atmosphere.
We strictly adhere to a policy that promotes the recovery and limits

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

concerning the use of refrigerants and the certification of technicians.
For additional information on regulations and technician certification
programs, contact your local Thermo King dealer.
R-404A
WARNING: Use only Polyol Ester-based refrigeration compressor oil in
R-404A. See Thermo King Parts Manual for part number.
Do not mix Polyol Ester and standard synthetic compressor oils. Keep Polyol
Ester compressor oil in tightly sealed containers. If Polyol Ester oil becomes
contaminated with moisture or standard oils, dispose of 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.
3
4
Table of Contents
List of Figures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
General Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Battery Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Refrigerant Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Refrigerant Oil Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Electrical Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
High Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Low Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Microprocessor Service Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Welding Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
First Aid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
First Aid, Refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
First Aid, Refrigerant Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
First Aid, Engine Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
First Aid, Electrical Shock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Belt Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Refrigeration System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Electrical Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Electrical Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Electric Standby (Model 50 Units Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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
5
Table of Contents
Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
SMART REEFER 2 Multi-Temp (SR-2 MT) Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Microprocessor On/Off Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
HMI Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Unit Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Manual Pretrip Inspection (Before Starting Unit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Turning Unit On . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Turning Unit Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Standard Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Operating The Unit In Single Zone Control Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Standard Display Variations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Alarm Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Temperature Watch Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Starting the Diesel Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
After Start Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Electric Standby Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Starting the Unit on Electric Standby Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Switching from Diesel to Electric . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Switching from Electric to Diesel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Changing the Setpoint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Turning a Zone On and Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Selection of Operating Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Selecting CYCLE-SENTRY or Continuous Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Initiating a Manual Defrost Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Terminating a Defrost Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Menu Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Navigating the Main Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Language Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Alarms Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Gauges Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Sensors Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Datalogger Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Hourmeters Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Mode Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Pretrip Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Diesel Mode/Electric Standby Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Adjust Brightness Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Time Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Loading Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Single Temperature Loading Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Post Load Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Post Trip Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Electrical Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Alternator Charging System Diagnostic Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Alternator Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Interface Board Fuse F4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Test Equipment for Checking Voltage and Current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Alternator Load Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
General Diagnostic and Warranty Evaluation Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Field Current Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Battery Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Interface Board LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Smart FETs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Expansion Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Expansion Module LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
SMART REEFER 2 Multi-Temp (SR-2 MT) Microprocessor Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
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Fuse Link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Air Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Unit Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Wire Harness Routing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
AC Components (Model 50 Units Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Electrical Contactors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Evaporator Heaters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Auto Phase System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Engine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
EMI 3000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Engine Lubrication System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Engine Oil Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Oil Filter Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Low Oil Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Engine Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
ELC (Extended Life Coolant) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Antifreeze Maintenance Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Bleeding Air from the Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Engine Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Coolant Level Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Engine Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Fuel Line Routing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Fuel Return Line Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Bleeding the Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Draining Water from Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Fuel Filter/Water Separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Fuel Filter/Water Separator Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Engine Speed Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Injection Pump Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Injection Pump Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Injection Pump Reinstallation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Fuel Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
Trochoid Feed Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
Cold Start Device Tier 2 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Engine Valve Clearance Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
Crankcase Breather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
EMI 3000 Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
Air Restriction Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
Belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
Model 30 Belt Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
Model 30 Fan Belt Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
Model 50 Belt Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
Model 50 Compressor Belt Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
Model 50 Fan Belt Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
Clutch (Model 50) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
Drive Bushing Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
Dowel Pin Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
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Refrigeration Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135

Refrigerant Charge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
Testing the Refrigerant Charge with an Empty Trailer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
Testing the Refrigerant Charge with a Loaded Trailer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
Testing for an Overcharge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
Adjusting Refrigerant Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
Moisture Indicating Sight Glass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
Refrigerant Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
Checking Compressor Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
High Pressure Cutout Switch (HPCO) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
High Pressure Switch (HPCS) Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
Pressure Transducers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
Evacuating and Charging Smart Reefer Multi-Temp Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
Set-up Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
Evacuating the System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
Charging the System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
Refrigeration Service Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
Low Side Pump Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
Compressor Coupling Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
Compressor Coupling Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
Condenser Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
Discharge Vibrasorber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
In-Line Check Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
Receiver Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
Filter Drier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
Expansion Valve Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
Heat Exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
Evaporator Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
Accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
Suction Vibrasorber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
High Pressure Cutout Switch and High Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
Discharge Pressure Transducer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
Suction Pressure Transducer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
High Pressure Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
Throttling Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
Liquid Line Solenoid Valve (LLS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
Hot Gas Solenoid Valve (HGS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
Suction Line Solenoid Valve (SLS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
Check Valve Repair (SLCV, SLCV2, SLCV3, LRCV, and PVC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
Check Valve Replacement (SLCV, SLCV2, SLCV3, LRCV, and PVC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
Condenser Inlet Solenoid Valve (CIS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
Condenser Inlet Check Valve (CICV) Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
Condenser Inlet Check Valve (CICV) Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
Receiver Tank Pressure Solenoid Valve (RTPS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
Purge Valve (PV) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
Compressor Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
Checking Compressor Oil Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
Priming New Compressor Installations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
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Table of Contents
Structural Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161

Unit and Engine Mounting Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
Unit Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
Condenser, Evaporator, and Radiator Coils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
Defrost Drains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
Unit Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
Defrost Damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
Condenser and Evaporator Fan Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
Condenser Fan Blower Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
Evaporator Fan Blower Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
Fan Shaft Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
Fan Shaft Assembly Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
Idler Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
Idler Assembly Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
Mechanical Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
Electric Standby Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
Refrigeration Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
Remote Evaporator Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
Refrigeration System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
Remote Evaporator Maintenance Inspection Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
Remote Evaporator Unit Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
Unit Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
Defrost . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
Operating Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
Unit Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
Unit Protection Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
Serial Number Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
Remote Evaporator Electrical Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
SR-2 Multi-Temp Microprocessor Controlled Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
Unit Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
Remote Evaporator Refrigeration Service Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
Expansion Valve Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
Evaporator Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
Solenoid Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
Liquid Return Check Valve Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
Liquid Return Valve Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
Heat Exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
Remote Evaporator Structural Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
Unit Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
Defrost Drains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
Evaporator Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
Remote Evaporator System Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
Diagrams Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
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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 Cool, Zone 2 Cool, and Zone 3 Heat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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:High Voltage Tray (Model 50 Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Figure 17:Control Box With Service Door Open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Figure 18:HMI Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Figure 19:Display and Keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Figure 20:Press On Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Figure 21:Turning Unit On Screen Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Figure 22:Press Off Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Figure 23:Turning Unit Off Screen Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Figure 24:Two Zone Standard Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Figure 25:Three Zone Standard Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Figure 26:Single Zone Standard Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Figure 27: Standard Display Variations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Figure 28:Alarm Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Figure 29:Zone Alarm Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Figure 30:Two Zone Temperature Watch Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Figure 31:Three Zone Temperature Watch Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Figure 32:Starting Diesel Engine Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Figure 33:Electric Power Receptacle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Figure 34:Electric Standby Detected Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Figure 35:Electric Motor Starting Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Figure 36:Electric Standby Detected Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Figure 37:Programming Electric Standby Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Figure 38:Electric Standby Undetected Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Figure 39:Programming Diesel Mode Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Figure 40:Press Zone Soft Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Figure 41:Changing the Setpoint Screen Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Figure 42:Press Zone Soft Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Figure 43:Zone 2 Setpoint Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Figure 44:Turning Zone On/Off Screen Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Figure 45:Changing Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Figure 46:Screen Sequence for Changing from Continuous Mode to CYCLE-SENTRY Mode . . . . . . . . . . . . . 57
Figure 47:Screen Sequence for Changing from CYCLE-SENTRY Mode to Continuous Mode . . . . . . . . . . . . . 57
Figure 48:Initiating a Manual Defrost Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Figure 49:Defrost Zone Select Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Figure 50:Initiating Manual Defrost Screen Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Figure 51:Menu Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Figure 52:Accessing Main Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Figure 53:Using Main Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Figure 54:Main Menu Choices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Figure 55:Standard Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Figure 57:Change Language Screen Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
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List of Figures
Figure 59:Viewing and Clearing Alarms Screen Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

Figure 60:Standard Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Figure 61:Viewing Gauges Screen Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Figure 63:Sensors Menu Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Figure 64:Soft Keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Figure 66:Start of Trip Screen Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Figure 67:Printer Port Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Figure 69:Print Report Screen Sequence. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Figure 71:Hourmeters Menu Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Figure 72:Soft Keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Figure 74:Selecting Mode Screen Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Figure 76:Mode Menu Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Figure 77:Single Zone Control On/Off Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Figure 79:Mode Menu Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Figure 80:Keypad Lockout Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Figure 82:Selecting Sleep Mode Screen Sequence. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Figure 84:No Pretrip Alarm Active Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Figure 85:Pretrip Test Screen Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Figure 87:Programming Electric Standby Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Figure 88:Programming Diesel Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Figure 90:Adjusting Display Brightness Screen Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Figure 91:Time and Date Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Figure 92:Two Compartments, Same Setpoint Temperature, Bulkheads In Place . . . . . . . . . . . . . . . . . . . . . . . 86
Figure 93:Two Compartments, Same Setpoint Temperature, Bulkhead(s) Removed . . . . . . . . . . . . . . . . . . . . 86
Figure 94:Thermo King Alternator Terminal and Component Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Figure 95:Prestolite Terminal Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Figure 96:Interface Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Figure 97:Expansion Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Figure 98:Expansion Module LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Figure 99:Air Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Figure 100:Wire Harness Routing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Figure 101:High Voltage Tray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Figure 102:ELC Nameplate Located On Expansion Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Figure 103:Engine Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Figure 104:Plastic Expansion Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Figure 105:Removing Coolant Level Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Figure 106:Coolant Level Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Figure 107:Expansion Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Figure 108:Expansion Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Figure 109:Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Figure 110:Fuel Return Line Replacement Decal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Figure 111:Fuel Return Line Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Figure 112:Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Figure 113:Injection Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Figure 114:Filling Fuel Filter/Water Separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Figure 115:Engine Speed Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Figure 116:Index Mark Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Figure 117:Index Mark Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Figure 118:Marking Gear Case . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
12
List of Figures
Figure 119:Place Injection Angle Sticker on Gear Case . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111

Figure 120:Injection Angle Sticker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Figure 121:Removing Injection Pump Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Figure 122:Injection Angle Mark Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Figure 123:Injection Angle Mark . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Figure 124:Injection Pump Serial Number Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Figure 125:Examples of Injection Pump Index Mark Alignment with Injection Angle Sticker . . . . . . . . . . . . . . 113
Figure 126:Timing Mark Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Figure 127:Align Flat Sides of Crankshaft Gear with Flat Sides of Inner Rotor in Timing Gear Cover . . . . . . . 113
Figure 128:Index Mark Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Figure 129:Index Mark Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Figure 130:Injection Pump Gear Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Figure 131:Fuel Solenoid Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
Figure 132:Fuel Solenoid Connector Pin Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
Figure 133:Fuel Solenoid Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Figure 134:Trochoid Feed Pump Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
Figure 135:Trochoid Feed Pump Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
Figure 136:Trochoid Feed Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
Figure 137:Cold Start Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Figure 138:Remove Engine Coolant Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Figure 139:Remove Cold Start Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
Figure 140:Clean Piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
Figure 141:Top Dead Center One and Four . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
Figure 142:Adjusting the Valve Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Figure 143:Crankcase Breather Tier 2 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Figure 144:EMI 3000 Air Cleaner Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
Figure 145:EMI 3000 Air Filter Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
Figure 146:EMI 3000 Air Cleaner System Model 30 Shown Model 50 Similar . . . . . . . . . . . . . . . . . . . . . . . . . 123
Figure 147:Air Restriction Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
Figure 148:Model 30 Belt Arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
Figure 149:Condenser Blower Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
Figure 150:Model 50 Belt Arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
Figure 151:Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
Figure 152:New Style, Bonded Drive Bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
Figure 153:Old Style Drive Bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
Figure 154:Press Old Bushings Out Of Hub With Removal Tool 204-1154 . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
Figure 155:Press New Bushing Into Hub With Installation Tool 204-1155 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
Figure 156:Pressing New Dowel Pin Into Flywheel Using Manual Pin Tool 204-1117 . . . . . . . . . . . . . . . . . . . 134
Figure 157:Driving New Dowel Pin Into Flywheel With Impact Pin Tool 204-1118 . . . . . . . . . . . . . . . . . . . . . . 134
Figure 158:Moisture Indicating Sight Glass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
Figure 159:Compressor Sight Glass Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
Figure 160:High Pressure Cutout Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
Figure 161:Multi-Temp Evacuation and Charging (Two Zone Unit Shown Other Units Similar) . . . . . . . . . . . 140
Figure 162:Compressor Coupling Removal Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
Figure 163:Keyway Tool P/N 204-972 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
Figure 164:Compressor Coupling Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
Figure 165:Cross Section of In-line Check Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
Figure 166:Location of Expansion Valve Bulb . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
Figure 167:Throttling Valve Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
Figure 168:Inspect the Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
Figure 169:Inspect for Wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
Figure 170:Inspect for Damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
Figure 171:Throttling Valve Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
Figure 172:Suction Line Check Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
Figure 173:Check Valve with Cap Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
Figure 174:Compressor Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
Figure 175:Unit and Engine Mounting Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
Figure 176:Defrost Damper Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
Figure 177:Condenser Blower Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
Figure 178:Evaporator Fan Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
13
List of Figures
Figure 179:Fan Shaft Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164

Figure 180:Idler Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
Figure 181:SPECTRUM S-3 Evaporator Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
Figure 182:SPECTRUM S-3 Evaporator - Front View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
Figure 183:SPECTRUM S-3 Evaporator - Back View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
Figure 184:Serial Number Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
Figure 185:Check Valve with Cap Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
14
Safety Precautions
Thermo King recommends that all service be
DANGER: Avoid engine operation in
performed by a Thermo King dealer. However,
confined spaces and areas or
you should be aware of several general safety
circumstances where fumes from the
practices:
engine could become trapped and cause
serious injury or death.
The symbol appears next to a point that is
particularly important WARNING: Make sure your gauge
manifold hoses are in good condition
DANGER: Denotes the possibility of before using them. Never let them come in
serious injury or death. contact with moving belts, fans, pulleys or
hot surfaces. Defective gauge equipment
WARNING: Denotes the possibility of can damage components or cause serious
serious equipment damage or serious injury.
personal injury.
WARNING: Always wear goggles or safety
CAUTION: Denotes the possibility of glasses when working on a unit.
minor to severe equipment damage or Refrigerant liquid, oil and battery acid can
personal injury. permanently damage your eyes. See First
Aid on page 18.
General Practices
WARNING: Use extreme caution when
DANGER: Do not operate the compressor drilling holes in a unit. Holes might
with the discharge service valve closed. weaken structural components. Holes
This condition increases internal pressure, drilled into electrical wiring can cause a
which can cause an explosion. fire or explosion.
DANGER: Never apply heat to a sealed WARNING: Exposed coil fins can cause
refrigeration system or container. Heat lacerations. Service work on the
increases internal pressure, which might evaporator or condenser coils is best left to
cause an explosion. a certified Thermo King technician.
DANGER: Refrigerant in the presence of WARNING: Do not apply heat to a closed

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

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

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

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

CPR (cardio pulmonary resuscitation) or
Take precautions before electrically welding any mouth-to-mouth resuscitation to restore breathing,
portion of the unit or the vehicle to which it is if necessary. Stay with victim until emergency
attached. Ensure that welding currents are not personnel arrive.
allowed to flow through the units electronic
circuits.
First Aid, Refrigerant Oil
Observe the following precautions when welding EYES : Immediately flush with water for at least
to avoid damaging electronic components. 15 minutes. CALL A PHYSICIAN. Wash skin
If the microprocessor has a power switch, turn with soap and water.
it OFF before connecting or disconnecting the INGESTION: Do not induce vomiting.
battery. Immediately contact local poison control center or
Disconnect power to the unit. physician.
Disconnect all wire harnesses from the First Aid, Engine Coolant
microprocessor. EYES : Immediately flush with water for at least
If there are any electrical circuit breakers in 15 minutes. CALL A PHYSICIAN. Wash skin
the control box, switch them OFF. with soap and water.
Close the control box. INGESTION: Do not induce vomiting.
Immediately contact local poison control center or
Components that could be damaged by physician.
welding sparks should be removed from the
unit. First Aid, Electrical Shock
Use normal welding procedures, but keep the Take IMMEDIATE action after a person has
ground return electrode as close to the area received an electrical shock. Get quick medical
being welded as practical. This will reduce the assistance, if possible.
likelihood of stray welding currents passing
through any electronic circuits. The source of the shock must be quickly stopped,
by either shutting off the power or removing the
victim. If the power cannot be shut off, the wire
First Aid should be cut with an non-conductive tool, such as
a wood-handle axe or thickly insulated cable
First Aid, Refrigerant cutters. Rescuers should wear insulated gloves
In the event of frostbite, protect the frozen area and safety glasses, and avoid looking at wires
from further injury, warm the area rapidly and being cut. The ensuing flash can cause burns and
maintain respiration. blindness.
EYES : For contact with liquid, immediately flush If the victim must be removed from a live circuit,
eyes with large amounts of water. CALL A pull the victim away with a non-conductive
PHYSICIAN. material. Use wood, rope, a belt or coat to pull or
SKIN: Flush area with large amounts of warm push the victim away from the current. DO NOT
water. Do not apply heat. Remove contaminated TOUCH the victim. You will receive a shock from
clothing and shoes. Wrap burns with dry, sterile, current flowing through the victims body. After
bulky dressing to protect from infection. CALL A separating the victim from power source,
PHYSICIAN. Wash contaminated clothing before immediately check for signs of a pulse and
reuse. respiration. If no pulse is present, start CPR
(cardio pulmonary resuscitation). If a pulse is
present, respiration might be restored by using
mouth-to-mouth resuscitation. Call for emergency
medical assistance.
18
Specifications
Engine
Model 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 111
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: Model 30 Direct to compressor; belts to fans, alternator, and water
pump
Model 50 Centrifugal clutch to compressor; belts to electric standby
motor, fans, alternator, and water pump
19
Specifications
Belt Tension
Model 30 Tension No. on TK Gauge P/N 204-427
Alternator Belt 67
Lower Fan Belt (Engine to Idler) 67
Upper Fan Belt (Fan to Idler) 74
Model 50
Alternator Belt 29
Compressor Drive Belts 79
Fan Belt 74
Water Pump Belt 35
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: Model 30 27 to 29 psi (186 to 200 kPa)
Model 50 23 to 25 psi (159 to 172 kPa)
Heat/Defrost Method: Engine Operation Hot gas
Electric Operation Hot gas and electric heater strips (host only)
High Pressure Cutout 470 +7/-35 psi (3241 +48/-241 kPa)
Automatic reset @ 375 38 psi (2586 262 kPa)
High Pressure 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 91.
Battery Charging: Model 30 12 volt, 120 amp, brush type, Thermo King Alternator
Model 50 12 volt, 105 amp, brush type, Prestolite 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 94 on page 87). The label on Prestolite
alternators states Made in USA (see Figure 95 on page 88).
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 Solenoid 5.7 2.2
High Speed (Throttle) Solenoid 2.9 4.3
Condenser Inlet Solenoid 1.3 9.6
Liquid Line Solenoid in Host Unit 1.5 8.3
Liquid Line Solenoids in Remote Units 1.3 9.6
Hot Gas Solenoids 1.5 8.3
Suction Line Solenoids 1.3 9.6
Receiver Tank Pressure Solenoid 0.7 17.0
Purge Valve 0.7 17.0
Air Heater 70.0-89.0 0.14
Starter Motor 350-475*
*On-the-engine cranking check. Bench test is approximately 140 amps.
Electric Standby (Model 50 Units Only)

Electric Motor and Overload Relay
Voltage/Phase/Frequency Horsepower Kilowatts rpm Full Load Overload Relay
(amps) Setting (amps)
230/3/60 14.0 10.4 1755 37.8 38
460/3/60 14.0 10.4 1755 18.9 20
Electric Heater Strips

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

Supply Circuit Breaker: 230/3/60 70 amps
460/3/60 40 amps
Extension Cord Size: 230/3/60 8 AWG Power Cable, 25-50-foot length
230/3/60 6 AWG Power Cable, 75-foot length
460/3/60 10 AWG Power Cable, up to 75-foot length
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 79).
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 123) at 3,000 hours or two years
(whichever occurs first) if indicator has not reached 25 in.
Drain water from fuel tank and check vent.
Inspect/clean fuel transfer pump inlet strainer (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 101).
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.
Inspect electric motor, replace bearings yearly or every 6,000 hours.
* 3,000 hours or two years, whichever occurs first.
23
Maintenance Inspection Schedule
Host Unit (Continued)

Every Every Annual/
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(s)
Every Every Annual/
Hours Hours* Hours
Electrical
Inspect/replace DC fan motors.
Structural
Visually inspect unit for damaged, loose, or broken parts.
Clean entire unit including evaporator coils and defrost drains.
Check all unit mounting bolts, brackets, lines, hoses, etc.
24
Unit Description
Unit Overview Key Features & Options Model Model

30 50
The SPECTRUM SB SR-2 is a multi-temperature
refrigeration system designed to control the CargoWatch
temperatures in two or three compartments EMI-3000
(zones). The system allows any compartment to High-Capacity Condenser Coil
be set at any temperature.
Whisper Quiet Technology
In the SPECTRUM SB SR-2 30/50-2 unit the Easy-Access Door Design
evaporator in the host unit controls one
Composite Exterior Panels
compartment (Zone 1), and a remote evaporator
controls the other compartment (Zone 2). The Long-Life Coolant/Silicone
SPECTRUM SB SR-2 30/50-3 has a second Hoses
remote evaporator, which controls a third Remote Status Light
compartment (Zone 3). Standard Unit Color White
Standard Grille Color Black
Directional Air Delivery
Vibration Isolation System
Aluminum Undermount Fuel
Tank 50 Gal. (186 Liter)
Alternator, 120 Amp, 12V dc
Alternator, 105 Amp, 12V dc
Fuel Heater
Frost Plug Heater
Special Color Grills
Fresh Air Exchange
i-Box Interface / /
Figure 1: Front View R:COM Automatic Data / /
Transmission System
Design Features FleetWatch Data Manager
The following chart lists key design features and TracKing Satellite / /
options. Communications Kit
Standard Features TracKing Cellular TBA TBA

Communications Kit
Option/Factory Installed
Rear Remote Control
Option/Dealer Installed
ServiceWatch/CargoWatch
Key Features & Options Model Model Accessories:
30 50 Door Switches / /
SMART REEFER SR-2 Temperature Sensor Kits / /
Multi-Temp Controller
Fuel Level Sensor Kits / /
OptiSet Programmable Modes
Megatech Battery, 12V
ServiceWatch
25
Unit Description
Host Unit Thermo King X430L Compressor

The host unit contains the diesel engine, the The unit is equipped with a Thermo King X430L,
compressor, the condenser, an evaporator and the four-cylinder compressor with 30 cu. in.
control box. The Model 50 host unit also contains (492 cm3) displacement. The unit is also equipped
an electric motor. The unit is equipped with an with a compressor oil filter.
SR-2 Multi-Temp Microprocessor, which controls
the operation of the host unit and any remote SMART REEFER 2 Multi-Temp (SR-2
evaporators. Refrigeration lines and wire harness MT) Control System
connect the host unit to the remote evaporators.
WARNING: Do not operate the unit until
The host unit mounts on the front of the trailer you are completely familiar with the
with the unit evaporator portion extending into location and function of each control.
trailer.
The SR-2 MT is a microprocessor control system
SPECTRUM Remote Evaporators designed for a transport refrigeration system. The
SR-2 MT Control System consists of the
A SPECTRUM Remote Evaporator is mounted on following main components:
the ceiling of each remote compartment to provide
temperature control for Zone 2 and Zone 3 (if Base Controller
used). A SPECTRUM Remote Evaporator with Interface Board
two fans is called an S-2. A SPECTRUM Remote
Evaporator with three fans is called an S-3. Two Multi-Temp Expansion Module
remote evaporators can be mounted in the same HMI (Human Machine Interface) Control
remote compartment to provide more capacity. Panel
Microprocessor (Base Controller) On/Off
Switch
Unit Sensors
Refrigeration Control Components
Engine Control Components
Communication Ports
AJA984
Optional Electric Standby
Figure 2: S-3 SPECTRUM Remote Evaporator
The heart of the control system is the
Diesel Engine microprocessor based controller. The interface
board is mounted on the base controller and is
The unit uses a quiet running TK486V (Tier 2), connected to it by means of connectors J1 and J2.
which is a 4-cylinder, water cooled, direct When connected, the base controller and interface
injection diesel engine. board form a one-piece base controller/interface
The engine is coupled directly to the compressor board, (C/IB) assembly. The base
on Model 30 units. A centrifugal clutch transfers controller/interface board controls most host unit
power from the engine to the compressor on the functions.
Model 50. The centrifugal clutch engages when
the engine reaches 400 100 rpm. Belts transmit
power to the fans and the alternator.
26
Unit Description
For multi-temp applications an expansion module NOTE: The SR-2 MT controller provides a wide
is connected to the base controller/interface board range of control and programming flexibility.
via a controller area network (CAN) connection. However, pre-programming of the unit
The expansion module provides the inputs and controller may prohibit operation in certain
outputs necessary to control the remote zone temperature ranges within some modes and may
evaporators. The expansion module is a slave also prohibit certain modes of operation. Refer
controller. The slave designation indicates that to the SR-2 Multi-Temp Microprocessor
the expansion module supports inputs and Controller Diagnostic Manual TK 53080 for
outputs, but it only executes instructions from the information about controller programming.
base controller. The expansion module must be
The system automatically monitors and maintains
connected to the controller/interface board, it is
the compartment temperature, engine block
not capable of stand-alone operation.
temperature, and battery charge levels at a
System conditions are displayed and operator condition where quick, easy starts are possible.
instructions are sent using the HMI (Human
If the block temperature falls below 30 F (-1 C),
Machine Interface) Control Panel.
the engine will start and run until the block
The base controller/interface board and the temperature is above 90 F (32 C). If the battery
expansion module are located inside the control voltage falls to the programmed limit selected by
box, which is located inside the lower roadside CYCLE-SENTRY Battery Voltage (typically 12.2
service door. The microprocessor is connected to volts) and Diesel CYCLE-SENTRY mode is
the HMI Control Panel via a CAN connection. selected, the engine will start and run until the
The HMI Control Panel is mounted on the face of charge rate falls below that programmed by
the control box. It is clearly visible through an CYCLE-SENTRY Amps (typically 5 amperes).
opening in the lower roadside service door.
Features of the CYCLE-SENTRY system are:
Refer to the SR-2 Multi-Temp Microprocessor
Offers either CYCLE-SENTRY or
Controller Diagnostic Manual TK 53080 for more
Continuous Run operation.
information about the SR-2 MT Control System.
Controller regulated all season temperature
See the Operating Instructions Chapter for
control.
information about operating the SR-2 MT
controller. Maintains minimum engine temperature in
low ambient conditions.
CYCLE-SENTRY Start-Stop Controls Battery Sentry keeps batteries fully charged
The CYCLE-SENTRY Start-Stop fuel saving during unit operation.
system provides optimum operating economy.
Variable preheat time.
WARNING: The unit can start at any time Preheat indicator buzzer.
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.
27
Unit Description
Data Logging OptiSet

There are two separate data loggers. The data is Optiset is a group of programmable functions
downloaded through the data ports on the front of that control how the unit will operate with specific
the control box using an IBM PC compatible setpoints. This assures that when a particular
laptop or desktop computer and Thermo King setpoint is selected, the unit will always operate
WinTrac 4.6 (or higher) software. the same way. Optiset can be programmed for up
to ten setpoints or setpoint ranges. This allows an
1 2 entire fleet to be configured to match customers
needs (up to 10 preset conditions). OptiSet is
standard equipment. Refer to the SR-2
Multi-Temp Microprocessor Controller
Diagnostic Manual TK 53080 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 SB 30 & 50 SR-2 Operators
1. CargoWatch Port
Manual TK 53084 or the SR-2 Multi-Temp
2. ServiceWatch Port Microprocessor Controller Diagnostic Manual TK
Figure 3: HMI Controller and Data Ports 53080 for information about the operation of the
remote control panel.
ServiceWatch: ServiceWatch is standard
equipment in the SR-2 base controller. It records
operating events, alarm codes and compartment Sequence of Operation
temperatures as they occur and at preset intervals. When the Microprocessor On/Off switch is turned
This information is typically used to analyze unit on and the HMI ON key is pressed, the LCD
performance. Use the ServiceWatch Port to display is illuminated and shows the setpoint and
downloaded the ServiceWatch data. the return air temperature for all zones. If the
CargoWatch: CargoWatch data logging is CYCLE-SENTRY mode has been selected, the
standard equipment in the HIM, but requires the unit will start and stop automatically. If the
installation of optional sensors. Up to six Continuous mode has been selected, the unit will
temperature sensor/probes and three digital inputs start and run automatically.
(typically used for door switches) can be installed. The microprocessor uses a complex program to
CargoWatch also logs the setpoint. Use the determine which operating mode each zone
CargoWatch Port to downloaded the CargoWatch should be in. Therefore, it is difficult to predict
data. If optional temperature sensors are installed, which operating mode an evaporator should be in
their readings are displayed as Datalogger Sensor by comparing its setpoint to the compartment
(1-6) Temperature in the sensor readings. See temperature. Also, the different versions of
Sensors Menu on page 68. software that are used have some operational
A printer can also be used to print a report of the differences.
optional sensor readings. See Printing a Trip
Report on page 70.
28
Unit Description
Each zone that is turned on will operate in one of When a zone is in heat while another zone is
the following modes: in cool, the evaporator in the zone that is in
heat acts as the condenser.
Cool
The condenser inlet solenoid and the suction
Heat
line solenoids are normally open solenoid
Defrost valves that close when energized.
Null The liquid line solenoids, the hot gas
solenoids, the receiver tank pressure solenoid
During engine operation, engine speed is
and the purge valve are normally closed
determined by a combination of the requirements
solenoid valves that open when energized.
of each zone and the discharge pressure. The
diesel engine will operate in High or Low Speed The flow of refrigerant through the system is
accordingly. controlled by the solenoid valves and the
check valves.
Defrost If the condenser inlet solenoid is energized
Defrost is initiated in each zone automatically or (closed) because a zone is in heat or defrost,
manually. and if the discharge pressure exceeds 400 psi
(2758 kPa), the condenser inlet solenoid is
Automatic Defrost: The controller is programmed de-energized until the discharge pressure
to automatically initiate timed or demand defrost drops below 250 psi (1724 kPa).
cycles. The controller can be programmed to
initiate timed defrost cycles at intervals of 2, 4, 6, The receiver tank pressure solenoid and the
8, or 12 hours. Demand defrost cycles occur if the purge valve are energized (open) when any
differences between the return air temperature, zone is in heat or defrost. If the discharge
discharge air temperature, and coil temperature pressure exceeds 300 psi (2068 kPa), the
exceed certain limits. The unit can enter defrost receiver tank pressure solenoid and the purge
cycles as often as every 30 minutes if required. valve are de-energized until the discharge
pressure drops below 225 psi (1551 kPa).
Manual Defrost: In Manual Defrost Mode, the
operator initiates a defrost cycle. See Initiating a During engine operation when all zones are in
Manual Defrost Cycle on page 58. cool, the microprocessor will shift the engine
to low speed if the discharge pressure exceeds
The evaporator coil temperature in the selected
425 psi (2930 kPa). High speed is enabled, if
zone must be below 45 F (7 C) to allow defrost. If
required, when the discharge pressure drops
the unit is in CYCLE-SENTRY Null mode, the
below 375 psi (2586 kPa).
engine will start when defrost is initiated.
During engine operation when all zones are in
The zone will stay in defrost until the evaporator
heat, the microprocessor will shift the engine
coil temperature rises to 58 F (14.5 C).
to low speed if the discharge pressure exceeds
375 psi (2586 kPa). High speed is enabled, if
System Operation required, when the discharge pressure drops
Several operating characteristics of the unit are: below 300 psi (2068 kPa).
All zones can cool at the same time.

Refrigeration System Diagrams
All zones can heat at the same time.
The following pages show examples of the
Any zone can cool while any other zone heats. refrigerant flow through a three zone system. The
two zone system is similar, except the Zone 3
When the host zone is in defrost, it may delay
evaporator and its components are removed.
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.
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
3R. Zone 3 Suction Line Check Valve
(SLCV3) Open
low pressure vapor. The refrigerant returns to the 4R. Zone 3 Suction Line Solenoid (SLS3)Open
compressor through the SLS2, the suction line, the
5R. Zone 3 Hot Gas Solenoid (HGS3)Closed
SLCV2, and the accumulator.
The LLS3 is open so some of the refrigerant flows
Host Unit and Zone 1 Evaporator

1. Liquid Line Solenoid (LLS)Open
2. Liquid Return Check Valve (LRCV)Closed
3. Suction Line Check Valve (SLCV)Open
4. Suction Line Solenoid (SLS)Open
5. Hot Gas Solenoid (HGS)Closed
6. Condenser Inlet Solenoid (CIS)Open
7. Condenser Inlet Check Valve (CICV)Open
8. Receiver Tank Pressure Solenoid
(RTPS)Closed
9. Condenser Check Valve (CCV)Open
10. Bypass Hand Valve
11. Purge Valve (PV)Closed
12. Purge Check Valve (PCV)Closed
30
Unit Description
Zone 1
Zone 2
AGA168
Zone 3
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
Zone 1 evaporator. There the liquid refrigerant 1R. Zone 3 Liquid Line Solenoid (LLS3)Open
2R. Zone 3 Liquid Return Check Valve
(LRCV3) Open
compressor through the SLCV, and the
accumulator. 3R. Zone 3 Suction Line Check Valve
(SLCV3) Closed
The LLS2 is also open so some of the refrigerant
flows through the Zone 2 expansion valve into the 4R. Zone 3 Suction Line Solenoid
Zone 2 evaporator. There the liquid refrigerant (SLS3)Closed
5R. Zone 3 Hot Gas Solenoid (HGS3)Open
Host Unit and Zone 1 Evaporator

1. Liquid Line Solenoid (LLS)Open
2. Liquid Return Check Valve (LRCV)Closed
3. Suction Line Check Valve (SLCV)Open
4. Suction Line Solenoid (SLS)Open
5. Hot Gas Solenoid (HGS)Closed
6. Condenser Inlet Solenoid (CIS)Closed*
7. Condenser Inlet Check Valve
(CICV)Closed
8. Receiver Tank Pressure Solenoid
(RTPS)Open*
9. Condenser Check Valve (CCV)Closed
10. Bypass Hand Valve
11. Purge Valve (PV)Open*
12. Purge Check Valve (PCV)Open
* The microprocessor will open and close these
valves as required to control the head pressure or
compensate for high ambient temperatures.
32
Unit Description
Zone 1
Zone 2
AGA169
Zone 3
Figure 5: Zone 1 Cool, Zone 2 Cool, and Zone 3 Heat
33
Unit Description
Opening the Front Doors Opening the Secondary Door Latch

Pull the door latch handle to open the doors and Later model units are equipped with a secondary
access the engine compartment. Slam the door to door latch. These units also have a secondary door
close it. Do not push the door closed while latch nameplate located below the front doors.
holding the door latch handle open or the door After opening the door latch, reach between the
will not close properly. 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
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 Overload RelayManual Reset (Model 50): An
protects the electric system from a short. If the overload relay protects the standby electric motor.
fuse link burns out, replace it by replacing the The overload relay opens the circuit to the electric
positive battery cable. motor if the motor overloads for any reason (e.g.,
low line voltage or improper power supply) while
Fuses: Various fuses are located on the controller the unit is on electric standby operation. The
interface board to protect circuits and microprocessor will record Alarm Code 90. Press
components. See Fuses on page 91 for more the reset button on the high voltage tray to reset
information. the overload relay. The high voltage tray is
Smart FETs: Smart FETs in the controller located behind the lower access panel on the
interface board and expansion module protect compressor side of the unit.
circuits and components. See Smart FETs on
page 92 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

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

(Located Where Shown Above)

Figure 10: Engine Serial Number Location
37
Unit Description
Figure 13: Front View
38
Unit Description
1. Access Panels
2. Defrost Damper
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
Unit Description
1 2
AJA1932
1. Overload Relay
2. Heaters Contactor
3. Phase Selector
4. Drive Motor Contactors
Figure 16: High Voltage Tray (Model 50 Only)
41
Unit Description
42
Operating Instructions
SMART REEFER 2 Multi-Temp HMI Control Panel

(SR-2 MT) Control System Use the HMI control panel to operate the unit.
The microprocessor control system components Refer to the SPECTRUM SB 30 & 50 SR-2
are located inside the control box, which is Operators Manual TK 53084 and the SR-2
located inside the lower roadside service door. Multi-Temp Microprocessor Controller
The microprocessor is connected to an HMI Diagnostic Manual TK 53080 for more
(Human Machine Interface) Control Panel, which information.
is used to operate the unit. The CargoWatch and The HMI (Human/Machine Interface) Control
ServiceWatch ports are used to retrieve data from Panel is connected to the microprocessor and is
the data logging system. used to operate the unit and display unit
information. The HMI communicates with the
controller via a controller area network (CAN)
1
bus.
2 The HMI control panel has a display and eight
touch sensitive keys.
3
The display is capable of showing both text and
4 graphics.
The keys on the left and right sides of the display
5 are dedicated or single function keys. These are
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
1. Control Box 4. CargoWatch Port soft key is active the current key function is
2. Microprocessor 5. HMI Control Panel shown in the display directly above the key.
On/Off Switch
3. ServiceWatch Port
Figure 17: Control Box With Service Door Open
CONTINUOUS
Microprocessor On/Off Switch ON
-8. 2
35.8 48.8
TEMP F
SET
This switch supplies or removes electrical power OFF

-10 35 50 POINT
ZONE 1 ZONE 2 ZONE 3 MENU

to the microprocessor. It is located on the left side
of the control box.
CAUTION: The unit can start at any time
without warning. Press the OFF key on the SmartRReefer22
microprocessor On/Off switch in the Off ARA794
position before inspecting or servicing any Figure 18: HMI Control Panel
part of the unit.
43
Display NOTE: Zone 1 is always on when the control

system is powered up. Zone 1 cannot be turned
The display presents information to the operator.
off using the HMI control panel menu.
This information can include setpoint and
temperature for each zone, unit or zone operating
Control Panel Keys
information, gauge readings, temperatures and
other information as selected by the operator. The keys on either side of the display (see Figure
19) are dedicated or hard keys. Their function
The default display is called the Standard Display.
always remains the same. They are described
See page 47 for more information about Standard
below.
Displays.
On Key: Press this key to turn the host
The Standard Display of box temperature and unit and Zone 1 on. First the display
setpoint for 3 zones is shown in Figure 19. The will briefly show the Thermo King
unit is running in Continuous Mode. Zone 1 has a Logo, and then the statement
setpoint of -10 F, and a return air temperature of Configuring System - Please Wait.
-8.2 F. The downward pointing arrow shows this When the power-up sequence is
zone is cooling. Zone 2 has a setpoint of 35 F, and complete, the display shows the
a return air box temperature of -35.8 F. The Standard Display of box temperature
absence of an arrow indicates that this zone is in and setpoint. For more information see
null. Zone 3 has a setpoint of 50 F, and a return air Turning Unit On on page 45.
temperature of 48.8 F. The upward pointing arrow
shows this zone is heating. Off Key: Press this key to turn the host
unit and Zone 1 off. First the display
NOTE: The zone temperature shown is always will briefly show System is Powering
return air temperature. Down - Please Wait. Press On to
Pressing the soft key under each zone allows the Resume, and then Off will appear
setpoint for that zone to be changed. In addition, momentarily. When the power-down
the soft keys under Zone 2 and Zone 3 are used to sequence is complete the display will
turn those zones on and off. Pressing the soft key be blank. For more information see
under MENU accesses the MAIN MENU. Turning Unit Off on page 46.
Defrost Key: Press this key to initiate a
3
Manual Defrost cycle. For more
CONTINUOUS
information see Initiating a Manual
2 4 Defrost Cycle on page 58.
2
35 .8 48 .8
ON TEMP F
-8 .
1 -10 35 50
SET
POINT 5 Mode Key: Press this key to select
OFF
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 57.
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 19: Display and Keys
44
The four soft keys under the display

CAUTION: Do not remove expansion
(see Figure 19) are multi-purpose keys.
tank cap while coolant is hot.
Their function changes depending on
the operation being performed. If a soft
key is active, the key function is shown CAUTION: Do not add GREEN or
in the display directly above the key. BLUE-GREEN conventional coolant to
The keys are numbered from left to cooling systems using RED Extended
right, with Key 1 on the far left and Life Coolant, except in an emergency. If
Key 4 on the far right. conventional coolant is added to Extended
Life Coolant, the coolant must be changed
Typical soft key functions: after 2 years instead of 5 years.
Zone On/Off and Setpoint Change Battery: The terminals must be clean and tight.
Menu Belts: The belts must be in good condition and
adjusted to the proper tensions.
Next/Back
Electrical: The electrical connections should be
Yes/No securely fastened. The wires and terminals should
+/ be free of corrosion, cracks or moisture.
Structural: Visually inspect the unit for leaks,
Select/Exit
loose or broken parts and other damage. The
Clear/Help condenser and evaporator coils should be clean
Hour Meters/Sensors and free of debris. Check the defrost drain hoses
and fittings to make sure they are open. Make sure
Gauges all the doors are latched securely.
Unit Operation Turning Unit On

Complete the following steps to turn on the unit:
Manual Pretrip Inspection (Before
Starting Unit) 1. Press the ON hard key.
The following Manual Pretrip Inspection should NOTE: With SPECTRUM Multi-Temp
be completed before starting the unit and loading applications, Zone 1 is turned on any time
the trailer. While the pretrip inspection is not a the host unit is turned on. Zone 1 is turned
substitute for regularly scheduled maintenance off when the host unit is turned off.
inspections, it is an important part of the
preventive maintenance program designed to head 2
1
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) 1. On Key
into oil pan. Never overfill. 2. Display
Coolant: The engine coolant must have antifreeze Figure 20: Press On Key
protection to -30 F (-34 C). Alarm Code 37
indicates low coolant. Add coolant in the 2. The display briefly shows a Thermo King
expansion tank. Logo as the display initializes.
45
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 22: 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 21: 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 23: 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.
46
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 25. 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
24. 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 25: 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 24: Two Zone Standard Display
47
Single Zone Control Standard Display Method 2:

This feature, if enabled in Guarded Access, allows If Single Zone Control Mode has been has been
Single Zone Control operation to be selected by enabled in the Guarded Access/Main Menu
choosing the Main Menu and then selecting Configuration menu, the following will apply.
Single Zone Control from the Mode submenu (see
Single Zone Control Mode will appear in the
Selecting Single Zone Control or Multi Zone
Mode Menu only if the Single Zone Control
Control on page 75). When this feature is
feature has been enabled in the Guarded
selected, all zones will be forced on and will
Access/Main Menu Configuration menu. IF
control to the same selected setpoint. The Single
the feature is enabled then Single Zone
Zone Control Standard Display is shown in Figure
Control will appear in the Main Menu/Mode
26. It functions the same way as the other
Menu.
Standard Displays. The top of the display shows
that the unit is operating in Continuous mode. The If Single Zone Control operation is selected
box temperature for all zones is 35.8 F and all then all zones will be forced on and will
zones are controlling to a 35 F setpoint. The control to the same setpoint. The Zone 1
down-pointing arrow indicates that all zones are sensors are used to determine box
cooling. The soft key labeled Setpoint allows the temperature.
setpoint for all zones to be changed. The soft key
NOTE: Using Method 2, it is recommended
labeled Menu allows the Main Menu to be
that all bulkheads should be taken down to
selected.
create one large compartment.
CONTINUOUS With the exception of defrost, the operating
mode of each zone evaporator(s) will be same
SETPOINT
F when in this mode. Unit control is based on
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 26: Single Zone Standard Display Figure 26. 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.
48
Standard Display Variations 1

The Standard Display has variations. A display CONTINUOUS
showing any of the following variations is still
considered a Standard Display.
-8 .2 35 .8
The top of the display will show that the unit is
operating in either CYCLE-SENTRY or
0 35
Continuous Mode. The temperature can be ZONE 1 ZONE 2 MENU
displayed in degrees Fahrenheit (F) or degrees ARA822
Celsius (C). See Figure 27.
1. Zone Alarm Icon
1 2
Figure 29: Zone Alarm Display
CYCLE SENTRY
NOTE: Zone specific alarm codes use the
TEMP C
2 8
-8 . 0. SET
standard Thermo King alarm code numbers. If
an alarm is specific to a zone then both the
-18 OFF POINT
alarm code number and affected zone number
ZONE 1 ZONE 2 MENU
are displayed.
ARA803 NOTE: If the large alarm icon only appears,
then the active alarm(s) are unit level alarm(s).
1. CYCLE-SENTRY or Continuous If a zone alarm icon and the large alarm icon
2. Degrees Celsius or Fahrenheit are displayed there is a zone level alarm or a
Figure 27: Standard Display Variations combination of zone level and unit level alarms
present.
Alarm Display See Alarms Menu on page 64 for information
If a unit alarm condition occurs the large Alarm about displaying and clearing alarms.
Icon will appear on the Standard Display as
shown below in Figure 28. Temperature Watch Display
1 If there is no key activity and no check, prevent,
CONTINUOUS
or shutdown alarms are present the Temperature
Watch Display appears 2-1/2 minutes after the last
key entry from the Standard Display. The
-8 .2 35 .8 Temperature Watch screen will remain on until
0 35 any key is pressed or a check, prevent, or
shutdown alarm occurs. The Temperature Watch
ZONE 1 ZONE 2 MENU
Display shows the return air temperature and
ARA821 setpoint for each zone. Tenths of a degree are not
shown by the Temperature Watch display. The
1. Alarm Icon
large numbers allow unit conditions to be checked
Figure 28: Alarm Display from a distance.
If an alarm specific to a zone occurs, then a small A Two Zone Temperature Watch Display is shown
zone alarm icon will appear next to the affected in Figure 30. The box temperature for Zone 1 is
zone as well. Both Alarm Icons will be present. -8.2 F with a -10 F setpoint. The down-pointing
Below in Figure 29 the small zone Alarm Icon arrow indicates that Zone 1 is cooling. The box
indicates that an alarm exists specific to Zone 2. 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.
49
Starting the Diesel Engine

Diesel engine preheating and starting is automatic
ON
-8 36 in both Continuous Mode and CYCLE-SENTRY
OFF
-10 35 Mode. The engine will preheat and start as
ZONE 1 F ZONE 2 MENU 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
ARA801
is pressed.
Figure 30: Two Zone Temperature Watch Display
See Turning Unit On on page 45.
If an alarm condition (other than a log alarm) is
NOTE: If the unit is equipped with optional
present the Temperature Watch Display will not
Electric Standby there may be some additional
appear. If an alarm condition occurs while the
prompts before the engine will start. See
Temperature Watch Display is present the display
Starting the Unit on Electric Standby
will return to the Standard Display. If the Defrost
Operation on page 52.
or Cycle Sentry keys are pressed the display will
return to the Temperature Watch Display after CAUTION: The engine may start
defrost is initiated or the operating mode is automatically any time the unit is turned
changed. on.
In the Three Zone Temperature Watch Display the
WARNING: Never use starting fluid.
Menu soft key label covers the Zone 3 label as
shown below in Figure 31.
If the unit is operating in Cycle-Sentry Mode, the When the engine is preparing to start the HMI
Cycle-Sentry icon will appear near Zone 2 as control panel will display the engine start screen,
shown below in Figure 31. If the unit is operating as shown below. The preheat buzzer sounds
in Continuous Mode the Cycle-Sentry icon will during the engine preheat and crank sequence.
not be present.
1 2 ON
DIESEL ENGINE STARTING
OFF
ON
-8 36 48
OFF
-10 35 50
ZONE 1 F ZONE 2 MENU
ARA840
Figure 32: Starting Diesel Engine Display
After the engine is started the display returns to

ARA908
the Standard Display of temperature and setpoint.
1. Cycle-Sentry Icon NOTE: Run a pretrip test if the unit has not been
2. Menu Soft Key Label used recently. See Pretrip Tests on page 79.
Figure 31: Three Zone Temperature Watch Display
50
Unit Fails To Start Defrost: When the unit has finished pre-cooling
the trailer interior, manually initiate a Defrost
If the engine does not start and the Alarm Icon cycle. See Initiating a Manual Defrost Cycle on
appears on the display, take the following steps. page 58. This will remove the frost that builds up
1. Check for and correct any alarm conditions. while running the unit to pre-cool the trailer.
See Viewing and Clearing Alarms Screen
Sequence on page 65. Electric Standby Operation
2. Clear all alarms. See Viewing and Clearing Model 50 units are equipped with Electric
Alarms Screen Sequence on page 65. Standby. This feature allows the unit to operate on
electric power as well as be powered by the
3. Press the OFF key to tun the unit off. standard diesel engine.
4. Press the ON key to turn the unit on. During Electric Standby operation, power to the
5. The controller will go through the start up unit is supplied by an electric motor connected to
screens and then after a 10 second delay the a high voltage power source. The required voltage
unit will start automatically. is shown on a decal on the units electric power
receptacle.
6. If the engine will still not start, turn the unit
off. Determine and correct the cause for not WARNING: Units equipped with electric
starting. standby may start at any time when the
7. Repeat the procedure. unit is connected to live electric power and
the controller is turned on.
After Start Inspection CAUTION: Always turn the electric
After the unit is running, check the following power supply off when handling,
items to confirm that the unit is running properly. connecting, or disconnecting high voltage
Oil Pressure: Check the engineoil pressure by power cords.
using the Gauges Menu. See Gauges Menu on
page 66. The Engine Oil Pressure Display should CAUTION: Do not start the electric drive
indicate OK not LOW. motor unless the diesel engine is
completely stopped.
Ammeter: Check the ammeter reading by using
the Gauges Menu. See Gauges Menu on page Electric Power Receptacle: The electric power
66. The Amps Display should indicate a positive receptacle is used to connect the unit to an
charge amperage rate to the battery. A negative (-) appropriate electric power source for electric
number indicates a discharge condition. standby operation. The electric power receptacle
is usually mounted on the front of the trailer
Compressor Oil: The compressor oil level should below the unit. Make sure the unit and the power
be visible in the compressor sight glass after 15 supply are turned off before connecting or
minutes of operation. If not, check the compressor disconnecting a power cord.
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 54. 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
AMA35
moisture from the trailer interior to prepare it for a
Figure 33: Electric Power Receptacle
refrigerated load.
51
Starting the Unit on Electric Standby 5. When the motor is preparing to start the HMI
Operation control panel will display the motor start
screen, as shown below. The preheat buzzer
Units equipped with the Electric Standby option
sounds for 20 seconds before the electric
only
motor starts.
Electric motor starting is automatic in both
Continuous Mode and Cycle Sentry Mode. The
motor will start as required when the unit is turned ELECTRIC MOTOR STARTING
on. If any keys are being pressed on the HMI
control panel prior to the motor start, the motor
start will be delayed until 10 seconds after the last ARA909
key is pressed. Start the unit on Electric Standby Figure 35: Electric Motor Starting Screen
operation as follows:
6. Complete an After Start Inspection (see
1. Press the controller OFF key to make sure the
page 51).
unit is turned off.
2. Connect the unit electric power receptacle to Unit Fails to Start
an appropriate electric power supply.
If the electric motor does not start and the Alarm
3. Press the controller ON key. Icon appears on the display, take the following
steps.
CAUTION: The motor may start
automatically any time the unit is turned 1. Check for and correct any alarm conditions.
on. See Viewing and Clearing Alarms Screen
Sequence on page 65.
4. If a screen asking if you wish to switch to
Electric Standby appears, press the YES soft 2. Clear all alarms. See Viewing and Clearing
key. This screen does not appear if the Alarms Screen Sequence on page 65.
controller is programmed to automatically 3. Press the Controller OFF key.
switch from Diesel to Electric Standby, or if
the unit was in Electric Standby when it was 4. Press the Controller ON key.
turned off. 5. If the unit still does not start, repeat the above
steps.
Figure 34: Electric Standby Detected Screen
52
Switching from Diesel to Electric Switching from Electric to Diesel

Units equipped with the Electric Standby option Units equipped with the Electric Standby option
only only
If the Electric to Diesel Autoswitch Enabled If the Diesel to Electric Autoswitch Enabled
feature in Guarded Access is set YES then the unit feature in Guarded Access is set YES then the unit
will automatically switch to Electric Mode will automatically switch to Diesel Mode
operation when standby power is connected and operation when standby power is turned off or is
available. no longer available.
If the Electric to Diesel Autoswitch Enabled If the Diesel to Electric Autoswitch Enabled
feature in Guarded Access is set NO, then the feature in Guarded Access is set NO then the
prompt screen shown below will appear when prompt screen shown below will appear when
standby power is connected and available. standby power is turned off or is no longer
available.
ELECTRIC STANDBY UNDETECTED
DO YOU WISH TO SWITCH TO

DIESEL?
YES NO
Figure 36: Electric Standby Detected Screen ARA910
If YES is selected then the display will briefly Figure 38: Electric Standby Undetected Screen
show the screen below. If YES is selected then the display will briefly
show the screen below.
PROGRAMMING DIESEL MODE
PLEASE WAIT
Figure 37: Programming Electric Standby Screen
ARA911
Electric Mode operation will briefly be
Figure 39: Programming Diesel Mode Screen
confirmed. If unit operation is required the
electric motor will start as shown in Starting the Diesel Mode operation will briefly be confirmed.
Unit on Electric Standby Operation on page 52. If unit operation is required the diesel engine will
start as shown in Starting the Diesel Engine on
page 50.
53
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 40. 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 40: Press Zone Soft Key appear.
3. The setpoint display appears as shown in 6. The Programming New Setpoint Screen will
Figure 41. appear. See Figure 41.
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 41.
is shown. The setpoint has been changed to
8. The Standard Display appears with setpoint
0 F using the + soft key in Figure 41.
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 41. Zone 1 is heating. See Figure 41.
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 41: Changing the Setpoint Screen Sequence
54
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 43: Zone 2 Setpoint Display
may operate in a slightly different manner. Refer
to the SPECTRUM SB 30 & 50 SR-2 Operators 4. The display briefly shows PROGRAMMING
Manual TK 53084 or the SR-2 Multi-Temp ZONE ON/OFF - PLEASE WAIT. See Figure
Microprocessor Controller Diagnostic Manual 44.
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 44.
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 44.
Display.
1. Press the ZONE soft key under the desired zone. PROGRAMMING ZONE ON/OFF
Zone 2 is selected here (see Figure 42).
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 42: Press Zone Soft Key SET
0 OFF POINT
ZONE 1 ZONE 2 MENU

2. The setpoint display appears as shown in ARA813
Figure 43. If the zone is turned on, the third

Figure 44: 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.
55
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.
56
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
74. -10 35 POINT
ZONE 1 ZONE 2 MENU
1. Press the MODE key. See Figure 45. ARA814
Figure 46: 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 45: Changing Mode
2. The Programming CYCLE-SENTRY Mode

or Programming Continuous Mode Screen
briefly appears. See Figure 46 and Figure 47.
3. The New System Mode CYCLE-SENTRY
or New System Mode is Continuous Screen CONTINUOUS
briefly appears. See Figure 46 and Figure 47. -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 46 and Figure 47. Figure 47: 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.
57
Initiating a Manual Defrost Cycle 5. The Defrost Started Screen briefly appears.
See Figure 50.
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 50) 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 50.
55F (13C).
Use the following steps to initiate a Manual
Defrost:
1. Press the DEFROST key. See Figure 48.
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 48: 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 50: Initiating Manual Defrost
Zone 1 has been selected here (see Figure 49). 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 70F
Figure 49: Defrost Zone Select Display (21C).
3. The Defrost Screen briefly appears. See NOTE: If the defrost timer consistently
Figure 50. 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 50.
58
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 51: Menu Overview
59
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 52.
MODE
CONTINUOUS
ON
TEMP F PRETRIP
2
-8 . 35 .8 SET
OFF -10 35 POINT
DIESEL/ELECTRIC STANDBY Does not appear on Model 30 units.

ZONE 1 ZONE 2 MENU
1
ADJUST BRIGHTNESS
ARA798 TIME
1. Press Menu Soft Key

Figure 54: Main Menu Choices
Figure 52: Accessing Main Menu
Main Menu Choices
3. The first Main Menu choice will appear. Press
Language Menu: This menu only appears if the
the NEXT and BACK soft keys to scroll through
the menu choices. See Figure 53. controller is programmed to activate more than
one language. It allows the operator to select
4. When the desired selection is shown on the which language is used. All other subsequent
display, press the SELECT soft key to access it. displays are shown in the selected language.
The Pretrip selection is shown here in Figure English is the default language. See page 62.
53.
Alarms Menu: Allows the operator to view any
active alarms, and allows most alarms to be
MAIN MENU cleared. If only one language is enabled this will
ON
PRETRIP
be the first menu item to appear. See page 64.
OFF
Gauges Menu: Allows the operator to view the
EXIT SELECT BACK NEXT
unit gauges and the state of the Inputs and Outputs
on both the Interface Board and Expansion
Module. See page 66.
ARA818
1 2 3 4 Sensors Menu: Allows the operator to view the
unit temperature sensors. If CargoWatch sensors
1. Exit Soft Key 3. Back Soft Key
are installed they can be viewed as well. See
2. Select Soft Key 4. Next Soft Key page 68.
Figure 53: Using Main Menu Datalogger Menu: Allows the operator to set a
5. To return to the Standard Display press the Start of Trip marker or print the contents of the
EXIT soft key. The Main Menu choices are
CargoWatch datalogger. See page 69.
shown in Figure 54. For detailed information
on each submenu, see the individual
explanations of each submenu item on the
following pages of this manual.
60
Hourmeters Menu: Allows the operator to view Adjust Brightness: Allows the operator to adjust
the unit hourmeters that have the view feature the HMI control panel display backlight intensity
enabled in the Guarded Access Menu. If the view as required by conditions. See page 84.
feature for a particular hourmeter is not enabled, Time: Allows the operator to view the unit time
then that hourmeter cannot be viewed. See and date. The time and date cannot be changed
page 71. from this menu. The Time is displayed in 24 hour
Mode Menu: Allows the operator to change the military time. See page 85.
following unit operating modes if allowed. Not all
modes may appear depending on the settings
selected from the Guarded Access Menu. See
page 73.
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 79.
Diesel Mode/Electric Standby (Model 50 Only):
This menu only appears on Model 50 units.
Electric Standby - If the Electric Standby
option is present and the Diesel to Electric
Auto-switch feature is set NO, this feature
allows the operator to manually select electric
mode operation. This feature does not appear
if the unit does not feature optional Electric
Standby or if the Diesel to Electric
Auto-switch feature is set YES. See page 83.
Diesel Mode - If a unit equipped with electric
standby is running in electric mode and the
Electric to Diesel Auto-switch feature is set
NO, this feature allows the operator to
manually select diesel mode operation. This
feature does not appear if the unit does not
feature optional Electric Standby or if the
Electric to Diesel Auto-switch feature is set
YES. See page 83.
61
Language Menu 3. If enabled, the Language Menu is the first

menu item to appear. Press the SELECT soft key
If the Language feature is enabled, an alternate
to choose the Language Menu. See Figure 57.
language can be selected from the Language
Menu. After a new language is chosen all displays 4. The NEW LANGUAGE WILL BE Screen
will appear in that language. If the language will appear. See Figure 57.
feature is not enabled this menu does not appear.
5. Press the + or - soft keys to select the desired
The default language is English. Only languages language. German is shown in Figure 57.
that have been enabled in Guarded Access will
6. When the desired language is shown, press the
appear. Refer to the SR-2 Multi-Temp
YES soft key to confirm the choice.
Microprocessor Controller Diagnostic Manual
TK 53080 for information about programming the 7. The PROGRAMMING
controller. LANGUAGE-PLEASE WAIT Screen briefly
appears in the new language.
The languages available are dependant on the
HMI control panel software revision. Languages 8. The display will then return to the Language
currently supported by software revision 65xx are Menu, but will show the new language.
English, Spanish, French, German, Italian, Dutch, German is shown below in Figure 57.
Portuguese, Greek, Turkish, Hebrew and Arabic.
NOTE: Exercise care when changing
Languages currently supported by software
languages, as once changed all HMI Control
revision 66xx are English, Russian, Polish,
panel displays will be in the new language. If
Hungarian, Romanian, Bulgarian, Czech, Danish,
the user is not familiar with the new
Swedish, Norwegian and Finnish. Languages
language, problems may be experienced
currently supported by software revision 67xx are
returning to the default language.
English and Japanese. Other than the languages
supported, software revisions 65xx, 66xx and 9. Repeat the process to select a different
67xx are identical. language. Press the NEXT soft key to select a
different Main Menu item. Press the EXIT soft
To select an alternate language:
key to return to the Standard Display.
1. Begin at 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
Display.
hold the first and last soft key for 5 seconds as
2. Press the MENU soft key on the Standard shown below in Figure 56.
Display.
CONTINUOUS
ON
TEMP F
2
ON
CONTINUOUS
-8 . 35 .8 SET
-8 .2 35 .8
TEMP F
OFF -10 35 POINT
SET
OFF -10 35 POINT ZONE 1 ZONE 2 MENU
ZONE 1 ZONE 2 MENU
1
ARA798
1
ARA798
1. Press Menu Soft Key 1. Press These Soft Keys
Figure 55: Standard Display Figure 56: Standard Display
62
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 57: Change Language Screen Sequence
63
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 49.
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.
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.
2. Press the MENU soft key on the Standard Controller Diagnostic Manual TK 53080 for more
Display. 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

Figure 58: 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 59.
5. If no alarms are present, the No Alarm
Screen will be shown on the display. See
Figure 59. 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 59),
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 59).
NOTE: For additional information
regarding the alarm shown on the display
press the HELP soft key. A help message will
appear.
64
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 59: Viewing and Clearing Alarms Screen Sequence
65
Gauges Menu 5. Press the BACK or NEXT soft keys to scroll

through the following gauges (see Figure 61):
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
Amps
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 67.
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 61. 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 61: Viewing Gauges Screen Sequence
66
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
Hot Gas Solenoid Zone 1
Suction Line Solenoid Zone 1
NOTE: Not all menu items may appear.
67
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
Zone 2 Temperature Differential
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
Spare 3 Temperature
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 63: 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 64: 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.
68
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 1. Press Menu Soft Key
of both the ServiceWatch and CargoWatch
Dataloggers. It is typically initiated when the
cargo is being loaded. The Start Of Trip marker 3. Press the NEXT soft key until the Datalogger
then shows when the trip started in the data that is Menu appears. See Figure 66.
downloaded or printed from the datalogger. A
Start Of Trip can be initiated through the use of 4. Press the SELECT soft key on the Datalogger
WinTrac datalogging software, or manually in the Menu. The Start Trip Screen will appear.
field. The following procedure covers manual 5. Press the SELECT soft key. The Start Of Trip
initiation. For more information on datalogging, Screen will appear.
see the WinTrac User Manual included with the
WinTrac software. The WinTrac User Manual is 6. Press the SELECT soft key to initiate a start of
also available on the Internet at trip.
HTTP://WWW.BLUETREE.IE. 7. A Start Of Trip Marker has been inserted into
1. Begin at the Standard Display. the datalogger memory.
If the Temperature Watch Display is showing, NOTE: The Start Of Trip Marker is sent to both
press any soft key to return to the Standard the CargoWatch and ServiceWatch dataloggers.
Display.
SELECT Key
SELECT Key
SELECT Key
Figure 66: Start of Trip Screen Sequence
69
Printing a Trip Report 2. Begin at the Standard Display.

This procedure prints the CargoWatch Datalogger
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 4. Press the NEXT soft key until the Datalogger

Menu appears. See Figure 69.
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 67: Printer Port Location including the current temperature.
1. Connect the printer to the 6-pin printer port 8. Press the NEXT soft key to go to the Trip
located inside the control box. Ticket Screen. Press the SELECT soft key to
print a Trip Ticket, which is a long ticket that
NOTE: The printer port can be mounted so it shows details for the current trip including a
is accessible without opening the control box. temperature history. The Trip Ticket is also
It is typically mounted between the called a Journey Ticket.
CargoWatch Port and the ServiceWatch Port.
SELECT Key
SELECT Key
NEXT Key NEXT Key
SELECT Key SELECT Key
Figure 69: Print Report Screen Sequence
70
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 72 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 for Model 30 units is to display
only the Engine Hours. The default setting for
Model 50 units is to display Total Run Time ON
TOTAL RUN TIME HOURS
Hours, Engine Hours, and Electric Run Hours. 138

The Hourmeters Menu will not appear if all OFF
EXIT LOCK BACK NEXT

hourmeters are hidden. Refer to the SR-2
Multi-Temp Microprocessor Controller
Diagnostic Manual TK 53080 for information
about programming the controller. ARA831
1 2 3 4
Hourmeters can be viewed in the Hourmeters
Menu as follows: 1. Exit Soft Key 3. Back Soft Key
1. Begin at the Standard Display. 2. Lock Soft Key 4. Next Soft Key
If the Temperature Watch Display is showing, Figure 72: Soft Keys
Display. 6. Press the LOCK soft key to lock the hourmeter
on the display. Press the key again to unlock
2. Press the MENU soft key on the Standard the display.
Display.
7. Press the Exit soft key to return to the
Standard Display. If no keys are pressed
CONTINUOUS
ON
TEMP F
within 30 seconds, the screen will return to the
2
-8 . 35 .8 SET Standard Display.
OFF -10 35 POINT
ZONE 1 ZONE 2 MENU
ARA798

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

1
ARA830
1. Press Select Soft Key

Figure 71: Hourmeters Menu Display
71
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.
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
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
Engine Reminder 2 Hours User Programmable The number of hours before an Engine Run Time
Electric Reminder 1 Hours User Programmable The number of hours before an Electric Run Time
Electric Reminder 2 Hours User Programmable The number of hours before an Electric Run Time
Only configured hourmeters that have been enabled in Viewable Hourmeter Setup Menu will be shown.
72
Mode Menu Sleep Mode

Various operating modes can be selected using the If enabled in Guarded Access, Sleep Mode is used
Mode menu. Not all modes may be available, to keep the engine warm and the battery charged
depending on OptiSet usage and settings of other when the unit is not in use. When the unit is in
programmable features. The following modes Sleep Mode the display will show SLEEP and
may be available. the current time. See Selecting Sleep Mode on
page 77.
Turn CYCLE-SENTRY On or Off
Program Wakeup Time: This feature allows a
The CYCLE-SENTRY Mode can be turned On or wakeup time to be specified. When the
Off. If CYCLE-SENTRY is turned off the unit selected time is reached the unit will start and
runs in Continuous mode. Either resume normal operation.
CYCLE-SENTRY or Continuous operation may
be disabled via OptiSet. See Turning If Wakeup Time is selected:
CYCLE-SENTRY On or Off on page 74. Day to Wake Up: This feature allows the
day the unit is to wake up to be specified.
Single Zone Control - Multi Zone Control
Hour to Wake Up: This feature allows the
If enabled in Guarded Access, Single Zone hour the unit is to wake up to be specified.
Control allows single temperature operation. If
Single Zone Control operation is selected then all Minute to Wake Up: This feature allows
zones will be forced on and will control to the the minute the unit is to wake up to be
same setpoint. All bulkheads should be removed specified.
to create one large compartment. Multi Zone Run Pretrip on Wake Up: This feature
Control allows separate control for each allows a Pretrip Test to be automatically
configured zone. See Operating The Unit In run when the unit wakes up.
Single Zone Control Mode on page 48 and
Selecting Single Zone Control or Multi Zone
Control on page 75 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 76.
73
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 57). But, you can also The CYCLE-SENTRY On/Off Screen will
switch modes in the Mode Menu as follows: appear (see Figure 74).
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
SELECT Key
SELECT Key SELECT Key
Figure 74: Selecting Mode Screen Sequence
74
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 48 and Single
Zone Control - Multi Zone Control on page 73 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
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 77: Single Zone Control On/Off Display
Display.
CONTINUOUS
seconds.
ON
-8 .2 35 .8
TEMP F
SET
-10 35 POINT
OFF
ZONE 1 ZONE 2 MENU

1
Standard Display.
ARA798

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

1
ARA832

Figure 76: Mode Menu Display
75
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 73 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

Display. ARA834

CONTINUOUS
ON
TEMP F Figure 80: Keypad Lockout Display
-8 .2 35 .8 SET
-10 35 POINT
OFF
ZONE 1 ZONE 2 MENU

1
seconds.
ARA798
1. Press Menu Soft Key Standard Display. If no keys are pressed
Figure 78: 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

1
ARA832

Figure 79: Mode Menu Display
76
Selecting Sleep Mode 5. Press the NEXT soft key as required to display
the Sleep Mode Screen.
This feature must be enabled in Guarded Access
to be available. Sleep mode starts and stops the 6. Press the SELECT soft key to start the Sleep
unit as required to keep the unit battery in a mode.
charged condition and keep the unit engine warm
7. You now choose to program a Sleep mode
in cold ambient conditions. Sleep mode does not
Wake-up Time or simply enter Sleep mode
maintain setpoint, it keeps the compartment
immediately. Press the NO soft key to
temperature near the ambient temperature when
immediately enter Sleep mode.
the unit is running. This is useful in extremely
cold weather or when the unit is to be out of a. The display will show SLEEP and the
service for an extended time. unit will start and stop as required to keep
engine warm and/or the battery charged.
Sleep mode operates in both Diesel mode and
Sleep mode does not maintain the
Electric mode. In Diesel mode the unit will start
compartment temperature.
and stop as required to maintain engine
temperature and battery charge. In Electric mode b. Press the EXIT soft key to exit Sleep mode
the unit starts and stops as necessary to maintain or turn the unit off and back on. The unit
battery charge only. will resume normal operation and control
to setpoint.
When Sleep mode is entered, the operator can
program an automatic Wake-up Time up to a week 8. To enter a Wake-up Time verify that the unit
away. Using this feature, the unit will clock is set properly (see Time Display on
automatically restart and run normally at the page 85). Then press the YES soft key at the
determined time. If a Wake-up Time is Program A Wake-Up Time? Screen.
programmed, the operator can also program an
9. Press the + or - soft keys to select the day the
automatic Pretrip Test when the unit restarts.
unit is to restart in normal operation. In this
Select Sleep Mode as follows: example Monday has been chosen. Press the
YES soft key to confirm the day.
If the Temperature Watch Display is showing, 10. The display will now prompt you for the hour
press any soft key to return to the Standard the unit is to restart in normal operation. In
Display. 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.
Display.
11. The display will now prompt you for the
CONTINUOUS
minute the unit is to restart in normal
ON
2 TEMP F operation. In this example 18:37 hours has
-8 . 35 .8
OFF -10 35
SET
POINT been chosen. Press the YES soft key to confirm
ZONE 1 ZONE 2 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
1. Press Menu Soft Key will show the unit is programming the Sleep
mode.
13. The display will show SLEEP and the unit
3. Press the NEXT soft key until the Mode Menu will start and stop as required to keep the
appears. See Figure 82. engine warm and/or the battery charged. Sleep
4. Press SELECT soft key to enter the Mode Menu. mode does not maintain setpoint.
77
14. The unit will restart at the programmed time 15. To exit Sleep mode before the selected
(in this example 18:37 hours) and perform a Wake-up time press the EXIT soft key or turn
Pretrip (if selected). After the Pretrip is the unit off and back on. The unit will resume
complete the test results will be displayed and normal operation and control to setpoint.
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 82: Selecting Sleep Mode Screen Sequence
78
Pretrip Tests Full Pretrip

A Pretrip Test verifies unit operation. The Pretrip A Full Pretrip occurs when Pretrip is initiated
Menu allows the operator to select and initiate a before the engine or electric motor starts running.
Pretrip Test. There are two different Pretrip Tests, The Full Pretrip test proceeds in the order shown
the Full Pretrip and the Running Pretrip. below:
CAUTION: Monitor the return air Amp Checks Each electrical control
temperature when performing a Pretrip component is energized and the current drawn
Test on a loaded trailer. The controller is confirmed to be within specification.
may not maintain setpoints during the Engine or Electric Motor Start The engine or
Pretrip Test. electric motor will start automatically.
Pretrip Test Conditions Defrost If the coil temperature in a zone is
below 45 F (7 C), a Defrost cycle is initiated
Current unit settings such as zones on or off for that zone.
and setpoints are saved and restored at the end
of the Pretrip Test or if the unit is turned off RPM Check (Diesel Mode only) If the unit
and back on. is running in the Diesel Mode, the engine
RPM in high and low speed is checked.
All zones are forced on.
Zone 1 Cool Check The ability of the zone
A Pretrip Test can be run in either Diesel or to cool in low speed is checked.
Electric Mode.
Zone 1 Heat Check The ability of the zone
The unit will auto switch from Diesel Mode to to heat in low speed is checked.
Electric Mode or from Electric Mode to Diesel
Mode during a Pretrip Test if these features Zone 1 Return to Cool Check The ability of
are enabled and the auto switch conditions the zone to return to cool mode is checked.
occur. Zone 2 Cool Check The ability of the zone
to cool in low speed is checked.
Conditions Where Pretrip Tests Are Not
Allowed Zone 2 Heat Check The ability of the zone
to heat in low speed is checked.
Any alarms are present.
Zone 2 Return to Cool Check The ability of
The unit is in Sleep Mode. the zone to return to cool mode is checked.
Unit is in Service Test Mode, Interface Board Zone 3 Cool Check The ability of the zone
Test Mode, or Evacuation Mode. to cool in low speed is checked.
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.
79
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
just been washed down, the extremely high
humidity inside the trailer may result in false
Zone 1 Heat Check The ability of the zone test results.
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
pre-trip operation.
Always perform Pretrip Tests with the trailer
cargo doors closed to prevent false test
failures.
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.
80
Initiating a Pretrip Test 6. The Pretrip display appears.

Before initiating a Pretrip Test, clear all alarm The top line of the display indicates the
codes. unit is performing the non-running (or
running) portion of the Pretrip Test.
To stop a Pretrip Test at any time, turn the unit off.
The second line shows Test 1 of 55 is
Use the following procedure to initiate a Full
being performed. Note that the tests may
Pretrip or a Running Pretrip. A Running Pretrip
not be performed in numerical order.
can also be initiated by starting at step 3 with the
unit running. The soft keys may be used during the
Pretrip Test to select the Hourmeter,
1. If the unit is running, press the OFF key to stop
Gauge, or Sensor menus.
the unit.
To stop a Pretrip Test at any time, turn the
2. Press the ON key to turn the unit on.
unit off. This will generate Alarm Code 28
3. To initiate a Full Pretrip press the MENU soft Pretrip Abort. Other alarm codes may also
key as soon as the Standard Display appears be generated. This is normal when the
and before the unit starts. Pretrip Test is halted before completion.
To initiate a Running Pretrip let the unit start
In a Full Pretrip, when the non-running tests
before pressing the MENU soft key on the
are complete the unit will start automatically
Standard Display.
and continue with the running tests.
CONTINUOUS
7. When all tests are complete, the results are
ON
TEMP F reported as PASS, CHECK or FAIL. If
-8 .2 35 .8
OFF -10 35
SET
POINT FAIL appears, the unit will shut down. If the
ZONE 1 ZONE 2 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
1. Press Menu Soft Key FAIL, the problem should be diagnosed and
corrected and the Pretrip Test repeated and
passed before the unit is released for service.
4. Press the NEXT soft key until the Pretrip Screen The Pretrip Test result screen will exit to the
appears. See Figure 85. Main Menu Alarm Submenu for convenient
access to any alarms generated during the
5. Press the SELECT soft key to start a Pretrip. Pretrip Test.
NOTE: If all alarms were not cleared a
prompt appears as shown below. Press the Stopping a Pretrip Test
EXIT key to exit the Pretrip Test, clear all Turn the unit off to stop a Pretrip Test at any time.
alarms and repeat the Pretrip Test. This will generate Alarm Code 28Pretrip Abort.
Other alarm codes may also be generated. This is
normal when the Pretrip test is stopped before
ON
NO PRETRIP -- ALARM ACTIVE completion.
OFF
EXIT
ARA835
1. Press Exit Soft Key

Figure 84: No Pretrip Alarm Active Display
81
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 85: Pretrip Test Screen Sequence
82
Diesel Mode/Electric Standby Menu 3. Press the NEXT soft key until the Diesel
Mode/Electric Standby Screen appears. See
The Diesel Mode/Electric Standby Menu allows
Figure 88 and Figure 87.
the operator to manually select Diesel Mode or
Electric Standby operation. The unit can also be NOTE: The Electric Standby Screen will not
programmed to automatically select Electric appear if diesel to electric switchover is
Standby operation when standby power is enabled. The Diesel Mode Screen will not
available and Diesel Mode operation if standby appear if electric to diesel switchover is
power fails or is removed. If the unit is enabled.
programmed to switch automatically from diesel
4. Press the SELECT soft key to select the mode
to electric and electric to diesel these screens do
shown on the display.
not appear. Refer to the SR-2 Multi-Temp
Microprocessor Controller Diagnostic Manual
TK 53080 for information about programming the
controller.
NOTE: Manual selection is the default setting
for both Electric Standby and Diesel Mode. SELECT Key
A screen asking if you wish to switch to Electric

Standby will appear if the unit is connected to
standby power when in the Diesel Mode.
A screen asking if you wish to switch to Diesel
Mode will appear if standby power fails or is
disconnected when in Electric Standby. Pressing
the YES soft key will switch unit operation to the
Diesel Mode. Pressing the NO soft key will force
the unit to remain in Electric Standby even though
standby power is not available. The unit will not
Figure 87: Programming Electric Standby Mode
run and Alarm Code 91 Check Electric Ready
Input will be set as a prevent alarm.
Select Electric Standby or Diesel Mode as
follows:
press any soft key to return to the Standard SELECT Key
Display.
Display.
CONTINUOUS
ON
TEMP F
2
-8 . 35 .8 SET
OFF -10 35 POINT
ZONE 1 ZONE 2 MENU
ARA798
Figure 88: Programming Diesel Mode

83
Adjust Brightness Menu 10. Press the Exit soft key to return to the
The brightness of the HMI Control Panel display
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:
Display. + Key

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
3. Press the NEXT soft key until the Adjust

Brightness Menu appears. See Figure 90.
4. Press the SELECT soft key to enter the Adjust
Brightness Menu. See Figure 90.
5. Press the + or - soft keys to select the desired
backlight brightness. See Figure 90. This
example shows changing backlight brightness
from low to medium.
6. Press the YES soft key to enter the new
backlight brightness level. Figure 90: 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.
84
Time Display Loading Procedure

The time and date held by the HMI Control Panel 1. Make sure the unit is turned off before
real time clock can be checked. Time and Date opening the doors to minimize frost
cannot be changed from the Main Menu. The time accumulation on the evaporator coil and heat
and date are changed by programming the gain in the trailer. (Unit may be running when
controller. Refer to the SR-2 Multi-Temp loading the trailer from a warehouse with door
Microprocessor Controller Diagnostic Manual seals.)
TK 53080 for information about programming the
2. Spot check and record load temperature while
controller.
loading. Especially note any off-temperature
View the time and date as follows: product.
1. Begin at the Standard Display. 3. Load the product so that there is adequate
If the Temperature Watch Display is showing, space for air circulation completely around the
press any soft key to return to the Standard load. DO NOT block the evaporator inlets or
Display. outlets.
2. Press the MENU soft key on the Standard 4. Products should be pre-cooled before loading.
Display. Thermo King transport refrigeration units are
designed to maintain loads at the temperature
3. Press the NEXT soft key until the Time Display
at which they were loaded. Transport
appears.
refrigeration units are not designed to pull hot
4. Press the SELECT soft key to view the time and loads down to temperature. Verify that the
date. setpoint temperatures are correct for your
cargo. Pre-cool the trailer as required.
1
CONTINUOUS
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
Procedures
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 48
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 48, the unit is operated
Figure 91: 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.
85
Figure 92 shows two Zones that have the same Post Load Procedure
setpoint. The bulkhead separating the
1. Make sure all the doors are closed and locked.
compartments is in place. Each Zone evaporator
senses temperature and controls to the 2. Start the unit if it was shut off to load (see
temperature setpoint in that Zone. Turning Unit On on page 45).
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
AMA719
Defrost. The microprocessor will terminate
Figure 92: Two Compartments, Same Setpoint Defrost automatically when the evaporator
Temperature, Bulkheads In Place
coil temperature reaches 58 F (14.5 C) or the
In this example, each Zone could be individually unit has been in the Defrost mode for 30 or 45
set to 35 F. The evaporator in each compartment minutes (depending on setting).
will then control the temperature in that
compartment to the same 35 F setpoint. Post Trip Checks
NOTE: Using the above method, it is 1. Wash the unit.
recommended that the bulkheads that separate 2. Check for leaks.
each compartment be in place to isolate the
compartments. 3. Check for loose or missing hardware.
Using Method 2 on page 48, Single Zone 4. Check for physical damage to the unit.
Control Mode has been enabled in the Guarded
Access/Main Menu Configuration menu.
Figure 93 shows two Zones that have the same
setpoint. The bulkhead separating the
compartments has been removed. The Host
evaporator senses temperature and controls both
evaporators to the temperature setpoint.
AMA720
Figure 93: 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.
86
Electrical Maintenance
Alternator Charging System The excitation circuit (EXC circuit) must

Diagnostic Procedures supply voltage to the excite terminal of the
alternator.
General Information The sense circuit (2 circuit) must supply
Poor charging performance may not be caused by voltage to the sense terminal of the alternator.
a bad alternator. The following conditions can The alternator must be properly grounded.
cause improper battery charging, even with a
good alternator. (See Service Bulletin T&T 388 The unit control circuits or installed
for more information.) accessories may be drawing excessive current.
A problem may exist in the 2A output circuit An overcharged battery is usually caused by a
from the alternator to the battery. Check for an defective voltage regulator.
open 2A circuit, loose connections, defective
battery cables or dirty battery terminals. Alternator Identification
The battery must be in good condition and Model 30 units use Thermo King Alternators
capable of accepting a charge. Check for a (see Figure 94), which are painted black.
damaged battery, correct electrolyte level, and Model 50 units use Prestolite Alternators (see
loose or corroded connections. Figure 95), which have a label that states
The alternator charging output will be low if Made in USA.
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.
1 2
3
4
5
7
6
1. B+ Terminal (Positive Output - 2A Wire) 5. F2 Terminal (Do Not Ground)

2. B- Terminal (Negative Ground - CH Wire) 6. Voltage Regulator and Brush Assembly
3. S Terminal (Regulator Sense - 2 Wire) 7. W Terminal (AC Output)
4. L Terminal (Regulator Excite - 7K Wire)
Figure 94: Thermo King Alternator Terminal and Component Locations
87
1 3
6 5
AGA219
1. EXC Terminal 5. NEGB- Terminal

2. F2 Terminal 6. POSB+ Terminal
3. VOLT SENSE Terminal 7. REGD+ Terminal
4. AC TAP Terminal
Figure 95: Prestolite Terminal Locations
Interface Board Fuse F4 Test Equipment for Checking

The interface board has a 300 ohm resistor and a Voltage and Current
resistor bypass fuse (F4) in the alternator Always use accurate test equipment such as the
excitation circuit. The fuse and resistor are Fluke 23 Digital Multi-Meter and the Fluke
connected in parallel and are located on the Clamp-On Ammeter accessory when checking
interface board. Removing the resistor bypass alternator circuit voltage and amperage. See the
fuse places the 300 ohm resistor in the excitation table below for Thermo King service parts
circuit as required for Thermo King alternators numbers. Be sure voltages are measured from the
(and Australian Bosch alternators). Installing the designated terminal to the alternator chassis
resistor bypass fuse removes the 300 ohm resistor ground. All voltages are DC voltages unless
from the excitation circuit as required for otherwise noted.
Prestolite alternators. See the specific unit wiring
diagram for exact details. Service
Meter Part
NOTE: The F4 fuse must be removed from the Number
interface board on units equipped with Thermo Fluke 23 Digital Multi-Meter 204-1079
King alternators. The voltage regulator on the
Clamp-On Ammeter for above Meter 204-947
Thermo King alternators will be damaged if the
unit is turned On with the F4 fuse in place on
the interface board.
88
Alternator Load Test NOTE: All voltage readings should be taken

between the chassis ground on the alternator
Thermo King no longer recommends a full field
and the terminals indicated, unless stated
test for determining the alternator current output.
otherwise.
Full fielding an alternator can cause increases in
alternator output voltage that may damage internal 4. Check that the resistor bypass fuse (F4).
alternator or unit components. This damage may
Model 30 units with Thermo King alternators
not be readily apparent.
must have the resistor bypass fuse (F4)
To test the alternator under load, Thermo King removed.
recommends the use of a clamp-on ammeter to
Model 50 units with Prestolite alternators
monitor output current, both on initial startup and
must have the resistor bypass fuse (F4)
under full unit load conditions. For example, on
installed.
multi-temp units, all remote evaporators should be
turned on. CAUTION: Energizing the circuit with
the resistor bypass fuse installed will
General Diagnostic and Warranty damage Thermo King alternators. Be sure
Evaluation Procedure the resistor bypass fuse is removed for
Complete the following diagnostic procedures Thermo King alternators.
before replacing an alternator or the voltage 5. Check and note the battery voltage at the
regulator. battery with the unit turned off.
1. When testing an alternator, use accurate 6. With the unit off, check the voltage at the B+
equipment such as a Thermo King P/N terminal on the alternator. Battery voltage
204-1079 digital multimeter and a Thermo must be present. If not, check the 2A circuit.
King P/N 204-947 amp clamp or an
equivalent. 7. Disconnect the alternator harness from the
voltage regulator. On Thermo King
2. Make sure the drive belts and pulleys of the alternators, carefully push on the spring clip to
charging system are in good condition and are release the plug lock.
adjusted properly before testing the alternator.
Be sure the pulleys are the correct size. Worn 8. Turn the unit on and enter Non-Running
belts, loose belts and worn or improperly sized Service Test Mode. Place the unit in Zone 1
pulleys will lower the output of the alternator. Cool. Refer to the appropriate Diagnostic
Manual for information about the Service Test
3. The battery must be charged and in good Mode.
condition, the battery cable connections must
be clean and tight, and the 2A, 2 (sense), and 9. Check the voltage at the sense circuit (2
EXC (excitation) circuits must be connected circuit). Battery voltage should be present. If
properly. All charging circuit connections not, check the sense circuit (2 circuit) in the
must be clean and secure. If the unit battery is alternator harness and in the main wire
questionable, a known good jumper battery harness.
should be substituted for alternator testing. 10. Check the voltage at the excitation circuit
NOTE: If the unit battery is questionable, a (EXC circuit). 10 Vdc or more should be
known good jumper battery should be present. If not, check the excitation circuit
substituted for alternator testing. (EXC circuit) in the alternator harness and in
the main wire harness.
NOTE: Do not perform this test with a
battery charger connected to the unit battery. 11. Turn the unit off and reconnect the alternator
harness.
89
12. Attach a clamp-on ammeter around the 2A 16. If the voltage does increase until it reaches the
wire connected to the B+ terminal on the anticipated voltage regulator setting, compare
alternator. All wires connected to the B+ the voltage at the B+ terminal to the voltage
terminal must pass through the clamp-on between the battery terminals. The voltage at
ammeter. the B+ terminal should be no more than 1.0
Vdc higher than the voltage between the
13. Connect a digital multi-meter between the B+
battery terminals.
terminal at the alternator and chassis ground.
If the voltage at the B+ terminal is no more
14. Turn the unit on and allow it to start. Using the
than 1.0 Vdc higher than the voltage between
clamp-on ammeter, check the current flow in
the battery terminals, continue with Step 17.
the 2A wire.
If the voltage at the B+ (POS) terminal is
A positive reading indicates the alternator is
more than 1.0 Vdc higher than the voltage
charging. On unit startup, the current flow
between the battery terminals, clean and check
should momentarily increase to allow for
the wires and connections in the 2A and 2
battery current used during preheat and
circuits and repeat this check.
cranking. Within a short time the current
should fall to normal unit load plus charge 17. Increase the charging system load as much as
current to the unit battery (typically 5-10 possible by running all zones.
amps).
18. Monitor the alternator output voltage.
A reading on the clamp-on ammeter at or near
With the increased load, the alternator output
0 amps indicates the alternator is not charging.
voltage should decrease no more than 0.5 Vdc.
Checking the unit ammeter will show a
The voltage may increase as much as 1.0 Vdc.
discharge condition. The alternator is
If the alternator output voltage decreases no
defective if there are no problems in the
more than 0.5 Vdc the alternator is good.
wiring. Recheck the wiring before assuming
the alternator is defective. If the alternator output voltage decreases more
than 0.5 Vdc, the alternator is defective if
15. Check the voltage at the B+ terminal. The
there are no problems in the wiring. Recheck
voltage should increase until it reaches the
the wiring before replacing the alternator.
anticipated voltage regulator setting as shown
in the table below. Record the voltage. Alternator Diode Quick Check:
The voltage regulator setting varies inversely This check confirms proper diode function.
with the temperature as shown below. 19. With the unit still running, set the digital
Regulator voltage can vary from multi-meter connected from the alternator B+
approximately 15.2 Vdc at -40 F (-40 C) to output to chassis ground for AC volts. No
approximately 13.2 Vdc at 176 F (80 C). more than 1.0 Vac should be present. A
Temperature Anticipated Regulator Voltage
reading of more than 1.0 Vac indicates
damaged alternator diodes.
-40 F (-40 C) From 15.2 Vdc to 14.0 Vdc
20. Turn the unit off.
77 F (25 C) From 14.4 Vdc to 13.6 Vdc
176 F (80 C) From 14.2 Vdc to 13.2 Vdc
Field Current Test
If the voltage does not increase to the Use this test to determine if the alternator can be
anticipated voltage regulator setting, the repaired. Perform this test with the unit turned off.
alternator is defective if there are no problems 1. Attach a clamp-on ammeter to the 2A wire
in the wiring. Recheck the wiring before near the B+ terminal on the alternator.
replacing the alternator.
2. Energize the field:
90
On the Thermo King alternator, connect a Fuses

jumper wire between the F2 terminal and
the B+ terminal. Do not connect the F2 A number of fuses, located on the interface board,
terminal to ground or the alternator will be protect various circuits and components. The
damaged. interface board is located inside the control box.
Refer to the SR-2 Microprocessor Controller
On the Prestolite alternator, connect a Diagnostic Manual TK 53080 for a complete list
jumper wire between the F2 terminal on of the size and function of the fuses.
the alternator and a chassis ground.
Fuse Size Function
3. Note the ammeter reading. The ammeter
F2 15A Power to On/Off Switch
reading indicates the field current, which
should be 2.0 to 6.0 amps at 12 volts. F3 40A Fuel Sol Pull-In/Starter Circuit
None No Fuse - All Bosch and Thermo
No field current or a low field current F4 King Alternators
indicates an open circuit or excessive 2A 2A Fuse - All Prestolite Alternators
resistance in the field circuit. Remove the F5 60A Preheat Circuit
voltage regulator and brush assembly and F6 15A Damper and High Speed Circuits
inspect the slip rings. If the slip rings and
8XP Circuit - Controller On Feedback
are acceptable, install a new voltage F7 2A
to HMI
regulator and brush assembly and repeat
F8 5A CAN Connector J12
the test. If the brushes are not the problem,
F9 5A CAN Connector J14
replace the alternator.
8X Power (Install fuse in upper
High field current indicates a short in the F10 10A
position)
field circuit. Replace the rotor or the F11 10A Zone 1 LLS
alternator. F12 5A CAN Connector J13
F13 2A 8FC Circuit (Remote Lights)
Battery F15 P/S On/Off Relay
Inspect/clean the battery terminals and check the F20 2A Alternator Sense
electrolyte level during scheduled maintenance F22 Not Used
inspections. A dead or low battery can be the F23 Not Used
cause of an ammeter indicating discharge due to
F25 7.5A HPCO/Run Circuit
lack of initial excitation of the alternator even
F4 Remove fuse F4 for Model 30 units with Australian
after the unit has been boosted for starting. The
Bosch or Thermo King Alternators. Install fuse F4 for
minimum specific gravity should be 1.235. Add Model 50 units with Prestolite Alternator.
distilled water as necessary to maintain the proper
F5 The F5 preheat fuse is a slow blow type. It is
water level. designed for use with the Yanmar engine air heater.
Always replace the fuse with the TK specified fuse.
Battery Cables F10 When fuse F10 is installed in the upper position
the On/Off keys on the HMI turn the unit on and off.
Units with Tier 2 engines use 0-gauge battery When fuse F10 is installed in the lower position the
cables to ensure reliable starting in extremely cold unit will start and run without the HMI control panel.
weather. Make sure to use the 0-gauge battery F15 The device identified as F15 is a poly switch.
cables when replacing the battery cables for a Tier These over-current devices reset automatically and
2 engine. Refer to the unit Parts Manual for the are not replaceable.
correct part numbers.
91
Interface Board LED Functions (Continued)

LED # Function
Status Flashes once per second when
the base controller is powered and
operating normally. Flashes several times
per second when flash loading. Is on
LED 21
without flashing during reboot and when
under test. Flashes twice within 1 second
followed by 1 second off if a CAN
communication error is present.
LED 22 Zone 1 Liquid Line Solenoid
LED 23 K9 On/Off Circuit
LED 24 K6 Fuel Solenoid Pull-In Circuit
LED 25 K7 Starter Circuit
LED 26 Future Use
LED 27 ETV (Not Used)*
* May be illuminated even though the ETV outputs
are not used.
Figure 96: Interface Board
Smart FETs
Interface Board LEDs A Smart FET (Field Effect Transistor) is a self
The interface board has LEDs that indicate which protecting device. Smart FETs halt current flow if
outputs are energized. The LED is illuminated an overcurrent condition exists, and resume
when the associated circuit output is energized. normal operation when current flow is within
limits. Smart FETs are not field repairable. Refer
Interface Board LED Functions to the SR-2 Microprocessor Controller Diagnostic
LED # Function Manual TK 53080 for more information about the
LED 3 K2 Preheat Circuit Smart FETs.
LED 4 K4 Damper Circuit Smart FETs are used to protect the circuits in the
LED 5 K3 High Speed Circuit expansion module.
LED 6 K1 Run Relay Circuit Smart FETs are also used to protect the interface
LED 7 K5 Diesel/Electric Relay board outputs listed in the following table.
LED 8 Condenser Inlet Solenoid Circuit
Interface Board Outputs With Smart FETs
LED 9 Receiver Tank Pressure Solenoid Circuit
Output Function
Hot Gas Bypass Valve Circuit / Loader
LED 10 ALPC Alarm Light
Valve 2 (Not Used)
LED 11 Purge Valve Solenoid Circuit ALM Alarm Light
LED 17 Loader Valve 1 (Not Used) EXC Alternator Excite
LED 18 Alternator Excite CIS Condenser Inlet Solenoid
LED 19 Liquid Injection Valve Circuit (Not Used) Receiver Tank Pressure
RTPS
Solenoid
LED 20 Water Valve (Not Used)
PV Purge Valve
92
Expansion Module 1
The expansion module allows the addition of up
to two additional temperature controlled zones.
The module provides the interface between the
base controller and the Zone 1, Zone 2, and Zone
3 (if used) multi-temperature components such as
sensors, solenoids, valves, and fan motors. It also
uses Smart FETs to provide overcurrent and short
circuit protection for the associated circuits.
All engine functions and some host unit valves are
controlled by the base controller. This includes the
receiver tank pressure solenoid (RTPS), purge
valve (PV) and condenser inlet solenoid (CIS). In
addition the liquid line solenoid for Zone 1 (LLS)
is controlled directly from the base controller. All
other Zone 1 devices and all remote evaporators
are controlled by the expansion module. 1. Expansion Module LEDs
Load power is supplied by the 2A wires to the Figure 97: Expansion Module
expansion module via two terminal studs. Power
from the 8X circuit in the base controller is Expansion Module LEDs
supplied to the expansion module via the YEL
The expansion module has LEDs that indicate
wire in the 8 pin connector. The expansion
which outputs are energized. These LEDs are
module communicates with the base controller via
located in the corner of the expansion module
a CAN bus connection. All remote zone input and
body and are defined in the following table. An
solenoid output functions are connected via the
LED is illuminated when its associated circuit
expansion module 35 pin connector harness.
output is energized. The circuit outputs are
Remote evaporator fan motor outputs are
protected by Smart FETs. All the LEDs are red,
provided for 6 variable speed remote fan motors.
except LED 16, which is green.
Each output is capable of operating two fans.
There are no user replaceable components on the Expansion Module LED Functions
expansion module. Refer to the SR-2 LED # Function
Microprocessor Controller Diagnostic Manual TK Fan 1 (Zone 2 Damper Solenoid on DE
LED 1
53080 for more information about the Expansion Units)
module. LED 2 Fan 3
LED 3 Fan 5
LED 4 Fan 2
LED 5 Fan 4
LED 6 Fan 6
LED 7 Zone 1 Drain Tube Heater (Not Used)
LED 8 Zone 2 Drain Tube Heater
LED 9 Zone 3 Drain Tube Heater
LED 10 Zone 1 Hot Gas Solenoid
LED 13 Zone 1 Suction Line Solenoid
93
Expansion Module LED Functions (Continued) SMART REEFER 2 Multi-Temp

LED # Function (SR-2 MT) Microprocessor
Status Flashes once per second when Controller
the base controller is powered and
operating normally. Flashes several time Refer to the SR-2 Multi-Temp Microprocessor
per second when flash loading. Is on Controller Diagnostic Manual TK 53080 for
LED 16 without flashing during reboot and when complete service information about the
under test. Microprocessor Controller and the related
Flashes twice within one second followed components.
by one second off if a CAN
communication error is present
Fuse Link
LED 17 Zone 2 Liquid Line Solenoid
LED 18 Zone 3 Liquid Line Solenoid 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.
1
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.
1. Green Status LED (All other LEDs are Red)

Check the resistance of the air intake heater with
an ohmmeter between the M6 terminal on the
Figure 98: Expansion Module LEDs 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.
94
AC Components (Model 50
Units Only)
CAUTION: Model 50 units use high
voltage ac for electric standby operation.
Lethal voltage potentials can exist on
connections in the high voltage box. Take
appropriate precautions and use extreme
1 care when testing the unit.
AEA693
Electrical Contactors
1. M6 Terminal
Periodically inspect all contactor points for pitting
Figure 99: Air Heater
or corrosion and repair or replace as necessary.
Test the contact points by checking the voltage
Unit Wiring drop across each set of points when the contactor
Inspect the unit wiring and the wire harnesses is energized and the system is operating. If the
during scheduled maintenance inspections for voltage drop across a set of points is more than 15
loose, chaffed or broken wires to protect against Vac, replace the contact points as a set.
unit malfunctions due to open or short circuits. Test the contactor coil by checking the voltage
across the coil. The contactor coil should be
Wire Harness Routing energized by a minimum of 10 Vdc.
The wire harness is routed in front of the starter
on the TK486V (Tier 2) engine. The wire harness Evaporator Heaters
is attached to a harness routing bracket, which is Test the resistance of each evaporator heater by
attached to the starter. disconnecting it from the circuit and checking it
with an ohmmeter. The resistance of each host
1 2 evaporator heater should be approximately
122 ohms.
Auto Phase System

The Auto Phase system automatically adjusts the
phase sequence of the power supply to correspond
with the wiring of the electric motor. The main
components of the system are the phase selection
module (PSM), and the two motor contactors
(MC1 and MC2). Contactor MC1 is wired to
retain the phase sequence. Contactor MC2 is
wired to change the phase sequence. The PSM
1. Wire Harness In Front Of Starter senses the phase sequence at the heater contactor
and energizes the appropriate motor contactor.
2. Harness Routing Bracket
Figure 100: Wire Harness Routing Troubleshooting the Auto Phase System
If the electric motor runs backwards (unit airflow
incorrect):
1. Turn the electric power supply Off and check

the unit wiring. See the appropriate wiring
diagrams, schematics, and Figure 101.
95
a. The three wires from the PSM should be If the electric motor does not run at all:
connected to the heater contactor terminals 1. Make sure that the unit is turned On, that
as follows: Brown wire to terminal L1, Electric Standby has been selected in the
Blue wire to terminal L2, and Black wire Operator Menu, and that the power supply is
to terminal L3. connected and turned On.
b. Wires L1, L2, and L3 should be connected 2. Check the CH wire to the PSM for continuity
respectively to terminals L1, L2, and L3 to the CH circuit (chassis ground). If there is
on the heater contactor and both motor no continuity to the CH circuit, check the CH
contactors. wire for continuity.
c. Wires T1A, T2A, and T3A should be 3. Check for battery voltage (12 volts) at the
connected respectively to terminals T1, 7EA wire to the PSM. Battery voltage should
T2, and T3 on MC1. be present. If not, check the 7E circuit, the
d. Wires T1A, T2A, and T3A should be diesel/electric relay (K5), the run relay (K1),
connected respectively to terminals T3, the HPCO circuit, the HPCO switch, the
T2, and T1 on MC2. PHPCO circuit, the F1 fuse, the 8 circuit, the
Microprocessor On/Off switch, the 2AB
e. Wires T1A, T2A, and T3A should be circuit, the F2 fuse, the RED circuit, the fuse
connected respectively to terminals L1, link, and the battery. Also make sure that the
L2, and L3 on the overload relay. microprocessor display is on and that the
f. Wires T1 & T7, T2 & T8, and T3 & T9 microprocessor is calling for Heat or Cool.
should be connected respectively to 4. Check for battery voltage at the 7EB and 7EC
terminals T1, T2, and T3 on the overload wires at the PSM. Battery voltage should be
relay. present on one of these wires when the correct
g. Wires Black, Blue, and Brown should be AC voltage is present on L1, L2, and L3. If
connected respectively to terminals 3, 4, battery voltage is not present, the PSM is
and 5 in the power receptacle. faulty.
h. Wires Brown, Blue, and Black should be 5. Check for battery voltage at the 7EB terminal
connected respectively to terminals L1, on MC1 and at the 7EC terminal on MC2.
L2, and L3 on MC1. Battery voltage should be present at one of
these terminals. If not, check the continuity of
i. The 9-pin wire connector between the the 7EB and 7EC wires.
PSM and the wire harness should be clean
and tight. 6. Check the continuity of the RED wires on the
motor contactors. The RED wires must have
j. The electric motor must be wired continuity.
correctly.
7. Check the CH circuit at MC1 and MC2 for
2. Check MC1 and MC2 to make sure that one of
continuity to a chassis ground. If the CH
them is not faulty (contacts stuck closed).
circuits do not have continuity to a chassis
3. If all of the wiring is correct, and the relays ground, check the CH wires.
and contactors are acceptable, but the electric
8. Check the continuity of the BLK wires on the
motor still runs backwards, switch the Brown
motor contactors. The BLK wires must have
wire and the Black wire from the PSM at the
continuity.
heater contactor: Black to L1, Blue to L2, and
Brown to L3. If the electric motor now runs 9. If the CH circuits and BLK wires do have
correctly, it is probably wired incorrectly. continuity to CH, the contactor that has
battery voltage present at 7EB (MC1) or at
7EC (MC2) is faulty.
96
1
2
1. Overload Relay
2. HCHeaters Contactor
3. PSMPhase Selection Module
4. MC2Motor Contactor
5. MC1Motor Contactor
Figure 101: High Voltage Tray
97
98
Engine Maintenance
EMI 3000 Engine Oil Change

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

The TK486 family of engines use a pressure Oil pressure is affected by oil temperature, oil
lubrication system. Refer to the TK482 and viscosity, and engine speed. Low oil pressure can
TK486 Engine Overhaul Manual TK 50136 for a usually be traced to the lack of oil, a faulty oil
detailed description of the engine lubrication pressure regulating valve, or worn bearings. Low
system. oil pressure is not normally caused by a faulty oil
pump. Use the Low Oil Pressure Flow Chart on
the following page to help diagnose low oil
pressure.
99
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
100
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 102: ELC Nameplate
Located On Expansion Tank
This provides the following:
The following are the Extended Life Coolants
1. Prevents freezing down to -30 F (-34 C). currently approved by Thermo King for use in
2. Retards rust and mineral scale that can cause ELC units for five years or 12,000 hours:
engine overheating. Chevron Dex-Cool
3. Retards corrosion (acid) that can attack Texaco ELC (nitrite free)
accumulator tanks, water tubes, radiators and
core plugs. Havoline Dex-Cool (with nitrates)
4. Provides lubrication for the water pump seal. Havoline Dex-Cool (nitrite free)
Shell Dexcool
ELC (Extended Life Coolant)
Shell Rotella
ELC has been phased into all trailer units
equipped with engines from the TK486 engine Havoline XLC (Europe)
family. A nameplate on the coolant expansion Saturn/General Motors Dex-Cool
tank identifies units with ELC.
Caterpillar ELC
NOTE: The new engine coolant, Texaco
Extended Life Coolant, is RED in color instead Detroit Diesel POWERCOOL Plus.
of the current GREEN or BLUE-GREEN
CAUTION: Do not add GREEN or
colored coolants.
BLUE-GREEN conventional coolant to
cooling systems using RED Extended
Life Coolant, except in an emergency. If
conventional coolant is added to Extended
Life Coolant, the coolant must be changed
after 2 years instead of 5 years.
101
Engine Maintenance
NOTE: The use of 50/50 percent pre-mixed changing the antifreeze. Change ELC (red) engine
Extended Life Coolant (ELC) is recommended to coolant every five years or 12,000 hours
assure that de-ionized water is being used. If 100 (whichever occurs first).
percent full strength concentrate is used,
Do not mix green or blue-green engine coolant
de-ionized or distilled water is recommended
with ELC (red) engine coolant. See ELC
over tap water to insure the integrity of the
(Extended Life Coolant) on page 101 for more
cooling system is maintained.
information about ELC.
Antifreeze Maintenance Procedure The factory recommends the use of a 50/50
antifreeze mixture in all units even if they are not
As with all equipment containing antifreeze,
exposed to freezing temperatures. This antifreeze
periodic inspection on a regular basis is required
mixture will provide the required corrosion
to verify the condition of the antifreeze. Inhibitors
protection and lubrication for the water pump.
become worn out and must be replaced by
1 2
4
3
6 7
1. Expansion Tank 5. Water Pump

2. Expansion Tank Cap 6. Coolant Hoses to Cold Start Device on Injection Pump
3. Coolant Level Switch 7. Thermostat
4. Radiator 8. Thermostat Housing
Figure 103: Engine Cooling System
102
Engine Maintenance
Checking the Antifreeze 7. If using ELC concentrate, mix one gallon of

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

1. Run the engine until it is up to its normal System
operating temperature. Stop the unit. Jiggle pin thermostats are original equipment on
units that have engines from the TK486 engine
2. Open the engine block drain (located behind
family. Jiggle pin thermostats make it unnecessary
the starter) and completely drain the coolant.
to bleed the air out of the engine block because
Observe the coolant color. If the coolant is
they keep air from being trapped in the engine
dirty, proceed with a, b, and c. Otherwise go
block. Normally, all but about 1.5 qt (1.4 liters) of
to 3.
coolant drain out of the cooling system when it is
CAUTION: Avoid direct contact with hot drained. If approximately half of the Cooling
coolant. System Capacity (see Specifications Chapter)
seems to fill the cooling system after it has been
a. Run clear water into the radiator and allow drained, air has been trapped in the block. Bleed
it to drain out of the block until it is clear. the air out of the block using the following
procedure:
b. Close the block drain and install a
commercially available radiator and block CAUTION: If you suspect that air is
flushing agent, and operate the unit in trapped in the block, do not start the
accordance with instructions of the engine without bleeding the air out of the
flushing agent manufacturer. block.
c. Open the engine block drain to drain the NOTE: If an engine runs with air trapped in the
water and flushing solution. block, the engine may be damaged. The high
water temperature switch may not protect an
CAUTION: Avoid direct contact with hot engine that has air trapped in the block, because
coolant. the high water temperature switch is designed to
protect an engine from overheating due to
3. Run clear water into the radiator, and allow it
failures in the cooling system.
to drain out of the block until it is clear.
1. Loosen the plug on the back of the water
4. Inspect all hoses for deterioration and hose
pump below the thermostat cover until coolant
clamp tightness. Replace if necessary.
comes out of the plug fitting.
5. Loosen the water pump belt. Check the water
2. Tighten the plug.
pump bearing for looseness.
3. Pour coolant into the system until it appears to
6. Inspect the radiator cap. Replace the cap if the
be full.
gasket shows any signs of deterioration.
103
Engine Maintenance
4. Make sure that the amount of coolant that NOTE: Figure 104 shows the expansion tank in
goes back into the system is approximately two pieces. The two pieces are bonded together
equal to the amount of coolant that came out when the tank is assembled, so it cannot be
of the system. disassembled, but the coolant level switch can be
replaced.
5. Start the unit on low speed heat, let it run for
two minutes, and then shut it off.
Testing the Coolant Level Switch
6. Check the coolant level and add coolant if
You can test the switch in the unit by adjusting the
necessary.
coolant level. You can also remove the expansion
7. Repeat steps 5 and 6 until the coolant level tank from the unit and test the switch by flipping
stabilizes. the expansion tank upside down and right side up.
1. Remove the wire harness connector from the
Engine Thermostat coolant level switch.
For the best engine operation, use a 160 F (71 C)
2. Use an ohmmeter to check the continuity of
thermostat year-round.
the switch at the connection pins.
Coolant Level Switch 3. Make sure the coolant level is above the
switch and check the continuity of the switch.
The plastic expansion tank uses a reed type
The switch should be closed. If you removed
coolant level switch. The coolant level switch
the tank from the unit, do this check with the
senses the position of the magnetic float inside the
tank upside down.
expansion tank. When the coolant level is above
the switch, the float is in the upper position and 4. Drain coolant from the expansion tank until
the switch is closed. When the coolant level is the coolant level is well below the switch and
below the switch, the float is in the lower position check continuity of the switch. The switch
and the switch is open. 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 2
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
1. Coolant Level Switch with a new one if the float is stuck or does not
2. Float move with the coolant level.
Figure 104: Plastic Expansion Tank
104
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 107: 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 105: 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 108: Expansion Tank
Figure 106: Coolant Level Switch
105
Engine Maintenance
8. Refill the expansion tank with coolant (after Injection pump leakage, injection nozzle overflow
installing the expansion tank if it was and excess fuel from the fuel filter orifice are then
removed). all sent back to the fuel tank in the return line.
9. Connect the wire harness connector to the
coolant level switch. Fuel Line Routing
The fuel lines inside the unit are installed and
Engine Fuel System routed at the factory. The fuel lines from the fuel
tank connect to the fittings on the bottom of the
TK486V engines use a mono-plunger and unit frame. Do not change the factory routing of
distributor injection pump. the fuel lines inside the unit. See the fuel line
The components of the fuel system are: routing diagrams in the Diagrams Chapter.
Fuel tank Maintenance

Inlet strainer (prefilter) The injection pump and fuel transfer pump are
Priming pump relatively trouble-free and if properly maintained
will usually not require major service repairs
Fuel transfer pump between engine overhauls.
Fuel filter/water separator Contamination is the most common cause of fuel
Injection pump system problems. Therefore, to ensure best
operating results, the fuel must be clean and fuel
Trochoid feed pump tanks must be free of contaminants. Change the
Injection nozzles fuel filter/water separator regularly and clean the
prefilter on the inlet side of the fuel transfer pump.
The priming pump is used to manually draw fuel
from the tank up to the fuel pump if the unit NOTE: The injection nozzles should be tested
should run out of fuel. (and repaired if necessary) at 10,000 hour
intervals when used in normal conditions.
Normal conditions are considered to be the use
Operation
of clean high quality fuel, no used oil blending,
Fuel is drawn from the fuel tank and through the and regular maintenance of the fuel system
prefilter by the fuel transfer pump. The fuel according to the Maintenance Inspection
transfer pump delivers fuel to the fuel filter/water Schedule. Refer to the TK482 and TK486
separator. Two orifices in the filter head control Overhaul Manual TK 50136 for injection nozzle
the pressure in the fuel system by allowing a testing and repair procedures.
certain amount of fuel to return to the tank. One
orifice is located in the center of the filter head. It Whenever the fuel system is opened, take the
bleeds off water. The other orifice is located following precautions to prevent dirt from
off-center on the filter head. It bleeds off air. entering the system:
Filtered fuel passes through a line from the outlet 1. Cap all fuel lines.
fitting on the filter base to the injection pump.
2. Work in a relatively clean area whenever
The injection pump forces the fuel, at a very high possible.
pressure, through the injection nozzles. The
injection nozzles atomize the fuel as it is injected 3. Complete the work in the shortest possible
directly into the combustion chambers. time.
106
Engine Maintenance
Any major injection pump or nozzle repairs 4. Fuel transfer pump replacement or repair.
should be done by a quality diesel injection
5. Injection line replacement.
service shop. The necessary service equipment
and facilities are not found in most engine rebuild 6. Engine speed adjustments.
shops because of the large investment required.
7. Injection pump timing.
The following procedures can be done under field
8. Nozzle spray pattern testing and adjustment.
conditions:
9. Injection nozzle testing, adjustment, and
1. Bleeding air from the fuel system.
minor repair.
2. Fuel tank and filter system maintenance.
10. Trochoid feed pump replacement.
3. Priming pump (hand) replacement or repair.
1 2
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 109: Fuel System
107
Engine Maintenance
Fuel Return Line Replacement 2. Discard the old clamps, end cap, and fuel
return lines.
The fuel return lines (hoses) and end cap on the
fuel injection nozzles should be changed every 3. Install the end cap and clamp. Note that the
10,000 engine operating hours. The return line kit end cap has a larger OD than the other hoses
(P/N 10-368) contains new return lines, clamps, and requires the larger clamp.
an end cap, and a decal like the one shown below.
4. Install the fuel return lines and clamps. It may
The decal is located near the unit serial plate. The
be necessary to adjust the banjo fitting slightly
date and engine hours must be entered on the
to obtain the straightest routing for the long
decal when the fuel return lines are changed.
return line.
5. Be sure all the fittings are tight and check for
leaks.
6. Write the date and engine hours on the decal.
Figure 110: Fuel Return Line Replacement Decal
Bleeding the Fuel System
Use the following procedure to replace the fuel
If the engine runs out of fuel, repairs are made to
return lines and end cap.
the fuel system, or if air gets into the system for
1. Remove the clamps, the end cap, the short fuel any other reason, the air must be bled out of the
return lines between the injection nozzles, and fuel system.
the long fuel return line from the injection NOTE: MAKE SURE the fuel tank vent is kept
nozzle to the banjo fitting on the injection open. If the vent becomes clogged, a partial
pump. vacuum develops in the tank, and this increases
1 the tendency for air to enter the system.
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 112: 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 111: Fuel Return Line Replacement
108
Engine Maintenance
1
2. Remove the drain plug from the bottom of the
fuel tank.
NOTE: Some fuel tanks have a check valve in
the drain plug fitting. Push the check valve open
with a small screw driver to drain the tank.
3. Let the water and fuel drain into the container
until no water is visible in the fuel draining
from the tank. If the water and fuel do not
drain freely, the vent may be plugged. If so,
clean or replace the vent.
4. Install the drain plug.
2
Fuel 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 113: 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 114: Filling Fuel Filter/Water Separator
109
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 115: 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.
110
Engine Maintenance
Injection Pump Timing

2
Use this timing procedure when installing a new
1
injection pump. It is not necessary to use this
timing procedure when removing and reinstalling 3
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. Index Mark on Injection Pump
2. Existing Index Mark on Gear Case
1. Before removing the old injection pump, note
3. Make New Mark on Gear Case If Needed
the alignment of the index marks on the
injection pump and the gear case. The index Figure 118: Marking Gear Case
mark on the injection pump is usually aligned
with the index mark on the gear case. If not, 2. Clean the area with brake cleaner or
make a mark on gear case in line with the something similar. Place an injection angle
index mark on the injection pump (see Figure sticker on the gear case so the center line on
118). 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 116: Index Mark Location Figure 119: 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 117: Index Mark Alignment Figure 120: Injection Angle Sticker
111
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 114).
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 122: 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 123: Injection Angle Mark
1. Do Not Loosen or Remove These Four Bolts NOTE: If you cannot read the injection angle
2. Remove Nut and Lock Washer mark, contact Yanmar (e-mail both Koichi
Figure 121: Removing Injection Pump Gear Sawada at koichi_sawada@yanmar.co.jp and
Hisashi Hamada at
4. Record the injection angle marked on the old hisashi_hamada@yanmar.co.jp) with the
injection pump (see the following injection pump serial number or the engine
photographs). The injection angle mark is serial number and they will provide the injection
located on the side of the pump facing the angle. The injection pump serial number is
engine. The injection angle mark on the pump located on the bottom of the sticker on the
does not use a decimal point. Add a decimal injection pump.
point before the last digit of the injection
angle mark to get the injection angle. The
injection angle mark in the following
1
photographs is 67. That equals an injection
angle of 6.7 degrees.
Examples
Injection Angle Mark Injection Angle
67 6.7 Degrees
85 8.5 Degrees 1. Injection Pump Serial Number
Figure 124: Injection Pump Serial Number Location
112
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 126: 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 125: 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 127: Align Flat Sides of Crankshaft Gear
when aligning the timing marks. with Flat Sides of Inner Rotor in Timing Gear Cover
113
Engine Maintenance
Injection Pump Removal 2. Remove the starter for clearance, remove

throttle linkage, fuel lines, harness and
The injection pump drive gear will not fit through
mounting hardware from injection pump.
the gear housing when removing the pump, the
gear must be separated from the pump. Using tool 3. Remove the cover plate from the gear case.
P/N 204-1011, it will not be necessary to remove Remove the nut and lock washer which secure
the belts, fuel pump, crankshaft pulley, crankshaft the gear to the injection pump shaft. Use a
seal or front plate. See Figure 130 Injection shop rag to prevent the lock washer or nut
Pump Gear Tool on page 115. from falling into the gear case.
1. Note the alignment of the index marks on the NOTE: The injection pump gear assembly is
injection pump and the gear case. The index made of three pieces; the flange, the gear,
mark on the injection pump is usually aligned and the transfer pump cam. Do not loosen or
with the single index mark on the gear case. If remove the four bolts that fasten the gear to
not, mark it so the injection pump can be the flange because that changes the timing.
returned to the same position when it is 4. Use the hardware from the cover plate to
reinstalled. 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
1 the gear. Caution should be made to align the
1. Index Marks screw over the center of the injection pump
shaft.
Figure 128: Index Mark Location
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
1 2
previously removed hardware. Make sure to
align the index marks on the injection pump
1. Index Mark on Injection Pump and the gear case like they were in step 1 of
2. Index Mark on Gear Case Injection Pump Removal.
Figure 129: Index Mark Alignment NOTE: If a different injection pump is being
installed, see Injection Pump Timing on
page 111 to set the timing.
114
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 130: Injection Pump Gear Tool
115
Engine Maintenance
Fuel Solenoid 2. Energize the run relay with the Interface

Board Test Mode. The fuel solenoid relay is
The fuel solenoid is located on the end of the
momentarily energized when the run relay is
injection pump. It contains two coils: the pull-in
energized with the Interface Board Test Mode.
coil, and the hold-in coil. The pull-in coil draws
This energizes the fuel solenoid, which makes
approximately 35 to 45 amps at 12 volts. The
a definite click when energized.
hold-in coil draws approximately 0.5 amps at
12 volts. 3. De-energize the run relay with the Interface
Board Test Mode. This de-energizes the fuel
The pull-in coil must be energized to move the
solenoid, which makes a definite click when
injection pump governor linkage to the fuel on
de-energized.
position. Once the injection pump governor
linkage has been moved to the fuel on position, 4. Repeat steps 2 and 3 a few times to check the
the hold-in coil will keep it in fuel on position operation of the fuel solenoid.
until the 8D circuit is de-energized. The pull-in
NOTE: The fuel solenoid may be removed
coil must be de-energized after a few seconds to
from the injection pump to visually check its
keep it from being damaged. The pull-in coil is
operation. The fuel solenoid must be
controlled by the microprocessor through the fuel
energized when it is re-installed in the
solenoid pull in relay (K6).
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.
1
1. Fuel Solenoid
Figure 131: Fuel Solenoid Location
Testing the Fuel Solenoid

NOTE: The fuel solenoid pull-in coil will AEA633
require 35 to 45 amps to turn on the fuel. The
units battery must be in good condition. If the 1. Red (8D)
battery has enough power to crank the engine 2. White (8DP)
over, it has enough power to energize the fuel
solenoid pull-in coil. 3. Black (CH)
Figure 132: Fuel Solenoid

If you suspect that the engine does not run Connector Pin Identification
because the fuel solenoid is not operating
correctly, use the following procedure: 7. Place a jumper wire between the black wire
1. Use the microprocessor keypad to enter the (CHpin C) in the fuel solenoid connector
Interface Board Test Mode. Refer to the and a good chassis ground.
appropriate Microprocessor Diagnostic 8. Test the pull-in coil by momentarily placing a
Manual for specific information about the jumper between the white wire (8DPpin B)
Interface Board Test Mode. in the fuel solenoid connector and the positive
116
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 133: 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.
117
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 135: 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 134: 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 136: Trochoid Feed Pump
4. Place the new trochoid feed pump on the
injection pump.
118
Engine Maintenance
5. Install and tighten four hex head screws that 2. Press the GAUGES key before the engine starts
attach the trochoid feed pump to the injection (to enter the Gauges Menu) and check the
pump. Torque the hex head screws to 6 to coolant temperature to make sure it is below
7 ft-lb (8 to 10 Nm). 32 F (0 C).
3. Let the engine start, then check the engine rpm
Cold Start Device Tier 2 Engine in the Gauges Menu. The engine rpm should
The TK486V engine has a cold start device be approximately 100 rpm higher than normal
located on the fuel injection pump. The cold start (see Specifications).
device has a plunger that retracts at engine coolant
4. Let the engine run to warm up and use the
temperatures below 41 F (5 C) to advance the
Gauges Menu to check the coolant
injection timing approximately 2 degrees. The
temperature and engine rpm. When the
plunger controls the position of a piston in the
coolant temperature rises above 41 F (5 C),
injection pump to change the timing. The plunger
the engine rpm should drop back to normal.
is extended and the injection timing is normal at
Replace the cold start device if the engine rpm
engine coolant temperatures above 41 F (5 C).
does not drop approximately 100 rpm when
Check the operation of the cold start device if it is
the engine warms up.
difficult to start the engine in cold weather.
NOTE: Do not pull the plunger out of a cold Cold Start Device Replacement
start device because that will damage it.
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.
1. Plunger (Extended) 3
Figure 137: 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 1. Banjo Bolt
start the procedure. 2. Engine Coolant Fitting
1. Press the ON key to turn the unit on. 3. Coolant Hoses to Cold Start Device
Figure 138: Remove Engine Coolant Fitting
119
Engine Maintenance
3. Remove the cold start device from the Engine Valve Clearance
injection pump fitting. Use a backup wrench Adjustment
on the injection pump fitting if necessary.
1. Remove the rocker arm cover.
2. Remove the round cover (plug) from the
timing mark access hole on the front of the
1 bell housing.
CAUTION: Loosen all of the injection
lines at the injection nozzles to prevent the
2 possibility of the engine firing while it is
being rotated.
3. Place the engine at top dead center of the
compression stroke for the number one
cylinder. See steps a through d.
1. Cold Start Device

1 2
2. Injection Pump Fitting
Figure 139: Remove Cold Start Device
4. Make sure the piston inside the injection
pump fitting is clean.
1
AEA701
1. Index Mark
2. Top Dead Center Mark for 1 and 4
Figure 141: Top Dead Center One and Four
a. Rotate the engine in the normal direction
of rotation (clockwise viewed from the
1. Piston water pump end) until the 1-4 timing mark
on the flywheel lines up with the index
Figure 140: Clean Piston
mark in the timing mark access hole.
5. Install the new cold start device with a new
b. Check the rocker arms on the number one
O-ring in the injection pump fitting. Torque
cylinder to see if they are loose.
the cold start device to 22 to 26 ft-lb (30 to 35
Nm). c. If the rocker arms are loose, the engine is
at top dead center of the compression
6. Install the coolant fitting and banjo bolt on the
stroke for the number one cylinder.
cold start device. Torque the banjo bolt to 16
to 18 ft-lb (22 to 25 Nm). d. If the rocker arms are tight, the engine is at
top dead center of the exhaust stroke for
7. Refill the engine cooling system and make
the number one cylinder. Rotate the engine
sure to bleed the air from the cooling system.
360 degrees to place the engine at top dead
center of the compression stroke for the
number one cylinder.
120
Engine Maintenance
4. Use a feeler gauge to check the valve

clearance on both valves for the number one
cylinder, the intake valve for the number two
cylinder, and the exhaust valve for the number
three cylinder. The valve clearance for both
the intake valve and the exhaust valve should
be 0.006 to 0.010 in. (0.15 to 0.25 mm).
NOTE: Check to make sure that the valve
stem cap is in good condition and is
positioned squarely on the top of the valve
stem. Replace the valve stem cap if it shows
significant wear.
5. Adjust the valves if necessary by loosening AEA705
the locknut and turning the adjustment screw Figure 142: Adjusting the Valve Clearance
until the valve clearance is correct. 7. Recheck the valve clearance.
6. Hold the adjustment screw in place and 8. Rotate the engine one full turn (360 degrees)
tighten the locknut. in the normal direction of rotation (clockwise
viewed from the water pump end), and align
the 1-4 timing mark on the flywheel with the
index mark in the timing mark access hole.
This is top dead center of the compression
stroke for the number four cylinder.
9. Check and adjust the exhaust valve for the
number two cylinder, the intake valve for the
number three cylinder, and both valves for the
number four cylinder.
10. Replace the rocker arm cover, the cover for
the timing mark access hole, and tighten the
fuel injection lines when finished.
Valve Adjustments and Cylinder Configurations

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

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

TDC on compression stroke
121
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 143: Crankcase Breather Tier 2 Engine
122
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 146: EMI 3000 Air Cleaner System
Model 30 Shown Model 50 Similar
ARA189
Figure 144: EMI 3000 Air Cleaner Assembly
ARA190
1. Dust Ejector Must Point Down When Installed

Figure 145: EMI 3000 Air Filter Element
123
Engine Maintenance
Air Restriction Indicator Belts

Excessive restriction of the air intake system Belts should be regularly inspected during unit
reduces the flow of air to the engine affecting pretrip inspections for wear, scuffing or cracking.
horsepower output, fuel consumption and engine Belt tension should also be checked during
life. scheduled maintenance inspections. Belts that are
too loose will whip and belts that are too tight put
An air restriction indicator is installed on the air
too much strain on the belt fibers and bearings.
intake manifold. Visually inspect the restriction
indicator periodically to assure the air filter is not Using belt tension gauge, P/N 204-427, is the best
restricted. Service the air filter when the yellow method of checking belts for tightness. Install the
diaphragm indicates 25 in. of vacuum. Press the belt gauge in the center of the longest belt span.
reset button on the top of the air restriction Press the plunger so the hook will engage the belt.
indicator after servicing the air filter. Make sure the hook is on the face of the belt, not
in a notch. Release the plunger with a quick
motion and without pulling on the belt. Then read
the dial. Use an average of three readings.
NOTE: Do not attempt to remove or install belts
without loosening adjustments. Belts that are
installed by prying over pulleys will fail
prematurely due to internal cord damage.
CAUTION: Do not attempt to adjust belts
with the unit running.
AEA710
CAUTION: Turn the unit off before
performing maintenance or repair
Figure 147: Air Restriction Indicator procedures. When the unit is turned on, it
can start at any time without warning.
124
Engine Maintenance
Model 30 Belt Adjustments Upper and Lower Fan Belt Adjustment

The upper fan belt should read 74 and the lower
Alternator Belt Adjustment
fan belt should read 67 on the belt tension gauge.
The alternator belt tension should read 67 on the NOTE: Both the upper and lower fan belts are
belt tension gauge. adjusted at the same time in one procedure.
1. Loosen the alternator pivot bolt and the NOTE: If a fan belt is loose or damaged, replace
adjusting arm bolt. the belt (see Model 30 Fan Belt Replacement
2. Move the alternator on the adjusting arm slots on page 126).
to adjust the belt to 67 on the belt tension 1. Loosen the idler assembly pivot bolts and the
gauge. idler adjusting arm bolts.
3. Tighten the adjusting arm bolt and alternator 2. Push in or pull out on the idler adjusting arm
pivot bolt. to center the idler assembly between the
belts and balance the tension equally between
the upper and lower belts.
2
3
4
13
7
12
8
9
11 9
10
1. Upper Fan Belt 8. Lower Fan Belt

2. Condenser Fan Pulley 9. Engine Pulley
3. Condenser Fan 10. Idler Adjusting Arm Bolt
4. Condenser Inlet Ring 11. Idler Adjusting Arm
5. Idler Assembly Pivot Bolt 12. Alternator Belt
6. Idler Assembly 13 Idler Adjusting Arm Pivot Bolt
7. Belt Guide
Figure 148: Model 30 Belt Arrangement
125
Engine Maintenance
3. Tighten both idler adjusting arm bolts and 3. Pull the idler adjusting arm OUT. The upper
both idler assembly pivot bolts. fan belt should slip off the idler pulley as the
idler pulley hub clears the curbside idler
NOTE: If the idler assembly binds when
mounting bracket.
moving for belt adjustment, loosen the upper
idler support bracket mounting bolts to free 4. Loosen the two condenser fan hub to the shaft
up the assembly. Check the main idler clamping bolts.
retainer nut assembly for proper alignment
5. Tap the blower wheel with a soft hammer to
between the nut and the support bracket
drive the blower wheel up the fan shaft to
slots.
provide 1/2 in. (13 mm) clearance between the
blower wheel and the inlet ring.
Model 30 Fan Belt Replacement
NOTE: If the condenser fan does not slide
NOTE: Do not attempt to remove or install the
on the fan shaft with light tapping, remove
belts without loosening the adjustments. Belts
the small access panel located on the
that are installed by prying over pulleys will fail
condenser coil header above the radiator
prematurely due to internal cord damage.
tank. Thread a 1/4-20 x 1 in. diameter bolt
into the end of the fan shaft. Tighten the bolt
Lower Fan Belt
and washer down on the condenser fan hub
Removal to loosen the blower wheel. Drive the blower
1. Loosen both idler adjusting arm bolts and both wheel back to provide 1/2 in. (13 mm)
idler pulley assembly bolts. clearance between the blower wheel and
condenser fan inlet ring.
2. Push the idler adjusting arm IN. The lower fan
belt will come off the engine pulley. Move the 6. Lift the belt up over the condenser blower
arm OUT far enough to clear the roadside wheel and remove it from the unit.
idler mounting bracket. Installation
Installation 1. Slip the belt over the condenser blower wheel
1. Slip the belt into the groove of the idler pulley. and place it in the condenser fan pulley.
2. Push the idler adjusting arm back in toward 2. Drive the condenser blower wheel out toward
the unit. the condenser fan inlet ring using a soft
hammer.
3. Slip the belt onto the pulley groove on the
engine. 3. Position the blower wheel so the edge of the
inlet ring lines up with the alignment mark on
4. Pull the idler adjusting arm back OUT and the blower wheel.
adjust the belts to the proper tension.
4. Check the radial clearance between the blower
5. Tighten the idler assembly pivot bolts and the wheel and inlet ring with a gauge wire. Check
idler adjusting arm bolts. around the entire circumference to the inlet
ring and blower wheel (see Condenser and
Upper Fan Belt Evaporator Fan Location on page 163).
Removal 5. Torque the blower hub clamping bolts to
1. Loosen the idler adjusting arm bolts and 18 ft-lb (24 Nm).
remove the lower fan belt (see Lower Fan 6. Seat the upper belt in the blower wheel pulley
Belt above). groove.
2. Push the idler adjusting arm in and the idler 7. Push inward on the idler adjusting arm and
assembly up. The upper belt should become slip the belt into the idler pulley groove.
slack and slip down out of the idler pulley
groove.
126
Engine Maintenance
8. Pull the idler adjusting arm forward and install Compressor Belt Adjustment
the lower fan belt.
The compressor drive belts should read 79 on the
1 2
belt tension gauge.
1. Loosen the back-up hex nut on the belt
tensioner compression spring adjustment
3 screw.
2. Move the hex nuts on the compression spring
adjustment screw to adjust the belt tension to
79 on the belt tension gauge.
4 3. With the proper belt tension adjustment,
tighten the back-up hex nut to the adjustment
hex nut on the compression spring adjustment
screw.
Water Pump Belt Adjustment

The water pump belt tension should be 35 on the
belt tension gauge.
AEA749
1. Remove the bolts from the water pump pulley.
1. Blower Wheel 2. Remove the pulley sliding section and add or
2. Inlet Ring remove shims to adjusting the belt tension
3. Alignment Mark
gauge.
4. Edge of Inlet Ring 3. Reinstall the belt on the pulley and replace the
Figure 149: Condenser Blower Alignment sliding pulley section on the pulley.
4. Tighten the mounting belts on the water pump
Model 50 Belt Adjustments pulley.
Alternator Belt Adjustment 5. The belt tension should read 35 on the belt
tension gauge.
The alternator belt tension should read 29 on the
belt tension gauge. Fan Belt Adjustment
1. Loosen the alternator pivot bolt and the The fan belt tension should read 74 on the belt
adjusting arm bolt. tension gauge.
2. Move the alternator on the adjusting arm slot 1. Loosen the idler pulley mounting bolts.
to adjust the belt to 29 on the belt tension
gauge. 2. Move the idler pulley assembly to adjust the
belt tension to 74 on the belt tension gauge.
3. Tighten the adjusting arm bolt and alternator
pivot bolt. 3. Tighten the idler pulley mounting bolt.
127
Engine Maintenance
1 2
3
12
11
10
6
8
AGA223
1. Condenser Fan Pulley 7. Electric Motor

2. Condenser Fan 8. Compressor Pulley
3. Condenser Inlet Ring 9. Compressor Belts
4. Idler Pulley 10. Belt Tension Adjustment Idler
5. Fan Belt 11. Alternator Belt
6. Water Pump Belt 12. Alternator
Figure 150: Model 50 Belt Arrangement
Model 50 Compressor Belt Installation

Replacement 1. Install the belts on the clutch pulley through
the gap between the clutch and the flywheel.
Removal
2. Place the compressor in position and install
1. Loosen the back-up hex on the belt tensioner
the mounting bolts.
compression spring adjustment screw.
3. Adjust the hex nuts on the compression spring
2. Move the hex nuts on the compression spring
adjustment to tighten the belts to 79 on the
adjustment screw to relieve belt tension.
belt tension gauge.
3. Support the compressor and unbolt the
4. Tighten the back-up hex nut on the belt
compressor form the flywheel housing (leave
tension compression spring adjustment screw.
the refrigeration lines connected).
4. Swing the compressor assembly away from
the flywheel housing.
5. Remove the belts through the gap between the
clutch and the flywheel.
128
Engine Maintenance
Model 50 Fan Belt Replacement 4. Check the radial clearance between the blower
NOTE: Do not attempt to remove or install the wheel and inlet ring with a gauge wire. Check
belts without loosening the adjustments. Belts around the entire circumference to the inlet
that are installed by prying over pulleys will fail ring and blower wheel (see Condenser and
prematurely due to internal cord damage. Evaporator Fan Location on page 163).
5. Torque the blower hub clamping bolts to
Removal 24 Nm (18 ft-lb).
1. Loosen the idler pulley mounting bolts. 6. Seat the upper belt in the blower wheel pulley
2. Move the idler pulley assembly to obtain groove.
enough slack to remove the belt from the idler 7. Place the belt in the idler and electric motor
and the electric motor. pulleys.
3. Loosen the two condenser fan hub to the shaft 8. Move the idler pulley assembly to adjust the
clamping bolts. belt tension to 74 on the belt tension gauge.
4. Tap the blower wheel with a soft hammer to 9. Tighten the idler pulley mounting bolt.
drive the blower wheel up the fan shaft to
provide 13 mm (1/2 in.) clearance between the Clutch (Model 50)
blower wheel and the inlet ring.
Periodically inspect the clutch for worn bearings,
NOTE: If the condenser fan does not slide worn friction shoes and for broken springs. To
on the fan shaft with light tapping, remove inspect the clutch:
the small access panel located on the
condenser coil header above the radiator 1. Loosen the back-up hex nut and move the hex
tank. Thread a 1/4-20 x 1 in. diameter bolt nuts on the compression spring adjustment
into the end of the fan shaft. Tighten the bolt screw to relieve the tension on the compressor
and washer down on the condenser fan hub belts.
to loosen the blower wheel. Drive the blower 2. Support the compressor and unbolt the
wheel back to provide 1/2 in. (13 mm) compressor from the bell housing studs.
clearance between the blower wheel and
condenser fan inlet ring. 3. Remove the compressor from the bell housing
and turn the compressor to provide better
5. Lift the belt up over the condenser blower access to the clutch.
wheel and remove it from the unit.
NOTE: The refrigeration lines may be
Installation removed from the compressor to allow more
movement of the compressor for better access
1. Slip the belt over the condenser blower wheel to the clutch.
and place it in the condenser fan pulley.
4. Remove the compressor belts.
2. Drive the condenser blower wheel out toward
the condenser fan inlet ring using a soft 5. Remove the clutch mounting bolt and special
hammer. washer.
3. Position the blower wheel so the edge of the 6. Remove the clutch with a clutch puller.
inlet ring lines up with the alignment mark on 7. Remove the key from the compressor
the blower wheel (see Figure 149 on page crankshaft and inspect the key and the
127). crankshaft for wear, burrs, or damage.
129
Engine Maintenance
8. To disassemble the clutch, press the pulley out c. Use a soft hammer to tap the friction shoe
of the bearing. mounting bolts out of the hub and remove
them from the friction shoes.
9. Inspect the friction shoes and springs.
d. Attach the new friction shoes to the hub
a. Replace the friction shoes if the linings are
with the mounting bolt plate, the mounting
worn to a thickness of less than 1/16 to
bolts, and the lock nuts. Torque the lock
3/32 in. (1.6 to 2.4 mm).
nuts to 30 to 35 ft-lb (41 to 47 Nm).
b. Replace the springs if they are worn or
11. To replace the bearing:
broken.
a. Remove the snap ring and press the
10. To replace the friction shoes:
bearing out of the hub.
a. Remove the springs from the friction
b. Press the new bearing into the hub and
shoes.
install the snap ring.
b. Remove the lock nuts from the friction
12. To assemble the clutch, press the pulley into
shoe mounting bolts.
the bearing.
11
10
8
7
AGA338
6
5
4
3
2
1
1. Clutch Mounting Bolt 7. Spring

2. Special Washer 8. Friction Shoe
3. Snap Ring 9. Mounting Bolt Plate
4. Bearing 10. Friction Shoe Mounting Bolt
5. Lock Nut 11. Pulley
6. Hub
Figure 151: Clutch
130
Engine Maintenance
13. Place the clutch on the compressor crankshaft,

align the keyways (use Keyway Tool 1
204-972), and insert the key to be flush with
the end of the crankshaft.
CAUTION: Do not place the key on the 2
compressor crankshaft before installing
the clutch because the key might be
pushed out of place behind the clutch
when the clutch is installed.
1. Elastomer
14. Install the special washer and the clutch
mounting bolt. Torque the clutch mounting 2. Outer Steel Sleeve
bolt to 90 ft-lb (122 Nm). Figure 153: Old Style Drive Bushing
15. Reinstall the compressor drive belts. The new style drive bushings and dowel pins
16. Reinstall the compressor on the bell housing should be used to replace the old style drive
studs. bushings and dowel pins. Use 8-Pin and Bushing
Replacement Kit 70-208.
17. Install and tighten the flatwashers, lock
washers and nuts on the studs. NOTE: The new bushing must be mated with a
newly designed, heat-treated dowel pin. It is
18. Readjust the compressor drive belts. imperative the old style dowel pins are replaced
with the new heat-treated dowel pins. See
Drive Bushing Replacement Dowel Pin Replacement on page 134.
A new style, bonded drive bushing was The design of the new style drive bushing requires
introduced in July 2004 in model 50 trailer units that the following procedure be used to replace the
with 8-pin clutches. drive bushings.
1. Loosen the compressor drive belt(s).
1
2. Remove the compressor, or pull the
compressor away from the bell housing and
turn the compressor to access the clutch.
2 Support the compressor so it is not hanging
from the vibrasorbers if you are not removing
it.
3. Remove the clutch mounting bolt and special
1. Elastomer washer, and remove the clutch.
2. Inner Fiber Sleeve 4. Remove the clutch pulley by pressing it out of
the bearing. It is not necessary to remove the
Figure 152: New Style, Bonded Drive Bushing
bearing to replace the drive bushings.
5. Remove the friction shoes.
a. Remove the springs from the friction
shoes.
b. Remove the lock nuts from the friction
shoe mounting bolts.
c. Use a soft hammer to tap the friction shoe
mounting bolts out of the hub, and remove
the mounting bolts and the friction shoes.
131
Engine Maintenance
6. Use the Clutch Bushing Removal Tool 9. Put a thick ring of Loctite adhesive 203-535
204-1154 to press the old bushings out of the around the bottom of the new bushing before
clutch hub (see Figure 154). pressing it into place. The adhesive will
squeegee up the entire length of bushing as it
7. Clean the holes from which the bushings were
is pressed into the hole.
removed.
8. Start fit the bushing in the clutch WARNING: If a thin coating of adhesive
hub/coupling about 1/8 in. (3 mm) to make is applied all over the bushing before it is
sure it fits in the hole and does not hang up on started in the hole, the adhesive will begin
something. Start fit the bushing in the side to cure before the bushing can be pressed
of the hub/coupling that faces the flywheel. completely into place.
NOTE: The Loctite adhesive has a working 10. Use the cupped end of the Clutch Bushing
time of 2 minutes so the bushing must be Installation Tool 204-1155 to press the new
installed within 2 minutes of when the bushing into the hub until the cup contacts the
adhesive was applied. Apply the adhesive and hub. Press the new bushing into the hub from
install the bushings one at a time to avoid side of the hub that faces the flywheel (see
exceeding the time limit. Figure 155).
NOTE: Let the Loctite adhesive cure for at
least 1 hour at 70 F (21 C) before running
the unit. The components can be
reassembled immediately.
1. Straight Pin End
Figure 154: Press Old Bushings Out Of Hub With Removal Tool 204-1154
132
Engine Maintenance
1 2
1. Clean Holes
2. Cupped End
Figure 155: Press New Bushing Into Hub With Installation Tool 204-1155
11. Inspect the clutch components before 17. Install the special washer and the clutch
reassembling the clutch and replace them if mounting bolt. Torque the clutch mounting
necessary. bolt to 90 ft-lb (122 Nm).
12. Install the friction shoes, mounting bolt plate, 18. If the clutch had old style drive bushings,
and friction shoe mounting bolts. replace the dowel pins in the flywheel with
new, hardened (black) dowel pins. See
13. Torque the lock nuts on the friction shoe
Dowel Pin Replacement on page 134.
mounting bolts to 35 ft-lb (47 Nm).
19. Install the compressor drive belts.
14. Install the springs on the friction shoes.
20. Install the compressor on the bell housing
15. Press the clutch pulley into the bearing.
studs.
16. Place the clutch on the compressor crankshaft,
NOTE: Do not place any kind of lubricant
align the keyways (use Keyway Tool
on the outside of the dowel pins or on the
204-972), and insert the key to be flush with
inside of the drive bushings. Lubricant
the end of the crankshaft.
between the dowel pins and drive bushings
CAUTION: Do not place the key on the will cause premature wear.
compressor crankshaft before installing 21. Install and tighten the flatwashers,
the clutch because the key might be lockwashers, and nuts on the studs.
pushed out of place behind the clutch
when the clutch is installed. 22. Adjust the compressor drive belts.
133
Engine Maintenance
Dowel Pin Replacement

1. Remove the flywheel.
2. Press the old dowel pins out of the flywheel.
3. Use the Manual Pin Tool 204-1117 or the
Impact Pin Tool 204-1118 to press or drive the
new dowel pins into the flywheel. The end of
each dowel pin should be 1.15 in. (29.2 mm)
from the outer face of the flywheel. The
proper dimension is critical and is set by using
either of the tools.
1 2
2
3 3
1.15 in. (29.2 mm) 1
1. Press Dowel Pin In Until Flush With 1. Drive Dowel Pin In Until Tool
Tool 204-1117 204-1118 Hits Flywheel
2. Dowel Pin 2. Dowel Pin
3. Outer Face Of Flywheel 3. Outer Face Of Flywheel
Figure 156: Pressing New Dowel Pin Into Flywheel Figure 157: Driving New Dowel Pin Into Flywheel
Using Manual Pin Tool 204-1117 With Impact Pin Tool 204-1118
4. Install the flywheel and align it with the dowel

pin in the end of the crankshaft.
5. Install the flywheel mounting bolts. Torque
the flywheel mounting bolts to 65 ft-lb (88
Nm).
6. Install the compressor and adjust the drive
belts.
134
Refrigeration Maintenance
NOTE: The following procedures involve Testing the Refrigerant Charge with
servicing the refrigeration system. Some of these a Loaded Trailer
service procedures are regulated by Federal, and NOTE: This test determines if there is enough
in some cases, by State and Local laws. refrigerant for the current temperatures, not if
In the USA all regulated refrigeration service there is a full charge of refrigerant.
procedures must be performed by an EPA
1. Install a gauge manifold.
certified technician, using approved equipment
and complying with all Federal, State and Local 2. Run all the evaporators on cool.
laws.
3. Build up and maintain 325 to 400 psig (2241
to 2758 kPa) of discharge pressure. If the
Refrigerant Charge pressure is below this, it can be raised by
covering the roadside condenser grille with a
Testing the Refrigerant Charge with piece of cardboard to block condenser air
an Empty Trailer flow.
If the unit has an insufficient charge of refrigerant, 4. Cool the compartments to lowest temperatures
the evaporators will be starved and the box required.
temperatures will rise even though the unit is
operating. The suction pressure will drop as the 5. Check suction pressure. It should be 13 to
refrigerant charge decreases. If the unit has an 22 psig (90 to 152 kPa).
overcharge of refrigerant, the unit may not cool 6. Under these conditions, the ball should be
properly and the suction and discharge pressure floating in the receiver tank sight glass. If
may be high. The charge may be determined by refrigerant is not visible in the sight glass, the
inspection of the refrigerant through the receiver unit is low on refrigerant.
tank sight glass with the following conditions
established: Testing for an Overcharge
1. Place a test box over each evaporator. Use the following procedure to identify a unit
2. Install a gauge manifold. with an excessive refrigerant charge:
3. Run all the evaporators on cool until the return 1. Install a gauge manifold on the compressor.
air temperature in each box is at 0 F (-18 C). 2. Operate the host unit in high speed with all the
By allowing a box to leak a small amount, you evaporators in cool to stabilize system
will be able to maintain 0 F (-18 C). pressures and reduce the compartment
4. The suction pressure should be 13 to 18 psig temperatures to approximately 60 F (16 C) or
(90 to 124 kPa). colder.
5. The discharge pressure should be 325 to 3. Observe discharge pressure and cover the
400 psig (2241 to 2758 kPa). If the pressure is condenser to increase the discharge pressure
below this, it can be raised by covering a approximately 50 psig (345 kPa) above the
portion of the roadside condenser grille with a observed pressure. Do not allow the discharge
piece of cardboard to block condenser airflow. pressure to go above 350 psig (2413 kPa).
6. Under these conditions, the ball should be NOTE: If the ball and liquid level in the
floating in the receiver tank sight glass. If receiver sight glass drops during step 3, the
refrigerant is not visible in the receiver tank unit is not overcharged and it is not
sight glass, the unit is low on refrigerant. necessary to complete the procedure.
4. Remove the condenser cover to rapidly reduce
discharge pressure.
135
5. Observe the receiver tank sight glass and the 4. Repeat the overcharge test.
units discharge pressure.
5. Remove the gauge manifold set and cap all
6. By the time the discharge pressure drops service ports and valve stems when the
approximately 50 psig (345 kPa) the ball in refrigerant level is correct.
the receiver tank sight glass should begin to
move and the liquid level should drop. Moisture Indicating Sight Glass
a. When discharge pressure stabilizes, the The receiver tank is equipped with a moisture
ball and liquid level will rise. indicating sight glass. The outer edge of the sight
b. If the ball will not begin to move or the glass has a colored ring approximately 0.1 in.
liquid level will not drop, the unit most (2.5 mm) thick. The color of the ring indicates the
likely has an overcharge of refrigerant. moisture content of the refrigerant, but it may not
The refrigerant level should be adjusted. be completely reliable.
Green = Dry
Adjusting Refrigerant Level
Chartreuse = Caution
1. Stop the unit and remove some refrigerant
with an approved refrigerant recovery device. Yellow = Wet
2. Perform a refrigerant level check and repeat

the overcharge test. 1
3. If the liquid level is low, add refrigerant as

follows:
a. Connect a refrigerant tank to the gauge 2
AEA672
manifold service line and purge the line.
b. Mid seat the suction service valve. 1. Floating Ball
2. Colored Ring
c. Set the refrigerant tank for liquid removal Figure 158: Moisture Indicating Sight Glass
and open the hand valve.
A system has to run for at least 15 minutes to
d. Operate the unit in high speed with all change the color of the indicator ring after the
evaporators in cool. moisture content of the system has been changed.
e. Observe the suction pressure and slowly For example, evacuating a system to remove the
open the gauge manifold low pressure moisture will not change the color of the indicator
hand valve to allow liquid refrigerant to ring until the system has been recharged and then
flow into the suction service valve. operated for at least 15 minutes.
f. Control the liquid flow so the suction
pressure increases approximately 20 psig Refrigerant Leaks
(138 kPa). Use a reliable leak detector that is suitable for
g. Maintain a discharge pressure of at least R-404A to leak test the refrigeration system.
325 to 400 psig (2241 to 2758 kPa) while Inspect for signs of oil leakage which is the first
adding refrigerant. sign of a leak in the refrigeration system.
h. Close the hand valve on the refrigerant

tank when liquid appears in the receiver
sight glass.
136
Checking Compressor Oil If the compartment is empty, you can run the
evaporator on the heat cycle instead of the defrost
The compressor oil should be checked when there cycle.
is evidence of oil loss (oil leaks) or when
components in the refrigeration system have been NOTE: Use refrigeration compressor oil ONLY.
removed for service or replacement. Use the Polyol Ester type (P/N 203-513) is required on
compressor sight glass to check the oil level. 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
1 160.
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 159: 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 160: High Pressure Cutout Manifold
up in the sight glass.
137
2. Use the Service Test mode to run the host unit 6. Monitor the discharge pressure. When the
in High Speed Cool. Refer to the appropriate discharge pressure reaches 300 +25/-0 psig
Diagnostic Manual for specific information (2068 +172/-0 kPa), the HPCS should open.
about the Service Test Mode.
7. Uncover the condenser to lower the discharge
3. Raise the discharge pressure of the pressure.
compressor first by blocking the condenser
8. Monitor the discharge and suction pressures.
coil air flow by covering the roadside
When the discharge pressure reaches 200
condenser grille with apiece of cardboard. If
20 psig (1379 138 kPa), the HPCS should
this does not raise the discharge pressure to
close.
the cutout level of the HPCO, increase the
engine speed by overriding the throttle 9. Replace the HPCS if it does not function
solenoid. This should increase the discharge properly.
pressure enough to cause the HPCO to cut out.
10. Reconnect the HPCS to the main wire harness
CAUTION: If the discharge pressure and remove the gauge manifold.
reaches 477 psig (3289 kPa), shut the unit
off immediately. Do not allow the Pressure Transducers
discharge pressure to exceed 477 psig
(3289 kPa). The discharge pressure transducer and the suction
pressure transducer supply pressure information
4. If the HPCO does not open to de-energize the to the microprocessor. These pressures can be
fuel solenoid and stop the engine, it must be monitored with the GAUGES key. Check the
replaced. readings by comparing them to the readings on a
gauge manifold set attached to the compressor.
High Pressure Switch (HPCS) Refer to the SR-2 Multi-Temp Microprocessor
Test Controller Diagnostic Manual TK 53080 for more
information about the testing and operation of the
The high pressure switch (HPCS) is located on the pressure transducers.
compressor discharge manifold. This switch is
used by the microprocessor to confirm the
operation of the discharge pressure transducer. It
Evacuating and Charging
is connected to the HPCS and CHHP wires in the Smart Reefer Multi-Temp
main wire harness. The HPCS opens when the Systems
discharge pressure rises above 300 psig (2068
kPa). The HPSW closes when the discharge Set-up Unit
pressure drops below 200 psig (1379 kPa). The SR-2 Multi-Temp microprocessor must be
Use the following procedure to test the HPCS: placed in the Evacuation Test to evacuate and
charge the unit. When the microprocessor is in the
1. Install a gauge manifold on the compressor. Evacuation Test it opens all the normally closed
2. Disconnect the HPCS from the HPCS and solenoid valves in the refrigeration system. This
CHHP wires in the main wire harness. allows the refrigeration system to be evacuated
properly. Refer to the appropriate Diagnostic
3. Check the HPCS for continuity. It should be Manual for complete information about the
closed when the unit is not running. microprocessor. Use the following procedure to
4. Use the Service Test mode to run the host unit set-up the unit and place the microprocessor in the
in High Speed Cool. Refer to the appropriate Evacuation Test:
Diagnostic Manual for specific information 1. Press the ON key to turn the unit on.
about the Service Test Mode.
2. Before the unit starts, press the MENU key. The
5. Cover the condenser to raise the discharge first screen in the Main Menu (either the
pressure. Language or Alarms Display) will appear.
138
3. Press the EXIT key and the unlabeled soft key 5. Install service valve stem caps with seals and
at the same time, and hold them down for 5 tighten them. The valve stems should remain
seconds to enter the Maintenance Menu. The capped while evacuating the unit.
first Maintenance Menu feature will appear.
6. Evacuate the unit to 500 microns, or the
4. Press the NEXT (or BACK) key to scroll through lowest achievable level between 500 and
the Maintenance Menu features until the 1,000 microns.
Evacuation Test appears.
7. Continue to evacuate the unit for one
5. Press the Select key to enter the Evacuation additional hour after reaching 500 microns, or
Test. the lowest achievable level between 500 and
1,000 microns. This insures complete
6. Connect a battery charger to the unit battery.
evacuation of the remote evaporators and
The battery charge must have an output of at
lines.
least 15 amperes. This will maintain the
charge level of the battery during the time 8. Close the Evacuation Station valve nearest the
required to evacuate and charge the unit. The vacuum pump (V1) to isolate the vacuum
Evacuation Test is used to open unit valves as pump from the system. Turn the vacuum
required for evacuation. Failure to connect a pump off.
battery charger may result in the battery
9. Observe the micron gauge.
voltage falling too low to reliably operate the
microprocessor and valves. The system pressure should remain below
2000 microns for 5 minutes.
7. The microprocessor is now in the Evacuation
Test. The refrigeration system is set-up for If the pressure does not hold, check for leaks
evacuation and charging. (if a leak is suspected) or continue evacuation
(if system is not dry).
Evacuating the System 10. Restart the vacuum pump, open the
CAUTION: Do not evacuate the system Evacuation Station valve nearest the vacuum
until it is leak free. A unit with less than pump (V1) and repeat steps 6, 8, and 9 as
full refrigerant charge should be leak required until system pressure remains below
checked and all leaks must be repaired 2000 microns for 5 minutes.
1. Be sure all refrigerant has been recovered 11. When system pressure remains below 2000
from the unit. microns for 5 minutes, restart the vacuum
pump and open the Evacuation Station valve
2. Connect a vacuum pump and gauge manifold nearest the vacuum pump (V1).
for three-point evacuation to the suction
service valve, discharge service valve, and 12. With the vacuum pump running, back seat the
receiver tank outlet valve (see Figure 161 on suction service valve. Replace the valve cap,
page 140). re-close the Evacuation Station valve nearest
the vacuum pump (V1), and stop the vacuum
NOTE: The use of the Thermo King pump.
Evacuation Station P/N 204-725 or 204-744
is recommended. 13. Close valve V4. The unit is ready to charge.
3. Verify proper operation of the Evacuation NOTE: Do not exercise the service valves with
Station as shown in the Evacuation Station the unit in a deep vacuum unless the vacuum
Operation Manual TK 40612. pump is operating.
4. Start the vacuum pump and mid-seat the
suction service valve, discharge service valve,
and receiver tank outlet valve.
139
Charging the System 2. Before charging system, make sure the

NOTE: The unit must be left in the Evacuation refrigerant lines from the gauge manifold to
Test. the refrigerant supply bottle have been
evacuated or purged, the suction service valve
1. Insure that all compartment bulkheads are is back seated, and the discharge service valve
open. Ceiling mounted bulkheads should not and receiver tank outlet valve are still open.
be stored close to the evaporator outlets as this
will restrict airflow.
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 161: Multi-Temp Evacuation and Charging (Two Zone Unit Shown Other Units Similar)
140
3. Set the refrigerant supply bottle for liquid. 13. Add refrigerant until the ball in the receiver
Open the gauge manifold hand valve and add tank sight glass rises to the middle of the sight
a partial charge of R-404A. Add 14 lb (6.4 kg) glass, then close the gauge manifold hand
to a unit with one remote evaporator. Add valve. Make sure the liquid level does not rise
15 lb (6.8 kg) to a unit with two remote above the top of the sight glass.
evaporators. Do not add more than this. The
14. Continue to operate the unit and monitor the
remainder of charge will be added through
sight glass until all compartment temperatures
suction service valve while unit is running.
are at or below 0 F (-18 C).
4. Close the gauge manifold hand valve.
15. Check the position of the ball in the receiver
5. Back seat (close) the receiver tank outlet valve tank sight glass. If the liquid level has
and discharge service valve. dropped, add liquid refrigerant until the level
stabilizes near the middle of the sight glass.
6. Exit the Evacuation Test by turning the unit
Do not exceed the recommended refrigerant
Off and then back On.
charge for the unit model.
7. Turn all zones On and set all zone setpoints
16. Close the hand valve on the refrigerant supply
for the lowest possible temperature to insure
bottle.
that all zones run in Cool mode. Allow the
unit to start. 17. Back seat the discharge service valve.
8. Front seat the suction service valve and allow 18. Open both hand valves on the gauge manifold.
the compressor to pump down to 1 to 3 psi (7
19. Front seat the suction service valve and allow
to 21 kPa). Stop the unit.
the compressor to pump down to 1 to 3 psi
9. Remove the evacuation manifold hoses from (7 to 21 kPa). Stop the unit.
the receiver tank outlet valve, the discharge
20. Remove the gauge line from the suction
service valve, and the suction service valve.
service valve and cap the service port.
Replace and tighten the service port and valve
stem caps on the receiver tank outlet valve. 21. Remove the gauge line from the discharge
service valve and cap the service port.
10. Attach the gauge manifold (with the
refrigerant supply bottle still connected) to the 22. Back seat the suction service valve and cap the
compressor. Attach the low side gauge to the valve stem.
suction service valve. Mid-seat the suction
23. Cap the valve stem on the discharge service
service valve. Attach the high pressure gauge
valve.
on to the discharge service valve. Open the
discharge service valve to monitor the 24. Secure all the gauge lines to the gauge line
discharge pressure. anchors.
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.
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).
141
142
Refrigeration Service Operations
NOTE: It is generally good practice to replace NOTE: Repeat the pump down procedure
the filter drier whenever the high side is opened if the pressures equalize above 20 psi
or when the low side is opened for an extended (138 kPa). If suitably low pressures cannot
period of time. be achieved after the third pump down, the
refrigerant must be recovered to perform
Low Side Pump Down service on the low side.
NOTE: Operate all the evaporators in Cool for c. If the reading on the gauge manifolds
2 to 5 minutes with the service valves in their high pressure gauge increases after the
normal operating positions before performing high and low side pressures have been
the low side pump down. Install a gauge equalized, the condenser inlet check valve
manifold at the compressor. is leaking.
1. Run all the evaporators in cool, front seat the d. Remember to reconnect the purge valve
receiver tank outlet valve and the bypass hand solenoid wires to the main wire harness
valve, and pump down the low side to 20 to when the service procedures have been
25 in. Hg vacuum (-68 to -85 kPa). Turn the completed.
unit Off.
If the unit pumps down acceptably and then Compressor
holds at least 15 in. Hg vacuum (-51 kPa) for The 7-quart sump extends below the top of the
2 minutes or more, it can be assumed that the lower frame rails. Therefore, a flat board cannot
receiver tank outlet valve, the compressor be used as a support when removing or installing
discharge valve plates, the HGS solenoid, the a compressor with a 7-quart sump. A Compressor
HGS2 solenoid, the HGS3 solenoid, and the Installation Tool P/N 204-1087 (two pieces) has
purge valve solenoid are sealing acceptably. been developed to aid in the removal and
2. Prepare to perform service on the units low installation of the 7-quart sump compressors.
side by equalizing the high side and low side
pressures. Removal
a. Disconnect the purge valve solenoid wires 1. Pump down the low side and equalize the
from the main wire harness. pressure to slightly positive.
NOTE: If the purge valve solenoid wires are 2. Loosen the compressor belts on Model 50
not disconnected from the main wire units.
harness, the purge valve is energized when 3. Front seat the discharge and suction service
the unit is placed in the Evacuation Test. valves. Remove the remaining refrigerant
This allows the refrigerant in the condenser pressure from the compressor.
to flow into the accumulator, undoing the
low side pump down. 4. Unbolt the discharge and suction service
valves from the compressor.
b. Place the unit in the Evacuation Test.
Refer to the appropriate Microprocessor 5. Remove the compressor oil filter and its lines.
Diagnostic Manual. The high and low side 6. Disconnect the HPCO wires and the HPCS
pressures should equalize in the wires.
Evacuation Test.
143
7. Support the compressor and remove the 5. Pressurize the compressor and test for
compressor mounting bolts from the flywheel refrigerant leaks.
housing. Use The Compressor Installation
6. If no leaks are found, evacuate the
Tool (P/N 204-1087) to support the
compressor.
compressor as follows:
7. Back seat the suction and discharge service
a. Identify the four machined feet on the base
valves.
of the compressor sump. The Compressor
Installation Tools bridge the lower frame 8. Tighten the compressor belts on Model 50
rails and support the compressor directly units.
under these feet.
9. Operate the unit at least 30 minutes and then
b. Position the Compressor Installation Tools inspect the oil level in the compressor. Add or
by inserting them from the end of the remove oil if necessary.
compressor and sliding them into place on
10. Check the refrigerant charge and add
the lower frame rails. Alternatively,
refrigerant if needed.
position the Compressor Installation Tools
by inserting them on a diagonal from
below the compressor and twisting them Compressor Coupling Removal
into position over the lower frame rails. 1. After the compressor has been removed from
the unit, use the appropriate Allen tool
8. Lift the service valves out of the way.
provided with removal tool P/N 204-991 (see
9. Slide the compressor to the left until the Figure 162 on page 145) to loosen the center
coupling pins are clear, and remove the bolt, which holds the coupling to the
compressor belts from Model 50 units. compressor shaft.
10. Remove the compressor from the front of the 2. Attach the tool to the coupling with the
unit. Keep the compressor ports covered to provided socket head screws and spacers. Two
prevent dust, dirt, etc., from falling into the sets of spacers are provided with the tool, use
compressor. the short spacers with shallow compressor
NOTE: When the compressor is removed mounting flanges and the longer set for deeper
from the unit, the oil level should be noted, flanges. The side with the countersunk holes
should be toward the coupling.
or the oil removed from the compressor
should be measured so that the same amount 3. To prevent the tool and crankshaft from
of oil can be added before placing the rotating, use one of the compressor to engine
replacement compressor in the unit. mounting screws to pin the tool to the flange.
If a nut is used to prevent the bolt from falling
Installation out, the nut should not be tightened.
1. Place the Compressor Installation Tools on the 4. Use the appropriate Allen tool to loosen the
lower frame rails to support the compressor. coupling mounting screw.
2. Slide the compressor into the unit. 5. Once the center screw has been loosened,
3. Place the compressor in position, install the back the head against the tool and it should
compressor belts on Model 50 units, and push the coupling off the crankshaft as you
install the mounting bolts. continuing turning the center screw in a
counter-clockwise direction. Using this tool
4. Install the service valves using new gaskets will prevent the coupling from popping off
soaked in compressor oil. Connect the HPCO because the center bolt and flatwasher will
wires, the HPCS wires, and install the hold it in place.
compressor oil filter.
144
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 162: Compressor Coupling Removal Tool
145
3. Using no lubricants, set the coupling on the 8. Install the key in the keyway. As above, it
crankshaft and align the keyways using the should fit with a light press fit requiring only a
Keyway Tool (P/N 204-972). Insert the minimum of light tapping. Do not install the
tapered end of the tool into the keyway and key into the keyway beyond the front face
gently move the coupling on the shaft while of the coupling. If tapped in farther it may
pressing the tool into the keyway. This will cause the coupling to move off center on the
align the keyway in the crankshaft with the shaft.
keyway in the coupler.
1
2
3
AGA333
Figure 163: Keyway Tool P/N 204-972
CAUTION: If you are assembling a used

coupler or crankshaft and the tool does 5 4
AGA1254
not fit easily there is a problem with one of
the keyways! Do not remove the coupler
and place the key in the crankshaft 1. Compressor Coupling or Clutch
keyway and then drop the coupler on. If Key tapped flush with outside face of coupling.
2.
the tool does not fit, the key will not fit, Do not tap key any farther into keyway.
and it will hold the taper in the coupler off 3. Torque bolt to 90 ft-lb (122 Nm)
the taper on the shaft. Check both keyways 4. Washer
for burrs or corrosion. A key can be Spray this area with corrosion inhibitor after
5.
coated with fine lapping compound and assembling.
used as a lapping tool to clean the Figure 164: Compressor Coupling Installation
keyways.
9. Re-install the bolt and heavy flat washer and
4. Remove the Keyway Tool and check the fit of snug the bolt down by hand. Torque the bolt to
the key (P/N 55-9024). It should fit into the 90 ft-lb (122 Nm).
keyway with a light press fit requiring only a
minimum of light tapping. If the key does not 10. Spray a corrosion inhibitor (such as spray
fit properly, remove the coupler and inspect paint) on the exposed part of the shaft and the
the keyways and key for burrs or other joint between the shaft and the coupling. This
problems. Recheck the fit as shown above. prevents moisture from wicking into the joint
and causing corrosion.
5. When the key fits properly, remove the
coupling and key from the shaft.
Condenser Coil
6. Re-install the coupling and align the keyways
with the Keyway Tool. Removal
7. Do not install the key at this time. Install the 1. Recover the refrigerant charge.
flat washer and bolt and pre-torque to 20 ft-lb
2. Drain engine coolant from the expansion tank.
(27 Nm). Remove the bolt and washer.
Unbolt and remove the coolant expansion tank
from the condenser coil frame. Unsolder the
tank breather tube.
146
3. Remove the condenser coil mounting bolts. In-Line Check Valves

Remove the mounting clamps from the
condenser inlet line. This unit uses some in-line check valves. An
in-line check valve is not repairable and must be
4. Unsolder the inlet line and liquid line replaced if it fails. A heat sink must be used on the
connections. Lift the coil from the unit. in-line check valve when it is being soldered in
place to prevent damage to the neoprene seal.
Installation
1. Clean the fittings for soldering.
2. Place the coil in the unit and install the
mounting bolts.
3. Solder the inlet line and liquid line
connections.
4. Pressurize the refrigeration system and test for
leaks. If no leaks are found, evacuate the
system.
5. Install the clamps on the condenser inlet line. 1. Valve
6. Install the engine coolant expansion tank and 2. Neoprene Seal
refill half way with engine coolant. 3. Valve Seat
4. Spring
7. Recharge the unit with proper refrigerant and
check the compressor oil. Figure 165: Cross Section of In-line Check Valve
Removal
Discharge Vibrasorber
1. Recover the refrigerant charge.
Removal 2. Place a heat sink on the check valve.
1. Recover the refrigerant charge. 3. Unsolder the lines and remove the check
2. Heat the connections on the vibrasorber until valve.
the vibrasorber can be removed.
Installation
CAUTION: Use a heat sink, P/N 204-584
or wrap the vibrasorber with wet rags to NOTE: A heat sink must be used on the in-line
prevent damaging the vibrasorber. check valve when it is being soldered in place to
prevent damage to the neoprene seal.
Installation 1. Clean the tubes for soldering.
1. Prepare the vibrasorber and tubing fittings by 2. Place the check valve in position. The arrow
cleaning thoroughly. on the valve body indicates the direction of
2. Solder the vibrasorber connections. refrigerant flow through the valve.
3. Place a heat sink on the check valve.
CAUTION: Use a heat sink, (P/N 204-584
or wrap the vibrasorber with wet rags to 4. Solder the inlet and outlet connections.
prevent damaging the vibrasorber.
3. Pressurize the system and test for leaks. If no leaks.
leaks are found, evacuate the system. 6. If no leaks are found, evacuate the system.
4. Charge the unit with the proper refrigerant and 7. Recharge the unit with proper refrigerant and
check the compressor oil level. check the compressor oil.
147
Receiver Tank 2. Install the new drier and tighten the mounting
screws and nuts.
Removal 3. Install and tighten the ORS nuts. Hold the
1. Recover the refrigerant charge. drier with a back-up wrench on the hex behind
the ORS fitting.
2. Unsolder the refrigeration lines from the
receiver tank. 4. Pressurize the low side and inspect for leaks.
If no leaks are found, evacuate the low side.
3. Unbolt the mounting brackets and remove the
receiver tank from the unit. 5. Open the refrigeration valves and place the
unit in operation.
4. Remove the high pressure relief valve from
the receiver tank. It will be installed on the
new receiver tank. Expansion Valve Assembly
NOTE: This procedure applies to the
Installation Zone 1/Host unit expansion valve.
1. Install the high pressure relief valve on the
Removal
new receiver tank. Make sure to use a new
O-ring and coated with refrigerant oil. 1. Pump down the low side and equalize the
pressure to slightly positive.
2. Place the receiver tank in the unit and install
the mounting bolts and nuts loosely. Position 2. Remove the evaporator access panels.
the receiver tank so that the sight glass is
3. Remove the feeler bulb from the clamp. Note
clearly visible.
the position of the feeler bulb on the suction
3. Solder the refrigeration lines to the receiver line.
tank.
4. Disconnect the equalizer line from the suction
4. Tighten the receiver tank mounting hardware line.
securely.
5. Disconnect the inlet liquid line and unsolder
5. Pressurize the refrigeration system and check the distributor from the expansion valve.
for leaks. If no leaks are found, evacuate the
6. Remove the expansion valve mounting bolt
system.
and remove the expansion valve from the unit.
6. Recharge the unit with proper refrigerant.
Installation
Filter Drier 1. Install and bolt the expansion valve assembly
in the unit.
Removal
2. Connect the inlet liquid line and solder the
1. Pump down the low side and equalize the distributor to the expansion valve.
3. Connect the equalizer line to the suction line.
2. Disconnect the ORS nuts at the ends of the
drier. 4. Clean the suction line to a bright polished
condition. Install the feeler bulb clamps and
3. Loosen the mounting hardware and remove the feeler bulb on the side of the suction line
the drier. in its former position. The feeler bulb must
make good contact with the suction line or
Installation operation will be faulty. Wrap with insulating
1. Place the new O-rings in the ORS fittings on tape.
the ends of the drier. 5. Pressurize the low side and test for leaks. If no
leaks are found, evacuate the low side.
148
6. Replace the access panels. 2. Place the heat exchanger assembly in the
evaporator housing and install the mounting
7. Open the refrigeration valves and place the
hardware loosely.
unit in operation.
3. Solder the liquid inlet and the suction outlet
8. Test the unit to see that the expansion valve is
line connections on the condenser side of the
properly installed.
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
7. Tighten the heat exchanger mounting
hardware securely.
8. Replace the evaporator access panels.
AEA713 9. Open the refrigeration valves and place the
unit in operation.
1. End View
2. Side View
Evaporator Coil
Figure 166: Location of Expansion Valve Bulb
NOTE: This procedure applies to the
Zone 1/Host unit evaporator coil.
Heat Exchanger
Removal
Removal
1. Pump down the low side and equalize the
2. Remove the evaporator access panels and
2. Remove the evaporator access panels.
damper assembly.
3. Remove the hardware that holds the heat
3. Disconnect and remove the sensors.
exchanger on the bulkhead.
4. Remove the feeler bulb from the suction line
4. Unsolder the liquid outlet line.
clamp. Note the position of the feeler bulb on
5. Unsolder the suction inlet line. the suction line.
6. Unsolder the remaining outlet suction line and 5. Unsolder the distributor from the expansion
inlet liquid line connections from the valve.
condenser side of the bulkhead. Remove any
6. Unsolder the hot gas line and the suction line
putty from around the lines before unsoldering
from the evaporator coil.
the connections.
7. Remove the mounting bolts, lift and slide the
7. Slide the heat exchanger assembly out of the
coil from the housing.
evaporator housing.
Installation
Installation
1. Place the evaporator coil in the evaporator
1. Clean the tubes for soldering.
housing and install the mounting bolts.
149
2. Solder the hot gas line and suction line 4. Open the refrigeration valves and place the
connections to the evaporator coil. unit in operation. Check the refrigerant charge
and the compressor oil, and add as required.
3. Solder the distributor to the expansion valve.
4. Replace and connect the sensors. Suction Vibrasorber
leaks are found, evacuate the low side. Removal
6. Clean the suction line to a bright polished 1. Pump down the low side and equalize the
condition. Install the feeler bulb on the side of pressure to slightly positive.
the suction line in its former position. The 2. Unsolder the suction vibrasorber from the
feeler bulb must make good contact with the suction service valve.
suction line or operation will be faulty. Wrap
with insulating tape. 3. Unsolder the connection to the accumulator
and remove the vibrasorber from the unit.
7. Replace the upper and lower evaporator
access panels. CAUTION: Use a heat sink or wrap the
vibrasorber with wet rags to prevent
damaging the vibrasorber.
unit in operation. Check the refrigerant charge
and compressor oil. Add as required.
Installation
Accumulator 1. Prepare the suction vibrasorber and tube

fittings for soldering by cleaning thoroughly.
Removal 2. Solder the vibrasorber to the suction service
1. Pump down the low side and equalize the valve.
pressure to slightly positive. CAUTION: Use a heat sink or wrap the
2. Unsolder the inlet and outlet suction lines vibrasorber with wet rags to prevent
from the accumulator. damaging the vibrasorber.
CAUTION: Use a heat sink or wrap 3. Solder the suction hose connection to the
vibrasorber with wet rags to prevent accumulator.
damaging the vibrasorber. 4. Pressurize the low side and check for leaks. If
3. Unbolt and remove the accumulator from the no leaks are found, evacuate the system.
unit. 5. Open the refrigeration valves and place the
Installation and the compressor oil, and add as required.
1. Place the accumulator in the unit and tighten
the mounting bolts and nuts. High Pressure Cutout Switch
2. Solder the inlet and outlet suction lines to the and High Pressure Switch
accumulator.
Removal
CAUTION: Use a heat sink or wrap
vibrasorber with wet rags to prevent
damaging the vibrasorber.
2. Front seat the discharge and suction service
3. Pressurize the low side and test for refrigerant valves. Remove the remaining refrigerant
leaks. If no leaks are found, evacuate the low from the compressor.
side.
150
3. Disconnect the wires and remove the switch 2. Disconnect the wire connector from the
from the compressor discharge manifold. suction pressure transducer.
3. Unscrew the suction pressure transducer from
Installation
the adapter on the end of the tube. Use a
1. Apply a refrigerant Loctite to the threads of backup wrench to hold the adapter.
the switch.
4. Remove the suction pressure transducer.
2. Install and tighten the switch and reconnect
the wires. Installation
3. Pressurize the compressor and test for leaks. 1. Apply refrigerant Loctite to the threads on the
suction pressure transducer.
4. If no leaks are found, open the refrigeration
service valves and place the unit in operation. 2. Screw the suction pressure transducer into the
Check the refrigerant charge and the adapter on the end of the tube. Use a backup
compressor oil, and add as required. wrench to hold the adapter.
3. Pressurize the low side and test for refrigerant
Discharge Pressure Transducer leaks. If no leaks are found, evacuate the low
side.
Removal
1. Recover the refrigerant charge. unit in operation. Check the refrigerant charge
2. Disconnect the wire connector from the and the compressor oil, and add as required.
discharge pressure transducer.
3. Unscrew the discharge pressure transducer
High Pressure Relief Valve
from the adapter on the end of the tube. Use a
Removal
backup wrench to hold the adapter.
4. Remove the discharge pressure transducer.
2. Unscrew and remove the high pressure relief
Installation valve. It is located near the top of the receiver
tank.
1. Apply refrigerant Loctite to the threads on the
discharge pressure transducer.
Installation
2. Screw the discharge pressure transducer into
1. Apply a refrigerant oil to the O-ring of the
the adapter on the end of the tube. Use a
high pressure relief valve.
backup wrench to hold the adapter.
2. Install and tighten the high pressure relief
3. Recharge the unit with the proper refrigerant
valve.
and check the compressor oil.
Suction Pressure Transducer leaks. If no leaks are found, evacuate the
system.
Removal 4. Recharge the unit with the proper refrigerant
1. Pump down the low side and equalize the and check the compressor coil.
151
Throttling Valve 2. Front seat the discharge and suction service

valves. Recover the refrigerant remaining in
See Figure 167 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.
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 167: Throttling Valve Assembly
152
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 169: Inspect for Wear
6. Note the number of shims next to the cap.
These can be reused.
1. Inspect for Damage

Figure 170: Inspect for Damage
1. Inspect Cap
2. Inspect Spring 9. Clean the parts that will be reused.
3. Shims
Reassembly
Figure 168: 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.
153
5. Back off the castle nut, one full turn only. Liquid Line Solenoid Valve
6. Insert the cotter pin. (LLS)
NOTE: Valves that have nylon seats must be
disassembled before soldering.
Removal
1. Pump down the low side and equalize pressure
to slightly positive.
3. Remove the coil and disassemble the valve.
4. Unsolder the liquid lines from the valve, and
remove the valve from the unit.
CAUTION: Use a heat sink to prevent
damage.
1. Tighten castle nut to bottom, then back
off 1 turn only. Insert cotter pin Installation
Figure 171: Throttling Valve Reassembly 1. Clean the tubes for soldering.
7. Oil the gasket and install the end cap. 2. Remove the coil, disassemble the valve, and
8. The throttling valve will have to be place the valve in position.
recalibrated on operating unit. (See the 3. Solder the inlet and outlet connections. After
Specifications Chapter for the setting.) the valve cools, assemble the valve and install
9. Adjust by adding or removing shims under the the coil.
spring.
damage.
Installation
1. Install the throttling valve using a new O-ring 4. Pressurize the refrigeration system and test for
soaked in compressor oil. Bolt the throttling leaks.
valve to the compressor. 5. If no leaks are found, evacuate the system.
2. Install the suction valve. 6. Install the evaporator access panels.
3. Pressurize the compressor and check for leaks. 7. Open the refrigeration valves and run the unit.
If no leaks are found, evacuate the Check the refrigerant charge and compressor
compressor. oil.
unit in operation.
154
Hot Gas Solenoid Valve (HGS) Suction Line Solenoid Valve

NOTE: Valves that have nylon seats must be (SLS)
disassembled before soldering. NOTE: Valves that have nylon seats must be
Removal
1. Pump down the low side and equalize the Removal
pressure in the high side to slightly positive. 1. Pump down the low side and equalize the
2. Remove the evaporator access panels. pressure in the high side to slightly positive.
3. Remove the coil and disassemble the valve. 2. Remove the evaporator access panels.
4. Unsolder the hot gas lines from the valve, and 3. Remove the coil and disassemble the valve.
remove the valve from the unit. 4. Unsolder the suction lines from the valve, and
remove the valve from the unit.
damage. CAUTION: Use a heat sink to prevent
damage.
Installation
1. Clean the tubes for soldering. Installation
2. Remove the coil, disassemble the valve, and 1. Clean the tubes for soldering.
place the valve in position. 2. Remove the coil, disassemble the valve, and
3. Solder the inlet and outlet connections. After place the valve in position.
the valve cools, assemble the valve and install 3. Solder the inlet and outlet connections. After
the coil. the valve cools, assemble the valve and install
the coil.
damage. CAUTION: Use a heat sink to prevent
damage.
leaks. 4. Pressurize the refrigeration system and test for
5. If no leaks are found, evacuate the system. leaks.
6. Install the evaporator access panels. 5. If no leaks are found, evacuate the system.
7. Open the refrigeration valves and run the unit. 6. Install the evaporator access panels.
Check the refrigerant charge and compressor 7. Open the refrigeration valves and run the unit.
oil. Check the refrigerant charge and compressor
oil.
155
Check Valve Repair (SLCV,

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

3
to slightly positive.
4
3. Remove the cap nut, or the four cap mounting
screws and the cap, from the check valve and 5
remove the spring and seat.
AGA173
1
1. Cap
4 2. Gasket
3. Spring
2
4. Seat
5. Body
3
Figure 173: Check Valve with Cap Nut
Installation
1. Inspect the inside of the check valve body for
damage or foreign particles that might adhere
5
to the seat and damage the new seat. If the
body is damaged, replace the check valve.
6 2. Install the new seat and spring. Place a new

AGA172 gasket on the cap and tighten the cap.
3. Pressurize the low side and test for leaks.
1. Cap Mounting Screw
2. Cap 4. If no leaks are found, evacuate the system.
3. Gasket 5. Install the evaporator access panels.
4. Spring
6. Open the refrigeration valves and run the unit.
5. Seat
Check the refrigerant charge and compressor
6. Body oil.
Figure 172: Suction Line Check Valve
156
Check Valve Replacement Installation

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

valve with wet rags to prevent damaging
the valve.
157
Condenser Inlet Check Valve 2. Remove the coil from the valve, and place the
(CICV) Replacement valve in position.
Removal the valve cools, install the coil on the valve.
1. Recover the refrigerant charge. CAUTION: Use a heat sink or wrap the
2. Unsolder the lines and remove the check valve with wet rags to prevent damage.
valve.
NOTE: Disassemble the valve before leaks.
unsoldering.
5. If no leaks are found, evacuate the system.
Installation 6. Recharge the unit with proper refrigerant and
1. Clean the tubes for soldering. check the compressor oil.
2. Place the disassembled check valve in
position. The arrow on the valve body Purge Valve (PV)
indicates the direction of refrigerant flow
through the valve. Removal
3. Solder the inlet and outlet connections. After 1. Recover the refrigerant charge.
the valve cools, reassemble it. 2. Remove the coil from the valve.
4. Pressurize the refrigeration system and test for 3. Unsolder the refrigeration lines from the
leaks. valve, and remove the valve from the unit.
5. If no leaks are found, evacuate the system. CAUTION: Use a heat sink to prevent
6. Recharge the unit with proper refrigerant and damaging the valve.
check the compressor oil.
Installation
Receiver Tank Pressure 1. Clean the tubes for soldering.
Solenoid Valve (RTPS)
2. Remove the coil from the valve, and place the
Removal valve in position.
1. Recover the refrigerant charge. 3. Solder the inlet and outlet connections. After
the valve cools, assemble the valve and install
2. Remove the coil from the valve. the coil.
3. Unsolder the hot gas lines from the valve, and CAUTION: Use a heat sink to prevent
remove the valve from the unit. damaging the valve.
valve with wet rags to prevent damage. 4. Pressurize the refrigeration system and test for
leaks.
Installation 5. If no leaks are found, evacuate the system.
1. Clean the tubes for soldering. 6. Recharge the unit with the proper refrigerant.
158
Compressor Oil Filter Use the following procedure to change the

compressor oil filter.
This unit is equipped with a compressor oil filter.
The compressor oil filter should be changed when 1. Pump down the low side and equalize the
the drier is replaced. pressure to slightly positive.
The outlet fitting is larger than the inlet fitting, so 2. Front seat the discharge and suction service
the compressor oil filter cannot be put on valves. Remove the remaining refrigerant
backwards. There are two fittings on the inlet end from the compressor.
of the compressor oil filter. The inlet fitting 3. Disconnect the oil lines from the compressor
contains a check valve that prevents reverse flow oil filter. Hold the oil filter with back-up
through the compressor oil filter. The capped wrench on the hex behind the ORS fitting.
fitting is called the oil pressure access port and is
used to check the compressor oil pressure (see 4. Remove the clamp and the compressor oil
Checking Compressor Oil Pressure on filter.
page 159). 5. Coat the new O-rings with clean compressor
oil and place them in the ORS fittings on the
ends of the new compressor oil filter.
6. Fasten the new compressor oil filter in place
with the clamp.
7. Attach and tighten the oil lines to the
compressor oil filter. Hold the oil filter with a
back-up wrench on the hex behind the ORS
fitting.
8. Evacuate the compressor and filter to a
maximum of 500 microns to remove trapped
air.
9. Open the service valves, operate the system,
and check the compressor oil filter for leaks.
1 Checking Compressor Oil

Pressure
The oil pressure at the oil pressure access port
3 varies with the suction pressure in the compressor.
Therefore, we need to calculate the net oil
pressure to determine the actual compressor oil
2 pressure. The net oil pressure is the pressure at the
AEA718
oil pressure access port minus the suction pressure
1. Oil Pressure Access Port
below the throttling valve. Use the following
procedure to check the compressor oil pressure.
2. Inlet Fitting
3. Outlet Fitting 1. Attach a suitable oil pressure gauge to the oil
pressure access port on the compressor oil
Figure 174: Compressor Oil Filter
filter.
159
2. Attach the low pressure gauge of a gauge NOTE: The microprocessor will probably
manifold to the fitting on the side of the record some alarm codes because the
throttling valve. This fitting allows you to solenoids are disconnected and the engine
monitor the suction pressure in the compressor does not start. Clear these alarm codes as
below the throttling valve. necessary.
3. Start the unit and note the pressure at the oil 5. Turn the unit on and let the engine crank (or
pressure access port and the suction pressure crank the engine) for 30 seconds, but do not
below the throttling valve. crank the engine for more than 30 seconds.
4. Subtract the suction pressure below the a. Note the pressure at the oil pressure access
throttling valve from the pressure at the oil port and the suction pressure below the
pressure access port to get the net oil pressure. throttling valve while the engine is
cranking. Subtract the suction pressure
Pressure at Oil Pressure Access Port
below the throttling valve from the
Suction Pressure Below Throttling Valve
pressure at the oil pressure access port to
= Net Oil Pressure
get the net oil pressure.
5. The net oil pressure should be at least 20 psi b. If the compressor does not develop at least
(138 kPa). If the net oil pressure is low, first 10 psi (96 kPa) of net oil pressure in the
check the compressor oil level, then check the first 30 seconds, allow the starter to cool
compressor oil pump and relief valve. for a few minutes and the crank the engine
again for 30 seconds. If 10 psi (96 kPa) of
Priming New Compressor net oil pressure still does not develop, first
Installations check the compressor oil level, then check
the compressor oil pump and relief valve.
Thermo King remanufactured compressors have
had a special break in process to assure that the oil 6. As soon as the compressor develops 10 psi
pump is primed, functioning, and broken in. The (96 kPa) of net oil pressure, re-connected the
following procedure is recommended, but not fuel solenoid wires, but do not re-connect the
required for factory-remanufactured compressors. high speed solenoid wires.
This procedure must be followed to prevent 7. Start unit and run the engine on low speed for
premature pump failure in any compressor that at least five minutes. If the net oil pressure is
has had an oil pump installed, especially a above 20 psi (138 kPa) for this period, stop the
compressor that has been stored for any length of unit and re-connect the high speed solenoid
time. wires.
1. Attach a suitable oil pressure gauge to the oil 8. Run the engine on high speed for at least five
pressure access port on the compressor oil more minutes. The compressor oil pump is
filter. now primed and broken in.
2. Attach the low pressure gauge of a gauge
manifold to the fitting on the side of the
throttling valve. This fitting allows you to
monitor the suction pressure in the compressor
below the throttling valve.
3. Disconnect the wires to the fuel solenoid.
4. Disconnect the wires to the high speed
solenoid.
160
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 175: 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).
161
Defrost Damper 4. If necessary, adjust Distance A to the proper

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

2. Mounting Bolts 7. Round Stop
3. Closed Position 8. Distance A 2.75 in. (69.85 mm)
4. Open Position 9. Solenoid
5. Damper Link
Figure 176: Defrost Damper Adjustment
162
8. De-energize and energize the damper several 5. Pass a gauge wire completely around the
times to make sure that the damper operates blower orifice to check for uniform clearance.
correctly and seals properly.
6. Spin the blower by hand to check for blower
9. Make sure the damper blade rests on the round distortion.
stops when the damper is open. Adjust the
7. Position the blower so the edge of the inlet
round stops if necessary.
ring lines up with the alignment mark on the
10. Install the damper assembly in the evaporator. blower.
8. Torque blower hub bolts to 18 ft-lb (24 Nm).
Condenser and Evaporator Fan
Location Evaporator Fan Blower Alignment
When mounting the condenser or evaporator fan 1. Loosen the inlet rings on the sides of the
and hub assembly on the fanshaft, the blowers and blower housing.
inlet orifices must be properly aligned for proper
air flow and to prevent damage to the blower. 2. Center the blower wheel in the blower housing
with equal overlap on both inlet rings. The
overlap on each ring should be approximately
Condenser Fan Blower Alignment 0.15 in. (3.8 mm).
1. Loosen the condenser inlet ring (spinning) on
the condenser coil bulkhead. 3. Tighten the hub bolts that hold the blower
wheel on the fanshaft.
2. Slide the blower towards the inlet ring until it
contacts the inlet ring. This centers the inlet 4. Center the inlet rings in the blower orifices.
ring in the blower orifice. Tighten the inlet rings securely.
3. Tighten the inlet ring securely. 5. Check the radial clearance by passing a wire
completely around the circumference of the
4. Slide the blower away from the inlet ring. inlet rings and the blower wheel.
1 6. Torque the blower hub bolts to 18 ft-lb
2
(24 Nm).
AEA720
1. Check Clearance with a Wire

2. Blower Housing Sides
AEA749
3. Inlet Rings
4. Evaporator Blower
1. Blower Wheel 3. Alignment Mark
5. Radial Clearance
2. Inlet Ring 4. Edge of Inlet Ring
6. Equalize Blower Inlet Overlap
Figure 177: Condenser Blower Alignment
Figure 178: Evaporator Fan Location
163
Fan Shaft Assembly 2. After draining the oil from the housing,
remove the four retaining bolts from the
The unit is equipped with a one-piece fan shaft condenser end of the assembly.
assembly that contains tapered roller bearings in a
sealed oil reservoir. 3. To remove the shaft from the assembly, tap the
opposite end of the shaft with a soft hammer.
This assembly does not require any maintenance. After the shaft has been removed, clean all
There is a level plug and a fill plug, but they are parts in clean solvent.
not normally used except after removal and repair
of the fan shaft assembly. The condenser and 4. Using a punch, remove the oil seal from the
evaporator end oil seals should be checked during evaporator end of the assembly. With the seal
the pretrip inspection for oil leakage. If there is removed, clean the housing in clean solvent.
any sign of leakage, the fan shaft assembly should 5. Check the condition of the vent. If it is loose
be removed and repaired. or damaged, it must be repaired or replaced.
NOTE: The fan shaft assembly requires a
6. After all the parts are cleaned, inspect the
special lubricant, Thermo King P/N 203-278.
bearings and bearing races for wear or
damage.
Fan Shaft Assembly Overhaul
7. If necessary, remove the bearings by tapping
Disassembly them off the shaft with a hammer and a punch.
Be careful not to damage the shaft with the
1. Remove the fan shaft assembly from the unit.
punch.
Remove both oil plugs and drain the oil from
the housing. 8. The bearing races can now be driven out with
a punch and replaced in the same manner.
AEA721
1. Cap and Shims 6. Oil Seal

2. Oil Plug Screw (Use Oil P/N 203-278) 7. Shaft
3. Breather Vent 8. Sleeve
4. Housing 9. Pin
5. Roller Bearing 10. O-ring
Figure 179: Fan Shaft Assembly
164
Reassembly Idler Assembly

1. Tap the new bearings on the shaft with a pipe. The unit is equipped with a one-piece idler
2. Install new oil seals after replacing the bearing assembly that contains tapered roller bearings in a
races. sealed oil reservoir. This assembly does not
require any maintenance. There is a level plug and
3. Replace the shaft in the housing. Install a new a fill plug, but they are not normally used except
seal in the retainer cap. Use the original shims after removal and repair of the idler assembly. The
and replace the O-ring if needed. roadside end oil seal and the curbside end oil seal
4. Install the retainer cap assembly over the should be checked during the pretrip inspection
shaft, then install the bolts. for oil leakage. If there is any sign of leakage, the
idler assembly should be removed and repaired.
5. Torque the bolts in a criss-cross pattern in
equal steps to 80 in-lb (9.04 Nm). Idler Assembly Overhaul
6. Lock the assembly in a vise and set up a dial
indicator to read end-play. To measure the Disassembly
end-play, rotate the shaft while pushing in one 1. Remove the idler assembly from the unit.
direction and set the dial indicator to 0. Now Remove both oil plugs and drain the oil from
rotate the shaft and pull in the opposite the housing.
direction while reading the dial indicator.
End-play should be 0.001 to 0.005 in. (0.025 2. After draining the oil from the housing,
to 0.127 mm). If end-play is incorrect, use remove the four retaining bolts from the
different shims to obtain correct end-play. curbside end of the assembly.
3. To remove the shaft from the assembly, tap the
Shims available from the Service Parts
opposite end of the shaft with a soft hammer.
Department
After the shaft has been removed, clean all the
0.020 in. (0.500 mm) Thermo King P/N 99-4231
parts in clean solvent.
4. Using a punch, remove the oil seal from the
curbside end of the assembly. With the seal
7. After correct end-play is obtained, add oil for removed, clean the housing in solvent.
the bearings.
5. Check the condition of the vent. If it is loose
8. Lock the assembly in a vise with the vent or damaged, it must be repaired or replaced.
facing up. Pour the oil (P/N 203-278) through
6. After all the parts are cleaned, inspect the
the top plug until it runs out of the side hole.
bearings and bearing races for wear or
The assembly holds 2.5 oz (74 ml). Check the
damage.
condition of the O-ring used on the plugs and
replace if necessary. Install the top and side 7. To replace the bearings, first drive bearing off
plugs. Clean up any spillage. shaft with a punch at notch in the base of the
shaft.
9. Place the assembly on the workbench with the
vent up. Rotate the shaft by hand. The shaft
Reassembly
should be free enough to rotate without having
to hold the housing. 1. Install the new bearings on the shaft with a
pipe. Place the pipe over the shaft and drive
CAUTION: When installing the fan shaft bearing down. Turn the shaft upside down,
assembly, make sure that the vent is and use the pipe to drive the other bearing
mounted facing up. down.
2. Install a new oil seal on the curbside end of
the assembly after replacing the bearing race
and splash guard.
165
3. Replace the shaft in the housing. Install a new 7. After the correct end-play is obtained, add
seal in the retainer cap. Use the original shims approximately 1.1 oz (33 ml) of oil
and replace the O-ring if needed. (P/N 203-278) for the bearings.
4. Install the retainer cap assembly over the 8. Lock the assembly in a vise with the vent
shaft, then install the bolts. facing up. Pour the oil through the top plug
until it runs out of the side hole. Check the
5. Torque the bolts in a criss-cross pattern in
condition of the O-ring used on the plugs and
equal steps to 80 in-lb (9.04 Nm).
replace if necessary. Install the top and side
6. Lock the assembly in a vise and set up a dial plugs. Clean up any spillage.
indicator to read end-play. To measure the
9. Place the assembly on the workbench with the
end-play, rotate the shaft while pushing in one
vent up. Rotate the shaft by hand. The shaft
direction, and set the dial indicator to 0.
should be free enough to rotate without having
Now rotate the shaft and pull in the opposite
to hold the housing.
direction while reading the dial indicator.
End-play should be 0.001 to 0.005 in. (0.025 CAUTION: Reinstall the assembly into
to 0.127 mm). If end-play is incorrect, use the unit, making sure the vent is mounted
different shims to obtain correct end-play. facing up.
Shims available from the Service Parts
Department
AEA722
1. Oil Seal 6. Shaft

2. Cap and Shims 7. Housing
3. O-ring 8. Breather Vent
4. Roller Bearing 9. Oil Plug Screw (Use Oil P/N 203-278)
5. Splash Guard Tube
Figure 180: Idler Assembly
166
Mechanical Diagnosis
Condition Possible Cause Remedy

Engine will not crank Electrical problem Check and repair electrical system
Defective starter solenoid Replace solenoid
Defective starter Repair starter
Water in cylinders Check for hydrostatic lock. Remove
injectors and turn engine slowly
Starter motor turns but engine Starter clutch defective Replace
does not crank
Engine cranks but fails to start Fuel solenoid not energized Check 8D and 8DP circuits and fuel
solenoid 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
Engine stops after starting Air in injection pump Bleed fuel system
Fuel filter obstructed Replace filter element
High head pressure Eliminate cause of high head
pressure
Vent of fuel tank obstructed Unclog vent
Clogged fuel tank or fuel lines Clean fuel tank and fuel lines
Engine does not develop full Air intake system clogged Clean air intake system
power Fuel tank vent clogged Unclog vent
Clogged fuel tank or fuel lines Clean fuel tank and fuel lines
Speed adjustment wrong Adjust speed
Insufficient fuel volume leaving filter Check for dirty filter or air in system
Air cleaner clogged Replace air filter
Delivery of fuel pump insufficient Repair pump
Injection pump timing off Adjusting timing
Injection nozzles defective Repair or replace nozzles
Compression low or unbalanced Overhaul engine
Worn injection pump plungers, Repair or replace pump
delivery valve defective, injection
rate too low, gum formations
167

Engine speed too high Misadjusted high speed solenoid Adjust high speed solenoid
Defective injection pump Repair injection pump
Engine fails to stop when unit is Fuel solenoid defective Replace
Off Injection pump defective Replace pump
Engine knocks heavily Air in system Bleed fuel system
Injection pump not timed Retime injection pump
Wrong fuel Change fuel
Compression too low Overhaul engine
Injection nozzles fouled or opening Clean, repair or replace injection
pressure too low nozzles
Delivery valve spring broken Replace spring or repair injection
pump
Valve out of adjustment Adjust valves
Fuel return line plugged Remove return line restriction
Rod or main bearing worn Replace rod or main bearings
Engine runs hot Dirty radiator Wash radiator
Coolant level is low Add coolant
Cooling system heavily scaled Cleaning cooling system
Cylinder head gasket leaks Replace cylinder head gasket. Use
correct gasket
Faulty thermostat Check or replace thermostat
Loose or worn water pump belt Replace belt
Oil pressure low Insufficient oil in pan Add oil
Faulty oil pressure switch Check oil pressure switch. Replace if
necessary
Oil control valve defective Check oil pressure control valve
Worn oil pump, camshaft, main or Repair engine
connecting rod bearings, loose oil
gallery plug
High oil consumption Oil leakage Check and eliminate possible
causes at rocker arm cover, oil lines,
oil filter, front timing cover or
crankshaft seals
Damaged valve seals Replace seals on valve stem
Worn valve stem Replace valves
Broken piston rings or cylinder bore Have engine repaired and rebored.
worn or scored Replace broken piston rings
Clogged air cleaner system Unclog air cleaner
168
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
169
170
Electric Standby Diagnosis

Unit turned ONLCD Blank Battery discharged Charge or replace battery
Faulty battery cable connections Clean battery cables
Check for short circuit and replace
Fuse link blown
fuse link
Check for short circuits and replace
Fuse F2 blown
fuse
Open circuit Check HMI Harness
Unit turned ON and LCD Diesel operation selected Select ELECTRIC
backlight ON but motor will not
start and run Unit in NULL Check setpoint and box temperature
Check for short circuit and replace

Fuse F1 blown
fuse
Faulty HPCO Check HPCO
Determine cause and rest or
Open or faulty overload relay
replace overload relay
Faulty PSM Check PSM
Faulty motor contactor Check motor contactors
Check 8, ER, 7E, 7EA, 7EB, 7EC,
Open circuit
CH, L1, L2, and L3 circuits
Faulty drive motor Check drive motor
Faulty electric standby power Check electric standby power
source source
Evaporator heaters do not heat Faulty heater contactor Check heater contactor
Check 7E, 26E, L1, L2, L3, BRN,
Open circuit
BLU and BLK circuits
Faulty heaters Check heaters
171
Electric Standby Diagnosis
172
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
173
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)
174
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 92 and Expansion Module on page 93)
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
175
Remote Evaporator Specifications
176
Remote Evaporator Maintenance Inspection
Schedule
Every Every Annual/

Hours Hours* Hours
Electrical
Inspect/replace DC fan motors.
Structural
Visually inspect unit for damaged, loose, or broken parts.
Clean entire unit including evaporator coils and defrost drains.
Check all unit mounting bolts, brackets, lines, hoses, etc.
177
Remote Evaporator Maintenance Inspection Schedule
178
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 181: SPECTRUM S-3 Evaporator Components
179
AJA984
Figure 182: SPECTRUM S-3 Evaporator - Front View
AJA985
Figure 183: SPECTRUM S-3 Evaporator - Back View
180
The SPECTRUM SB 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 evaporator(s). The evaporator fan stops during defrost. The
The host unit mounts on the front of the trailer Defrost mode will continue until the evaporator
with the evaporator protruding into the trailer. The coil temperature rises to 58 F (14.5 C), causing
remote evaporator(s) 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(s) are 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(s) 12 Vdc Fan Motor
at 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.
181
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 184: Serial Number Location
182
Remote Evaporator Electrical Maintenance
SR-2 Multi-Temp
Microprocessor Controlled
Components
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.
183
Remote Evaporator Electrical Maintenance
184
Remote Evaporator Refrigeration Service
Operations
NOTE: It is generally good practice to replace Evaporator Coil
the filter drier whenever the high side is opened
or when the low side is opened for an extended Removal
period of time.
Expansion Valve Assembly
2. Disconnect the distributor from the expansion
Removal valve.
1. Pump down the low side and equalize the 3. Remove the insulating tape and feeler bulb
pressure to slightly positive. Remove the from the suction line. Note the position of the
evaporator access panels. feeler bulb on the suction line. Disconnect the
equalizer line from the suction line.
2. Disconnect the liquid inlet line and distributor
from the expansion valve. 4. Heat and unsolder the suction line connection
to the evaporator coil.
3. Remove the feeler bulb from the clamp. Note
the position of the feeler bulb on the suction 5. Remove the mounting bolts and slide the coil
line. from the housing.
4. Disconnect the equalizer line. Installation
5. Remove the expansion valve assembly from 1. Place the evaporator coil in the evaporator
the unit. housing and install the mounting bolts.
Installation 2. Clean and solder the suction line connections
to the evaporator coil.
1. Place the expansion valve in the unit.
3. Connect the distributor to the expansion valve.
2. Connect the equalizer line to the expansion
valve. 4. Clean the suction line to a bright polished
condition. Install the feeler bulb clamps and
3. Connect the liquid inlet line and distributor to the feeler bulb on the suction line. Locate the
the expansion valve. bulb on the side of the suction line in its
4. Clean the suction line to a bright polished former position. The feeler bulb must make
condition. Install the feeler bulb clamps and good contact with the suction line or the
feeler bulb on the side of the suction line in its operation will be faulty. Wrap it with
former position. The feeler bulb must make insulating tape.
good contact with the suction line or the 5. Connect the equalizer line to the suction line.
operation will be faulty. Wrap it with
insulating tape. 6. Pressurize the low side and test for leaks. If no
leaks are found, evacuate the low side. 7. Install the access panels.
6. Install the access panels. 8. Open the refrigeration valves and place the
7. Open the refrigeration valves and place the and compressor oil. Add as required.
unit in operation.
8. Test the unit to see that the expansion valve is
properly installed.
185
Remote Evaporator Refrigeration Service Operations
Solenoid Valves Liquid Return Check Valve

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

place the valve in position.
the valve cools, assemble the vale and install
AGA173
the coil.
CAUTION: Use a heat sink to prevent 1. Cap
damaging the valve. 2. Gasket
3. Spring
4. Pressurize the low side and test for leaks. If no 4. Seat
leaks are found, evacuate the low side. For the
5. Body
hot gas valve, pressurize the refrigeration
system and test for leaks If no leaks are found, Figure 185: Check Valve with Cap Nut
evacuate the system.
Installation
5. Install the access panels.
1. Inspect the inside of the check valve body for
6. Open the refrigeration valves and run the unit. damage or foreign particles that might adhere
Check the refrigerant charge and compressor to the seat and damage the new seat. If the
oil. Add as required. For the hot gas valve, body is damaged, replace the check valve.
recharge the unit with proper refrigerant.
2. Install the new seat and spring. Place a new
gasket on the cap and tighten the cap nut.
4. If no leaks are found, evacuate the low side.
oil.
186
Liquid Return Valve Installation

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

heat exchanger.
pressure to slightly positive. 3. Reinstall the mounting hardware used to
mount heat exchanger to the panel.
2. Remove the access panels.
4. Solder the refrigeration lines from the heat
3. Unsolder the lines and remove the check exchanger ports to the tubes.
valve.
NOTE: Disassemble the valve before
damage to nearby valves.
unsoldering.
Installation leaks.
1. Clean the tubes for soldering. 6. If no leaks are found, evacuate the low side.
2. Place the disassembled check valve in 7. Install the access panels.
position. The arrow on the valve body
indicates the direction of refrigerant flow 8. Open the refrigeration valves and run the unit.
through the valve. Check the refrigerant charge and compressor
oil. Add as required.
the valve cools, reassemble the valve.
5. If no leaks are found, evacuate the low side.
oil.
Heat Exchanger
Removal
2. Remove the access panels.
3. Remove the mounting hardware used to
mount heat exchanger to the panel.
4. Unsolder the refrigeration lines from the heat
exchanger ports and remove it from the unit.
damage to nearby valves.
187
188
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.
189
Remote Evaporator Structural Maintenance
190
Remote Evaporator System Diagnosis

Load temperature too high Refrigerant shortage Repair leak and recharge
Setpoint too high Adjust setpoint
Expansion valve plugged Clean or replace
Partial obstruction in low side of Locate obstruction and repair
refrigeration system
Iced or dirty evaporator coil Defrost or clean evaporator coil
Expansion valve open too much Replace or adjust valve
Poor fitting trailer door Repair or replace doors
Liquid line solenoid partially closed Repair or replace
or defective
Evaporator fan not operating Check and correct evaporator fan
Evaporator fan motor does not
Open in 2A circuit Locate open and repair
run
Open in FM circuit Locate open and repair
Open circuit between interface board Locate open and repair
and expansion module
Defective fan motor Replace fan motor
Defective expansion module Replace expansion module
191
Remote Evaporator System Diagnosis
192
Index
A compressor oil
AC components 95 checking 137
accumulator, replacement 150 compressor oil filter, replacement 159
adjust brightness menu 84 compressor oil pressure, checking 159
air cleaner 123 compressor oil sight glass 35
air cleaner restriction indicator 35 condenser coil, replacement 146
air cleaner, EMI 3000 123 condenser inlet check valve
air heater 94 repair 157
air restriction indicator 124 replacement 158
alarms menu 64 condenser inlet solenoid valve, replacement 157
alternator 87 continuous mode
field current test 90 selecting 57
general diagnostic and warranty evaluation proce- control panel 43
dure 89 display 44
identification 87 keys 44
load test 89 coolant level switch 36, 104
antifreeze checking the float 104
changing 103 replacing 105
checking 103 testing 104
maintenance procedure 102 cooling system, engine 101
auto phase system 95 bleeding air from 103
crankcase breather
B TK486V (Tier 2) 122
battery 91 CYCLE-SENTRY
battery cables 91 operation 27
belt adjustments, model 30 125 selecting 57
alternator belt 125 start-stop controls 27
upper and lower fan belts 125
belt adjustments, model 50 127 D
alternator belt 127 data logging 28
compressor belts 127 datalogger (CargoWatch) menu 69
fan belt 127 defrost 29
water pump belt 127 remote evaporator 181
belt replacement, model 30 defrost damper, adjustment 162
lower fan belt 126 defrost drains 161
upper fan belt 126 defrost drains, remote evaporator 189
belt replacement, model 50 Defrost key 44
compressor 128 design features 25
fan 129 diagnosis
belts 124 electric standby 171
mechanical 167
C refrigeration 173
charging refrigeration system 140 remote evaporator system 191
charging system diagnostic procedures 87 diagrams
check valve fuel line routing 197
repair 156 refrigeration system 29
replacement 157 wiring 197
clutch 129 diesel mode, selecting 83
dowel pin replacement 134 discharge pressure transducer, replacement 151
drive bushing replacement 131 discharge vibrasorber, replacement 147
cold start device 119
compressor E
priming new compressor installations 160 ELC (Extended Life Coolant) 101
replacement 143 electric power receptacle 51
X430L 26 electric standby
compressor coupling operation 51
installation 145 selecting 83
removal 144 starting unit on 52
193
Index
electrical contactors 95 hourmeters menu 71

EMI 3000 99
engine compartment components 35 I
engine coolant temperature sensor 36 idler assembly 165
engine speed adjustments 110 overhaul 165
high speed 110 injection pump
low speed 110 reinstallation 114
evacuating and charging multi-temp systems 138 removal 114
evacuating refrigeration system 139 timing 111
evaporator coil, replacement 149 in-line check valves, replacement 147
evaporator heaters 95 inspection, unit 161
expansion module 93 installation, unit 161
LEDs 93 interface board LEDs 92
expansion valve, replacement 148
K
F keypad lockout 73
fan alignment selecting 76
condenser blower 163
evaporator blower 163 L
fan shaft assembly 164 language menu 62
overhaul 164 liquid line solenoid valve, replacement 154
filter drier, replacement 148 loading procedure 85
first aid 18 low oil level switch 36
electrical shock 18 low oil pressure 99
engine coolant 18 low oil pressure switch 36
refrigerant 18 low side pump down 143
refrigerant oil 18 lubrication system, engine 99
fuel filter/water separator, replacement 109
fuel line routing 106
M
fuel return line replacement 108
main menu
fuel solenoid 116
choices 60
replacement 117
navigating 60
testing 116
manual defrost cycle, initiating 58
fuel system 106
manual pretrip inspection 45
bleeding 108
microprocessor On/Off switch 43
maintenance 106
Mode key 44
fuel tank, draining water from 109
mode menu 73
fuse link 36, 94
moisture indicating sight glass 136
fuses 36, 91
mounting bolts, unit and engine 161
G
O
gauges menu 66
Off key 44
general description 25
oil change, engine 99
oil filter change, engine 99
H On key 44
high pressure cutout 36 opening front doors 34
high pressure cutout switch (HPCO) operating modes, remote evaporator 181
replacement 150 OptiSet 28
testing 137 overload relay 36
high pressure relief valve 36
replacement 151
P
high pressure switch (HPCS)
post load procedure 86
replacement 150
post trip checks 86
testing 138
preheat buzzer 36
high pressure switch (HPSW)
pretrip tests 79
replacement 150
priming new compressor installations 160
HMI control panel 43
protection devices 35
host unit 26
purge valve, replacement 158
hot gas solenoid valve, replacement 155
194
Index
R start of trip, initiating 69

receiver tank pressure solenoid valve, replacement suction line solenoid valve, replacement 155
158 suction pressure transducer, replacement 151
receiver tank sight glass 35 suction vibrasorber, replacement 150
receiver tank, replacement 148 system operation 29
refrigerant charge 135
adjusting refrigerant level 136 T
testing for an overcharge 135 temperature watch display 49
testing with a loaded trailer 135 thermostat, engine 104
testing with an empty trailer 135 throttling valve 152
refrigerant leaks 136 installation 154
remote control box 28 reassembly 153
remote evaporator coil removal 152
cleaning 189 time display 85
replacement 185 trip report, printing 70
remote evaporators 26 trochoid feed pump 118
remote expansion valve, replacement 185
remote heat exchanger, replacement 187 U
remote liquid return check valve unit description 25
repair 186 remote evaporator 179
replacement 187 unit features, remote evaporator 181
remote solenoid valves, replacement 186 unit inspection, remote evaporator 189
routing unit operation
fuel line 106 remote evaporator 181
wire harness 95 unit overview 25
unit protection devices
S remote evaporator 182
safety precautions 15 unit wiring 95
battery removal 16
electrical hazards 17 V
general practices 15 valve clearance adjustment, engine 120
microprocessor service precautions 17
refrigerant hazards 16 W
refrigerant oil hazards 16
wire harness routing 95
welding precautions 18
selection of operating modes 56
sensors menu 68
Z
serial number locations 37 zone, turning on and off 55
remote evaporator 182
setpoint, changing 54
single temperature loading procedures 85
single zone control 48, 73
selecting 75
sleep mode 73
selecting 77
Smart FETs 36, 92
SMART REEFER 2 (SR-2) Control System 43
soft keys 45
specifications
belt tension 20
electric standby 21
electrical components 21
electrical control system 20
engine 19
refrigeration system 20
remote evaporator electrical 175
remote evaporator refrigeration system 175
SR-2 Control System 43
standard display 47
195
Index
196
Diagrams Index
Drawing No. Drawing Title Page
1E34219 Schematic Diagram 199-205
1E34218 Wiring Diagram 206-213
Model 30 with Tier 2 Engine Fuel Line Routing Diagram 214-216
Model 50 with Tier 2 Engine Fuel Line Routing Diagram 217-219
197
Schematic Diagram - Page 1 of 7
199
200
201
202
203
204
205
Wiring Diagram - Page 1 of 8
206
207
208
209
210
211
212
213
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
214
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
215
1. Outlet from Fuel Filter to Injection Pump

2. Return from Injection Pump to Fuel Filter
3. Injection Pump
5. Inlet from Fuel Tank to Fuel Transfer Pump
6. Outlet from Fuel Transfer Pump to Fuel Filter
7. Return from Fuel Filter to Fuel Tank
216

2. Screw 1/4-20 X 0.75 in. 55-145
3. Flatwasher 1/4 in. (2) 55-411
4. Nylock Nut 1/4 in. 55-4118
6. 3/8 in. Inlet Line from Fuel Tank
7. 1/4 in. Return Line to Fuel Tank
217
1. Inlet to Fuel Transfer Pump

2. Return to Fuel Tank
3. Return from Injection Pump
4. Inlet from Fuel Transfer Pump
5. Outlet to Injection Pump
6. Fuel Filter 11-9342
7. Clamp 1-1/4 in. Diameter 55-5274
10. Flatwasher M8 55-7069
11. Lockwasher M8 55-7727
12. Screw M8 X 110 55-5424
218
1. Outlet from Fuel Filter to Injection Pump

2. Return from Injection Pump to Fuel Filter
3. Injection Pump
5. Inlet from Fuel Tank to Fuel Transfer Pump
6. Outlet from Fuel Transfer Pump to Fuel Filter
7. Return from Fuel Filter to Fuel Tank
219

SPECTRUM SB 30 50 SR-2 (TK53087-2-MM Rev 0, 01-07)

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SPECTRUM SB

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

For further information, refer to:

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

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

In addition, service personnel must be aware of Federal regulations

Refrigeration Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135

Structural Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161

Figure 59:Viewing and Clearing Alarms Screen Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

Figure 119:Place Injection Angle Sticker on Gear Case . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111

Figure 179:Fan Shaft Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164

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

NOTE: In the USA, EPA Section 608

Battery Removal CAUTION: When transferring

Electrical Hazards WARNING: Do not wear jewelry, watches

Welding Precautions INHALATION: Move victim to fresh air and use

Electrical Control System

Electric Standby (Model 50 Units Only)

Electric Heater Strips

Standby Power Requirements

Host Unit (Continued)

Unit Overview Key Features & Options Model Model

Standard Features TracKing Cellular TBA TBA

Host Unit Thermo King X430L Compressor

Data Logging OptiSet

Remote Control Panel (Optional)

All zones can cool at the same time.

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

Host Unit and Zone 1 Evaporator

Figure 4: Zone 1 Cool, Zone 2 Cool, and Zone 3 Cool

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

Host Unit and Zone 1 Evaporator

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

Opening the Front Doors Opening the Secondary Door Latch

1. Air Filter Restriction Indicator 9. Alternator

Serial Number Locations

1. Serial Number Location

1. Serial Number Location

1 Figure 12: Laminated Serial Number Plate

1. Serial Number Location

Figure 13: Front View

SMART REEFER 2 Multi-Temp HMI Control Panel

Microprocessor On/Off Switch ON

This switch supplies or removes electrical power OFF

ZONE 1 ZONE 2 ZONE 3 MENU

Display NOTE: Zone 1 is always on when the control

ZONE 1 ZONE 2 ZONE 3 MENU

1. Off Key (Hard Key)

The four soft keys under the display

Unit Operation Turning Unit On

NOTE: With extremely cold ambient Turning Unit Off

OFF -10 35 POINT

ZONE 1 ZONE 2 MENU

TEMP F Figure 22: Press Off Key

ARA796 3. The System is Powering Down Screen will

ZONE 1 ZONE 2 MENU

3. The Configuring System Screen briefly

Standard Display Three Zone Standard Display

4 ZONE 1 ZONE 2 ZONE 3 MENU

1. Continuous Mode 5. Zone 1 Soft Key

Single Zone Control Standard Display Method 2:

Standard Display Variations 1

Starting the Diesel Engine

Figure 32: Starting Diesel Engine Display