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caution - Sunbelt Transport Refrigeration

1. LJ Manual Fuel Pump Plunger NON ESC ENGINE Figure 6 4 Priming Fuel Pump 6 7 2 Electrical Fuel Pump If the unit is equipped with an optional electrical fuel pump it will be mounted on the fuel tank mounting bracket Use the following steps to bleed out the fuel system a Turn the bleed valve Red counter clockwise until fully opened See Figure 6 4 b Place unit in Manual Start Mode ManOp See Sec tion 3 2 Once the Run Relay energizes the fuel pump will start 62 10450 6 8 c Allow the electric pump to operate for 2 3 minutes d Place controller in Auto Op to start engine e When engine is running properly turn bleed valve clockwise until fully closed 6 8 Servicing Fuel Pump The fuel filter may become plugged or restricted with for eign particles or wax as a result of using the wrong grade of fuel or untreated fuel in cold weather This will cause the engine to lose capacity The filter must be cleaned on a regular schedule such as unit pre trip or when the oil and fuel filters are changed Refer to Section 6 1 a Turn bolt counter clockwise to loosen and remove item 1 Figure 6 5 NOTE Once bolt is removed fuel may drain from the fuel line Care should be taken to avoid sp
2. 4 5 20 Figure 5 11 Micro Diagnostic Tree Cond 6 Unit will not run in low speed 5 21 Figure 5 12 Micro Diagnostic Tree Cond 7 Data Recorder Data Download Problems when using ReeferManager and a download cable 5 22 vii 62 10450 FIGURE NUMBER Page Figure 6 1 Door Latch Maintenance And Grille Insert 6 5 Figure 6 2 Surround Removal 1 2 2 2 6 6 Figure 6 3 Side Door Latch Lower Cable Removal 6 7 Figure 6 4 Priming Fuel 1 2 2 6 8 Figure 6 5 Mechanical Fuel Pump 6 9 Figure 6 6 Fuel System Diagram 6 10 Figure 6 7 Lube Oil Flow Diagram 6 10 Figure 6 8 Speed Control Solenoid 6 11 Figure 6 9 Electronic Speed Control Components 6 11 Figure 6 10 Frame Mounted Engine Speed Control Unit 6 12 Figure 6 11 DI Engine Crankcase 6 12
3. 6 34 Figure 6 27 Discharge Check Valve Serviceable Prior to S N JAW90756460 6 34 Figure 6 28 Discharge Check Valve Non Serviceable Beginning With S N JAW90756460 6 35 Figure 6 29 Hot Gas Check Valve Non Serviceable 6 35 Figure 6 30 Thermostatic Expansion Valve Bulb and Thermocouple 6 36 Figure 6 31 Typical Setup for Testing High Pressure Switch 6 37 Figure 6 32 SV 2 SV 4 MARKING 6 38 Figure 6 33 SV 2 and SV 4 2 4 6 38 Fig re 6 34 SV d i Um tee d Etats en bur hale ds EDUC ds Sue ru eig Las 6 39 Figure 6 35 Defrost Air Switch Test Setup 6 41 Figure 6 36 Display Module Assembly 6 45 Figure 6 37 Unidrive Torque Requirements Non ESC 6 51 Figure 6 38 Unidrive Torque Requirements Electronic Speed Control Engine 6 52 62 10450 LIST OF ILLUSTRATIONS CONTINUED viii LIST OF TABLES TABLE NUMBER Page Table 2 1 Model Chart esis in v ere Ewa nr CIT e ee AD Fertur 2 1
4. Replace the fuse and look for shorted wires between RS terminal 2 amp F9 fuse System OK Remove J1 jumper and reinstall shutdown options and or telematics System system OK Remove new switch and reirlstall old Switch Switch is notthe fault Review results of above tests with your su pervisor If necessary go to the be ginning of the table amp test again Remove J1 jumper and reinstall shut down options and or telematics system Remove J1 jumper and reinstall shutdown options and or telematics system Is there voltage at F9 NOTE Take care not to short ribbon cable ter fuse terminal minals during testing B side YES Check voltage between closest to re terminals 45 and 58 and lays NO 59 and 60 Voltage higher Is voltage within Remove J1 jumper and reinstall shutdown options and or telematics system Repair wiring for an open or high resistance between F9 terminal A side away from the relays and J1 terminal A should read 11 volts or range Repair grounds at terminals 58 and 60 Did you find and cor rect the condition NO Check displ isplay YES Repair wiring for an open or high resistance between F9 terminal B and unit battery Check
5. 2 13 2 4 EVAPORATOR SECTION 2 13 2 4 1 Thermal Expansion Valve 1 1 41 4 4 2 13 24 2 Heat Exchanger ooa sete eee ERR rad eri adc Rer grece 2 13 2 4 3 Evaporator Goll eoo bu er eeu 2 13 2 5 SYSTEM OPERATING CONTROLS AND COMPONENTS 2 13 2 5 1 Special Features oor er RR ADM We RR bee ADU EAD RR ER 2 14 2 5 2 Component Description And Location 2 14 Key Descriptions geri the eg cte cte te eoe x patet DU ON ERE RO EN 2 20 2 6 Datalink MODULE Optional 2 23 2 6 1 Brief Description DRE E 2 23 2 6 2 Components and Descriptions 2 24 2 6 3 Functions ead epa eri amem dg eign ened 2 24 2 6 4 Status S ee o erc mte UD RE 2 25 2 6 5 Message Trip 1 2 2 25 2 6 6 DataLink Communications 2 25 27 REMOTE MONITORING Optional 2 27 2 8 ENGINE DATA nur pe eren ea tel ba teh an e enc n ER TIS 2 27 2
6. 6 38 Change 11 2008 y 62 10450 TABLE OF CONTENTS CONTINUED PARAGRAPH NUMBER Page SERVICE Continued 6 27 CHECKING DEFROST OR HEATING 6 39 6 27 1 Defrost Operation ELE Sb a etti sb 6 39 6 27 2 Hot Gas Solenoid Valve SV 1 amp SV 4 Heating and Defrosting 6 39 6 27 39 Defrost Air Switch DA rese ids bed Sh RU ep RM 6 40 6 27 4 Solid State Defrost 6 40 6 28 CHECKING CALIBRATION OF THE DEFROST AIR 5 6 40 6 29 EVAPORATOR COIL CLEANING 2 6 41 6 30 CONDENSER COIL CLEANING 6 41 6 31 MICROPROCESSOR CONTROLLER 6 42 6 31 1 Replacing Keypad Window or Door 6 42 6 32 MICROPROCESSOR REPLACEMENT AND CONFIGURATION 6 45 6 32 1 To Remove and Replace Microprocessor Logic Board Short Box 6 45 6 32 3 To Remove and Replace Microprocessor Logic Board 6 45 6 32 4 To Reach The Configuration Fields From The 6 46 6 32 5 s re rene tee PERDU eue 6 46
7. IN 1d YOLVALOW 04345 CIVNOILdO dWNd 133 1 4000 ONY 1H9I D 1H9I CIVNOILdO LVLSOWYSHL H3lV3H CIVNOTLdO AV 13H WdlV3H CIVNOTLd0 W3lV3H G3d3dNv 01 53H3dNV SD 3H3dWV 5 QGW3dv 5 uad S 2 GWH3dWwv SD CIVNOILgO 3U3dWV OZ WH3dWV 08 3803 1XVWD YOSN3S 03345 f 10 81 02 03348 Hn 1VISOWH3HI CHIGI 15101 81702554 OL 0 0 0 0 vd es 8 AN 133 L1H9I D 1 9 1 90 8245 150 vog 220 28 9 ANI VIVO e O 8 6 amp LL LL LL LL LL LL LL UL Uu 22 2 2 CIVNOI 140 133 21412413 13 HOLIMS 150 HO V8 911 YOSNSS 34 l1VH3dW3l 39 92510 3055334 05 11 8 447708 YOSNSS J4nivu3dW3l IN3ISAVY 133 LUVI1S34 OLAV Cava 1H9I D 1H9I 191594 OLAV YOLVNYAL TV 0 CN 00 CO 25 7 c O5 lt rr Ou c 049 32
8. YES Check the resistance value of the water Replace temperature sensor as outlined in Section Y SCS 2 14 Replace defective sensor or repair faulty Is box temperature 3 F System wiring Did you find and correct the condition or more away from set T OK 4 YES point NO There is one minute delay for high speed after switching to Check for an cool from heat If cool is required upon start up then there is no open or high delay for high speed Did you find and correct the condition resistance in the SCS wiring NO Did you find and There may be a 5 minute delay for the unit to energize correct the the speed relay when switching to heat from low speed condition cool Did you find and correct the condition NO Is the unit in high ambient de The micro will place the See Section 5 4 Did Does the unit have frost pump down or exiting de unit into low speed you find and correct electronic speed control frost operation during pump the condition down or until the clutch is NO engaged System NO NO NO Both RAS and SAS are either shorted or open and the Y unit is locked into low speed Repair or replace defective Did you find iri i i ition Review results of above tests 22 Correct the condition
9. Kg cm Bar Kg cm 5 10 5 00 5 32 5 21 78 8 5 54 5 43 82 1 5 77 5 66 85 5 6 01 5 90 89 0 6 26 6 14 92 5 6 50 6 38 96 2 6 63 6 89 15 6 8 69 40 32 34 36 38 40 4 4 46 48 50 55 72 5 75 6 431 49 68 89 1 43 154 1 65 1 77 88 01 13 26 R 3 1 1 1 1 2 2 2 2 3 3 N 2 N N 143 154 168 1 65 177 188 0 201 65 70 75 A 9 9 2 5 5 9 6 4 5 0 2 6 8 10 50 11 40 12 34 13 33 14 38 15 48 5 18 16 65 6 33 17 87 7 53 19 15 8 78 115 46 291 6 20 50 20 11 120 49 311 8 21 92 50 125 52 332 9 23 41 5 130 54 355 0 24 96 48 135 57 378 1 26 58 6 07 140 402 3 28 28 7 74 145 63 427 6 30 06 9 48 150 454 0 31 92 31 30 0 30 8 0 07 10 2 24 2 3 3 3 3 3 8 _ 2 2 2 2 1 2 2 3 3 7 3 6 3 3 4 4 1 4 4 5 5 5 5 h h h o als 85 EE a o 95 100 105 110 4 304 299 2 1 A 2 272 AJN 0 54 68 83 99 14 31 47 65 83 4 01 4 20 4 39 4 59 4 79 oy 7 co 489 479 ERE 4 3 2 a0 1 AJN gt N PO M 12 1 1 1 2 3 3 63 6
10. CAUTION Under no circumstances should a techni cian electrically probe the processor at any point other than the connector terminals where the harness attaches Microproces sor components operate at different volt age levels and at extremely low current lev els Improper use of voltmeters jumper wires continuity testers etc could perma nently damage the processor CAUTION Most electronic components are suscepti ble to damage caused by electrical static discharge ESD In certain cases the hu man body can have enough static electric ity to cause resultant damage to the compo nents by touch This is especially true of the integrated circuits found on the truck trailer microprocessor As mentioned above some microprocessor inputs op erate at voltage levels other than the conventional 12 VDC Connector points and the associated approximate voltage levels are listed below for reference only Under no circumstances should 12 VDC be applied at these connection points Grounded wrist cuffs are available from Carrier P N 07 00304 00 These should be worn whenever han dling a microprocessor Table 6 2 Connection Point Voltage Connection Point Approximate Voltage ATS CDT RAS SAS WTS MP23 5 0 VDC 2 5 VDC Variable 62 10450 Although there is less danger of electrical static dis charge ESD damage in the outdoor environment where the processor is likely to be handled proper boar
11. B B B B DOOR SWITCH FUEL LEVEL SENSOR SPARE VOLTAGE SENSOR SYMBOL DESCRIPTION PP POWER PACK DK DATALINK MODULE DP DOWNLOADER PLUG DS DOOR SWITCH FLS FUEL SENSOR PTS REMOTE TEMPERATURE SENSOR OPT 1 2 3 RAS2 REMOTE RETURN AIR SENSOR COPT SAS2 REMOTE SUPPLY AIR SENSOR SLP SERIAL PORT SP SPLICE POINT INDICATES SOLDERED SPLICE POINT INDICATES WIRES IN SYSTEM COMPONENT CONNECTION NUMBER OR LETTER INDICATES STANDARD OPTIONS DATAL INK LABEL NO REV 62 10534 00 Figure 2 19 DataLink Electrical Schematic 62 10450 2 26 2 7 REMOTE MONITORING Optional The microprocessor controller is equipped with 232 communication port This port can be used to communicate unit operating data to a mobile satellite transmitter This information will then be relayed back to the office via a modem to a computer 2 8 ENGINE DATA There are presently three 3 protocols supported The protocol for the QualComm transmitter the protocol for the HUGHES transmitter and Carrier Communication Protocol The microprocessor will power up and transmit a HUGHES protocol packet and continue to transmit a packet every hour The microprocessor will transmit in the Carrier QualComm protocol if a data
12. 6 33 6 21 1 To Service Check Valve 6 34 6 21 2 To Replace Check Valve 6 34 6 22 CHECKING AND REPLACING FILTER DRIER 6 35 6 22 1 To Check Filter Drier 6 35 6 22 2 To Replace Filter Drier 6 35 6 23 THERMOSTATIC EXPANSION VALVE 6 35 6 23 1 Replacing Expansion Valve amp Screen 6 35 6 23 2 Checking Superheat opui ek eR eL E ENERO UE DOC E PENIS E ES 6 35 6 23 9 To Measure Superheat o eoe ets c 6 35 6 24 CHECKING AND REPLACING HIGH PRESSURE CUTOUT SWITCHES 6 36 6 24 1 Replacing High Pressure 6 36 6 24 2 Checking High Pressure Switch HP 1 or 2 6 36 6 25 REPLACING RECEIVER SIGHTGLASS ASSEMBLY AND FUSIBLE PLUG 6 36 6 26 SERVICING SOLENOID VALVES 6 37 6 26 1 SV 2 8V 4 e oU e 6 37 6 26 2 Solenoid Valve SV1
13. LD see S EA 12 QA T A L d Wis ne i I A 9 Strainer 10 Suction Manifold 11 Cylinder Discharge Valve 12 Valve Plate 13 Cylinder Suction Valve 14 Discharge Piston Check Valve Assembly 15 Discharge Manifold 7 y lt gt Figure 2 11 Compressor Cylinder Head Loaded 2 3 4 Filter Drier The drier is a cylinder shell containing a drying agent and screen It is installed in the liquid line and functions to keepthe system clean and remove moisture from the refrigerant 62 10450 2 3 5 Receiver Liquid refrigerant from the condenser is pushed into the receiver by system pressure The receiver serves as a liquid reservoir when there are surges due to load changes in the system as a storage space when pump ing down the refrigeration system The receiver is provided with either one or two sight glass es for the observation of liquid level and a fusible plug safety device 2 3 6 Transducers and Sensors a Compressor Suction Pressure Transducer SPT Provides micro with suction pressure information to be displayed recorded in the DataRecorder and used to control the refrigeration system It cannot be calibrated It is located near the oil pump on the compressor b Ambient Air Temperature Sensor ATS ATS is a temperature control probe which provides mi cro with ambient air temperature information to be dis played recorded in the DataRecorder and used to con
14. VI9OS IDI X2 1800 NDL 93S 05G 37cfm wvoo03 DI X2 2100 NDL 93S 05G 05G 41cfm 5 Table 2 2 Additional Support Manuals Extra XT Ultra XT Equipment Covered X2 1800 2100 62 10601 Units With Standard Microprocessor Operator s Manual 62 10600 Units With Standard Microprocessor Easy To Run 62 10295 Engine V2203 DI Extra and Ultra XT 62 10864 Engine 1903 E28 Extra Engine 2203 E28 XT 6210863 Engine V2208 DI Tier 2 62 11168 Engine Electronic Speed Contra 62 10301 Workshop 62 10866 Engine 1903 E2B Extra XT Workshop Engine 2203 E2B Ultra XT Workshop Heating is accomplished by circulating hot gas directly from the compressor to the evaporator coil Three Change 11 2008 electric solenoid valves control the refrigerant circuit to operate the heating cooling system 62 10450 Automatic evaporator coil defrosting is initiated by either sensing the air pressure drop across the coil with a differential air switch or with the defrost timer in the microprocessor The control box include manual switches microprocessor fuses and associated wiring Also the unit can be equipped with an optional remote light bar which mounts separately on the front roadside corner of the trailer 62 10450 2 2 The temperature controller is a microprocessor solid state controller Refer to Section 2 5 Once the controller is set at the desired temperature the uni
15. a Store the refrigerant in an evacuated container Re fer to Section 6 14 b Replace necessary parts c Evacuate and dehydrate unit Refer to Section 6 16 d Add refrigerant charge Refer to Section 6 17 6 21 2 To Replace Check Valve See Figure 6 26 and Figure 6 27 NOTE These check valves are not serviceable and must be removed and replaced as an assembly a Store the refrigerant in an evacuated container Re fer to Section 6 14 b Using a pipe cutter cut the valve stub outs on valve and unsweat the remaining stub out from the con necting copper in the unit NOTE Inert brazing techniques MUST be followed during replacement of valves NOTE Place magnetic discharge check valve tool 07 00457 00 on top of discharge check valve Figure 6 26 to pull the plunger from the body Seat c Replace valve d Evacuate and dehydrate unit Refer to Section 6 16 e Add refrigerant charge Refer to Section 6 17 Change 11 2008 6 22 CHECKING AND REPLACING FILTER DRIER 6 22 1 To Check Filter Drier Check for a restricted or plugged filter drier by feeling the liquid line inlet and outlet connections of the drier cartridge If the outlet side feels cooler than the inlet side then the filter drier should be changed 6 22 2 To Replace Filter Drier a Pump down the unit per Section 6 14 Remove bracket then remove drier b Install and lubricate o rings on drier c Position drier so that arrow points in do
16. 6 33 SENSOR CHECKOUT 222552 REIR HR EA ee Rr RR ACRES 6 49 6 34 SUCTION PRESSURE 6 49 6 35 UNIDRIVE TORQUE REQUIREMENTS 6 49 6 35 1 Drive Geal e adc E ac a E e a 6 49 WIRING SCHEMATIC rre pee xr eR ar ede aia da eee 7 1 PART NUMBER INDEX Index 1 62 10450 vi Change 11 2008 LIST OF ILLUSTRATIONS FIGURE NUMBER Page Figure 2 1 Front View Of Unit With Non ESC Engine 2 3 Figure 2 2 CUIDSIde MS 2 4 Figure 2 3 Roadside wale odin Eu eu Ree eed Rees 2 4 Figure 2 4 Front View Of Unit With Electronic Speed Control 2 5 Figure 2 5 Ultra XT and Extra XT Splice Pack Locations 2 6 Figure 2 6 X2 Splice Pack Locations 2 7 Figure 2 7 Evaporator Section Panels and Grille Removed 2 8 Figure 2 8 Frame Mounted Engine Speed Control Unit ENSCU 2 9 Figure 2 9 Alternator and Regulator 2 2 2 10 Figure 2 10 Compressor Cylinder Head U
17. IN 314 331 347 72 3 65 390 383 401 420 439 459 5 1 9 6 7 9 0 9 5 6 7 3 9 1 0 9 8 8 6 8 8 9 1 1 5 6 8 0 0 4 2 9 5 5 8 1 7 6 5 9 5 EZ 32 29 28 27 26 24 23 22 21 20 18 71 16 EE 10 zo Ea 2 6 6 53 62 10450 05701 69 1 2 5 011140 LINN 53 91315373 135310 303 533 1 254 SLINA vuijdn 39 3 1X YALIN LX vulx3 H31SAS SHL NI SAYIM 31VOIONI SANIT LHS NO 3HIM AINO SLINA VON NO YOLOSNNOD 7 GWIM 0049 SISSVHO V 6541 910 dNNOId 03345 YNIWWLVG 8 004849 3HIM 5319 34un0390Hd 9NII00HS3 180041 303 IWANVW SH3NMO OL 33333 75110 CL M0138 38 110 2 NOILO3S NOILO3NNOO 138902 HOTH 9014 3141 4g 1 1 ONY ZL Lf 9n1d N33M138 3HIM 531 210 1 NOILOANNOO S3l1VOIQ 1 1 1 didWvX3 W31S8AS SSdudQv SONnOH9 OV 3339 SLOVLNOD 330 ATIVWH 51119319 OV 033 SIOVINOO 435012 ATIVWY S 50 0089 30V 18 T SLIQOHIO 10 1 02 9G 3LIHM 480102 SIOVINOO AWVIN3AON S31VOIQNI 1084AS HOLT EdS 81 A318AS NOILVOIJIIN3GI 3 0111504 330 NMOHS LINO Y31131 S38WRN NO UN 9 son ass URO RN 3 G 6 SHOLIMSNN 3ovd 321145 937935 Y SALVOIONI AdS
18. OPERATION amp SERVICE for X SERIES Trailer Refrigeration Units With Standard Microprocessors 62 10450 Rev E Change 11 2008 TRANSICOLD OPERATION AND SERVICE MANUAL NOSEMOUNT TRAILER REFRIGERATION UNITS WITH STANDARD MICROPROCESSORS TABLE OF CONTENTS PARAGRAPH NUMBER Page SAFETY PRECAUTIONS erue a RI I RR te E rer hr se ERN ERE EET Ra 1 1 1213 SAFETY PRECAUTIONS scant oeste esta ness SEE DEM SE SLT E anes 1 1 1 2 SPECIFIC WARNING AND CAUTION STATEMENTS 1 1 13 gt SAEETYSDEGALS Leber ERE et spe D MEER eU EE eee 1 5 UNIT DESCRIPTION pan 5 9 exe a Rep D BER eus 2 1 2 31 INTRODUCTION pa aia ee pa E 2 1 22 GENERALE DESCRIPTION ek RE Re Rete Re RU AR 2 1 2 9 CONDENSING SECTION asic 5 nni ives DESEE ITE UE Gules eR UO IU Eu 2 9 2 9 1 ENGING AS te ie toa eee rele 2 9 2 3 2 Alternator Regulator 2 9 2 3 3 GOMPICSSON ca estne bead oct Tau Teste d iquat tci ot ede 2 10 Compressor nloadets 2 coco ER Oe ate a hae eee 2 10 23 47 FINCHER e der tis tre entre sewn tate ed pue dass ia 2 12 2 34 s iot tes cue usu E cree 2 12 2 3 6 Transducers and Sensors
19. Replace the fuse and correct the condition with your supervisor If ne YES NB Check the YES Y cessary go to the beginning Is there at least F4 fuse of the table and test again 11 volts at the SCS Did SR relay contacts or ENSCU 16 System 30 amp 87 OR 3 amp 5 close OK NO gt when battery voltage YES was applied to terminals 85 amp 86 1 amp 2 NO YES Check solenoid coil for open circuit and linkage for correct operation Did you find and correct the condition NO Does the unit have T electronic speed control No y NO Does the SCS pull in when YES battery voltage is applied to VER relay coil Replace the relay s there at least 11 volts at SR coil 85 amp 86 OR 1 amp Y System OK Review results of above tests YES with your supervisor If ne Enter hours from old micro cessary go to the beginning YES into new micro and verify of the table and test again configurations amp functional parameter settings 5 YES Replace micro and operate System OK re Check for an open em Check for an open system in order to verify repair or high resistance at Remove new micro and reinstall old micro Mi Did you find and correct the N3 OR SHES
20. START RUN e N N 62 10450 AX WARNING Under no circumstances should ether or any other starting aids be used to start en gine NOTES 1 Whenever starting the engine in order to reduce starter cranking and engine loads the microprocessor starts and operates in low speed unloaded cool for the first 15 seconds After the first 15 seconds the microprocessor will allow the unit to operate normally 2 The unit will remain in low speed for 5 minutes after engine start up when Auto Start Stop is at any setpoint or Continuous Run setpoint is below 10 F 12 C Place the Start Run Off switch position in the Start Run The microprocessor controller will run a self test All of the mode lights will light all of the segments on the display will be turned on The display will then show the setpoint temperature on the left and the box temperature of the trailer on the right The last character after the degree symbol shows the temperature units as F Fahrenheit or C Celsius If the unit is in Auto Start Stop mode or Continuous Run Auto Operation mode the glow plugs will energize 62 10450 3 2 The length of time of glow cycle depends on engine temperature See 4 1 5 The buzzer on units so equipped will sound for 5 seconds and the diesel engine will start If the unit is set for Continuous Run Manual Operation mode the unit must be started manually The microprocessor controller monitor
21. refrigeration system is warmed up and the box tem perature is less than 45 F 7 2C and then partially block off air flow to condenser coil so discharge pres sure will rise 10 PSIG 0 68 Bar Check the appropriate sight glass to determine charge See Step g for determination of charge If undercharged proceed with step e Frontseat the king valve and monitor the second set of manifold gauges When the king valve pressure drops below the pressure in the refrigerant drum open the manifold gauge set discharge valve and al low liquid refrigerant to flow into the system While monitoring the appropriate sight glass careful ly weigh the refrigerant into the system Because the unit is in this charging state it is not possible to accu rately determine when the system is full Therefore never allow more than 3 Ibs 1 4 kg of refrigerant into the system at a time After metering 3 Ibs 1 4 kg of refrigerant into the sys tem close the valve of the manifold gauge set con nectedto the King Valve Openthe king valve partial ly block the air flow to the condenser coil and allow the system to balance out approximately 4 5 minutes and the box temperature is less than 45 F 7 2C Check sight glass es to determine charge Units With S N Prior to JAR90710713 Once the re frigerant level is at centerline of the lower sight glass weigh in another Ibs 1 4 kg of refrigerant Units With S N Beginning With JAR9
22. 1 4 jumper wire with spring clips No Before starting test install a manifold gauge set on com pressor service valve gauge ports and a second man ifold gauge set with the high pressure gauge connected to the king valve All gauge lines must be purged of air which could enter the system The procedure may now be started It may be helpful to refer to the refrigeration flow diagram Section 2 16 when following this procedure 6 13 1 Checking Refrigerant Charge and High Am bient Compressor Operation a Start the unit setpoint at 11 F 11 7 Allow the unit to run until the engine reaches high speed The engine may start in low speed and remainthere for 15 seconds or until the engine coolant temperature reaches 78 F 25 6 C Partially cover the condens er to raise the discharge pressure to 260 280 PSIG 17 7 19 1 Bar Check the receiver tank sight glasses for proper re frigerant charge See Section 6 17 for differences in receiver sight glasses See Section 6 17 for instructions on adding refriger ant to the system Cover the condenser further to raise the discharge pressure to 350 375 psig 23 8 25 5 Bar This en sures that the compressor can achieve sufficient dis charge pressure to operate in high ambient tempera tures It may be necessary to unplug the front un loader Uncover the condenser The unit should be left run ning in High Speed Cool 62 10450 6 13 2 C
23. 41 Nm 3 8 24 x 1 00 19 Grade 8 28 ft lbs 38 Nm DIRECT DRIVE M12 x 1 25 x 25 mm lg 8 Required 65 ft Ibs 88 Nm 3 8 16 x 1 Ig Grade 5 12 Required 28 ft lbs 38 Nm Figure 6 36 Unidrive Torque Requirements Electronic Speed Control Engine Change 11 2008 6 51 62 10450 62 10450 Table 6 3 404 Temperature Pressure Chart RINI Temperature Kg cm 0 32 IRE 122 142 salsa EARE 40 40 45 35 37 71 30194799 251 32 129 20 29 16 3 18 28 17 7 16 27 19 2 14 26 207 12 24 223 10 23 239 22 25 6 21 27 3 4 20 29 1 2 19 309 18 32 8 2 17 34 8 368 14 38 9 18 411 12 433 i2 n 456 14 10 48 0 16 9 504 18 8 52 9 20 7 55 5 22 6 58 1 24 4 60 9 26 3 637 28 2 66 5 30 1 69 5 N NIO 5 00 5 21 5 43 5 66 5 90 6 14 6 38 6 63 6 89 5 6 8 69 AN 001 A N 0 30 18 10 07 10 5 18 53 20 1 SISID 50 95 4 48 6 07 7 74 9 48 31 30 MST mimm Change 11 2008 Table 6 3 R 404A Temperature Pressure Chart Temperature C 40 37 34 32 29 28 27 26 24 2 2 2 2 1 1 1 1 1 1 Temperature C Sjo N
24. BLACK 5 Install coil assembly and retainer 6 Start unit and check refrigerant charge per Section 7 Check refrigeration cycles 1 Coil Assembly 2 Enclosing Tube Assy 7 Body 6 Piston Assy 3 Plunger Assy 4 Seal 8 Bracket Adapter Figure 6 31 SV 2 and SV 4 6 37 62 10450 6 26 2 Solenoid Valve SV1 a Replacing the Coil NOTE The coil may be replaced without removing the refrigerant or pumping the unit down Remove top locknut spacer cup and nameplate SV1 2 Disconnect wiring and remove coil 3 Replace coil by reversing steps 1 and 2 Replacing Internal Components See Figure 6 32 Remove and store the refrigerant charge in an eva cuated container Refer to Section 6 14 2 Remove the top locknut spacer cup nameplate coil assembly and spacer SV1 3 Using a 12 point 1 3 8 inch box wrench loosen the enclosing tube locknut and bleed off remaining refrig erant 4 Remove enclosing tube and locknut assembly The gasket is inside the enclosing tube 5 Remove seat disc from inside of body check for ob structions foreign material and wear inside valve o body 1 Locknut Screw 7 Enclosing Tube 6 Place the seat disc into the valve body with the small 2 Spacer Cup 8 Gasket er diameter end facing up 3 Nameplate 9 Closing Spring 7 Place the enclosing tube locknut over the enclosing 4 Coil 10 Seat Disc tube Install spacer over enclosing tube m
25. EA 00 LED LIGHT BAR Figure 2 17 Light Bar 2 6 DATALINK MODULE Optional 2 6 1 Brief Description WARNING Do notattemptto service the DataLink mod ule Breaking the warranty seal will void the warranty CAUTION Remove DataLink module and unplug all wire harness connectors before performing any arc welding on any part of the unit Do not remove wire harness from module unless you are grounded to the unit frame with a static safe wrist strap Carrier Transicold has developed a recorder DataL ink it is a self contained module which consists of Microprocessor Program memory Data memory nternally battery backed real time clock bthermistor inputs FuelLevel inputs Door open closed switch Four status LEDs Software ports Electronic backup power pack This recorder eliminates the mechanical recorder and paper chart and replaces it with a custom designed module see Figure 2 18 that interfaces with the controller module and the Datalink Toolbox PC based software program Operate as a stand alone device or as part of a net work b Log data at 2 15 30 60 or 120 minute intervals 2 23 c Log DataLink alarms d Can be custom configured to record up to 13 different sensors e Reco lows Mai rd DataLink Network generated events as fol n Setpoint Change Defrost Initiation Defrost Termination Pre Trip Initiation Pre Trip
26. Figure 2 16 Display and Keypad 2 19 62 10450 The Display and Keypad module is located for operator access at the lower roadside corner of the unit The display board is mounted in the Keypad and Display module The display board includes the LCD display keypad and keypad interface The Display and Keypad module provides the user with a panel to view and control the functions of the refrigeration unit The module consists of a switch keypad and main display Setpoints and other system information are selected using the keypad Figure 2 16 shows the Display and Keypad module Display The main display has nine characters each character has 14 elements two decimal points or commas and a degree symbol The display is used to provide the user a setpoint and box temperature either in degrees Centigrade or Fahrenheit The comma symbols are used as the decimal indicators in Europe When Metric Units is selected in the Functional Parameters the two comma icons are used instead of decimal points When English Units is selected in the Functional Parameters decimal points are used The display illuminates the entire LCD segment when the Ru Stop switch RS is turned OFF The design appears as shown in the display graphic of Figure 2 16 As the internal capacitor discharges the LCD segments fade out to a blank display Some units have a change in information displayed while the capacitor is discharging Instead of the snowflake pa
27. Table 6 4 R 404A Temperature Pressure Chart 6 53 ix 62 10450 SECTION 1 SAFETY 1 4 SAFETY PRECAUTIONS Your Carrier Transicold refrigeration unit has been designed with the safety of the operator in mind During normal operation all moving parts are fully enclosed to help prevent injury During all pre trip inspections daily inspections and problem troubleshooting you may be exposed to moving parts Please stay clear of all moving parts when the unit is in operation and when the unit main power switch is in the START RUN position CAUTION Under no circumstances should anyone at tempt repair the Logic or Display Boards Should a problem develop with these com ponent contact your nearest Carrier Tran sicold dealer for replacement CAUTION Under no circumstances should a techni cian electrically probe the processor at any point other than the connector terminals where the harness attaches Microproces sor components operate at different volt age levels and at extremely low current levels Improper use of voltmeters jumper wires continuity testers etc could perma nently damage the processor CAUTION Most electronic components are suscepti ble to damage caused by electrical static discharge ESD In certain cases the hu man body can have enough static electric ity to cause resultant damage to the components by touch This is especial
28. and resumes normal operation vA EXTERNAL EQUALIZER HOT GAS EXPANSION VALVE BYPASS LINE lt EXPANSION VALVE FUSIBLE BULB EVAPORATOR PLUG _ RECEIVER BYPASS HEAT EXCHANGER gt CHECK VALVE LIQUID LINE DISCHARGE P 2 HP SERVICE MAINE VALVE Y HOT GAS SV4 NC DISCHARGE CHECK VALVE COMPRESSOR HOT GAS LINE A SHUT OFF KING SOLENOID VALVE lt VALVE SV2 NC o FILTER Y SUBCOOLER DRIER SOLENOID 1 VIBRASORBER gt CONDENSER PRESSURE CONTROL SOLENOID SV1 NO CONDENSER Figure 2 21 R 404A Refrigerant Circuit Heating and Defrosting 62 10450 2 32 3 1 STARTING UN SECTION 3 OPERATION IT AUTO 7 FAULT STAND BY SETPOINT BOX TEMPERATURE SELF TEST FAULT STAND BY 200 404 5 F SETPOINT BOX TEMPERATURE START RUN e Y N
29. defective closed Refrigerant level is over full Compressor valve s worn or broken 6 20 1 Head pressure control switch HP 2 defective open 6 24 Solenoid valve SV 1 malfunction 5 3 11 Low refrigerant charge 6 15 amp 6 17 Bypass check valve defective Replace Low Refrigerant level 6 15 amp 6 17 Solenoid SV 1 open 5 3 11 Head pressure control switch HP 2 defective open 6 24 Bypass check valve defective Replace 5 3 7 Abnormal Noise Compressor Condenser or evaporator fan Clutch Gearbox Loose mounting bolts Tighten Worn bearings Worn or broken valves Liquid slugging Insufficient oil Drive adaptor loose or defective Loose or striking shroud Bearings defective Bent shaft 6 18 6 20 1 5 3 10 6 19 Tighten or re place Check Replace Replace 5 3 8 Control System Malfunction Will not control Sensor s defective or incorrectly mounted Check amp 6 33 Relay s defective Check Microprocessor controller malfunction 6 31 Bulkhead is damaged or incorrect for application Replace 5 3 9 No Evaporator Air Flow or Restricted Air Flow Evaporator coil blocked No or partial evaporator air flow Frost on coil Dirty coil Debris shrinkwrap caught behind bulkhead Return air bulkhead is not in good condition or is attached Check Replace incorrectly or is not correct for application V belt broken or loose 6 11 Clutch Gearbox defective Replace Evaporator fan loose or defective Check Evaporat
30. down options and or telematics system Disconnect NO shutdown options and or telematics Is the micro Replace RS switch system and install display still lit Did you find and cor J1 jumper up rect the condition gt YES Did disconnecting the shutdown v NO options allow the unit to shut Check for defective NO down shorted RS switch Is switch defective YES Fault is with one of the unit shut OK down options and or telematics Check wiring to RS system Diagnose shutdown op Switch for a short Did tion and repair as required you find and correct the condition Review results of above tests with your supervisor ne Replace Run Relay Did you cessary go to the beginning Verify the Run Rel of the table and test again kd erdi 52 MER find and correct YES 4 the RS switch is in the theicondition OFF position NO 1 Check for defective or mechanically seized TOME Check wiring to Run fuel solenoid OR en Se fe pi Relay for a short Did gine mechanical defective you find and correct lems Did you find and the condition correct the condition ves hr 59 NO Review results of above tests with your supervisor If ne go to the beginning Remove connectors one at a shutdown options of the table and test ag
31. into place Position the fan shaft so that the housing is in the nor mal mounting position with the shaft horizontal and the vent hole facing directly up Remove both pipe plugs 1 8 NPT from fan shaft Ensure that oil in the fan shaft is at proper level If not fill the fan shaft with oil 07 00373 00 until oil is at the bottom of the level hole on the bottom of the fanshaft approximately 3 0z 89 ml Apply pipe thread sealant to the pipe plug on the side of fan shaft housing and tighten Reinstall pipe plug on hub to prevent oil spill age Install the fan shaft into the unit with the four fan shaft mounting bolts and torque bolts to 28 to 30 ft lb 38 to 40 6 Nm making sure the plug for the vent is pointing up 62 10450 Nozzle Cover Be sure to adjust cover placement so that blower wheel is centered in opening 13 5 15 Nm Torque Nozzle Cover Bolts to 20 inch Ibs 2 3 Nm Do Not Over tighten Drain Hole Fanshaft Seal Torque to 50 in lbs 5 6 Nm Split Taper Bushing Torque Bolts Evenly 10 11 ft lbs Blower Wheel Nozzle Cover Gasket Fanshaft Secure Fanshaft Seal Ring Clamp Tightly around Seal and Fanshaft Torque to 50 inch Ibs 5 6 Nm IMPORTANT Make sure there is even clearance between blower wheel and pod approx 1 4 and between blower wheel and nozzle cover approx 1 4 Nozzle cover center venturi lip should overlap into bl
32. oo OT INIOd 321145 93830705 v 631 210 1 dS perdo VAG 9f E TOE 7 200 v HALAV Q3AONW3H 013 901 381M NOII23NNOO V 631 210 1 519 27025 3 01 Q v dS Sai 93391193 NIVYLS OOA3H T c 2 c WS amp UN 93 N YOSNSS d3univuddW4dl W3lVM AV 133 9939 u3dvo IND 333 u3dvo INO I38 044 u3dvo INO 04 4 M3dvO INN CIN 01084105 SV9 10 CIN SAWA GION31OS 101911 CO ND SAWA 10 81 03 0553 QNOO CA INO 3 0 HOLIMS 80123135 133 01049705 3549915 YOLOVLNOD 91043705 3319915 GION310S 93413915 133 03345 d3onasNvHl 33055394 011205 OLOW 314 15 1404 1VI1335 CIVNOILdO YOSNAS NIV 1 5 133 NOH HOLIMS 4015 YOSNAS MIV 1133 3000 ANY LHOT 1 33 0 Cava 1H9I D 1H9I SONVY 30 100 AV 133 39NVH 30 100 CO ND HOLIMS 14 5 330553 110 QVO 1H3AO 3010 2002 08 3055350840351 Haldv GSAOWS NV32 M0 19 TWANY 0061 0041 93 5 01140 1 5 ye AVI E AYT AVI AYT CON 1081NO2
33. packet is requested ULTRA EXTRA X21800 2100 EXTRA NDL 93E 218002100 1800 NDL 93W Engine Models 4 114 V1903 V2203 DI ESC V1903 IDI ESC Displacement 134 in3 2 2 liters 114 in3 1 9 liters 134 in 2 2 liters 114 13 1 9 liters No Cylinders 422 Ibs 191 4 kg 417 8 lbs 189 5 kg Coolant Capacity Oil Capacity with Filter a Lubrication System Oil Pressure 40 to 60 psig 2 7 to 4 1 Bar Engine in high speed Oil Pressure Safety Switch Setting Closes 15 3 psig 1 02 Bar Lube Oil Viscosity Fahrenheit Centigrade Extended Service Interval ESI packages are standard on X Series units beginning with S N JAB90602792 The ESI package reduces the frequency of scheduled service intervals The two tables below reflect the differences between standard and ESI packages Oil Change Intervals Standard Service Interval API MOBIL Class Cl or higher DELVAC 2000 Hours or 1 yr 4000 Hours or 1 yr Oil Change Intervals Extended Service Interval PI MOBIL DELVAC A Class CG or higher 3000 Hours or 2 yr 4000 Hours or 2 yr 2 27 1 675 gallons 6 3 liters 50 50 mix never to exceed 60 40 15 quarts 14 liters Winter Diesel No 1 Summer Diesel No 2 Glow Plug Amperage 7 5 amps per plug at 12 vdc nomina 4 CAUTION When changing oil filters the new filters should be primed partially filled with clean oil if possible If the filt
34. 100 109 38056344 HOLIMS 1n0 1n9 38055344 VB 1HOI D 1HOI 133 9n ld 5 00245 mMm E KHI CE CO CE CC OD 00 gt 00 C0 OO UO c e mM i a ES 8 dS BLNdS eX 145 OL eO 8JdS 7139 SL n9SN3 01 330 EdS HH 9 a a e a WM 07 lt b lt gt N 6 9 9 9 OL og 9 0 amp amp 5 0 9 O 60 6 9 9 amp 9 9 Gres ce 9 ERE Dio N O
35. 2 SR coil circuit 86 cro is not the fault Review results of above Condition Did you and OR 1 Did you find tests with your supervisor If necessary go to S and correct the NO NO condition condition the beginning of table amp test again MPR Code 5 Figure 5 10 Micro Diagnostic Tree Cond 5 Models with Speed Control Solenoid Unit will not run in high speed 62 10450 5 20 START HERE 1 the unit operating in Defrost T NO Y For units equipped with Speed Control Solenoid check solenoid amp linkage for Is the micro providing a ground to SR85 OR SR2 Check ribbon cable circuit 38 for continuity Did you find and correct the condition NO MPR Code 6 d Replace ribbon cable binding Did you find and correct the condition Check Functional Parameter settings for air flow Does the setting show high NO Y Check setpoint v Is box temperature more than 3 5 F from setpoint once initial setpoint has been reached YES Do SR Relay contacts 30 amp 87 OR 3 amp 5 open when ground is removed from terminal 85 OR 1 Is voltage present at the SCS EP YES System OK YES Check f
36. 2 7 The Carrier Transicold microprocessor controller incorporates the following features a Control supply or return air temperature to tight limits by providing refrigeration control heat and defrost to ensure conditioned air delivery to the load b Dualindependent readouts of set point and supply or return air temperatures c Digital readout and ability to select data Refer to 3 8 for Function Code and 3 9 for Unit Data For alarm digital display identification refer to 3 10 o 2 A pre trip checkout of refrigeration unit operation Refer to Section 3 3 f A self test check on program memory and data memory The self test is executed each time the System is switched from Stop to Start Errors if any shall be indicated on the display as a ERR X where X is a number corresponding to the number of the test The unit shall display this error for 5 seconds and then reset the micro ERROR CAUSE ERR 1 Processor failure ERR 2 Check chip installation or Replace ERR 3 microprocessor Display board to logic board communication failure This can be caused by a defective ribbon cable or ribbon cable not plugged in properly ERR 4 or Display 62 10450 2 5 2 Component Description And Location CAUTION Under no circumstances should anyone at tempt to repair the Logic Relay or Display Boards see section 6 31 Should a prob lem develop with these components con tact your nearest Carrier Transicold d
37. 4 3 4 2 1 Heat Cool Mode RE eR ged Bale eG da Sale nea a 4 3 4 22 Detrost GyCle ek ie eet LEER 4 4 4 2 3 Unloader Operation 4 6 4 2 4 Suction Pressure Operation 4 7 43 ULTRAFRESH 2 TEMPERATURE 4 12 4 4 ULTRA FREEZE TEMPERATURE 4 13 4 4 1 Ultra Freeze Offset b eda RR 4 13 4 4 2 Ultra Freeze Start Stop 4 13 443 Default OG OMS ERO RO DR ERO RO RU RO Rn 4 13 4 5 OVERRIDES uut pU I ERR i Ei UII Ned 4 13 4 5 1 SPEED SOLENOID OVERRIDES 4 13 4 5 2 UNLOADER OPERATION OVERRIDES 4 13 62 10450 ii TABLE OF CONTENTS CONTINUED PARAGRAPH NUMBER Page SERVICE Continued 6 10 ENGINE SERVICE amp COMPONENTS 6 9 6 10 1 Cooling System once eere d ep Eq UR UR Eu eoe 6 9 6 10 2 L be OILFIlterS 6 10 6 10 3 Servicing the Speed Control Solenoid and
38. 42 F 0 and 5 6 C the unit will always operate in Continu ous Run If the setpoint is outside this range either Start Stop or Continuous Run can be selected The maximum setpoint and function lock are controlled via a combination of CNF3 and CNF11 CNF11 OFF CNF3 OFF Maximum set point 86 F 30 C No function lock CNF11 ON CNF3 OFF Maximum set point 86 F 30 C Standard function lock CNF11 OFF CNF3 ON Maximum set point 90 F 32 2 C No function lock CNF11 CNF3 ON Maximum set point 90 F 32 2 C Modified function lock CNF20 allows the Fahrenheit Celsius func tion to be locked In order to change the units setting CNF20 must be OFF The units set ting can then be changed in the functional pa rameters list If CNF20 is ON the units setting cannot be changed from the functional pa rameters list 62 10450 Table 6 1 Configuration Codes Continued CONFIGU OFF Normal Multi Temp Logic Rev 3 23 and 21 a Multi Temp Frozen Priority Logic higher only Set Point not Locked Rev 3 29 and CNF23 OFF Set Point Locked po only NEM m All trailer units are OFF ON Truck units only ME 3 81 and Engines with glow plugs CNF25 higher only Tier 4i Engine with air heater DIS or reris OFF For future use Do nottumon CNF28 OFF For future use Do nottumon CNF29 OFF For future use Do nottu
39. 6 START HERE Does the engine starter engage amp turn the engine over YES Check for high resistance or an open on the FSA ground circuit terminal 2 Did you find and correct the condition YES 1 Ensure FSA is unplugged for testing Verify the proper voltage going into FSA termi 12 VDC when RS switch is first turned on for the pull in voltage 1 VDC for hold in voltage amp 0 8 VDC during starter engagement Do you have the correct voltage With the FSA disconnected check the resistance of the FSA coil Spec is 2 5 to 3 1 ohms Is ohm reading within spec NO Replace the FSA Did you find and correct the condition NO Remove new FSA and re install old FSA back into unit FSA is not the fault Review results of above tests with your supervisor If necessary go to the beginning of the table amp test again YES Using jumper wire the proper voltages present at ENSCU terminal 7 _ Replace ENSCU Did you find and correct the condition NO Remove the FSA engine amp inspect move freely without binding and from the FSA should Remove new ENSCU shaft should be straight Is FSA functioning properly YES Review results of ab
40. 6 17 ADDING REFRIGERANT TO SYSTEM 6 17 1 Checking The Refrigerant Charge CAUTION c Do not vapor charge 404 Only liquid High speed operation at some conditions may charging through the receiver king valve create high turbulence inside the receiver If itis is acceptable difficult to see the refrigerant settling properly in the receiver sight glass unplug the speed sole noid forcing low speed operation There should be less turbulence in the receiver and the liquid refrigerant should settle properly 62 10450 6 28 Change 11 2008 Checking Refrigerant Level on Units With S N Prior to JAR90710713 NOTE The ambient air entering the condenser air temperature should be above 40 F 4 4 C 1 Start unit in cooling mode Run approximately ten minutes until the refrigeration system is warmed up and the box temperature is less than 45 F 7 2C 2 Partially block off air flow to condenser coil so dis charge pressure rises to 230 PSIG 15 65 Bars 3 Check the lower sight glass on the receiver to deter mine charge The system is correctly charged when refrigerant level is at centerline of sight glass then weigh in another 3 Ibs 1 4 kg of refrigerant Checking Refrigerant Level on Units With S N Be ginning With JAR90710713 NOTE The ambient air entering the condenser air temperature should be above 40 F 4 4 C 1 Start unit in cooling mode Run approximately ten minutes until the refrigeration system is warm
41. 8 3 4 Ig and 3 3 8 Ig with a blunt tip to the keypad board Check alignment of window and keypad to endure proper sealing at bezel Torque screws to 12 16 1 3 Nm Hold the display board in place and connect the rib bon cable from the keypad and window assembly while you can still see the pins on the circuit board Place display board onto the 2 locating pins and se cure display board with the 4 3 8 Ig Phillips head screws Torque screws to 12 1 3 Nm Remove old gasket from door mounting bracket Ensure surface is completely free of old gasket ma terial and install new gasket Plug 10 pin wire harness into new display board and reconnect wires to SROS 62 10450 i Secure the bezel to the control door with the 4 5mm k Reconnect negative battery cable and check unit op X 20mm Ig hex head bolts Torque bolts to 26 in Ibs eration 8 Nm j Reconnect wiring harness 14 pin connector from microprocessor DETENT SPRINGS DISPLAY WINDOW KEYPAD DOOR WINDOW GASKET DISPLAY BEZEL DISPLAY BOARD WINDOW GASKET NOTE GASKET IS NOTCHED KEYPAD BOARD FOR CLEARANCE AROUND DETENTS MOUNTING BRACKET CONTROL BOX GASKET Figure 6 34 Display Module Assembly 62 10450 6 44 Change 11 2008 6 32 MICROPROCESSOR REPLACEMENT and CONFIGURATION 6 32 1 To Remove and Replace Microprocessor Logic Board Short Box 44 CAUTION Do not drill out the logic board standoffs to re
42. 8 1 4 2 TEMPERATURE CONTROL 4 2 1 Heat Cool Mode The system is configured for cooling mode for engine start and during the oil pressure delay Hot gas heating is applied by energizing the HR1 and HR2 relays which will energize the hot gas solenoids These re lays will also control the remote heat and cool lights 8 Light Bar only For UltraFreeze Refer to Section 4 4 a Cooling There are two control ranges Frozen and Perishable The Frozen range is active with set points at or below 10 F 12 and the Perishable range is active at set points above 10 F 12 C The controller automatically selects the mode s neces sary to maintain box temperature at set point Refer to Section 4 3 for description of UltraFresh 2 If the unit is in high speed loaded cool the microproces sor will pull terminal 38 low to energize the speed relay A set of normally open contacts SR close to energize the speed control solenoid SCS The engine will be in high speed When the unit is running in high speed loaded cool and with the evaporator coil temperature below 40 F 4 4 C to close at least one defrost termination thermo stat a pre trip may be initiated by depressing the PRE TRIP key The operator now may verify the pre trip se quence Refer to Section 3 3 Asthe trailer temperature falls toward set point the mi croprocessor will place the unit in low speed loaded cool The temperature at which this occurs is not
43. 9 ENGINE SCREW THREADS 2 28 2 10 ENGINE AIR SYS TEM unt esit EP See ean Dk ERU Lawn Deed Tasse dite guttas s 2 28 2 11 COMPRESSOR es ee MER TE E eee 2 28 2 12 REFRIGERATION SYSTEM 1 2 29 2 13 SAFETY DEVICES oux eae in cette EE PRA Cu AU NNI EE a 2 29 2 14 COMPONENT RESISTANCE amp CURRENT DRAW 2 30 2 15 REFRIGERANT CIRCUIT DURING COOLING 2 31 2 16 REFRIGERANT CIRCUIT HEATING AND DEFROSTING 2 32 2 16 1 Heating and Defrost 2 32 i 62 10450 TABLE OF CONTENTS CONTINUED PARAGRAPH NUMBER Page OPERATION NEUE LI BEIM epa EE etre 3 1 3 17 4SSTARTINGAUNIT AUTO EC d ema 3 1 3 2 MANUAL START GLOW AND CRANK IF EQUIPPED 3 3 3 3 PRETRIP a acci PUMP hace dig ERE mU IAN Tae 3 4 3 4 CHANGING SETPOINT 45 bee 3 5 3 5 START STOP OPERATION EAR ei Pies EET ES 3 6 3 6 CONTINUOUS RUN OPERATION 3 7 37 MANUAL DEFROST ates EC VEDI 3 8 3 7 1 Auto
44. ADD GLOW If the ADD GLOW selection is entered the control will add 30 seconds of glow to the glow times listed in section 3 2 This feature must be selected before the 3 start attempts have been 3 11 completed At higher ambients this override will only affect the second or third start attempt The add glow time is deselected when the engine starts or fails to start This parameter will not change due to the Code vs English selection Defrost Interval The defrost interval is displayed with the description DEFR or FNO The data for the interval will be displayed with one decimal place and then the capital letter H for hours i e DEFR 12 0H The defrost intervals are 1 5 3 6 or 12 hours Airflow The status of the speed control solenoid override is displayed as HIGH AIR or NORM AIR The code display is 1 The high air setting is and the NORM AIR setting is OFF If the display shows HIGH AIR the unit is locked into high speed Off Time The off time selection for the auto start mode is displayed with the description OFF T or FN2 The off times are 10 20 30 45 or 90 minutes The data for the off time will be displayed with two digits and then the capital letter M for minutes i e OFF T 20M On Time The on time selection for the auto start mode is displayed with the description ON T or FN3 The on time is 4 or 7 minutes The data for the on time will be displayed with two digits and then the capit
45. Figure 6 12 TV Engine Crankcase Breather 6 12 Figure 6 13 DI Belt Tension 6 13 Figure 6 14 V Belt Arrangement 1 6 14 Figure 6 15 Gauge 6 15 Figure 6 16 Upper Belt Replacement Plastic 6 16 Figure 6 17 Removing V Belt from Engine Adapter Drive Sheave 6 16 Figure 6 18 Evaporator Blower Wheel and Nozzle 6 18 Figure 6 19 Condenser Fan and Clutch 6 20 Figure 6 20 Plastic Condenser Fan and Clutch 6 21 Figure 6 21 Vacuum Pump Connection 6 29 Figure 6 22 Compressor Drive Assembly 6 32 Figure 6 23 Pressure Switches HP 1 and 2 6 32 Figure 6 24 Oil Level in Sight Glass 6 32 Figure 6 25 Compressor 6 33 Figure 6 26 Unloader Solenoid Valve
46. Look at battery voltage in data list to find out whether shutdown voltage has been reached If there is a in front of the number the voltage is enough to shutdown and restart If only the number appears the voltage is still too low for shutdown The controller will restart the engine if any of the following criteria have been met eBox temperature has moved away from setpoint by 11 F 6 1 C for setpoints in the perishable range and 11 F 6 1 C for setpoints in the frozen range DURING minimum off time temperature has moved away from setpoint by 0 5 F 0 3 C AFTER minimum off time for setpoints in the perishable range or 0 5 F 0 3 C for setpoints in the frozen range The battery voltage drops below 11 Vdc 12 2 VDC for units with EEPROM Rev 3 25 and higher Refer to Section 3 9 1 for unit data engine coolant temperature drops below 34 F 1 C 3 6 CONTINUOUS RUN OPERATION START STOP Must not be Displayed o e FAULT STAND BY 200 945 SETPOINT BOX TEMPERATURE t UNIT PRETRIP DATA CHECK AUTO S S CONTINUOU MANUAL DEFROST Check if START STOP is displayed If it is press the AUTO S S CONTINUOUS toggle key to place unit in Continuous Run mode In the Continuous Run mode the diesel engine will run continuously providing constant air flow temperature control to the product The engine will not be allowed to shut off e
47. adjusted place a small amount of paint Adjustment Screw 0 050 socket head size 1 2 3 Low Side Connection 4 Pressure Line or Aspirator Bulb P N 07 00177 01 5 Magnehelic Gauge P N 07 00177 6 High Side Connection Figure 6 33 Defrost Air Switch Test Setup 2 Ohmmeter or Continuity Device 62 10450 6 40 Change 11 2008 6 29 EVAPORATOR COIL CLEANING WARNING Personal protection equipment must be utilized when performing coil cleaning The use of recycled cardboard cartons is increasing across the country The recycled cardboard cartons create much more fiber dust during transport than new cartons The fiber dust and particles are drawn into the evaporator where they lodge between the evaporator fins If the coil is not cleaned on a regular basis some times as often as after each trip the accumulation can be great enough to restrict air flow cause coil icing re petitive defrosts and loss of unit capacity Due to the washing action of normal defrost the fiber dust and particles may not be visible on the face of the coil but may accumulate deep within Clean the evaporator coil on a regular basis not only to remove cardboard dust but to remove any grease or oil film which sometimes coats the fins and prevents water from draining into the drain pan Cardboard fiber particles after being wetted and dried several times can be very hard to remove Therefore several washings may be
48. air plus an integrator error which is based on the selected control ling active probe When not in pulldown mode and the setpoint is greater than or equal to 60 F 15 6 C the ac tive probe is used for control and integration There are three possible modes for UltraFresh 2 control These are heat cool and null To enter COOL the control temperature must be greater than or equal to 1 8 F Cool Pulsed Mode Speed Engine UL1 1 above setpoint To exit cool and enter NULL the control temperature must be less than 1 4 F 0 8 C above setpoint To exit NULL and enter HEAT the con trol temperature must be more than or equal to 1 8 F 1 C below setpoint and to exit heat and enter NULL the control temperature must be less than 1 4 0 8 C below setpoint See Figure 4 3 Null mode operates with a pulse which combines cooling or heating with a null valve combination over a 10 second period See operation of relays and valves in chart below The null valve portion of the period is defined as HR1 and 4 de energized and HR2 energized The system will pulse between Cool and Null when the control temperature is above setpoint or it will pulse between Heat and Null when the control temperature is below setpoint The length of time the pulse spends in the Cool or Heat Mode plus the time it spends in the Null Mode will be 10 seconds The closer the control temperature is to set point the longer the Null Mode Pulse
49. amp rect the condition NO System starter dor proper YES YES Check amperage YES tion Check all associate Y wiring and connectors YES System Does the Pus deus YES Load test battery Repair ENSCU flash 6to7 amps Each or replace as required on LED NO glow plug draws 0 7 Check fuel flow from YES Check ground connections diagnostic code to 1 2 amps Did fuel tanks through the 8 atthe battery starter engine you find and fuel lines to the injec System block and inside the control YES correct the condition tion pump Did you find OK 4 YE box Did you find and correct and correct the condi 1 the condition See Section tion NO MPR Code 3 54 Did you check for voltage find and cor Revi f jumper and reinstall 1 between ENSCU 13 eview results Replace micro and operate rect the condi p above tests with your shutdown option system in order to verify re tion amp 19 Do you have at GOL and or telematics system pair Do not install micro least 11 volts at the d hours at this time Did youfind ENSCU sary go to the begin un ning of the table and Enter eur and correct the condition Review results of NO g 5 test again micro into new micro Remove n
50. and fan shaft for oil leaks 8 Check fan shaft idler and gearbox bearings 9 Check clutch air gap and adjust as required 1 Check oil filter change interval refer to section f of this table 2 Check for oil leaks 3 Check low oil pressure safety 4 Clean crankcase breather 5 Check engine speeds for units without electronic speed control Fuel System 1 Clean fuel pump strainer 2 Change fuel filter s refer to section f of this table 3 Check fuel heater optional Cooling 1 Clean radiator condenser fin surface 6 10 1 and 6 30 System 2 Check antifreeze concentration 6 10 1 3 Check water pump Check 4 Check water temperature sensor functions 2 8 Exhaust 1 Check mounting hardware Check System 2 Check muffler and exhaust pipes Check Air Intake 1 Change air cleaner element Check System 2 Check and replace air filter indicator if needed 6 10 5 Starting 1 Check battery condition Check Replace System 2 Clean battery connections and cable ends Check Replace 3 Check battery hold down clamps Check 4 Check starter operation Check Charging 1 Check alternator brushes and replace if necessary Check System 2 Check alternator output 2 14 62 10450 6 2 ACTION SYSTEM OPERATION REFERENCE SECTION b Every Service Interval or Annually Continued Refrigera Check air switch amp calibrate tion Check amp clean evaporator coil and defrost drain hoses System Check operating refrigerant pressure
51. compressor will operate on either 4 or 6 cylinders during the Defrost Cycle Suction Pressure Control For all XT and X2 model units in addition to loading and unloading the front unloader based on the suction pres sure Refer to section 4 2 4 after the unit has been in the Defrost Cycle for more than 90 seconds the suction pressure will be monitored to help keep it from going too high If the suction pressure rises to 57 psig 3 9 Bar will de energize to open SV1 for one second then energize again The opening of SV1 will decrease the discharge pressure which will keep the suction pres sure lower This will not occur more than 2 times each minute e Fail Safe Defrost Termination Should the defrost cycle not complete within 45 minutes or ifthe defrost air switch contacts do not open at defrost termination the defrost cycle is terminated The internal timer is reset for 1 5 hours and the external defrost sig nal is ignored for defrost initiation The manual defrost Switch will override this mode and start a new 45 minute cycle When defrost override is active the Defrost Fail alarm will be indicated If the run relay is de energized during defrost due to a shut down alarm or the Start Run Off Switch being turned off defrost will be termi nated f Defrost Termination at Low Speed The defrost terminates with HR1 and speed relay de energizing This places the engine in low speed and opens the SV1 solenoid val
52. dented enclosing tube e Install new parts Do not over tighten enclosing tube assembly Torque to a value of 20 to 22 ft Ibs 27 to 30 Nm f Remove supplied installation removal tool Install coil and retaining cap if equipped g Evacuate and dehydrate the compressor Refer to Section 6 18 p through 6 18 w h Start unit and check unloader operation Refer to Section 6 20 a 6 21 REPLACING OR SERVICING CHECK VALVE A check valve allows the hot gas to travel in one direc tion only The function of the Hot Gas Bypass Check Valve is to raise the receiver pressure when the ambient tempera ture is low so that refrigerant can flow from the receiver to the evaporator when the unit is in heating or defrost The function of the Discharge Line Check Valve is to prevent any liquid refrigerant from migrating into the compressor during the unit off cycle Cap Spring Gasket Stem Seat Body Figure 6 25 Discharge Check Valve Serviceable Prior to S N JAW90756460 DPN 6 33 62 10450 07 00457 00 Figure 6 26 Discharge Check Valve Non Serviceable Beginning With S N JAW90756460 Figure 6 27 Hot Gas Check Valve Non Serviceable 62 10450 6 34 6 21 1 To Service Check Valve See Figure 6 25
53. different The gas ket for the window and bezel is notched for clearance around the detents b Place the clear window and new keypad on the 3 alignment pins of the bezel Loosely install the 11 Phillips head screws 8 3 4 Ig and 3 3 8 Ig with a blunt tip to the keypad board Check alignment of window and keypad to endure proper sealing at bezel Torque screws to 12 16 1 3 Nm d Hold the display board in place and connect the rib bon cable from the keypad and window assembly while you can still see the pins on the circuit board Place display board onto the 2 locating pins and se cure display board with the 4 3 8 Ig Phillips head screws Torque screws to 12 1 3 Nm Remove old gasket from door mounting bracket Ensure surface is completely free of old gasket ma terial and install new gasket h Plug wire harness into new display board and recon nect wires to SROS i Securethe bezelto the control door with the 4 5mm Nm Ig hex head bolts Torque bolts to 26 in Ibs 3 Nm j Fasten bezel and bracket assembly to unit side door using 4 hex head 1 4 20 bolts Reconnect wiring harness 60 pin connector from microprocessor Reconnect negative battery cable and check unit op eration x Change 11 2008 Keypad Removal Tall Box a Place the SROS in the OFF position and discon nect the negative battery cable Attach a gr
54. display is CD8 The evaporator temperature sensor input will be used as a discrete input to indicate the door open closed condition The display will always show dashes Discharge Temperature The discharge temperature is displayed with the description CDT or CD9 The data is displayed with the proper unit designator Degree C or Degree F i e CDT 85F The display range is 40 F to 392 F 40 C to 200 C If there is no sensor then the display will read for the data Battery Voltage The battery voltage is displayed with the description BATT or CD10 The data is displayed with one decimal place and then the capital letter V for volts i e BATT 12 2V or CD10 12 2V The voltage reading is displayed with a plus sign ifthe battery status is high enough to allow unit shut down Auto Start Stop Standby Hours Not Applicable This data is not applicable for this unit The display is SBY or CD11 Mod V Future Expansion This unit data is not used at this time The Code display is CD12 Software Revision The Eeprom software revision number is displayed with the description REV or CD13 on the left and Eeprom software revision number on the right side Pressing the ENTER key for 3 seconds will display REV U2 or CD13A on the left and the board mounted software revision number on the right side Serial Number Low The low serial number of the unit is displayed with the description SERL or CD14
55. for leaks k The thermal bulb is located at 5 or 7 o clock position on the suction line See Figure 6 28 This area must be clean to ensure positive bulb contact Apply ther mal mastic and strap thermal bulb to suction line and insulate both with presstite Wrap power head with presstite Change 11 2008 m Evacuate by placing vacuum pump on suction ser vice valve n Open king valve and then check refrigerant level Re fer to Section 6 17 6 23 2 Checking Superheat NOTE Superheat cannot be adjusted on the braze in TXV superheat is out of adjustment the valve must be replaced 6 23 3 To Measure Superheat NOTE The expansion valve and bulb location are shown in Figure 2 7 a Remove evaporator panel from rear of unit and then remove Presstite from expansion valve bulb and suc tion line b Loosen one TXV bulb clamp and make sure area un der clamp above TXV bulb is clean 1 Suction Line 2 TXV Bulb Clamp 3 Nut and Bolt Clamp 4 Thermocouple 5 TXV Bulb Figure 6 28 Thermostatic Expansion Valve Bulb and Thermocouple NOTE When conducting this test the suction pressure must be at least 6 psig 0 4 Bar below expan sion valve maximum operating pressure MOP Refer to Section 2 12 c Place thermocouple above parallel with the TXV bulb and then secure loosened clamp making sure both bulbs are firmly secured to suction line as shown in Figure 6 28 d Connect an accurate g
56. jumper wire check for 5 VDC at ENSCU terminal 10 Do you have 5 VDC at terminal 10 Check for open or high resistance on circuit between ENSSN and ENSCU Did you find and correct the condition v supervisor If necessary go to the beginning of the table amp test again YES Y Set proper high speed RPM per this manual Did you find and correct the condition YES Y System OK v v Check for proper internal mechanical operation of injection pump assembly and governor assembly Did you find and correct the condition Replace ENSCU Did you find and correct the condition Replace ENSSN Did you find and correct the condition NO YES NO Review results of above tests with your super visor If necessary go to the beginning of the table amp test again and re install old above tests with your supervisor If Remove new ENSSN ENSSN back into unit ENSSN is not the fault Review results of necessary go to the beginning of the table amp test again Figure 5 1 ESC Diagnostic Tree 1 Long 1 Short LED Code Engine RPM is Over 2530 RPM 62 10450 5 10 START HERE Verify unit starts go into x high speed and stall after running for a few seconds Using jumper wire ve
57. key must be pressed first 3 8 1 FUNCTIONAL PARAMETERS The following table has columns for Code and English displays English is the default setting Change Functional Parameter to Code to see Code display format Table 3 1 Function Codes FNO ENT OFF Start Stop CODE PROBE Return and Supply Air Maximum Off Time 30 Min Restarting For AutoStart FNIO ON Manual Glow Crank Code vs English Code vs English display format Start Stop Degrees Temperature Unit Temperature and Minimum TEMP STRT Stop FN10 OFF MAN Manual Start Operation Switch Manual Glow Override Normal or add 30 sec REM Controlling Probe PROBE Return Air Displayed in C or F Off Time Based STD Unloader Control On units equipped with T RANGE Out of Range Tolerance Alarm Reset Alarm reset or no alarms Code Vs English Messages The description for messages of the functional parameters unit status and alarms can be displayed in English or Codes through this function selection The two choices will be displayed as ENGLISH or CODES With this parameter set to CODES all display descriptions will be set to their code display This parameter will not change due to this selection Refer to each section for the alternate display description Manual Glow Override The auto start glow time can be manually overridden through this function The messages is displayed as NORM GLOW or
58. minimum of 2 minutes This 2 minute timer can be overridden by turning power off and back on The alarm will reset when the control power is cycled as long as the high pressure switch has reset or high pressure has fallen below 350 10 psig 23 8 Bar Auto Start Failure Alarm The auto start failure alarm is displayed with the description STARTFAIL or AL3 This alarm is generated ifthe engine fails to start The fault light FL is turned on The alarm STARTFAIL is also generated if the system fails to heat three consecutive times Once activated for this condition the engine will be prevented from starting until the alarm is cleared or power is cycled on the controller Alarm will not be generated when the unit is defrosting executing pretrip or when run relay is open or the engine not running If any of these conditions occur while any of the three 3 error timers are running the timers will be cleared If function MAN OP manual start mode is selected the start failure alarm will be generated if the engine is not started in 5 minutes Low Battery Voltage Alarm The low battery voltage alarm is displayed with the description LOW AL4 This alarm is generated if the battery voltage falls below 10 VDC The fault light FL is turned on and engine will shut down when The engine is off and Software Version is greater than or equal to 3 27 and Auto Start has not started cranking the engine Initial Startup or St
59. must be successfully completed in se quence Any problems found must be repaired immediately and the step repeated before continuing the proce dure unless otherwise noted Equipment must be operated in High Speed Cool for 20 minutes prior to starting this procedure Operate with a 35 F 1 7 setpoint fully loaded un plug both unloaders when box temperature reaches 35 F 1 7 This action allows the compressor oil to come up to operating temperature When these conditions are met plug in both unloaders The ambient air entering the condenser air temper ature should be above 60 F 15 6 C Ambient temperatures below 60 F 15 6 C could cause inaccurate results in any step of this procedure Change 11 2008 6 21 f On units with automatic start stop the microproces sor must be set for MAN OP and CONTINUOUS RUN operation and left in this mode during the entire test The following tools are required to perform this proce dure Refrigeration Ratchet Refrigeration manifold gauge set 2 required 5 feet square plastic sheet 2 4 mil 8 10 inch adjustable end wrench Wire cutters DC volt ohm meter 07 50006 00 Quick Check Jumper Kit which includes 1 Coil Tester 2 wire plug with 24 wire leads and spring clips 1 Circuit Tester male and female 2 wire plugs wired together with bare wire for volt age test 1 Bypass plug 2 wire plug with jumper loop
60. on fanshaft pin Change 11 2008 6 12 2 Blower Wheel And Fanshaft Removal a b h i j Remove bulkhead and air chute if equipped Re move evaporator back panel Remove the bolts that secure the upper DTT mount ing plate and SAS mounting clamp to the nozzle cov er Hang harness down out of way using care to pre vent cutting wires on evaporator coil Remove the remaining bolts in the nozzle cover and carefully remove it from the pod NOTE The nozzle cover P N 58 04469 00 is sealed with a gasket CTD P N 42 00506 00 If the gasket is damaged during removal it MUST be replaced Remove the two 1 4 20 X 1 Ig bolts from the blower wheel split taper bushing Insert them into the threaded holes Tighten bolts evenly to push the blower wheel away from the bushing Remove blower wheel and bushing from fanshaft Remove the fan shaft seal ring clamp and carefully peel seal from pod use a putty knife if needed NOTE The fan shaft seal CTD P N 42 00372 00 is caulked to the pod If seal is damaged during re moval it MUST be replaced Remove the four 3 8 bolts from the fan shaft Remove vent from fanshaft Remove fanshaft from unit Inspect key keyway and shaft for wear 6 12 3 Fanshaft Installation a Install key included into the shaft keyway NOTE If itis necessary to drive the key into place be sure to support the shaft while tapping the keys
61. open or the compressor discharge temperature CDT reaches 310 F 154 4 C for 1 continuous minute High Ambient Defrostterminates with HR1 and HR4 de energizing and UFR energizing This opens the SV1 and SV2 valves turns off the Heat Light and turns on the Cool Light 8 light bar and unloads the Front Unloader After the suction pressure has risen by 10 psig or ina maximum of 15 seconds the SR and HR2 will de ener gize and the engine will go to low speed and SV4 will close URR will energize and unload the Rear Unloader After 5 seconds the DR will de energize to engage the clutch and turn off the Defrost Light 8 light bar After another 5 seconds the unit will return to normal tempera ture control If the unit should remain in High Ambient Defrost for 45 minutes the Fail Safe Defrost Termination logic will stop the Defrost Cycle and put the unit into temperature con trol mode see section NO TAG 62 10450 Table 4 3 Stages for High Ambient Defrost Ambient temperature Greater Than 80 F 26 7 STAGE OPEN De energ CLOSED Energ OPEN De energ CLOSED Energ OPEN De energ OPEN Energ SV1 SV2 4 HR1 HR2 CLOSED De energ HP2 OPEN Control Energ Low High Low De energ De energ De energized Energ Energized 4 2 3 Unloader Operation a Unloading in Temperature Mode The compressor is equipped with unloaders electroni cally controlle
62. opened it must be evacuated and dehydrated Refer to Section 6 16 4 WARNING Do not use a disposable refrigerant tainer to store the charge as an explosion may occur Equipment Required a Appropriate returnable refrigerant cylinder prefer ably 125lb 57 kg net capacity Also a 50 Ib 23 kg capacity returnable cylinder may be used Re frigerant removal will be faster and more complete with the larger cylinder b Refrigerant manifold gauge set c Vacuum pump preferably 5 cfm 8m3H P N 07 00176 01 d Weight scales 0 to 300 Ib 0 to 91 kg range mini mum e A 12 foot length of 3 8 1 0 evacuation hose or 3 8 copper tubing with 3 8 female flare adapter on each end Do not use hose or tubing of smaller diameter or the removal process will take considerably longer 6 13 10 Refrigerant Removal From An Inoperative Compressor To remove the refrigerant from a compressor that is not operational do the following a Recover refrigerant with a refrigerant reclaimer b Service or replace components as required and leak check the entire system c Using refrigerant hoses designed for vacuum service connect a vacuum pump to center connection of man ifold gauge set Evacuate compressor to or below 500 microns Close off pump valve isolate vacuum gauge and stop pump Wait 5 minutes to verify that vacuum holds at or below 500 microns d Once vacuum is maintained recharge high side with R 40
63. relay SR coils Terminals 37 55 and 38 will be pulled low The only change from the low speed loaded heat mode is that the speed relay is now energized SR contacts close to en ergize the speed control solenoid SCS The engine will be in high speed 4 2 2 Defrost Cycle NOTE The unit will be in high speed in defrost mode If both defrost thermostats klixons are open no volt age at 31 defrost cannot be initiated by any means A few models may have only one DTT Defrost is an independent cycle overriding cooling and heating functions to de ice the evaporator as required The controller displays DF during defrost mode on the right hand temperature display The left hand display will continue to display the setpoint In defrost the microprocessor pulls terminals 37 55 and 38 low to shift the unit into high speed heat The proces sor also pulls terminal 53 low to energize the defrost relay coil This closes the N O defrost relay contacts to energize the defrost light on the remote 8 light bar The defrost and heat display will also be illuminated Also N C defrost relay contacts open to de energize the clutch CLH to stop the evaporator fan Defrost will continue and does not terminate until the mi croprocessor senses both defrost termination thermo stats DTT s reach termination temperature and open or the compressor discharge temperature CDT reach es 310 154 4 C for 1 continuous minute If the uni
64. sure negative battery terminal is disconnected and remove old belt b Place V belt on alternator sheave and then install al ternator with two bolts loosely in position Use a belt tension gauge tester P N 07 00253 shown in Figure 6 13 whenever V belts are adjusted or re placed A belt tension gauge provides an accurate and easy method of adjusting belts to their proper tension Prop erly adjusted belts give long lasting and efficient service Too much tension SHORTENS belt and bearing life and too little tension causes slippage and excessive belt wear It is also important to keep belts and sheaves free of any foreign material which may cause the belts to slip The belt tension gauge can be used to adjust all belts The readings which we specify for Carrier Transicold units are applicable only for our belts and application as the tension is dependent on the size of the belt and dis tance between sheaves When using this gauge it should be placed as close as possible to the midpoint between two sheaves The V belts must be kept in good condition with the proper tension to provide adequate air movement across the coils Figure 6 13 DI Belt Tension Gauge Part No 07 00253 c Check the center alignment of the engine drive alter nator and water pump sheaves to ensure proper alignment Pulley misalignment will create excess belt wear and shorten alternator bearing life The cen ter line of all three sheaves must be i
65. temperature is below 40 F pretrip alarms will be generated Pretrip must be 4 4 C monitored by the user to verify that the unit operates b Operator presses the PRETRIP key If the defrost through all cycles thermostat DTT is closed the controller will display PPPP If DTT is open no response end of test Controller displays PPPP Pre trip mode is started After 30 seconds in high speed cool unit cycles to low speed loaded cool e After 30 seconds unit cycles to low speed unloaded cool f After 30 seconds unit cycles to low speed unloaded heat g After 30 seconds unit cycles to low speed loaded heat 2 After 30 seconds unit cycles to high speed heat and displays coolant temperature i After 30 seconds unit cycles to high speed cool and displays defrost interval selected for 30 seconds then unit cycles to defrost if DTT is closed 62 10450 3 4 3 4 CHANGING SETPOINT Press UP arrow key to increase displayed setpoint FAULT COOL HEAT 200 SETPOINT t UNIT PRETRIP DATA CHECK Setpoints of 22 F to 86 F 30 C to 30 C may be entered via keypad The controller always retains the last entered setpoint in memory If no setpoint is in memory i e on initial startup the controller will lock out the run relay and flash SP on the left hand display until a valid setpoint is entered NOTE The microprocessor Configurations allow a mini
66. the PRETRIP CHECK key on the control panel or use the DataLink Tool Box program to initiate Trip Start d Additional Data Sensors DataLink can have up to 5 thermistors 1 fuel level sensor and 1 door open closed switch 2 6 4 Status LEDs The DataLink contains four status LEDs These are as follows Fault Alarm Red Battery Status Yellow Communication Green Status Power Executing Code Yellow Fail Fault Alarm LED The Fault Alarm LED indicates if a hardware fault or alarm has occurred in the DataLink If a hardware fault occurs the LED will flash the fault code three times then the processor will reset The fault codes and their code numbers are defined in Table 2 3 Fault codes will only be displayed on power up If the DataLink powers up properly then this LED will indicate an alarm condition that has been detected The alarm LED should turn on when the alarm is detected and off when the alarm goes away If an alarm occurs then the LED will be on solid until the alarm goes away The out of range values are as follows Thermistor Inputs Low limit 2 58 0 High limit 158 F F 50 C 70 C For sensor input alarms the alarms can only be cleared by using DataLink Toolbox PC Program See 2 6 6 Batt Battery Status LED The Battery status LED pulses at a rate of 1 second on 1 second off when the battery voltage is greater than or equal to 6 0V It will be on solid when the battery voltage is
67. the designated hour meter is greater than maintenance hour meter 2 Out of Range Alarm The out of range alarm is displayed with the description RAS OUT or AL2O This alarm is generated when the refrigerated compartment is out of range Refer to Section 3 8 1 The fault light FL is turned on System Check Alarm CNF18 must be On The system check alarm is displayed with the description SYSTEM CK or AL23 if CNF 18 is On The SYSTEM CK alarm is generated when any of the following conditions occur Ifthe unit is in cool mode and not in the UltraFresh 2 or UltraFreeze null or heat bands and the supply air temperature becomes 5 F 2 8 C higher than the re turn air temperature for five continuous minutes f the suction pressure becomes greater than 100 psig 6 8 Bar in heat mode for 60 continuous sec onds for both perishable and frozen setpoints If the suction pressure becomes less than 10 2 inHg 0 34 Bar for 120 continuous seconds while the re frigerated compartment is in cool mode and while the return air temperature for the compartment is greater than O F 17 8 C and the ambient temperature is greater than or equal to 40 F 4 4 C the alarm will be activated If either the return or supply probe fails only the suc tion pressure logic will be used to test for the alarm conditions In case of either probe failing the 5 minute supply temperature greater than return by 5 F 2 8 C is not done With a single
68. the engine is not running 4 1 8 Battery Voltage Provisions are made to sense when the battery is good A good battery is defined as having 13 4v at 75 F 23 9 C This condition is used to allow shut off of the diesel engine If the battery voltage falls below 10v during glow cycle the starter will not engage and the start sequence will continue this is considered a failed start The start se quence will be repeated until the unit starts or three con secutive start attempts have failed Table 4 2 Battery Voltages Message Voltage ig LOW BATT 10 Unit will shut down except AL4 or Less during cranking If the unit has cycled off in auto start stop mode and battery voltage drops below 11 0 volts 12 2 volts for Rev 11 to 3 25 and higher the unit is automati 13 4 cally started to charge battery Unit will operate until a battery voltage of 13 4 volts is obtained at which level unit will stop if temperatures are satisfied HI BATT 17 Unit will shut down 4 1 9 Oil Pressure Signal When the oil pressure switch is closed it shows that the engine is running and prevents engagement ofthe start er motor when operating in the auto mode Refer to Section 2 3 for oil pressure switch settings 4 1 10 Maximum Off Time Provision for a keypad selectable feature is provided which will cause the engine to be started 30 minutes af ter the engine has stopped regardless of the box tem perature Refer to Section 3
69. to cool HR1 de ener gizes 2 seconds before HR2 This allows time for SV 1 to open and clear the condenser of liquid before 4 closes This will eliminate any high pressure buildup which could occur During this time only a remote 8 light bar the heat and cool lights will be on together The heat and cool display on the control panel change immediately NOTE for X2 units only When the unit has cycled Off in Start Stop and the ambient air temperature is is at or rises to 115 F 46 C HR2 will energize and open the SVA valve for 45 seconds to equalize the refrig erant system pressures across the high and low pressure sides of the system While the SV4 valve is energized the Heat Light will also be on 8 Light Bar only even though the engine is not running Refer to Section 2 16 for description on heating cycle Refer to Section 4 4 for description of UltraFreeze The controller automatically selects the mode s neces sary to maintain box temperature at set point The heat ing modes are as follows with descending tempera tures a Low Speed Unloaded Heating b Low Speed Loaded Heating c High Speed Loaded Heating The controller will shift the unit into low speed unloaded heat when the trailer temperature falls below set point compressor in four cylinder heating The microproces sor pulls terminals 37 55 and 57 low to complete the ground paths for the heat relays HR1 and HR2 and un loader front relay UF
70. to fully loaded for setpoints greater than 10 F 12 C and high speed loaded for setpoints of 10 F 12 C or less The unit will not cycle off if the engine coolant tempera ture is less than 122 F 50 C orthe battery is not good If the unit can not cycle off it will operate normally in con tinuous mode If all temperature probes fail and the set point is 10 F 12 C or less the unit will not shut down The unit will shut down when the box temperature is within 0 5 F 0 3 C of setpoint for setpoints in the Perishable range or 0 5 F 0 3 C above setpoint for setpoints in the Frozen range 4 1 7 Minimum Off Time Keypad provision is providedto selectthe minimum off time of 10 20 30 45 or 90 minutes Refer to Section 3 8 1 After the minimum off time the unit will restart for tem peratures beyond 3 6 F 2 0 C of setpoint for the Perishable range or above 3 6 F 2 0 C of setpoint for the Frozen range The minimum off time is overridden if the temperature is more than 11 F 6 C from setpoint 62 10450 NOTE for X2 units only When the unit has cycled OFF in Start Stop andthe ambient air temperature is at or rises to 115 F 46 C HR2 will energize and open the SVA valve for 45 seconds to equalize the refrig erant system pressures across the high and low pressure sides of the system While the SV4 valve is energized the Heat Light will also be on 8 Light Bar only even though
71. will destroy the rectifier diodes in alternator As a precau tionary measure disconnect positive bat tery terminal when charging battery in unit Connecting charger in reverse will destroy the rectifier diodes in alternator The alternator converts mechanical and magnetic energy to alternating current A C and voltage by the rotation of an electromagnetic field rotor inside a three phase stator assembly The alternating current and voltage is changed to direct current and voltage by passing AC energy through a three phase full wave rectifier system Six silicon rectifier diodes are used 62 10450 The regulator is an electronic switching device It senses the system voltage level and switches the voltage applied to the field in order to maintain proper system voltage b Integral Voltage Regulator Operation 12 VDC The regulator is an all electronic transistorized device No mechanical contacts or relays are used to perform the voltage regulation of the alternator system The electronic circuitry should never require adjustment and the solid state active elements used have proved reliable enough to warrant a sealed unit The system is temperature compensated to permit the ideal charging rate at all temperatures The D circuit provides voltage reading to the micro The micro looks at two separate inputs to determine if the
72. 0 3 C Low Speed 6 Cylinder Heat 1 5 F 0 8 C 2 0 F 1 1 C Low Speed High Speed 6 Cylinder Heat 3 6 F 2 0 6 Cylinder Heat FALLING BOX TEMPERATURE During the minimum off time the unit will restart at the override temperature selected in the functional parameter list Figure 4 6 Start Stop Perishable Temperature Control Operating Sequence After Minimum Run Time 4 11 62 10450 4 3 ULTRAFRESH 2 TEMPERATURE CONTROL CNF 6 must be set to OFF and CNF 15 must be set to ON NOTE In high ambient temperatures 120 F 48 9 and above the unit will operate only in Low Speed UltraFresh 2 temperature control algorithm is a method of producing a reduced capacity state between heat and cool modes This is done by combining a null pulse with either heat or cool The capacity in this band can vary by adjusting the duty cycle of the portion of operation During this null operation heat and cool valves are opened simultaneously to reduce heating or cooling ca pacity UltraFresh 2 temperature control uses both supply and return air sensors to achieve control If both probes are present and neither is defective or out of range the se lected probe is the active probe The controlling probe will switch depending on if the unit has pulled down to setpoint yet During pulldown the controlling tempera ture is from the active probe When not in pulldown mode the controlling temperature is supply
73. 018 9N3 l r AZL GSHOLIMS onmoocoocoodocdd 0114189540 p e N Index A Air Switch 2 29 6 40 Alarm Display And Reset 3 16 Alternator 6 9 Alternator Operation 2 9 Alternator Regulator 2 9 Ambient Air Temperature Sensor 2 13 Auto Start Sequence 4 1 Automatic Defrost 3 9 B Belt Tension Gauge 6 13 C Changing Setpoint 3 5 Checking For Noncondensibles 6 36 Checking The Refrigeration System 6 21 Compressor 6 30 Compressor Data 2 28 Compressor Discharge Temperature trans ducer 2 13 Compressor Oil Level 6 31 Compressor Suction Pressure Transducer 2 13 Compressor Unloader 6 32 Condenser Coil 6 41 Configuration Of Microprocessor 6 45 Continuous Run Operation 3 7 Controller 6 42 Controller Sensor 6 49 Cool Mode 4 3 Cooling 4 3 Change 11 2008 D Data Ohms And Amps 2 30 DataLink 2 23 DataTrak 2 27 Defrost Air Switch 2 29 4 4 6 40 Defrost Cycle 4 4 6 39 Defrost Function 4 4 Defrost Termination at Low Speed 4 5 Defrost Thermostats 2 29 Defrost Timer 4 4 Dehydration 6 27 Display 2 20 Door Latch Cable Replacement 6 7 Door Latch Maintenance 6 5 E Electronic Speed Control 6 11 Electronic Speed Control Troubleshooting 5 8 Engine Air Cleaner 6 12 Engine Air System 2 28 Eng
74. 0710713 Charge the system until the refrigerant levelis at cent erline of the lower sight glass THE LOWER SIGHT GLASS SHOULD NOT BE EMPTY AND THE UP PER SIGHT GLASS SHOULD NOT BE FULL Start unit and check for noncondensibles Refer to Section 6 25 1 62 10450 6 17 3 Adding Full Charge 4 CAUTION Do not vapor charge 404 Only liquid charging through the receiver king valve is acceptable a Dehydrate unit to 500 microns and leave in deep vac uum Refer to Section 6 16 Place drum of refrigerant on scale and connect charg ing line from drum to king valve Purge charging line at king valve Note weight of drum and refrigerant d Open liquid valve on drum Midseat king valve and al low the liquid refrigerant to flow into the unit until the correct weight of refrigerant has been added as indi cated by scales Correct charge will be found in Table 2 1 It is possible that all liquid may not be pulled into the receiver as outlined in step d In this case frontseat the receiver valve king valve and run the unit in cooling until the correct amount of re frigerant is added e When scale indicates that the correct charge has been added close liquid line valve on cylinder and backseat the king valve Remove charging hose f Start unit and check for noncondensibles Refer to Section 6 25 1 6 18 REPLACING THE COMPRESSOR NOTES The service replacement compressor is s
75. 08 TABLE OF CONTENTS CONTINUED PARAGRAPH NUMBER Page SERVICE Continued 6 17 ADDING REFRIGERANT TO 6 6 28 6 17 1 Checking The Refrigerant Charge 6 28 6 17 2 Adding A Partial Charge nd Ri ves 6 29 6 17 3 Adding A Full Cha rge eed AR TR ae ee T 6 30 6 18 REPLACING THE COMPRESSOR 6 30 6 19 CHECKING COMPRESSOR OIL LEVEL 222222222 2 2 6 31 6 19 1 To Check the Oil Level in the Compressor 6 31 6 19 2 Adding Oil with Compressor in System 6 32 6 19 3 Adding Oil to Service Replacement Compressor 6 32 6 19 4 Removing Oil from the Compressor 6 32 6 20 COMPRESSOR UNLOADER VALVE 6 32 6 20 1 Checkout Procedure 2 6 32 6 20 2 Unloader Coil 6 33 6 20 3 Replacing Solenoid Valve Internal Parts 6 33 6 21 REPLACING OR SERVICING CHECK VALVE
76. 4 Defrost DR Fault FR Out of Range OR Auto Restart ARR Fuel Heater FHR OPTIONAL Relay Board o 00000000 0000000 b id Carrier TRANSICOL gt o H 1 Figure 2 14 Control Box Redesigned Tall Box 2 17 62 10450 EEPROM Figure 2 15 Logic Board 2 18 62 10450 d Display and Keypad MODE LEDs DISPLAY O FAULT STAND BY SETPOINT BOX TEMPERATURE START RUN f N N OFF FAULT STAND BY 200 945 SETPOINT BOX TEMPERATURE UNIT PRETRIP AUTO S S MANUAL DATA CHECK CONTIN ON DEFROST
77. 4a to proper charge Backseat compressor ser vice valves and disconnect manifold gauge set Change 11 2008 6 25 6 13 11 Refrigerant Removal From An Operable Compressor To service an operable compressor pump the refriger ant into the condenser coil and receiver as follows a Frontseat the compressor suction service valve by turning clockwise b Start the unit and run in cooling until a slight vacuum 1 2 is reached Shut the system down and tag out system power source c Frontseat the compressor discharge service valve and wait 5 minutes to verify vacuum is maintained If the pressure rises above vacuum open the compres sor discharge service valve and repeat steps b and c until a vacuum is maintained d Service or replace compressor components as re quired and leak check the entire system e Using refrigerant hoses designed for vacuum service connect a vacuum pump to center connection of man ifold gauge set Evacuate system to to below 500 mi crons Close off pump valve isolate vacuum gauge and stop pump Wait 5 minutes to verify that vacuum holds at or below 500 microns NOTE Refrigerant will flow from the system into the evacuated cylinder until system pressure is equivalent to container temperature For exam ple if a cylinder is at 90 F 32 2 C given a sys tem containing R 404A the system pressure reaches 204 psig 13 9 Bar no further transfer Will take place For this reason it is possible t
78. AUSES SECTION 5 3 2 Unit Runs But Has Insufficient Cooling Compressor Compressor valves defective 6 20 1 Refrigeration system Abnormal pressure 5 3 6 Unloader malfunction 6 20 1 Expansion valve malfunction 5 3 10 No or restricted evaporator airflow 5 3 9 Clutch Failure Replace Low refrigerant level 6 13 1 Engine does not Speed control linkage units with non ESC engines develop full rpm Engine malfunction Refrigerant pressure 5 3 3 Unit Operates Long or Continuously in Cooling Trailer Hot Load Allow time to pull down Defective box insulation or air leak or door is open Correct Refrigeration system Abnormal pressure 5 3 6 Temperature controller malfunction micro 5 3 8 Refrigerant charge 6 13 1 Solenoid valve malfunction Perform quick check 6 13 Fanshaft seal leaking Repair Compressor Defective Compressor valves defective Unloader malfunction 5 3 4 Unit Will Not Heat or Has Insufficient Heating Refrigeration Head pressure control switch HP 2 defective Abnormal pressure Temperature controller malfunction Solenoid valve malfunction 1 4 check valve bypass defective Clutch Failure Low refrigerant level SV1 malfunction SV4 malfunction Compressor Compressor drive defective Compressor defective Unloader Compressor gaskets or valves defective 20 Engine does not develop Speed control linkage units with non ESC engines 6 10 3 full rpm Engine malfunction 5 1 62 10450 5 4 INDICATION REF
79. Bar Do not use oxygen in or near a refrigerant system as an explosion may occur See Figure 6 29 Cylinder Valve and Gauge Pressure Regulator Nitrogen Cylinder Pressure Gauge 0 to 400 psig 0 to 27 2 Bar Bleed Off Valve 1 4 inch Connection Figure 6 29 Typical Setup for Testing High Pressure Switch 62 10450 6 36 a Remove switch as outlined in Section 6 24 1 b Connect ohmmeter or continuity light across switch terminals Ohmmeter will indicate resistance and continuity light will be lighted if switch closes after re lieving pressure Connect switch to a cylinder of dry nitrogen See Figure 6 29 Set nitrogen pressure regulator higher than cutout point on switch being tested Pressure switch cutout and cut in points are shown in Section 2 12 Close valve on cylinder and open bleed off valve Open cylinder valve Slowly close bleed off valve and increase pressure until the switch opens If light is used light will go out If an ohmmeter is used the me ter will indicate open Open pressure on gauge Slow ly open bleed off valve to decrease pressure until switch closes light will light or onmmeter will move 6 25 REPLACING RECEIVER SIGHT GLASS ASSEMBLY AND FUSIBLE PLUG Remove refrigerant from unit and store the refrigerant in an evacuated container Refer to Section 6 14 Unscrew the sight glass assembly Wrap threads with Teflon tape or spread some sealing compound on pipe threa
80. CHECK 1 Press UNIT DATA key to scroll thru data list one item at a time BOX TEMPERATURE AUTO 5 5 CONTINUOU 2 To scroll through the list faster use the UP or DOWN ARROW keys 3 Data will display for 5 seconds 4 Press the ENTER key to display data for 30 seconds The UNIT DATA key can be used to display the unit operating data values The data values will be displayed for 5 seconds and then the display will revert back to the normal display if no further action is taken The following sections describe the list of data which can be displayed via the keypad The description of the data will be displayed onthe left side with the actual data on the right side The unit data list can be scrolled through by pressing the UNIT DATA key With each successive key push the list will be advanced one If the UNIT DATA UP or DOWN Arrow key is held for one second the list will change at a rate of one item every 0 5 seconds This list will be circular meaning once the end of the list is reached the list will go to the first entry Each time the UNIT DATA key or the UP DOWN Arrow key is pressed the display time will be reset to 5 seconds If the ENTER key is pressed the display time will be set to 30 seconds The position in the unit data list will remain at the last selected value except if power is removed If the display were to time out and revert to the default display the operator would only have to press
81. Check all sensor calibrations Check manual defrost operation Check Compressor drive coupling Perform Pre Trip inspection c Every 6000 Hour Maintenance Normal Operating Conditions with conventional coolant Cooling 1 Drain and flush cooling system 12 000 hours with Extended Life d Every 10 000 Hour Maintenance Perform complete 2000 and 3000 hour Preventive Maintenance and the following Fuel System 1 Clean and adjust injector nozzles Engine Service Guide e Every 12 000 Hour Maintenance with extended life coolant Cooling 1 Drain and flush cooling system 6 000 hours with Conventional f Oil And Filter Change Intervals Oil amp Filter Change Interval using Oil amp Filter Change Interval us API Class CG engine oil ing Mobil Delvac engine oil Standard Oil Filter 2000 hrs 1yr 4000 hrs 1yr ESIOilFilter 3000 hrs 2 yrs 4000 hrs 2 yrs Mobil Delvac is the only approved synthetic oil Maximum oil drain interval is two 2 years These maintenance schedules are based on the use of approved oils and regular pretrip inspections ofthe unit Failure to follow the recommended maintenance schedule may affect the life and reliability of the refrigeration unit 6 3 62 10450 6 2 PRETRIP INSPECTION WARNING Inspect battery cables for signs of wear abrasion or damage at every Pre Trip inspection and replace if necessary Also check battery cable routing to ensure that clamps are secure and that cables ar
82. Do not smoke when checking the battery A battery explosion can cause serious physical harm and or blindness 1 2 SPECIFIC WARNING AND CAUTION STATEMENTS To help identify the label hazards on the unit and explain the level of awareness each one carries an explanation is given with the appropriate consequences DANGER warns against an immediate hazard which WILL result in severe personal injury or death WARNING warns against hazards or unsafe condi tions which COULD result in severe personal injury or death CAUTION warns against potential hazard or unsafe practice which could result in minor personal injury or product or property damage The statements listed below are specifically applicable to this refrigeration unit and appear elsewhere in this manual These recommended precautions must be un derstood and applied during operation and maintenance of the equipment covered herein WARNING Do notattemptto servicethe DataLink mod ule Breaking the warranty seal will void the warranty 62 10450 WARNING Beware of V belts and belt driven compo nents as the unit may start automatically Before servicing unit make sure the Start Run Off switch is in OFF position Also disconnect the negative battery cable WARNING Under no circumstances should ether any other starting aids be used to start en gine WARNING WARNING Do not use a nitrogen cylinder without a pressure
83. Ds will also turn off 62 10450 3 20 SECTION 4 ENGINE AND TEMPERATURE CONTROL 4 4 AUTO START STOP OPERATION Automatic start stop is provided to permit starting re starting of the diesel driven compressor as required This feature fully enables automatic control of the diesel engine starting and stopping The main function of auto matic engine cycling is to turn off the refrigeration sys tem near setpoint to provide a fuel efficient temperature control system and to initiate a restart sequence after conditions are met System shut off is allowed only if the battery condition signal is good sign in front of voltage reading in Unit Data List The engine coolant tempera ture shall override the minimum off time and out of range condition to force engine restarting when the en gine coolant temperature drops below 34 F 1 C A restart will also be initiated if the battery voltage falls be low 12 2 VDC 11 0 VDC for units with EEPROM Rev 3 24 and lower Refer to Section 3 9 1 for unit data A restart will also be initiated if box temperature is more than 11 F 6 C from set point NOTE The unit will remain in low speed for 5 minutes after engine start up when Auto Start Stop is at any setpoint or Continuous Run setpoint is below 10 F 12 C 4 1 1 Start Stop Continuous A key is provided to select between continuous run and auto start stop operating mode In the continuous run mode the diesel engine will not s
84. EFORE D ANY ELECTRICAL WELDING UNIT OR CHASSIS TO WHICH U IS ATTACHED TRAI RAIL CA OING ON LER CONTAINER R METAL BUILDING ETC NIT HAS A TIVE GROUND SYSTEM REVERSE POLARITY REVERSED POLARITY WILL CAUSE IMMEDIATE FAILURE OF ELECTRICAL SYSTEM 52 02139 01 REV_C 1 5 62 10450 SECTION 2 UNIT DESCRIPTION 2 1 INTRODUCTION WARNING Beware of V belts and belt driven nents as the unit may start automatically Before servicing unit make sure the Run Stop switch is in the STOP position Also disconnect the negative battery cable This manual contains Operating Data Electrical Data and Service Instructions for the refrigeration units listed in Table 2 1 Additional support manuals are listed in Table 2 2 The model serial number plate is located inside the unit on the frame as shown in Figure 2 3 2 2 GENERAL DESCRIPTION The unit is a one piece self contained fully charged pre wired refrigeration neating nosemount diesel powered unit for use on insulated trailers to maintain cargo temperatures within very close limits Table 2 1 Model Chart Refrigerant Engine Speed Models R 404A Compressor 18 High Low X2 1800 NDL 93W Special Order Extra XT NDL 93E CT4 114 TV Extra XT NDL 93N 05G 37cfm Special Order CT4 134 DI Ultra XT NDL 93M 05 41 CT4 134 DI 1700 1350 m 05G 7
85. ERENCE TROUBLE POSSIBLE CAUSES SECTION 5 3 5 Defrost Cycle Malfunction Will not initiate defrost automatically Will not initiate defrost manually Initiates but does not defrost Frequent defrost Does not terminate or cycles on defrost Defrost air switch DA out of calibration Defrost thermostats DTT open or defective DTT not properly installed in correct location Defrost air switch DA defective Loose defrost air switch connections Air sensing tubes defective or disconnected Microprocessor defective Loose terminal connections Defrost thermostats DTT or circuit open or defective Keypad defective Solenoid valve malfunction SV 1 SV 4 Defrost relay DR defective Clutch Gearbox defective Low refrigerant level HP2 malfunction Defrost air switch DA out of adjustment Wet load Trailer doors open or there is an air leak Fanshaft seal leaking Defrost thermostats DTT shorted closed Head pressure control switch HP 2 defective Low refrigerant level Defrost air switch DA out of adjustment or shorted Solenoid SV1 not closing DTT not properly installed in correct location 5 5 6 28 Replace Repair Replace Tighten Check Repair Replace Tighten Replace or Re pair Replace 5 3 11 Replace Replace 6 13 1 Replace 6 28 Normal Close Doors Repair Replace 6 24 6 15 amp 6 17 6 28 Replace Repair 62 10450 INDICATION REFERENCE TROUBLE POSSIBLE CAUSES SECTION 5 3 6 Abnormal Pres
86. F 0 2 0 7 F 0 4 C Low Speed 2 Cylinder Cool 1 2 0 6 C Low Speed 1 5 F 0 8 2 Cylinder Null Cool Null Pulse Setpoint 3 0 F 1 7 C Cont Run Control Point 3 2 F 1 8 C 3 6 F 2 0 C Low Speed 2 Cylinder Null Cool Null Pulse 4 4 F 2 5 C 4 8 F 2 6 C Low Speed 4 Cylinder Heat FALLING BOX TEMPERATURE Figure 4 4 UltraFreeze Start Stop And Continuous Run Temperature Control 62 10450 4 10 Low Speed 6 Cylinder RISING BOX Cool High Speed TEMPERATURE 6 Cylinder Cool 3 6 2 0 2 0 1 8 C 2 0 1 1 1 5 F 0 8 Low Speed 0 5 40 3 C 2 Cylinder Cool Start Stop Off Cycle Start Stop Off Cycle 0 5 0 3 C 1 0 0 5 1 5 F 0 8 C MEE Low Speed ow Spee 6 Cylinder Heat 4 Cylinder Heat 3 2 F 1 8 C 3 6 F 2 0 C High Speed Low Speed FALLING BOX 6 Cylinder Heat 2 Cylinder Null TEMPERATURE Cool Null Pulses During the minimum off time the unit will restart at the override temperature selected in the functional parameter list Figure 4 5 Start Stop Perishable Temperature Control Operating Sequence During Minimum Run Time RISING BOX TEMPERATURE High Speed 3 6 F 2 0 C 6 Cylinder Cool 2 5 1 4 C 2 0 F 1 8 C Low Speed 6 Cylinder Coo 0 5 F 0 3 C Start Stop Off Cycle Start Stop Off Cycle 0 5
87. Linkage Non ESC engines only 6 11 6 10 4 Electronic Speed Control ESC 6 10 5 Engine Air Cleaner Feb 6 12 6 10 6 Engine Crankcase Breather 6 12 6 10 7 Servicing Glow Plugs 6 13 6 11 SERVICING amp ADJUSTING V BELTS 6 13 6 11 1 Belt Tension 6 13 6 11 2 Water Pump Alternator V Belt eee eens 6 13 6 11 3 Gearbox To Fanshaft And Engine To Gearbox 6 15 6 12 FANSHAFT 5 lt lt x RR 6 17 6 1231 Glutch Removal ERA E ERO RA pe d ds 6 17 6 12 2 Blower Wheel And Fanshaft 6 17 6 12 3 Fanshaft Installation 6 17 6 12 4 Blower Wheel 2 2 6 18 6 12 5 Glutch Installation eee pete ro m woe nep eor uo ox eg an een 6 19 6 13 CHECKING THE REFRIGERATION 6 5 6 22 6 13 1 Checking Refrigerant Charge and High Amb
88. ONDENSER Figure 2 20 R 404A Refrigerant Circuit Cooling 2 31 62 10450 2 16 REFRIGERANT CIRCUIT HEATING AND DEFROSTING See Figure 2 21 For units with UltraFreeze Refer to Section 4 4 For units without UltraFreeze the unit will only heat when the controller is set above 10 F 12 2 C as the heat relays are electronically locked out with set points below 10 F 12 2 C Heat lockout can be overridden by setting CNF4 to ON When vapor refrigerant is compressed to a high pressure and temperature in a reciprocating compressor the mechanical energy necessary to operate the compressor is transferred to the gas as it is being compressed This energy is referred to as the heat of compression and is used as the source of heat during the heating cycle 2 16 1 Heating and Defrost NOTE Solenoid valve SV 2 remains open during heating or defrosting to allow additional refrigerant to be metered into the hot gas cycle through the expansion valve providing additional heating capacity until de energized by head pressure control switch HP 2 When the controller calls for heating hot gas solenoid valve SV 4 opens and the condenser pressure control solenoid valve SV 1 closes The condenser coil then fills with refrigerant and hot gas from the compressor enters the evaporator Also the liquid line solenoid valve SV 2 will remain energized valve open as the head pressure control switch HP 2 will
89. OP position or the unit is in Maintenance mode Also dis connect the negative battery cable 6 12 1 Clutch Removal a Place the Run Stop switch in the STOP position and disconnect the negative battery cable Loosen the fan belt idler and remove upper drive belt Remove the top 8 bolts 4 along top and 2 down each side that hold fan shroud to condenser frame Remove the 3 bolts that thread through the back of the clutch rotor pulley forward into the condenser fan hub Carefully remove the condenser fan amp hub as sembly from unit See Figure 6 18 NOTE The armature retaining bolt is a LEFT HAND THREAD BOLT Remove the clutch armature A standard 5 8 11 x 1 right hand thread bolt can be threaded through the center to jack the armature off the shaft Use spanner socket P N 07 00303 02 to remove the spanner nut that secures the clutch rotor NOTE The spanner nut is a LEFT HAND NYLOCK THREAD NUT Slide off and remove the clutch rotor pulley If the ro tor will not slide off easily remove the condenser fan hub adapter from the fan Place the adapter back wards against the fanshaft hub and thread three 5 16 18 x 2 3 4 long bolts from the back of the rotor forward into the hub adapter Tighten the bolts evenly to pull the rotor off the fanshaft hub h Unplug the clutch coil connector from the wiring har ness then remove the clutch coil Be sure to retain all shims on fanshaft hub correctly positioned
90. Pressure Switch OP Compressor 05G Mechanical Fuel Pump Compressor Sight Glass Fuel Bleed Valve Suction Pressure Transducer SPT Speed Control Solenoid SCS Suction Service Valve Ambient Temperature Sensor ATS Figure 2 1 Front View Of Unit With Non ESC Engine 2 3 62 10450 Condenser Pressure Control Condenser Radiator Solenoid Valve SV 1 Radiator Fill Neck Defrost Air Switch Radiator Overflow Reservoir Filter Drier DataLink Recorder Location Receiver Optional See Figure 2 18 Receiver Sight Glass Engine Air Cleaner Liquid Line Solenoid Valve SV 2 Alternator See Figure 2 9 Discharge Check Valve Model Serial No Location starting Model Serial No Location prior to with HAH90553679 HAH90553679 Control Box See Figure 2 12 9 Battery Location Figure 2 2 Curbside Figure 2 3 Roadside UNIT WITH NON ESC ENGINE SHOWN 62 10450 2 4 King Valve Hot Gas Solenoid Valve SV4 Discharge Service Valve Compressor Discharge Transducer CDT High Pressure Cutout Switch HP1 and HP2 and Unloader Solenoid Valve Compressor 05G Compressor Sight Glass Suction Pressure Transducer CSP Suction Service Valve Engine Oil Drain Starter Motor Lube Oil Fill and Dipstick Lube Oil Filter Mechanical Fuel Pump Oil Pressure Switch OP Engine Speed Sensor ENSSN Fuel and Speed Actuator FSA Fuel Bleed Valve Engine Air Cleaner
91. R Unloader Rear URR Heat HR1 HR2 HR3 amp HR4 Defrost DR Fault FR Out of Range OR Auto Restart ARR Fuel Heater FHR Fuses F2 20A F4 15A F5 7 5A F6 F9 5A F11 F12 10A Tethers Fuse F1 80A 0 o9 2 gt 5A 7 5A Hal a gt 9 0000000 E D E x T Carrier TRANSICOL gt o Mi gt 1 Figure 2 13 Control Box Short Box 2 16 Starter Solenoid Relay SSR 70 amp Glow Plug Relay GPR 70 amp Logic Board Fuse F1 80A Fuses F2 20A F4 15A F5 7 5A F6 5A F9 5 or 7 5 10 92A F11 F12 10A Relays Run RR Speed SR Unloader Front UFR Unloader Rear URR Heat HR1 HR2 HR3 amp HR
92. R When these relays energize several things happen This opens the N C contacts to the cool light on an 8 light bar and solenoid valve SV2 SV2 now operates in conjunction with the head pressure control switch HP2 Refer to section 2 16 Also HR1 closes a set of normally open contacts to en ergize solenoid valve SV1 to close the condenser outlet line When the unloader front relay UFR energizes a set of N O contacts UFR close to energize the compressor front unloader UF Compressor will be in four cylinder heating Energizing HR2 closes two sets of N O contacts Sole noid SV4 energizes and opens to allow hot refrigerant vapor to enter the evaporator section 2 16 The other set of HR2 contacts supply power to the heat light on an 8 light bar If more heating capacity is required the unit will shift to low speed loaded heating The microprocessor will break the ground path to de energize the front unloader relay which in turn de energizes the compressor un loaders compressor shifts from four cylinder to six cyl inder operation 62 10450 High speed heat is locked out for 1 minute after switching from cool to heat when CNF15 is ON UltraFresh enabled High speed heat is locked out for 5 minutes after switching from cool to heat when CNF15 is OFF When maximum heating capacity is required the unit will shift to high speed loaded heat The microprocessor energizes the HR1 HR2 and speed
93. Stop mode Automatic start stop is provided to permit starting restarting of the diesel driven compressor as required This gives the microprocessor automatic control of starting and stopping the diesel engine The main function of automatic start stop is to turn off the refrigeration system near the setpoint to provide a fuel efficient temperature control system and then restart the engine when needed Start Stop operation is normally used for frozen loads The unit will remain in low speed for 5 minutes after engine start up 10 minutes for units with EEPROM prior to Rev 3 24 If the unit fails to start shuts down on a safety or fails to run for the minimum run time three consecutive times the fault light will come on Low speed Start up for low coolant temperatures is available on Configuration 7 Refer to Table 6 1 for all units starting with EEPROM REV 3 25 Refer to Section 3 9 1 for unit data The microprocessor controller monitors box temperature battery voltage and engine coolant temperature Whenever the unit starts in Start Stop it will run until elt has run for the predetermined minimum run time engine coolant temperature is above 122 F 50 C eThe box temperature is at setpoint 62 10450 3 6 The controller will not shut off the engine if the battery voltage is not sufficient to restart it Battery voltage above approximately 13 4 volts is required for shutdown This varies depending on ambient
94. T Measure the clutch air gap with the air gap tool 07 000432 00 The gap should be between 0 015 and 0 090 0 38 and 2 29 mm If it is not remove the entire clutch If the gap is less than 0 015 re move one of the fanshaft hub shims If the gap is greater than 0 090 add enough shims to reduce the gap to approximately 0 020 shims are 0 010 each P N 50 00232 30 Re install clutch as sembly Reinstall upper drive belt Re attach the condenser fan and hub assembly if ap plicable to the clutch rotor Thread the 3 bolts from behind the clutch rotor into the condenser fan hub and torque the bolts to 18 to 22 ft lbs 24 to 30 Nm Re install fan shroud if applicable and the upper drive belt and adjust idler to attain a belt tension of 70 to 80 ft los 95 to 108 Nm j Remove condenser fan shroud spacers supports that may have been inserted Re install upper 8 bolts that hold shroud to condenser frame Plugthe clutch coil connector back into the wiring har ness Tie wrap harness as needed to secure Re connect negative battery cable m Check unit for proper clutch operation 4 WARNING Do not start unit without installing the evapo rator panels as unit damage or body harm may result 62 10450 Apply thin layer of anti seize compound to smooth fanshaft hub surface behind threads Fanshaft Hub Clutch air gap is set with shims that mount here over fanshaft pin Torque 3 Bolts 18
95. TV Engine Crankcase Breather 6 10 7 Servicing Glow Plugs The glow plugs when energized draw a nominal 6 to 9 amps at 12 VDC When servicing the glow plug is to be fitted carefully into the cylinder head to prevent damage to glow plug Torque value for the glow plug is 14 to 18 ft Ib 19 to 24 Nm Checking for a Defective Glow Plug a To test individual glow plugs disconnect all glow plugs from each other and place an ammeter or clip on ammeter in series with each glow plug and ener gize the plugs Each plug if good should show 6 to 9 amps draw at 12 VDC b Asecond method is to disconnect the wire connection to the plug and test the resistance from the plug to a ground on the engine block The reading should be 0 7 to 1 2 ohms if the plug is good 6 11 SERVICING amp ADJUSTING V BELTS AX WARNING Beware of V belts and belt driven compo nents as the unit may start automatically Before servicing unit make sure the Run Stop switch is in the STOP position Also disconnect the negative battery cable 6 11 1 Belt Tension Gauge 6 11 2 Water Pump Alternator V Belt The water pump V belt is driven by a sheave on the en gine crankshaft Frayed cracked or worn belts must be replaced Adjustment is achieved by altering the posi tion of the alternator When replacing a V belt avoid excessive force when applying tension to the V belt to prevent damage to the water pump bearings Refer to Table 6 1 a Make
96. Table 2 2 Additional Support Manuals 2 1 Table 2 3 Datalink Codes 2 24 Table2 4 Safety Devices eek be 2 29 Table 2 5 Component Resistance amp Current 2 30 Table 3 1 Function Codes 3 11 3 2 gt Unit Data Godes iia osi tries Shea ied 3 14 6 3 3 Alarni Display I be Babee Pe MAT 3 17 Table 4 1 Auto Start Glow Time 4 2 Table4 2 Battery Voltages ee S rori ove pide Meus eke dee eb EHE Ce DOES DERE E 4 2 Table 4 3 Stages for High Ambient Defrost 4 6 Table 4 4 Unloading in Temperature Mode 4 6 Table 5 1 LED Fault Chart 5 8 Table 6 1 Tension See Figure 6 14 6 13 Table 6 2 Connection Point Voltage 6 43 Table 6 3 Sensor Resistance 6 50
97. Termination Alarm Activity Controller Software Upgrade Controller Replacement Trailer ID Change Trip Start Trip Comment Unit Start Stop Controller Configuration Change Function Parameter Change Controller System Mode Change diesel elect Control Mode Change In Range Indicator RTC Battery Replaced Internal Battery Remote 1 Setpoint Change Remote 2 Setpoint Change DataLink Alarm Activity Power off Power on Data Retrieval RTC Modification DataLink Software Upgrade Network Failure Network Recovery Door Opened Closed Fuel Level Low Normal f Download files contain the following information Description Header DataLink Header Memory Configuration Current Values Alarm Table Time and Date Selected Event Data Recorded Sensor Values 62 10450 1 2 3 y Data Link SOFTWARE PROGRAMMING PORT _ TT n an ES DataCORDER pa m TREE E z 99 BATTERY 50 gt ERE 5 5 4 4 6 5 4 1 DataLink Module 2 Backup Power Pack 3 Software Port 6 Fuse 4 Connector 5 Status LEDs Figure 2 18 DataLink Module 2 6 2 Components and Descriptions Operational Software DataLink Software controls the unit s o
98. The datais the lower 3 digits ofthe serial number burned into the Eeprom i e SERL 504 or CD14 504 Serial Number High The high serial number of the unit is displayed with the description SERU or CD15 The data is the higher 3 digits of the serial number burned in to the Eeprom i e SERU 001 or CD15 001 2 RA Not Applicable This data is not applicable for this unit The display is 2 or CD16 3 RA Not Applicable This data is not applicable for this unit The display is or CD17 Maintenance Hour Meter 1 The maintenance hour meter 1 setting is displayed with the description MHR1 or CD18 The maintenance hour meter is compared to one of the hour meters diesel standby or switch on determined by its mode If the hour meter is greater than the maintenance hour meter an alarm will be generated The display is MHR1 Maintenance Hour Meter 2 The maintenance hour meter 2 setting is displayed with the description MHR2 or CD19 The maintenance hour meter is compared to one of the hour meters diesel standby or switch on determined by its mode If the hour meter is greater than the maintenance hour meter an alarm will be generated The display is 2 Switch On Hour Meter The number of switch on hours is displayed with the description SON or CD20 The data will be displayed with integer resolution and units designator H i e SON 2347H OR CD20 2347H The available display range will be O to 99999 Th
99. USE BAD Fuse Blown Or Dirty Battery Cables 4 Check Refrigeration DISPLAY Display AL18 SERVICE 1 Maintenance Hour Meter 1 AL19 SERVICE2 Maintenance Hour Meter 2 120 OUT RANGE Out of range FAULT LIGHT ON Low Oil Pressure Alarm The low oil pressure alarm is displayed with the description ENG OIL or ALO This alarm is generated if the control senses low oil pressure under the proper conditions The fault light FL is turned on Engine will shut down Oil pressure switch must be open for 15 seconds to generate alarm High Coolant Temperature Alarm The high coolant temperature alarm is displayed with the description ENG HOT or AL1 This alarm is generated if the control senses a high coolant temperature 230 to 240 F 110 to 116 C for 5 minutes or immediately if over 240 F 116 C The fault light FL is turned on and engine will shut down Prior to S N S N KAK90661828 the engine coolant temperature sensor WTS was located on the rear of the thermostat housing on the engine cylinder head Beginning with S N 90661828 the sensor is located on the front of the engine near 4 injector ALO AL1 AL2 AL3 AL4 AL5 AL6 AL7 AL8 AL9 AL10 AL11 AL12 AL13 AL15 AL16 AL17 High Pressure Alarm The high pressure alarm is displayed with the description HI PRESS or AL2 This alarm is generated if the high pressure switch opens The fault light FL is turned on and engine will shut down for a
100. Water Temperature Sensor WTS Fuel Filter Location of Engine Speed Control Unit Ambient Air Temperature AAT Figure 2 4 Front View Of Unit With Electronic Speed Control 62 10450 1 5 1 283 Off of white connector out of back of micro SP6 Under micro mount next to the right engine mount SP5 In wiring harness for the fuel solenoid SPK 6 Left of the oil pan SPK 8 Ty wrapped to wiring harness left of compressor SP8 Left of compressor cylinder head SPK 18 Ty wrapped to harness leading to SV2 SP 19 Behind SV4 OND Figure 2 5 Ultra XT and Extra Splice Pack Locations 62 10450 2 6 1 19 main harness near king valve 5 SPK6 engine harness left of the oil pan 2 18 On main wiring harness above door 6 9 main harness under the engine latch mount 3 8 engine wiring harness left of and 7 5 1 283 On J1 harness white connector above compressor from micro 4 SP8 Onengine wiring harness left of the SP14 A breakout on the J1 harness leading to compressor discharge the DataLink connector 8 SPK 20 On the main harness between the micro amp engine Figure 2 6 X2 Splice Pack Locations 2 7 62 10450 62 10450 Evaporator Fan Blower Wheel 6 Defrost Termination Thermostat s Expansion Valve DTT Heat Exchanger 7 Sup
101. adings The compressor discharge pressure will rise because SV 1 should be closed with only SV 4 open When the discharge pressure rises to 300 psig 20 4 Bar the HP 2 switch contacts will open causing SV 2 to close This can be seen by the volt meter reading dropping to O VDC and the compres sor discharge pressure decreasing When the dis charge pressure drops to 200 psig 13 6 Bar the HP 2 switch contacts will close and open SV 2 caus ing the discharge pressures to rise and 12 VDC to show onthe voltmeter This action shows proper cycl ing of SV 2 by HP 2 Immediately reconnect the wire to SV 3 The HP 2 SV 2 cycling interval will depend on the ambient and box temperatures e Remove circuit tester from SV 2 valve plug front un loader back into wire harness and make sure the wires to the SV 3 valve are properly connected f The unit should be OFF at the end of this step NOTE This procedure does not check the actual set tings for the HP 2 switch If the switch opens and closes within 15 20 psig of the rated set tings the switch is functioning properly To actu ally determine the opening and closing settings of the switch refer to Section 2 12 6 23 62 10450 6 13 7 SV 1 for Seating Sv 4 for Opening For Units With Individual Wires Connected To the Unloaders and SV 2 a Unplug the wire harness from the engine oil pressure switch and install the bypass jumper plug into the wire harness b Remove the wh
102. afety switch and place a jumper across the plug termi nals 2 Remove the wires from SV 4 Front Unloader and the HP 2 switch 3 Re adjust setpointto 20 F to 25 F 11 1 to 13 9 C above box temperature so that the unit will be able to start It may be necessary to run unit in Cool prior to this step 4 Start the unit Allow the unit to run 30 45 seconds The suction pressure should fall to approximately 0 psig and the receiver pressure near or below 200 psig Closely monitor both high pressure gauges while connecting the wire to the HP 2 switch Com pressor discharge pressure will begin to rise Re ceiver pressure should not rise When the compres sor discharge pressure reaches 390 psig shut the engine off using the stop lever on the injection pump The microprocessor will remain energized The compressor discharge pressure will drop off but the receiver pressure should not change Any rise in receiver pressure indicates internal leakage at the SV 1 valve See Section 6 26 2 for instruc tions on repair and replacement 5 Observe the suction gauge Using a jumper wire momentarily energize SV 4 The valve should open and the suction pressure begin to rise Remove the jumper and observe The valve should close and the suction pressure should stop rising Energize the valve 2 to 3 times to verify consistent valve opera tion 6 Place the Run Stop switch in the STOP position Reconnect the wires to SV 4 Front Unloa
103. ain time to determine if any other and or telematics sys devices are providing power tem feedback causing the micro to remain powered Did you find and correct the condition Check voltage to fuel solenoid Must be 0 volts Did you find and 12 correct the condition System OK Remove J1 jumper and reinstall System OK Unplug fuel YES solenoid Does the unit stop Figure 5 9 Micro Diagnostic Tree Cond 4 Models with Speed Control Solenoid RS Switch Off Engine fails to stop 5 19 62 10450 START HERE Check the Speed Solenoid and linkage for correct op eration Did you find and correct the condition NO y Is ambient temperature above 120 F Wait until minimum run time is complete Did you find and cor NO rect the condition Trailer minimum low speed run time at start up is based on Is engine coolant temper run mode CONT 5 5 and setpoint Are you waiting 10 YES ature above 79 NO minutes after unit is started to determine if unit should be in Y high speed 7 Unit will operate in low speed until water All ors E ow engine to run and reach NA gal Mna Mn Mes DUNT operating temperature Is engine you find and correct the condition temperature above 79 F
104. aking sure it 5 Spacer 11 Body is seated properly inthe enclosingtube locknut Tight 6 Enclosing Tube en enclosing tube locknut to a torque value of 250 Locknut inch Ib 28 Nm Do not over tighten Figure 6 32 SV 1 8 Install coil assembly nameplate and top locknut or Screw 9 Dehydrate and evacuate the system Refer to Sec tion 6 16 Charge unit with refrigerant per Sections 6 17 10 Start unit and check operation Refer to Section 2 62 10450 6 38 Change 11 2008 Solenoid Valve SV1 Checkout Procedure To obtain proper heating and defrost the normally open N O SV 1 solenoid valve must energize and close tightly during the heat and defrost cycles If the valve does not close tightly due to physical damage foreign material or wear refrigerant leakage through the valve can reduce heating capacity During normal heat or defrost cycles the following conditions will be observed when the valve is operating properly 1 Receiver refrigerant level will drop quickly at the initia tion of heating or defrost mode 2 Suction pressure will rise slowly to 90 100 PSIG 6 12 to 6 80 Bar 3 Discharge pressure will drop quickly but begin to rise to a minimum of 250 psig 17 0 Bar within 15 to 20 minutes If suction and discharge pressures remain low and the receiver level does not drop the valve may be inoperative and can be checked by the follow ing method 1 With the unit off disconnect the oil pressure s
105. al letter M for minutes i e ON T 4M Controlling Probe The number of controlling probes is displayed with the following abbreviations REM PROBE selects the return air sensor as the controlling probe SUP PROBE sets the supply air probe for all setpoints above 11 For setpoints of 10 or below the unit will always control on return air regardless of selection The code display is FN4 The 1 probe setting is A and the 2 probe setting is B Standard Units Select The standard unit selects how all parameters are displayed The two choices are DEGREES F and DEGREES C This parameter also controls whether pressure datais displayed in psig or bars i e Degrees F Or v ba e The code display is FN5 The selections are or d Maximum Off Time The descriptions for the maximum off time are TEMP STRT OR TIME STRT The code display is FN6 and the selections are or OFF corresponds to TIME STRT With the unit in time start the control will force the engine to restart 30 minutes after shutoff MOP STD This function code allows the standard MOP equations to be offset by a fixed pressure amount The descriptions are STD MOP AND The display is FN7 and the selections are 0 4 and 5 The is equal to 4 psig 0 3 Bar The MOP is equal to 5 psig 0 3 Bar 62 10450 Start Mode Selection The selection for starting the unit are displayed AUTO OP code FN10 ON for
106. all the protec tive cap The configuration screen will now remain available for five minutes Scroll through the configu ration list using the FUNCTION key and compare the settings with those shown in Table 6 1 If any of the configurations need to be changed continue with the following steps d To change the configuration selection 1 Bring the configuration to be changed onto the display Press the ENTER key to allow change access to the displayed configuration 2 Press either the UP or DOWN keys to dis play available selections for that configuration Leave the correct selection on the screen The selection display will flash warning the operator that the displayed value has not been entered Press the ENTER key to enter the new selec tion into memory The display will revert to the original selection if no further action is taken for the next five seconds 3 Continue to scroll through the configuration list by pressing the FUNCTION key Change any other configurations as required e When finished place the SROS inthe OFF position then back to the RUN position to start the unit 62 10450 6 46 6 32 4 Hour Meters Using ReeferManager the hour meters can be set to any value via the serial port if the meters have less then 5 hours on them This allows a replacement micropro cessor to be set to the same hours as the microproces sor it is replacing The microprocessor has 2 programma
107. and the shorter the Cool or Heat Mode Pulse At the end of each 10 second period the type of pulse Cool Null or Heat Null and percentage of time for each is recalculated When in the null mode The HEAT and COOL LCDs on the microprocessor display will blank out The heat and cool lights on 8 light bar will flash back and forth every 10 seconds or so UltraFresh 2 only operates when Setpoint is in the perishable range above10 F 12 C and the unit is set for continuous run operation There is a delay of 10 seconds between de energizing one unloader to de energizing the other unloader under all operating conditions excluding engine starting UL2 OPEN OPEN CLOSED UNLOAD UNLOAD Null Pulsed Mode Engine Speed OPEN OPEN OPEN UNLOAD UNLOAD Heat Pulsed Mode Engine OPEN CLOSED CLOSED BY OPEN UNLOAD UNLOAD HP2 62 10450 4 4 ULTRA FREEZE TEMPERATURE CONTROL CNF 6 must be set to OFF and CNF5 and CNF 17 must be set to ON NOTE In high ambient temperatures 120 F 48 9 C and above the unit will operate only in Low Speed For frozen setpoints a modified UltraFresh 2 temperature control is used to keep the unit from over cooling and driving the box temperature far below setpoint UltraFreeze operates the same as UltraFresh 2 except as noted in this section UltraFreeze control will be used anytime a frozen setpoint is selected in both diesel and standby units in both continuous and star
108. andreinstallshutdownoptionsand to the beginning of the table and parameter settings or telematics system test again Enter hours from old micro into new micro Y System Figure 5 7 Micro Diagnostic Tree Cond 2 ESC RS Switch On Engine does not operate 5 17 62 10450 START The RS switch is ON Does the engine start amp run YES Unit may be running on old software Check the soft ware REV in the data list Reference the appropriate service bulletin to see if the functionality you are ex pecting is available in your software REV Depending upon customer concern a software update may be re quired Did you find and correct the condition Go to Cond 2 Table Micro may not be configured properly Verify that the RO to configurations are set correctly Scroll through the list using the keypad and compare the settings with those this chart shown in Table 6 1 Change as necessary Did you find and correct the condition v Operate system in Verify functional parameter settings are correct order to verify as outlined in Section 3 8 1 Did you find and cor repair Did you find rect the condition and correct the condition Use to check unit operation Refer to Section 3 3 for Pre Trip details NOTE his is not a
109. ange Any rise in receiver pressure indicates in ternal leakage at the SV 1 valve Observe the suction gauge Momentarily energize SV 4 by connecting the white wire of the coil tester to the positive starter post or battery post The valve should open and the suction pressure begin to rise Remove the wire and observe the pressures The valve should close and the suction pressure should stop rising Energize the valve 2 to 3 times to verify consistent valve operation Reconnect unit harness wires to SV 4 front unload er and remove the bypass plug from the wire har ness and reconnect harness to the engine oil safety Switch The unit should be OFF at the end of this step 6 13 8 SV 1 Defrost Operation a b Place the unit into defrost manually Make sure the unit goes into defrost properly and the engine is running in High Speed NOTE If the ambient temperature sensor is above 100 F 37 8 C the high ambient defrost cycle may be initiated Checkthat the fan clutch has disengaged and the fan shaft is not turning The unit should come out of defrost automatically The engine will shift to low speed engage the fan clutch and resume High Speed Cool Change 11 2008 6 13 9 Removing the Refrigerant Charge NOTE Store the refrigerant charge in an evacuated container if the system must be opened be tween the compressor Discharge Service Valve and Receiver Outlet King Valve Whenever the system is
110. ar the HP 2 switch contacts will close and open SV 2 causing the discharge pressures to rise and 12 VDC to show on the voltmeter This action shows proper cycling of SV 2 by HP 2 Immediately reconnect the wire to SV 3 The HP 2 SV 2 cycling interval will de pend on the ambient and box temperatures d Refer to Section 6 26 1 for information on repairing SV 2 and Section 6 24 1 to replace HP 2 e Reconnect wire to front unloader and make sure wires to SV 2 are on coil f The unit should be OFF at the end of this step NOTE This procedure does not check the actual set tings for the HP 2 switch If the switch opens and closes within 15 20 psig of the rated set tings the switch is functioning properly To actu ally determine the opening and closing settings of the switch refer to Section 2 12 Change 11 2008 For Units With The Unloader s and SV 2 Plugged Into the Wire Harness a Unplug the front unloader from the wire harness and remove the white wire from SV 3 valve b Unplug SV 2 and connect the circuit tester between the wire harness and the SV 2 valve c Adjust setpoint to 77 F 25 or higher and start the unit The unit will run in low speed for 15 seconds then go into High Speed Heat It may be necessary to place the unit in High Airflow so that the engine will run in high speed d Connect avoltmeter to the circuit tester wires at SV 2 Observe the voltmeter and compressor discharge gauge re
111. ar with 3 control box standoff pins Logic board MUST interlock with standoffs Make sure the tether cords are secured prop erly with the front 2 logic board mounting Screws Use caution when installing control box cover Do not get tethers or harness pinched behind the gasket Change 11 2008 h Place the removed logic board back into the anti static bag and part box for return i Reconnect negative battery cable and check micro processor configurations NOTE BEFORE STARTING THE UNIT When replacing a microprocessor it is important to check that the configurations are compatible with the unit into which it will be installed 6 32 2 To Remove and Replace Microprocessor Logic Board Tall Box CAUTION Do not drill out the logic board standoffs to remove the plastic cover Permanent dam age to the microprocessor will result a Before removing the microprocessor turn the SROS to the OFF position and disconnect the negative battery cable Attach a grounded wrist strap CTD P N 07 00304 00 to your wrist and ground it to a good unit frame ground b Open the roadside side door of the unit and loosen the 2 bolts holding the cover display assembly onto the front of the control box Lift cover and use prop rod to hold cover up c Unplug the 2 ribbon cables from the micro but leave them connected to the relay board and display d Loosen the 5 hex head screws securing the logic board
112. art Stop restart The fault light is turned on immediately The engine is off and Software Version is greater than or equal to 3 27 and Auto Start has started cranking the engine Initial Startup or Start Stop restart The fault light is prevented from turning on for 15 seconds If the engine fails to start after 15 Seconds the fault light will turn on immediately if the voltage is still lower than 10 VDC Engine Running Fault light will turn on if the battery voltage is less than 10 VDC for 5 continuous seconds If the battery voltage goes to a value greater than or equal to 10 VDC the 5 second timer is reset High Battery Voltage Alarm The high battery voltage alarm is displayed with the description HI or AL5 This alarm is generated if the battery voltage is above 17 VDC The fault light FL is turned on and engine will shut down Defrost Override Alarm The defrost override alarm is displayed with the description DEFR FAIL or AL6 This alarm is generated if the unit is in a defrost override mode See Section 4 2 2 62 10450 Alternator Auxiliary Alarm The alternator auxiliary alarm is displayed with the description ALT AUX or AL7 This alarm is generated if the alternator auxiliary signal is not present with the engine running and the ALT AUX signal is not present for any 5 consecutive second period The fault light FL is turned on Starter Motor Alarm The starter motor alarm is displayed with the des
113. ataLink module and unplug all wire harness connectors before performing any arc welding on any part of the unit Do not remove wire harness from module unless you are grounded to the unit frame with a static safe wrist strap CAUTION When changing oil filters the new filters should be primed partially filled with clean oil if possible If the filters are not primed the engine may operate for a period with no oil supplied to the bearings Change 11 2008 CAUTION Unit uses R404A and POE The use of in ert gas brazing procedures is mandatory for all Carrier Transicold refrigeration units otherwise compressor failure will occur For more information Refer to Technical Procedure 98 50553 00 Inert Gas Brazing CAUTION Use only ethylene glycol anti freeze with inhibitors in system as glycol by itself will damage the cooling system Always add pre mixed 50 50 anti freeze and water to ra diator engine Never exceed more than a 60 concentration of anti freeze Usea low silicate anti freeze meeting GM specifica tions GM 6038M for standard life coolant or use Texaco Havoline extended life coolant or any other extended life coolant which is Dexcool approved and has 5 150 5 years 150 000 miles on the label CAUTION Do not get anti seize oil compound onto clutch contact surfaces Thoroughly clean off oil compound with contact or brake cleaner if this occurs CAUTION Only a refrigerant drum
114. auge to the 1 4 port on the suction service valve e Run unit until stabilized Set controller 10 F 5 5 C below box temperature f From the temperature pressure chart Refer to Table 6 3 determine the saturation temperature cor responding to the evaporator outlet pressure 6 35 62 10450 9 Note the temperature of the suction gas at the sion valve bulb h Subtract the saturation temperature determined in Step f from the average temperature measured in Step g The difference is the superheat of the suction gas 6 24 CHECKING AND REPLACING HIGH PRESSURE CUTOUT SWITCHES 6 24 1 Replacing High Pressure Switch a Pump down the refrigeration system and shut unit off Refer to Section 6 13 11 WARNING Never run unit with discharge service valve frontseated b Frontseat the discharge service valve in order to isol ate the compressor c Slowly release compressor pressure through the ser Vice valve gauge ports d Disconnect wiring from defective switch The high pressure switches are located on the top cylinder head See Figure 6 23 e Install new cutout switch after verifying switch set tings Refer to Section 6 24 2 f Evacuate and dehydrate the compressor Refer to Section 6 18 p through 6 18 w 6 24 2 Checking High Pressure Switch HP 1 or HP 2 WARNING Do not use a nitrogen cylinder without a pressure regulator Cylinder pressure is approximately 2350 psig 159 9
115. auto start operation or MAN OP code FN10 OFF for manual start operation Tostartthe unit in manual start mode the START STOP CONTINUOUS selection must be in continuous run mode Out of Range Selection The out of range temperature tolerance selection is displayed with the description T RANGE or code FN11 The selection are 2 3 or 4 These selections are the temperature values in degrees C 62 10450 3 12 Manual Glow Override Selection The auto start glow time can be manually overridden through this function The messages are displayed as NORM GLOW or ADD GLOW If the ADD GLOW selection is entered 30 seconds of glow time will be added to the standard glow times Refer to Section 4 1 5 This feature must be selected before the three start attempts have been completed At higher ambient this override can only affect the second or third start attempt The add glow time is de selected when the engine starts or fails to start This parameter will not change due to the code vs English selection Alarm Reset Alarms can be reset through this function The messages are displayed as ALARM RST or ALARM CLR If ALARM RST is displayed there is at least one alarm present Pressing the enter key will clear all alarms There are no alarms present if ALARM CLR is displayed This parameter will not change due to the code vs English selection 3 9 UNIT DATA FAULT STAND BY COOL SUT 25P SETPOINT t PRETRIP
116. be repaired before continu ing The unit should be OFF at the end of this step 6 13 5 Discharge Line Check Valve Leakage amp a SV 2 Seating amp Opening Ability Midseat open the hand valves on the manifold gauge set connected to the compressor This action will allow the high pressure refrigerant in the dis charge line to bleed to the low side of the system and the gauge readings will balance out After a short time 10 15 seconds frontseat close the hand valves on the manifold gauge set connected to the compressor and observe the high side gauge A continuous rise in pressure would indicate that the Discharge Check Valve is allowing pressure to leak back into the compressor NOTE If the check valve is leaking internally it does not have to be repaired until after completing this procedure It will have no effect on the re maining steps See Section 6 26 1 Very slowly open the king valve to allow refrigerant to pass through the filter drier to the liquid line solenoid valve SV 2 Bring the king valve to the midseat position SV 2 should remain closed and there should be no rise in suction pressure A rise in suction pressure indicates that SV 2 is leaking and not prop erly seated See Section 6 26 1 Change 11 2008 d Place the Run Stop switch in the RUN position Ob serve the suction pressure gauge After 5 seconds SV 2 will energize and open causing the suction pressure to rise to a ma
117. ble maintenance hourmeters which are set via the serial port These maintenance hourmeters are compared to one of the hour meters diesel standby or switch on If the hour meter is greater than the maintenance hourmeter then the proper service alarm is triggered Change 11 2008 Table 6 1 Configuration Table CDT not used CONFIGU RATION DESCRIPTION OFF DI Long glow cycle Std Emission DI Engines CNF1 Note 1 m Short glow cycle LE DI Engines TV Engines CNF2 m CDT used CNF3 Max Set Point 86 F Al functions locked Note 3 Max Set Point 90 F Modified function lock OFF All trailer units must be OFF CNF4 OFF oN All R 22 and 404 trailer units Trailer unit _ OFF ONE OFF Normal speed warm up Rev 3 25 and Low speed only engine warm up higher only OFF All trailer units ON Out of range alarm only Note 2 Out of range alarm and unit shut down OFF All units OFF CNF10 Do Not Turn On CNF11 OFF Functions changes normal Note 3 Functions amp Start Stop locked OFF R 22 CNF12 on OFF Refrigeration unit Trailer or Truck Ss Heat only unit Solara OFF Standard unit CREME Reversible Multi Temp UltraFresh 1 SEIS UltraFresh 2 OFF Alt Aux alarm only Alt Aux alarm shuts unit down UltraFreeze disabled UltraFreeze control SYSTEM CK alarm Off CNF18 SYSTEM CK alarm On OFF on all uni
118. ce When the defrost air switch contacts close there is a 12 vdc potential to terminal 33 on the microprocessor The microprocessor looks for voltage at terminal 31 Voltage at 31 indicates that at least one defrost termination ther mostat is closed The unit will shiftto the defrost mode if voltage is present at 31 c Manual Defrost Initiation The defrost cycle may be initiated by pushing the MANUAL DEFROST key d Normal Defrost Mode Ambient temperatures less than 80 F 26 7 C The defrost mode may be initiated by either of the three methods just described above Once a Defrost Cycle has been initiated Defrost will continue and does not terminate until the microprocessor senses both defrost termination thermostats DTT s reach termination temperature and open removing the 12 VDC signal to terminal 31 of the microprocessor or the compressor discharge temperature CDT reaches 310 F 154 4 C for 1 continuous minute The defrost relay is energized during defrost mode to open the normally open contacts within the Defrost Relay which will de energize the clutch and stop the evaporator fan to prevent hot air circulation to the load In addition the speed and heating outputs SR HR1 amp HR2 are enabled to apply high speed heat for hot gas heating The compressor operates at maximum capacity on die sel and diesel electric units during defrost The suction pressure signal can force the unloaders to be unloaded The
119. ck into induced voltage unit ENSCU is not the creating the 26 VDC Remove new fault Review results signal alternator or voltage of above tests with Did you find and regulator and your supervisor If correct the condition re install old necessary go to the alternator back into beginning of unit alternator is not the table amp test again the fault Review results of above tests with your supervisor If necessary go to the beginning of the table amp test again Review results of above tests with your super visor If necessary go to the beginning of the table amp test again Figure 5 4 ESC Diagnostic Tree 2 Long 7 Short LED Code ENSCU voltage is over 26 VDC 5 13 62 10450 5 4 1 Microprocessor Troubleshooting Guide The following diagnostic tables are intended to assist technicians in diagnosing problems with the standard microprocessor These tables are not intended to replace a good technician s knowledge of the control and electrical systems but to supplement it When using these tables it is important to verify the reported symptom or problem and then correctly identify the appropriate table for that particular condition Using the incorrect table will lead to an incorrect diagnosis When using these Diagnostic Tables it is very important to skip any steps Follow the flow of the tables in the order that t
120. containing R404a should be connected to an XTC refrigera tion unit in order to pressurize the system Any other gas or vapor will contaminate the system which will require additional purg ing and evacuation of the high side dis charge of the system CAUTION Do not vapor charge R404a systems Only liquid charging through the receiver King valve is acceptable 1 3 CAUTION Do not over tighten damage the enclos ing tube assembly Torque to 17 ft pounds 23 Nm Also make sure all parts are placed on the enclosing tube in proper sequence to avoid premature coil burnout CAUTION Do not drill out the logic board standoffs to remove the plastic cover Permanent dam age to the microprocessor will result CAUTION Do not allow the insulated jumper wire be used to configure unit to touch any ground 62 10450 1 3 SAFETY DECALS CAUTION DANGER PRESSURIZED KEEP CLEAR OF SYSTEM ROTATING BELTS DO NOT REMOVE AND PULLEYS CAP WHEN HOT 52 02144 03 REV D 52 10794 00 REV DO FILL BOTTLE ABOVE MAX LINE CAP AND SENSOR TO BE HAND TIGHTENED ONLY WARNING UNIT MAY START AUTOMATICALLY 62 02146 02 REV C 7 WARNING 62 03958 00 Heat Warning BLADES D WARNING UNIT MAY START AUTOMATICALLY 62 02509 00 REV 2 62 10450 1 4 DISCONNECT BATTERIES B
121. cription STARTER or AL8 This alarm is generated if the starter motor input signal is not present with starter solenoid energized The fault light FL is turned on Return Air Sensor Alarm The return air sensor alarm is displayed with the description SENSOR or 19 This alarm is generated ifthe return air sensor is open or shorted The fault light FL is turned on if the unit shuts down because there is no controlling probe Supply Air Sensor Alarm The supply air sensor alarm is displayed with the description SENSOR or AL10 This alarm is generated if the supply air sensor is open or shorted This alarm will be disabled if the REM PROBE is selected in the controlling probe functional parameter The exception to the SA SENSOR alarm being disabled is if the REM PROBE is selected and configuration bit 15 UltraFresh 2 is active Coolant Temperature Sensor Alarm The coolant temperature sensor alarm is displayed with the description WT SENSOR or AL11 This alarm is generated if the coolant temperature sensor circuit is open or shorted Discharge Temperature Alarm The compressor discharge temperature alarm 15 displayed with the description HIGH CDT or AL12 This alarm is generated and unit shuts down if the temperature 5 sensed above 310 F 154 4 for 3 minutes If the discharge temperature exceeds 350 F 176 7 C the 3 minute timer will be overridden and the unit will shut down immediately If ambient temperature
122. d by the microprocessor for capacity con trol The capacity controlled cylinders are easily identified by the solenoid which extends from the upper side of the cylinder head When the solenoid coil is energized the cylinders unload The unloaded cylinders operate with little or no pressure differential consuming very little power A de energized solenoid coil reloads the cylin ders NOTES 1 unloader relay is locked in for a mini mum of 2 minutes once it is energized due to suction pressure 2 Thereisadelay of 30 seconds between de energizing one unloader to de energizing the other unloader There are two modes of unloader operation tempera ture control and suction pressure control b Temperature Control Within 1 4 F 0 8 of Set Point 1 Cool LED or Heat LED on the display and for units with an 8 light bar Cool light CL or heat light HL il luminated depending on mode of operation 2 If in low speed cooling unloader relays UFR or UFR amp URR may energize to unload those compressor cylinders Refer to Table 4 4 3 The heat mode forces the rear unloader UR to a loaded condition de energized for diesel operation In low speed heating front unloader relay UFR may energize to unload the front compressor cylinders Table 4 4 Unloading in Temperature Mode SETPOINT SETPOINT AT OR BELOW ABOVE 10 F 12 C 10 F 12 C Cool High Speed Cool Low Speed Cool Low Speed Heat Low Sp
123. d handling techniques should always be stressed Boards should always be handled by their edges in much the same way one would handle a photograph This not only precludes the possibility of ESD damage but also lowers the possibility of physical damage to the electronic components Although the microprocessor boards are fairly rugged when assembled they are more fragile when separated and should always be han dled carefully When welding is required on the unit frame or on the front area of the trailer ALL wiring to the microprocessor MUST be disconnected When welding is performed on other areas of the trailer the welder ground connection MUST be in close proximity to the area being welded It is also a good practice to remove both battery cables be fore welding on either the unit frame or the trailer to pre vent possible damage to other components such as the alternator and voltage regulator 6 31 1 Replacing Keypad Window or Door Should damage to the keypad of the microprocessor oc Cur it is possible to replace only the keypad All replacement keypads are packaged with replace ment gaskets Keypad Removal Short Box a Place the Start Run Off switch SROS in the OFF position and disconnect the negative battery cable Attach a grounded wrist strap CTD P N 07 00304 00 and ground it to a good unit frame ground b Open the roadside side door of the unit and loosen the 4 hex slotted head 1 4 20 bolts that ho
124. defrost cycle Pressing the manual defrost key will override this mode and start a defrost cycle If a shutdown alarm occurs defrost will be terminated 3 7 1 Automatic Defrost The defrost mode may be automatically initiated by either of the following two devices when the evaporator coil temperature DTT2 is below 40 F 4 4 C a Defrost Interval Timer The defrost interval for the Defrost Timer is set in the Functional Parameter List Refer to Section 3 8 1 When a Defrost Cycle is initiated by any method the timer is reset to zero and will not begin counting until the defrost cycle has terminated When the Start Run Off Switch is in the off position the defrost timer will be reset to zero b Defrost Air Differential Switch The Defrost Air Differential Switch measures the difference in air pressure entering the evaporator against the pressure ofthe air leaving the evaporator A build up of ice will cause the difference to increase Once the pressure difference increases to the setting of the switch the contacts will go closed and initiate a defrost cycle providing that the evaporator coil temperature is at or below 40 F 4 4 C 3 9 The Defrost Timer is reset to zero whenever a defrost cycle ends regardless of how it was initiated and begins counting down until the next defrost cycle Total defrost cycle time 15 monitored by the microprocessor Once the unit has been in a defrost cycle for 45 minutes thi
125. den reduction of crank Compressor Locking Tab case pressure at defrost termination could Bolts Nylon Drive Gear cause a temporary increase in oil circulation Spacer Drive Sheave Bolts and give a false oil level reading a Roy c After 3 to 5 minutes of defrost operation turn the unit Compressor Drive Engine Adapter off and wait 5 to 15 seconds ODSOIUG the compres Gear Drive Sheave sor oil level in the sightglass See Figure 6 22 Oil SE be between the Minimum and Maximum marks Figure 6 21 Pressure Switches HP 1 and HP 2 Figure 6 22 Oil Level in Sight Glass Change 11 2008 6 31 62 10450 6 19 2 Adding Oil with Compressor System A manual oil pump that may be purchased is a Robinair part no 14388 This oil pump adapts to a one U S gallon 3 785 liters metal refrigeration oil container and pumps 2 1 2 ounces 0 0725 liters per stroke when connected to the oil fill 3 Figure 6 23 An oil hose must be adapted to fit the fill port Start unit frontseat suction service valve and pump compressor down See section 6 13 11 to approx 1 to 2 psig 0 07 to 0 14 Bar Place the Run Stop switch in the STOP position Frontseat discharge service valve and recover remaining refrigerant from compressor AX WARNING Never run unit with discharge service valve frontseated Never remove fill plug with pressure in compressor Remove oil fill plu
126. der and the the oil safety switch Change 11 2008 6 39 6 27 CHECKING DEFROST OR HEATING 6 27 1 Defrost Operation Turn the unit on and re adjust the setpoint to O F 17 8 C Run the unit in High Speed Cool and al low the box temperature to drop below 35 F 1 7 C b Place the unit into defrost manually Make sure the unit goes into defrost properly and that the engine is running in High Speed NOTE If the ambient temperature sensor is above 80 F 26 7 C the high ambient defrost cycle may be initiated Refer to Section 4 2 2 d Check that the fan clutch has disengaged and that the fan shaft is not turning e The unit should come out of defrost automatically NOTE The box temperature must be 40 F 4 4 C or lower before any checks can be made 6 27 2 Hot Gas Solenoid Valve SV 1 amp SV 4 Heating and Defrosting a Connect adischarge pressure gauge to the king valve and another gauge to the compressor discharge ser vice valve Connect a gauge to the compressor suc tion service valve b Start unit with controller set at least 10 F 5 5 C be low indicated box temperature to obtain high speed cooling Press the MANUAL DEFROST key to initiate defrost Box temperature must be below 40 F 4 4 C The hot gas solenoid valve SV4 will ener gize and the hot gas line will be hot to touch on both sides of the valve The condenser pressure control solenoid SV1 closes and suction pressure wil
127. down the unit when such conditions occur This Table 2 4 Safety Devices Unit Shutdown Safety Devices Unsafe Conditions Safety Device Device Setting Low engine lubricating oil Oil pressure safety switch Opens below 15 psig pressure OP microprocessor reset 1 02 0 2 Bar High engine cooling water Water temperature sensor Refer to Section 3 10 temperature WTS microprocessor reset AL1 ENG HOT Excessive current draw by glow plug circuit Fuse Opens at 80 amps control circuit or starter solenoid SS Excessive current draw by fuel heater optional Opens at 20 amps 1 2 Excessive current draw speed relay and Fuse F4 Opens at 15 amps front unloader Excessive current draw by auto restart or Fuse F5 Opens at 7 1 2 amps out of range lights F9 11 Excessive current draw by fault light Opens at 5 amps Excessive current draw by microprocessor Opens at 5 amps Excessive current draw by fuel solenoid clutch Opens at 10 amps or defrost light Excessive current draw by SV1 SV2 SV4 Fuse F12 Opens at 10 amps heat light cool light or rear unloader Head Pressure Control Cutout 300 10 psig Switch HP2 20 4 0 68 Bar Cut in 200 10 psig 13 6 0 68 Bar Other Safety Devices Unsafe Conditions Safety Device Excessive compressor High pressure cutout switch Refer to Section 2 12 discharge pressure HP 1 automatic reset Excessive compressor Com
128. draw a deep vac uum Shut off the pump and check to see if the vac uum holds This operation is to test the evacuation setup for leaks repair if necessary Midseat the refrigerant system service valves Open the vacuum pump and electronic vacuum gauge valves if they are not already open Start the vacuum pump Evacuate unit until the electronic vac uum gauge indicates 2000 microns Close the elec tronic vacuum gauge and vacuum pump valves Shut off the vacuum pump Wait a few minutes to be sure the vacuum holds Break the vacuum with dry nitrogen Raise system pressure to approximately 2 PSIG 0 14 Bar Purge nitrogen from system Repeat steps e through g one time Evacuate unit to 500 microns Close off vacuum pump valve and stop pump Wait five minutes to see if vacuumholds This checksfor residual moisture and or leaks With unit stillin a vacuum the refrigerant charge may be drawn into the system from a refrigerant container on weight scales The correct amount of refrigerant may be added by observing the scales Refer to Table 2 1 62 10450 Refrigerant Recovery Unit Refrigerant Cylinder Evacuation Manifold Valve Vacuum Pump Vacuum Gauge King Valve Receiver Condenser Evaporator Discharge Service Valve Suction Service Valve Compressor OONAN Figure 6 19 Vacuum Pump Connection
129. ds of new sight glass assembly or plug and install The torque value for either the sight glass as sembly or the plug is 20 25 ft Ibs 27 to 34 Nm Leak check receiver sight glass or fusible plug per Section 6 15 After leak checking unit evacuate and dehydrate as outlined in section 6 16 Add refrigerant charge Refer to Section 6 17 Check for noncondensibles Refer to Section 6 25 1 6 25 1Checking For Noncondensibles To check for noncondensibles proceed as follows Stabilize system to equalize pressure between the suction and discharge side of the system The en gine needs to be off for several hours Measure temperature at any of the copper tubing in the condenser Check pressure at the compressor discharge ser vice valve Determine saturation pressure as it corresponds to the condenser temperature using the Temperature Pressure Chart Table 6 3 If gauge reading is 3 psig 0 2 BAR or higher than the calculated P T pressure in step 4 nonconden sibles are present Remove refrigerant using a refrigerant recovery sys tem Refer to Section 6 14 Evacuate and dehydrate the system Refer to Sec tion 6 16 Charge the unit Refer to Section 6 17 1 11 2008 6 26 SERVICING SOLENOID VALVES 6 26 1 SV 2 SV 4 CAUTION Do not over tighten or damage the enclos ing tube assembly Torque to 17 ft pounds 23 Nm Also make sure all parts a
130. e not pinched or chafing against any components The following pretrip inspection should be performed before every trip and at regular maintenance intervals BEFORE STARTING ENGINE Drain water from bottom of fuel tank Drain water from water separator on fuel filter if applicable Check all defrost water drains Place in Continuous Run and start unit ENGINE Check oil lines and filters for leaks Ensure clutch engages properly no slip or unusual noises Check for unusual noises alternator fan shaft water pump idler and gearbox bearings etc Check bulkhead and return air screen If applicable 62 10450 6 4 PRETRIP List any Pretrip Alarms AFTER OPERATING UNIT FOR 15 MINUTES OR MORE Check refrigerant level Check compressor oil level Refer to Section 6 19 Check for proper temperature control Check auto start stop operation Initiate Pretrip OPERATE IN HIGH SPEED COOL AND RECORD From Microprocessor Unit Data List Review Functional Parameters Download recorder data if equipped with DataLink Change 11 2008 6 3 DOOR LATCH MAINTENANCE Door latch mechanisms require periodic lubrication Use of spray white lithium grease is recommended for the latch assembly and the latch pins that are mounted on the unit s frame See Figure 6 1 GRILLE INSERT MOUNTING BOLTS GRILLE INSERT 6 4 GRILLE INSERT REMOVAL See Figure 6 1 Removal of insert will ease in condenser coil cl
131. e Push logic board down The top of the logic board will unhook from the standoff pins Remove the board from the control box f Take the new logic board from the anti static bag and install in the control box following steps b to f in reverse order NOTE Logic board is secured at top with 3 control box standoff pins Logic board MUST interlock with standoffs Use caution when lowering control box cover Do not get harness pinched behind the gasket g Place the removed logic board back into the anti stat ic bag and part box for return h Reconnect negative battery cable and check micro processor configurations NOTE BEFORE STARTING THE UNIT When replacing a microprocessor it is important to check that the configurations are compatible with the unit into which it will be installed 6 45 62 10450 6 32 3 Reach The Configuration Fields From The Keypad a Place the SROS in the OFF position b With the unit off locate the serial port plug behind the control panel Remove the protective cap to gain ac cess to the wire terminals Place an insulated jump er wire between wires SPA and SPB the serial port plug CAUTION Do not allow the insulated jumper wire be used to configure unit to touch any ground c Place the SROS switch in the RUN position The FAULT light will come on and the micro display will read CNF1 TV or CNF1 DI Remove the jumper wire from the serial port and reinst
132. e lower latch assembly See Figure 6 3 c Remove the upper cable from the upper latch d Reverse above steps to install new cable REMOVE CIRCULAR CLIP PADDLE ASSEMBLY Figure 6 3 Side Door Latch Lower Cable Removal 62 10450 6 7 PRIMING FUEL SYSTEM 6 7 4 Mechanical Fuel Pump The mechanical fuel lift pump is mounted on the engine next to the injection pump This pump has a manual plunger for priming the fuel system when the fuel tank has been run dry See Figure 6 4 To prime the fuel system use the following steps Turn the bleed valve Red counter clockwise until fully opened b Turnthetop ofthe manual fuel pump plunger counter clockwise to unlock it S L O W L Y up down once per second pump the manual plunger until posi tive pressure resistance is felt This may take up to 200 strokes This will indicate fuel flow Red Fuel Bleed Valve Manual Fuel Pump Plunger ENGINE WITH ELECTRONIC SPEED CONTROL c Continue to pump S L O W L Y up down once per second approximately 100 more strokes to fill the filter and bleed the air out of the lines d Start engine It may be necessary to continue to pump until the engine starts e Depress and turn the top of the manual plunger clock wise to lock in place f When engine is running smoothly turn bleed valve clockwise until fully closed Red Fuel Bleed Valve
133. ealer for replacement The microprocessor controller is housed in the control box on the lower roadside corner of the unit This controller consists of 3 control boards a The Logic Board includes the microprocessor pro gram memory and necessary input output circuitry to interface with the unit The Display Board Figure 2 16 is mounted in the same control box as the processor board The display board includes the LCD display keypad and keypad interface The Relay Board Figure 2 14 is mounted to the back ofthe control box into which replaceable relays and fuses are mounted The main wiring harness plugs into this board The microprocessor Figure 2 15 is totally self contained and does not contain any serviceable components 1 Run Stop Switch RS 5 2 Keypad Door 6 J2 Plug 7 8 Buzzer B 3 Microprocessor Control Panel See Figure 2 16 J1 Plug 4 Manual Glow Crank Switch MGC If equipped Fault Light Figure 2 12 Control Box Short Box Shown 2 15 62 10450 62 10450 Glow Plug Relay 70 amp Starter Solenoid Relay SSR 70 amp Relay Board Logic Board Relays Run RR Speed SR Unloader Front UF
134. eaning Refer to Section 6 30 a Remove the 3 bolts on each side of the grille insert b Remove the 2 bolts on top of the grille insert c Swing insert down and lift out of locating holes d Reverse above steps to install new grille insert SURROUND LUBRICATE LATCHES AND PINS Figure 6 1 Door Latch Maintenance And Grille Insert Removal 62 10450 6 5 SURROUND REMOVAL b Open both side and front doors Turn the SROS to the OFF position and disconnect c Removethe bolts that secure the surround to the unit the starter d Reverse above steps to install new surround SURROUND MOUNTING BOLTS IF DECAL IS NOT REMOVABLE TYPE REPLACE WITH NEWER DECAL WHICH ALLOWS ACCESS TO UNIT MOUNTING C SURROUND MOUNTING BOLTS Figure 6 2 Surround Removal 62 10450 6 6 6 6 DOOR LATCH CABLE REPLACEMENT 6 6 1 Front Door Latch Cable Replacement a Remove circular clip that secures the cable to the paddle assembly b Slide cable from paddle and rotate other end out of latch assembly c Reverse above steps to install new cable UPPER CABLE UN THREAD THE LOWER CABLE FROM THE UPPER CABLE AND LATCH ASSEMBLY 6 6 2 Side Door Latch Cable Replacement a Remove circular clip that secures the cable to the paddle assembly b Remove the lower cable from the paddle assembly and the lower latch NOTE The lower cable is threaded through the upper cable eyelet and th
135. ed to display the unit operating data This key in conjunction with the UP DOWN Arrow keys will allow the user to display the units operating data values i e coolant temperature battery voltage etc See Section 3 9 EJ FUNCTION CHANGE Key FUNCTION CHANGE AUTO S S ONTINUOUS PRETRIP CHECK UNIT DATA 2 21 The FUNCTION CHANGE key is used to display the operating parameters Each time this key is pressed the display will advance to the next parameter This key in conjunction with the UP DOWN Arrow and ENTER keys will allow the user to change the parameters See Section 3 8 1 e LIGHT BAR Optional The Light Bar is an external set of indicator lights which can be seen in the mirror from the cab of a truck See Figure 2 17 They controlled the microprocessor The lights are Two Light Bar Green Light Indicates OK Amber Light Indicates Check Unit Amber follows the microprocessor fault light and alarms can be read on the micro display Eight Light Bar These lights correspond to the microprocessor LEDs HEAT COOL DEFROST START STOP and ALARM The ENGINE AUTO START light is only illuminated when the unit is operating in Start Stop The OUT OF RANGE light is illuminated when the Out of Range Alarm is active 62 10450 62 10450 STANDARD LIGHT BAR TRANSIGOLD ENGINE coo AUTO START WERT a FAULT DEFROST 4 l oF RANGE STANDBY lv 5172 POWER un
136. ed up and the box temperature is less than 45 F 7 2C 2 Partially block off air flow to condenser coil so dis charge pressure rises to 230 PSIG 15 65 Bar 3 Check the lower sight glass to determine charge The system is correctly charged when refrigerant level is at centerline of lower sight glass NOTE The lower sight glass should not be empty and the upper sight glass should not be full 4 If the system appears to be overcharged Remove re frigerant through the king valve to correct refrigerant level 5 Iftherefrigerant system appears to be undercharged Add refrigerant through the king valve 6 17 2 Adding A Partial Charge CAUTION Do not vapor charge R 404A Only liquid charging through the receiver king valve is acceptable NOTE The ambient air entering the condenser air temperature should be above 40 F 4 4 C Change 11 2008 Place drum of refrigerant on scale and note weight Backseat discharge and suction service valves and install a manifold gauge set Purge lines Connect a second manifold test set discharge gauge to the king valve Connect the suction pressure hose to manifold dead head port Connect a charging line between the center tap of the second gauge set and refrigerant drum Open the LIQUID valve on drum and purge all hoses Start the unit Adjust the setpoint so that the unit will run in high speed cool mode Runthe unit for approximately ten minutes until the
137. eed H eat Low Speed Heat High Speed Cool High Speed Cool Low Speed Cool Low Speed 4 62 10450 c Perishable Set Point 10 F 12 C or lower Cooling Unloader Control UltraFresh 1 During perishable cooling the unloaders are energized when the temperature approaches setpoint If a supply airtemperature probe is presentthe unloaders are ener gized when the supply air temperature decreases 5 4 F 3 below setpoint It will stay unloaded until the sup ply air temperature rises above setpoint If a supply probe is not present the unloaders are energized when the return air temperature is less than 9 F 5 C above setpoint It will stay unloaded until the return tempera ture rises to more than 14 4 F 8 C above setpoint The return air probe logic is disabled for ambient tem perature higher than 90 F 32 2 C d Perishable Set Point 11 F 11 C and higher Heating Unloader Control During perishable heating the front unloader is ener gized when the control temperature increases to 0 9 F 0 5 C below setpoint The unloader will stay ener gized until the control temperature decreases to 1 5 F 0 8 C below setpoint NOTE These switch points may vary slightly depend ing on the amount of overshoot around set point e Frozen Set Point Unloader Control CNF 17 UltraFreeze On Off For units with UltraFreeze Refer to Section 4 4 For units without UltraFreeze during frozen mode heat ing
138. ehydrated Refer to Section 6 16 6 15 REFRIGERANT LEAK CHECKING a b If the system was opened and repairs completed leak check the unit The recommended procedure for finding leaks in a system is with a electronic leak detector A halide torch will not work on units with HFC refriger ants such as R 4044 Testing joints with soapsuds is satisfactory only for locating large leaks or pin pointing small leaks once a general area has been located If the system is without refrigerant charge system with refrigerant to build up pressure between 30 to 50 psig 2 04 to 3 4 Bar Remove refrigerant drum and leak check all connections CAUTION Only a refrigerant drum containing R404a should be connected to an XT refrigeration unit in order to pressurize the system Any other gas or vapor will contaminate the sys tem which will require additional purging and evacuation of the high side discharge of the system Remove refrigerant using a refrigerant recovery sys tem and repair any leaks Evacuate and dehydrate the unit Refer to Section 6 16 Charge unit with re frigerant Refer to Section 6 17 Change 11 2008 6 16 EVACUATION AND DEHYDRATION 6 16 1 General Moisture is the enemy of refrigerant systems The pres ence of moisture in a refrigeration system can have many undesirable effects The most common are cop per plating acid sludge formation freezing up of me tering devices TXV b
139. engine is running 1 It looks to see that the oil pressure switch is closed 2 It looks for and alternator ouput voltage on the D cir cuit With the unit OFF and the alternator not rotating the D circuit will be 0 VDC See 6 9 for information on improper voltage reading With the engine running and the alternator rotating voltage on the D circuit will match the charging voltage to the battery This will be approximately 14 5 VDC POS OUTPUT GRN Q4 b MH 9 FIELD GRN PUT D EMULATION REGULATOR D Emulation Orange 10 24 AC Terminal 10 24 Ground Screw 1 4 20 Positive Output Cable Figure 2 9 Alternator and Regulator 2 3 3 Compressor The compressor assembly includes the refrigerant com pressor suction and discharge service valves high pressure switch and the suction pressure transducer The compressor withdraws refrigerant gas from the evaporator and delivers it to the condenser at an in creased pressure and temperature The pressure is such that refrigerant heat can be absorbed by the sur rounding air at ambient temperatures Compressor Unloaders The refrigeration compressor used is 37 or 41 model 05G equipped with unloaders as standard equipment Unloaders are used as a compressor capacity control to unload the compressor during periods of reduced loads This provides closer
140. enu to set sensors amp events to be viewed OR ReeferManager to correctly setup recording parameters Operate the sys tem in order to verify the repair START HERE What does the ReeferManager program display on the bottom of the screen of your PC There serial NOT CONNECTED is no connection Is the DataLink status light blinking 1 second second off amp 1 Verify the integrity ofthe download cable and connections Did Check power to DataLink Intermittent communication problem Ensure AC cord is properly connected or PC bat tery is fully charged Did you find and correct the problem Verify PC power saving fea tures are OFF i e screen saver monitor time out hard disk time out auto power down sleep mode Did you find and correct the condition Verify the integrity of the download cable and con nections Did you find and correct the condition Try another computer or check with super visor you find and correct the condition Use an ohmmeter to veri fy the download port wir ing is correct and doesn t have an open high res istance or a short Refer to NO TAG Verify the correct com port is se lected in the PC software See Help gt Contents gt PC Setup for additional information Did you find and correct the condition Verify com port availability i e Infrared devices turned off PDA applications turned off compu
141. ere will be no space between the designator and the number of hours once the hours are greater than 9999 62 10450 3 10 ALARM DISPLAY AND RESET 1 Press FUNCTION CHANGE key FAULT LIGHT e FAULT STAND BY COOL ENG OL 2 Press UP DOWN arrow key until ALARM RST is displayed BOX TEMPERATURE MANUAL AUTO S S CONTINUO 3 Press ENTER to clear alarm ALARM CLR will be displayed Unit will restart if alarm condition has been corrected and unit is in Start Stop or Auto OP The fault light FL is turned on only for alarms that specify it The default display will be overridden if a alarm is generated When an alarm is generated the display will alternate the default display setpoint air temperature and the active alarm s Each item will be displayed for 3 to 10 seconds and will continue to scroll through the list For 5 seconds or the low temperature alternating interval for ambient temperatures at or 62 10450 above 0 For temperatures below 0 each item will be displayed for 10 seconds ALTERNATE ALARM RESET Place START RUN OFF switch to OFF position Unit can now be restarted after alarm condition has been corrected The following table has columns for Code and English displays English is the default setting Change Functional Parameter to Code to see Code display format Coolant Temperature 4 High Discharge Compressor Discharge F
142. ers are not primed the engine may operate for a period with no oil supplied to the bearings NOTE Themaximum oil change interval is one year for Cl oil or two years for Mobil Delvac unless units are equipped with Extended Service Interval Packages The only approved synthetic lube oil is Mobil Delvac The normal oil change intervals should be reduced if the equipment is operated under extreme conditions such as in dirty envi ronments Refer to Section 6 1 for more detailed information on service intervals 62 10450 2 9 ENGINE SCREW THREADS All threads used on the diesel engine are metric 2 10 ENGINE AIR SYSTEM The air cleaner is put on the engine prolong its life and performance by preventing dirt and grit from getting into the engine causing excessive wear on all operating parts However it is the responsibility of the operator to give the air cleaner equipment regular and constant attention in accordance with the instructions Refer to Section 6 10 5 Clean air is supplied to the engine through the air cleaner Refer to Section 6 3 4 The air is necessary for complete combustion and scavenging of the exhaust gases As the engine piston goes through the intake stroke the piston draws clean fresh air down into the cylinder for the compression and power strokes As the engine goes through its exhaust stroke the upward 62 10450 2 28 movement of the piston forces the hot exhaust gases out of the cylinders th
143. ery insufficiently charged Battery cable connections loose or oxidized Battery cables defective Starter brushes shorted out Starter brushes hang up or have no contact Starter solenoid damaged Run Stop switch defective Engine lube oil too heavy Pinion or ring gear obstructed or worn Starter clutch not engaging 5 1 4 Malfunction In the Engine Starting Circuit No power to starter motor solenoid SS Stop Fuel solenoid does not energize or does not remain energized 62 10450 Battery defective Loose electrical connections Defective starter solenoid relay SSR Defective Glow Crank switch if equipped Voltage at D on alternator Battery defective Loose electrical connections Oil pressure safety switch OP defective Run relay RR defective Water temperature sensor WTS defective Stop Fuel solenoid defective Run Stop switch defective 5 2 Engine Manual Check Check Check Engine Replace Engine Manual Engine Manual 6 10 5 2 13 and Table 3 3 Replace 6 7 5 4 6 7 Check Check Replace Engine Manual Engine Manual Engine Manual Replace 2 8 Clean both remove burrs or replace apply grease Repair or re place Replace Engine Manual Check Tighten Check Check 2 3 2 Check Tighten Replace Replace Replace Replace Replace INDICATION REFERENCE TROUBLE POSSIBLE CAUSES SECTION 5 2 ALTERNATOR Alternator fails to charge Limited charging system operating time Check Battery condit
144. ery post apply 12 VDC to the front unloader coil terminal The suction pressure should rise noticeably approx 5 10 psig 0 34 0 68 Bar NOTE If no change in suction pressure occurs check the unloader coil ground connection and the coil resistance before making any repairs to the un loader solenoid valve Remove the white lead from the positive starter or battery post and the suction pressure should drop Repeat steps e amp f to cycle the unloader 3 4 times to verify consistent operation Repeat steps b to e to check the rear unloader Reconnect the unloader wires Leave the unit running in High Speed Cool 6 22 6 13 4 SV 4 And By Pass Check Valve Seating a d Ability During Cool Slowly frontseat the king valve receiver tank outlet valve and pump down the low side of the system to 0 psig Do not allow the system to run in vacuum Shut off unit and observe the suction and discharge pressures at the compressor They should not equal ize in less than 30 seconds If they do it will indicate 1 The by pass check valve is leaking 2 Internal leakage inside the compressor unloader valves reed valves or head gaskets 3 SV 4 is leaking and not properly seated NOTE This problem can be verified by carefully feeling the refrigerant lines for hot cold spots or by listening for internal leakage Any leakage internal or external found while per forming this step MUST
145. evaporator This cold air is circulated throughout the trailer to maintain the cargo at the desired temperature The transfer of heat from the air to the low temperature liquid refrigerant causes the liquid to vaporize This low temperature low pressure vapor passes through the suction line liquid line heat exchanger where it absorbs more heat from the high pressure high temperature liquid and then returns to the compressor EXPANSION VALVE 9 EXTERNAL EQUALIZER TXV lt HOT GAS BYPASS LINE 3YPASS LINE _ du BULB FUSIBLE EVAPORATOR PLUG _ RECEIVER NGA BYPASS gt gt gt lt CHECK VALVE LIQUID LINE VIBRASORBER HOT GAS LINE SUCTION SERVICE VALVE DISCHARGE P 2 HOT GAS LIQUID SOLENOID VALVE SV2 NC SHUT OFF KING VALVE FILTER SUBCOOLER DRIER SOLENOID SV4 NC COMPRESSOR DISCHARGE CHECK VALVE 3e CONDENSER VIBRASORBER gt PRESSURE CONTROL SOLENOID SV1 NO C
146. ew micro and reinstall above tests with your and verify configura old micro Micro is not the fault supervisor If neces Check for an open or high resist tions amp functional Review results of above tests with sary go to the begin ance in the wiring to the ENSCU parameter settings your supervisor If necessary go ning of the table and Did you find and correct the con to the beginning of the table and test again dition System _ ygs test again Check for a constant OK voltage between Check for an open ENSCU pin 13 amp 19 Replace micro and operate Review results of above tests or high resistarte you get a steady system in order to verify re with your supervisor If ne between ENSCU pin reading of at least 11 pair Do not install micro cessary go to the beginning 13 and 19 Did Volts when run relay hours at this time Did you find I NO of the table and test again find and correct is energized ane correct the condition condition NO YES Remove new micro and reinstall old micro Micro is not the fault Review results of above tests with and verify configura Remove J1 jumper OK your supervisor If necessary go tions amp functional
147. ey until MAN OP is displayed Press ENTER key to lock in manual mode 4 Hold GLOW CRANK switch in the GLOW position for 5 to 15 seconds Side of Control Box see chart on next page Then hold the GLOW CRANK switch inthe CRANK position for up to 10 seconds to start the diesel engine 5 With MAN OP selected press AUTO S S CONTINUOUS key to toggle between Auto Start Stop and Manual Start Continuous Run modes NOTE NOTE The GLOW CRANK switch was removed from Refer to Section 4 1 5 for glow times units built beginning in March 2007 Units without the GCS have serial numbers begin ning with LAF AX WARNING Under no circumstances should ether or any other starting aids be used to start en gine 3 3 62 10450 3 3 PRETRIP o FAULT STAND BY COOL PPPP SETPOINT BOX TEMPERATURE UNIT PRETRIP AUTO S S MANUAL DATA CHECK DEFROST 1 Start and run unit until box temperature is 40 F 4 4 C or lower 2 Press PRETRIP CHECK key to start PRETRIP PPPP will appear on the display The PRETRIP mode is for checking unit operation and j After standard defrost cycle Pretrip is terminated and evaluating operation of all modes and indicating a failure unit returns to normal operation when detected The following details the sequence This is not a self diagnosing pretrip test No specific a Unit operating and box
148. fixed but depends upon the rate at which the trailer tempera ture is approaching set point The speed relay SR de energizes to open the circuit to the speed control solenoid SCS Engine speed de creases from high speed to low speed As the trailer temperature falls closer to set point the controller will shift the operation from low speed loaded cool to low speed unloaded cool to further reduce cool ing capacity To do this the microprocessor will pull ter minals 57 or 57 amp 56 low completing the ground path for the unloader relays UFR amp URR The coils energize to close the UFR amp URR contacts One or both unloaders UF and UR may energize to unload the compressor Refer to Section 4 5 1 With decreasing temperature the unit will shift to low speed unloaded heat Refer to Section 4 4 Unit will remain in various stages of heating until the box temperature increases enough to place the unit in the low speed unloaded cool mode As the box temperature increases the unit will shift to low speed loaded cool and then to high speed cool mode speed relay ener gizes NOTE High Speed Coolis locked out for 10 minutes af ter switching from Null to Cool or from High Speed Coolto Low Speed Cool when CNF15 is ON UltraFresh enabled There is no delay when CNF15 is OFF b Heating NOTE Whenever the unit shifts to heat or defrost HR1 and HR2 energize simultaneously When switch ing from heat or defrost
149. frigerant Charge 6 26 6 28 Refrigerant Circuit Heating amp Defrosting Refrigerant Circuit Cooling 2 31 Refrigerant Leak Checking 6 26 Refrigerant Removal From Compressor 6 25 Refrigeration Charge 2 29 Refrigeration System Data 2 29 Replacing Check Valve 6 33 Index 2 Change 11 2008 Index S U Safety Devices 2 29 Sensor 6 49 Servicing Check Valve 6 33 Solenoid Valves 6 37 Ultra Freeze Temperature Control 4 13 Ultrafresh 2 4 12 Unidrive Torque Requirements 6 49 Speed Control Solenoid 6 11 UNIT DATA 3 13 3 14 Speed Solenoid Overrides 4 13 Unit Weight 2 29 Start Stop Operation 3 6 Unloader 6 32 Stopping Unit 3 20 Suction Pressure Operation 4 7 Unloader Coil Replacement 6 33 Unloader Operation 4 6 Suction Pressure Transducer 6 49 Surround Removal 6 6 Switch Descriptions 2 20 V T V Belts 6 13 Temperature ControL 4 3 Thermal Expansion Valve 2 13 W Thermostatic Expansion Valve 2 29 6 35 Transducers and Sensor 2 13 Water Pump V Belt 6 13 Change 11 2008 Index 3 62 10450 TRANSICOLD North America Central America Carrier Transicold and Mexico 700 Olympic Drive Ejercito Nacional No 418 Athens GA 30601 USA Piso 9 Torre Yumal Tel 1 706 357 7223 Col Chapultepec Morales Fax 1 706 355 5435 11570 Mexico D F Tel 5255 9126 0300 Fax 5255 9126 0373 A member of the United Technologies Corporation family Stock symbol UTX 2008 Carrier Corporati
150. g item 3 Figure 6 23 purge the oil pump hose with clean fresh oil Connect oil hose to oil fill port Add oil as required to raise level in sight glass as needed Refer to Section 2 11 Re install fill plug and evacuate compressor Backseat suction and discharge service valves Start unit and check oil level High Pressure Switch Connection Suction Service Valve Oil Fill Plug Bottom Plate Oil Drain Plug Oil Level Sight Glass Oil Pump Unloader Solenoid Discharge Temperature Sensor Connection Discharge Service Valve Odvcoco o0ci25onm Figure 6 23 Compressor 62 10450 6 19 3 Adding Oil to Service Replacement Compressor Service replacement compressors may or may not be shipped with oil If compressor is without oil Add correct oil charge Refer to Section 2 11 through the suction service valve flange cavity or by removing the oil fill plug See Figure 6 23 6 19 4 To remove oil from the compressor a Close suction service valve frontseat and pump unit down to 1 to 2 psig 0 07 to 0 1 Bar Shut off unit and front seat discharge service valve Slowly bleed re maining refrigerant b Slowly remove the oil drain plug item 5 Figure 6 23 from the compressor and drain the proper amount of oil Replace the plug securely back into the compres sor Open service valves and run unit to check oil level re peat as required to en
151. gher and correct the condi tion NO NO NO v Enter hours from old Remove new micro and reinstall micro into new micro old micro Micro is not the fault Check for an open or high Review results of above tests and verify configura Review results of above tests with resistance in the wiring with your supervisor If ne tions amp functional your supervisor If necessary go between the battery and cessary go to the beginning parameter settings to the beginning of the table and the fuel solenoid Did you of the table and test again test again find and correct the con dition system Figure 5 6 Micro Diagnostic Tree Cond 2 Models with Speed Control Solenoid RS Switch On Engine does not operate 62 10450 5 16 NOTE RS switch must be on for re Disconnect shutdown op mainder oftesting Is the unit equipped tions and or telematics sys START HERE The RS with shutdown options and or telemat tem and install J1 jumper switch is ON Does the en ics system remote communication gine run NO YES Does the Y NO micro Is there a START FAIL gt power up alarm in the micro Did disconnecting the shutdown options allow the unit to operate T System No YES OK ne Repair alarm per this manual Note oil pressure Go to Cond 1 Switch stuck closed can generate an ALT AUX alarm Table O
152. hey are laid out These tables are formatted into a logical troubleshooting sequence Skipping around the tables Will most likely lead to errors in diagnosis Throughout the tables the steps will point the technician to areas to look at or check for a problem Most of the steps will lead the technician to a circuit or other area of the unit to check test and possibly repair other than the microprocessor Some steps will point to a possible problem with the microprocessor Whenever reaching one of these steps it is a very good practice to install the new microprocessor then verify unit operation PRIOR TO writing hours into the new microprocessor Once the technician is satisfied that a new microprocessor is required the hours should be entered Should the problem remain even with the new microprocessor in place once all repairs are made the original microprocessor is to be reinstalled into the unit to avoid unnecessary costs to the customer or having the Warranty Request rejected if there is no problem found with the returned microprocessor All steps leading to replacement of the microprocessor have a number associated with them When filling out the MPR tagthat will be attached to the returned part write the step number on the upper half of thetag inthe Failure Description Field Include the same information in the Failure Description Field when entering the warranty claim information on line This will show which diagnostic table was used and the
153. hut down except for safeties or if the engine stalls This function also apply to the operation of the electric motor 4 1 2 Auto Mode Indicator The Auto Start Stop indicator is lit and ARL light 8 light bar only will be on to indicate the start stop mode has been selected 4 1 3 Auto Start Failure If the unit fails to start shuts down on safety or fails to run for the minimum run time three consecutive times the Auto Start Failure is activated 4 1 4 Auto Start Sequence When the starting conditions are met the start se quence will begin by energizing the run relay and after 5 seconds energize the glow plug relay GPR to supply power to the glow plugs units with buzzer will sound for 5 seconds then the starter is energized On initial pow er up the control will delay 5 seconds before the starting sequence begins If the required glow time is zero the control will energize the starter after a 5 second delay After a period of time the starter solenoid SS is ener gized to crank the engine The engine will crank for 10 seconds or until engine operation is sensed by the alter nator signal The glow relay will be de energized after the auxiliary input is sensed on A 15 second null cycle will elapse before subsequent start attempts The run relay will remain energized until the next starting se quence Before the next starting sequence the oil pressure is checked to determine if the engine is running a
154. hutdownoptionsand Y or telematics System Check RS switch l Does the engine start amp SSR relay starter Go to Cond stall after a few solenoid amp starter for OK 3 Table seconds proper operation Check all associated wiring and connectors NO Load test battery Re pair or replace as re Check ground connections Check the fuel solenoid AH circuitfor bad con nection to starter or open winding in fuel solen quired at the battery starter engine bis i e block and inside the control oid Did you find and correct the condition box Did you find and correct ition the condition YES Check amperage on glow plugs Glow Replace alternator NO plug circuit draws 6 to 7 amps Each glow plug draws 0 7 to 1 2 amps Did you find and correct the condition YES e YES MPR jos 2 Remove J1 jumper and reinstall shutdown options Replace micro and operate NO 74 system in order to verify re Check fuel flow from and or telematics pair Do not install micro Check for voltage at fuel tanks through the hoursatthis une Did you find the fuel solenoid circuit fuel lines to the injec and correct the condition BP and AH Is voltage tion pump Did you find 11 volts or hi
155. i formly Refer to Figure 6 20 and Section 6 35 1 drive gear installation w Attach manifold gauges with hand valves near vacu um pump to the suction and discharge service valves Dehydrate and evacuate compressor to 500 microns 29 90 Hg vacuum 75 9 cm Hg vacuum Turn off valves on manifold gauges x Reconnect battery cable y Start unit and check for noncondensibles Refer to Section 6 25 1 z Check refrigerant level Refer to Section 6 17 x 11 2008 aa Check compressor oil level Refer to Section 6 19 6 19 CHECKING COMPRESSOR OIL LEVEL Add oil if necessary ab Check compressor unloader operation Refer to 6 19 1 To Check the Level in the Compressor Section 6 20 a Operate the unit in high speed fully loaded cool for at ac Check refrigerant cycles Refer to Section 2 least 15 minutes Unplug wires to the unloaders if necessary to ensure 6 cylinder operation NOTE Check the oil sight glass on the compressor to ensure that no foaming of the oil is present after 15 minutes of operation If the oil is foaming check the refrigerant system for flood back of liquid refrigerant Correct this situation before performing step 2 b After 15 minutes initiate a defrost cycle This will al low any residual oil in the system to be returned to the compressor NOTE Operate the unit in defrost for 3 5 minutes only Do not allow the unit to terminate defrost automatically The sud
156. id valve control device is de energized and the gas bypass port is closed Solenoid Valve Valve Stem Gas Bypass Port Spring Guide Spring Piston Piston Bypass Valve Bleed Orifice 9 Strainer 10 Suction Manifold 11 Cylinder Discharge Valve 12 Valve Plate 13 Cylinder Suction Valve 14 Discharge Piston Check Valve Assembly 15 Discharge Manifold Figure 2 10 Compressor Cylinder Head Unloaded c Loaded Operation Discharge pressure bleeds from the discharge manifold Figure 2 11 item 15 through the strainer 9 and 8 bleed orifice to the solenoid valve stem 2 chamber and the back of the piston bypass valve 7 With the solenoid valve 1 de energized the solenoid valve stem will close the gas bypass port 3 Refrigerant pressure will overcome the bypass valve spring 5 tension and force the piston 6 forward closing the gas bypass from the discharge manifold to the suction manifold 10 Cylinder discharge pressure will force open the discharge piston check valve assembly 14 Refrigerant gas will pass into the compressor discharge manifold The loaded cylinder bank will continue to operate fully loaded until the solenoid valve control device is energized and the gas bypass port is opened 62 10450 3 JE 14 E Solenoid Valve Valve Stem Gas Bypass Port Spring Guide Spring Piston Piston Bypass Valve Bleed Orifice 6
157. ient Compressor Operation 6 21 6 13 2 Compressor Unloader Valve Operation 6 22 6 13 4 SV 4 And By Pass Check Valve 6 22 6 13 5 Discharge Line Check Valve Leakage amp SV 2 Seating amp Opening Ability 6 22 6 13 6 HP 2 and SV 2 for Cycling During Heat and Defrost 6 23 6 13 7 SV 1 for Seating Sv 4 for Opening 6 24 6 13 8 SV 1 Defrost Operation 6 24 6 13 9 Removing the Refrigerant Charge 6 25 6 13 10 Refrigerant Removal From An Inoperative Compressor 6 25 6 13 11 Refrigerant Removal From An Operable 6 25 6 14 PUMPING DOWN THE UNIT OR REMOVING REFRIGERANT CHARGE 6 26 6 14 1 Pumping Down The Unit 6 26 6 15 REFRIGERANT LEAK CHECKING 6 26 6 16 EVACUATION AND DEHYDRATION 6 27 6 16 2 Preparation exu ue eeu 6 27 6 16 3 Procedure for Evacuation and Dehydrating System 6 27 62 10450 iv Change 11 20
158. ill resume auto c Install tee in pressure line to high side connection Tee matic operation Check the defrost thermostat s if should be approximately half way between gauge and unit fails to terminate defrost See Section 1 5 air switch or an improper reading may result c If the above test indicates satisfactory operation test d Attach an ohmmeter to the air switch electrical con defrost air switch DA settings using a Dwyer Magne tacts to check switch action helic gauge P N 07 00177 or similar instrument NOTE Refer to Section 6 28 hand aspirator P N 07 00177 01 si 4 se a hand aspirator 01 since State DeITOSETImer blowing into tube by mouth may cause an incor Refer to Section 4 2 2 for description rect reading 6 28 CHECKING CALIBRATION OF THE DEFROST AIR SWITCH e With the gauge reading at zero apply air pressure very slowly to the air switch An ohmmeter will indi cate continuity when switch actuates The switch contacts should close and the ohmmeter needle should move rapidly to O Any hesitation in the ohm meter indicates a possible problem with the switch and it should be replaced f Refer to Section 2 12 for switch settings If switch fails to actuate at correct gauge reading adjust switch by turning adjusting screw clockwise to increase setting or counterclockwise to decrease setting g Repeat checkout procedure until switch actuates at correct gauge reading After switch is
159. illage b Remove banjo fitting item 2 and let it hang loose making sure to keep copper rings item 4 for replace ment c Turn filter item 3 counter clockwise and remove Check and clean d Replace copper rings item 4 with new rings e To install reverse steps 1 through 3 T Copper Rings Figure 6 5 Mechanical Fuel Pump 6 9 ALTERNATOR REGULATOR With the unit OFF and the alternator not rotating the D circuit should be 0 VDC If voltage is present when the unit is OFF the regulator has failed and needs to be re placed See 2 3 2 b for information on proper voltage of D circuit 6 10 ENGINE SERVICE amp COMPONENTS 6 10 1 Cooling System Air flows through the condenser radiator The radiator externally and internally must be clean for adequate cooling The upper drive V belt must be ad justed periodically to provide maximum air flow Refer to Section 6 11 3 CAUTION Use only ethylene glycol anti freeze with inhibitors in system as glycol by itself will damage the cooling system Always add pre mixed 50 50 anti freeze and water to radiator engine Never exceed more than 60 concentration of anti freeze Use a low silicate anti freeze meet ing GM specifications GM 6038M or equal Do the following to service the cooling system a Remove all foreign material from the radiator coil by reversing the normal ai
160. ine Cooling System 6 9 Engine Crankcase Breather 6 12 Engine Data 2 27 Engine Oil 2 27 Engine Screw Threads 2 28 Engine Speed Control Unit 2 9 Engine to Gearbox V Belt 6 16 Engine Transducers and Sensors 2 9 Evacuation 6 27 Evaporator Coil 2 13 6 41 Evaporator Section 2 13 Expansion Valve 2 29 6 35 Index 1 62 10450 Fail Safe Defrost Termination 4 5 Fan Clutch Air Gap 2 29 Fan Shaft V Belt 6 15 Fanshaft Oil 2 29 Filter Drier 2 12 Filter Drier 6 35 Fuel and Speed Actuator 2 9 Fuel Flow Diagram 6 10 Fuel Pump 6 9 Functional Parameters 3 10 3 11 Fusible Plug 2 29 G Gearbox Oil 2 29 Glow Plugs 6 13 Glow Crank Switch GCS 2 20 Grille Insert Removal 6 5 H Heat Exchanger 2 13 Heat Mode 4 3 Heating 4 3 Heating Cycle 6 39 High Pressure Switch 2 29 High Pressure Switches 6 36 Indicator LEDs 2 20 Integral Voltage Regulator Operation 12 VDC 2 10 Introduction 2 1 K Key Descriptions 2 20 62 10450 Index L LEDs 2 25 Light Bar 2 21 Lube Oil Diagram 6 10 Lube Oil Filter 6 10 Lubrication System 2 27 Maintenance Schedule 6 2 Manual Defrost 3 8 4 4 Manual Start Glow amp Crank 3 3 Microprocessor Controller 6 42 Microprocessor Troubleshooting Guide 5 14 OVERRIDES 4 13 Pretrip 3 4 Pretrip Inspection 6 4 Priming Fuel System 6 8 Pumping Unit Down 6 26 R Receiver 2 12 Receiver Sight Glass 6 36 Re
161. ines only Refer to Section 6 10 4 for information on units with Elec tronic Speed Control Solenoid Linkage Speed Clip Adjustment Nut Adjustment Bracket Solenoid Bracket Bolt NOOR OM Figure 6 8 Speed Control Solenoid a Solenoid Removal Replacement 1 Disconnect wiring to solenoid Disconnect linkage arm item 2 Figure 6 8 from solenoid Remove mounting hardware from solenoid and then remove solenoid 2 Install replacement solenoid Item 1 and mount ing hardware Do not tighten at this time 3 Attach linkage to solenoid and install the clip Item 3 to the linkage rod b Low Speed Adjustment 1 Hold the speed lever against the low speed stop and check the RPM Refer to Table 1 1 Adjust the low speed stop screw if necessary 2 Check engine speed With the engine stopped place a mark on the crankshaft sheave white paint for example Speed may be verified by a Strobette model 964 strobe tachometer Carrier Transicold P N 07 00206 c High Speed Adjustment Energize the speed solenoid Adjust the adjustment nut Item 4 until the correct RPMs are obtained then tight en the solenoid mounting bolts Item 7 NOTE LE Low Emission DI engines are delivered with a tamper resistant high speed adjustment screw on the engine High speed adjustments are made using the slotted holes in the solenoid mounting bracket and the speed solenoid ad justing bracket with solenoid adjusti
162. ion Check Alternator belt loose broken 6 11 Loose dirty corroded terminals or broken wires Check Repair Excessively worn open or defective brushes Check Regulator faulty Check Ammeter faulty Replace Alternator faulty Replace Low or unsteady charging rate Alternator belt loose broken 6 11 Loose dirty corroded terminals or broken wires Check Repair Excessively worn sticky or intermittent brushes Check Faulty regulator Check Alternator faulty Replace Ammeter wires loose Check and Tighten Ammeter faulty Replace Excessive charging rate Regulator leads loose dirty corroded terminals or as evidenced by battery wires broken Clean Repair requiring too frequent refilling or Defective regulator Check charge with engine idling Noisy alternator Defective or badly worn V belt 6 11 Worn bearing s Replace Misaligned belt or pulley 6 11 Loose pulley Tighten 5 3 REFRIGERATION NOTE Refrigeration System problems should be investigated by following the Quick Check Refrigeration System Troubleshooting Procedure Refer to Section 6 13 5 3 1 Unit Will Not Cool Compressor malfunction Compressor drive defective 6 18 Compressor defective 6 18 Compressor unloaders not working 6 20 1 Compressor reed valves or valve plate gaskets defective Replace Refrigeration system Defrost cycle did not terminate Abnormal pressure Solenoid valve malfunction Clutch Failure 5 3 62 10450 INDICATION REFERENCE TROUBLE POSSIBLE C
163. is not allowed The front unloader is energized when the control temperature decreases to 1 5 F 0 8 C above setpoint The unloader will stay energized until thecontrol temperature reaches 2 F 1 1 aboveset point NOTE During frozen mode only the front cylinder can be unloaded 4 6 4 2 4 Suction Pressure Operation The microprocessor will monitor suction pressure of the refrigeration system and control the unloaders to load de energize as the suction pressure drops and unload energize as the suction pressure rises A suction pressure transducer is used to signal the microproces sor when to load or unload the compressor During the diesel heating and defrosting cycles the rear unloader is always loaded forcing the compressor to operate with at least four cylinders loaded High Ambient Override for XT and X2 Models only CNF 19 ON NOTE XT and X2 model units REV 3 25 and higher with CNF 19 ON use the suction pressure loading amp unloading chart See Figure 4 2 but also use the following overrides during unit op eration For ambient air temperatures above 125 F 52 C or if the Ambient Air Sensor is defective suction pressure Will determine when the Front or Rear Unloader will load or unload See Figure 4 2 For ambient air temperatures between 125 F and 110 F 52 C to 43 C the Rear Unloader UR will oper ate per the suction pressure chart See Figure 4 2 for the first 30 seconds after the e
164. ite wire from SV 4 front unloader and 1 wire from the HP 2 switch Readjust setpoint to 20 to 25 F 11 to 14 C above box temperature high speed heat operation It may be eee to run the unit in COOL prior to this step Start the unit Allow the unit to run for 30 to 45 seconds The suction pressure should fall to approx imately O psig and the receiver pressure to near or below 200 psig 13 6 Bar Closely monitor both high pressure gauges while connecting the wire to the HP 2 switch Compressor discharge pressure will begin to rise Receiver pressure should not rise When the compressor discharge pressure reaches 390 psig 26 6 Bar shut the engine off using the en gine stop lever near the injection pump The micro processor will remain energized The compressor discharge pressure will drop off but the receiver pres sure should not change Any rise in receiver pressure indicates internal leakage at the SV 1 valve Observethe suction gauge Using a jumper wire mo mentarily energize SV 4 by clipping one end to the post on SV 4 and toughing the other end to the posit starter post or battery post The valve should open and the suction pressure begin to rise Remove the jumper and observe The valve should close and the suction pressure should stop rising Energize the valve 2 or 3times to verify consistent valve operation Reconnect the unit s harness wires to SV 4 and the front unloader Remove the bypass
165. iver is equipped with a fusible plug which melts if the refrigerant temperature is abnormally high and releases the refrigerant charge The refrigerant leaves the receiver and flows through the receiver outlet shutoff valve King valve The refrigerant then flows through the subcooler The subcooler occupies a portion of the main condensing surface and gives off further heat to the passing air The refrigerant then flows through a filter drier where an absorbent keeps the refrigerant clean and dry and the electrically controlled liquid line solenoid valve SV 2 normally closed which starts or stops the flow of liquid refrigerant The refrigerant flows to the Liquid suction heat exchanger Here the liquid is further reduced in temperature by giving off some of its heat to the suction gas The liquid then flows to an externally equalized thermostatic expansion valve which reduces the pressure of the liquid and meters the flow of liquid refrigerant to the evaporator to obtain maximum use of the evaporator heat transfer surface The refrigerant pressure drop caused by the expansion valve is accompanied by a drop in temperature thus the low pressure low temperature fluid that flows into the evaporator tubes is colder than the air that is circulated over the evaporator tubes by the evaporator fan The evaporator tubes have aluminum fins to increase heat transfer therefore heat is removed from the air circulated over the
166. l rise approx 10 to 15 psig 0 68 to 1 02 Bar after 5 minutes of unit operation Refer to Section 4 2 if unit does not heat properly c Unit should remain in defrost until evaporator coil temperature reaches 55 F 12 8 C At this point the defrost cycle will terminate and the unit will resume automatic operation 62 10450 6 27 3 Defrost Air Switch DA Make sure magnehelic gauge is in proper calibration NOTE NOTE Box temperature must be 140 4 4 C or low The magnehelic gauge may be used in any er to initiate defrost position but must be re zeroed if position of gauge is changed from vertical to horizontal or a To check the defrost air switch run unit in high speed vice versa USE ONLY IN POSITION FOR cooling and place a jumper wire across the air switch WHICH IT IS CALIBRATED The Defrost Air terminals This will start the defrost cycle as it simu lates the action of the defrost air switch Bypassing switch MUST be in the same orientation as it will the switch in this manner operates all components in be in when installed in the unit volved in defrost Unit should remain in defrost until evaporator coil temperature reaches approx 50 F 10 C At this point the defrost thermostat s should open to termi b With air switch in vertical position connect high pres sure side of magnehelic gauge to high side connec tion of air switch See Figure 6 33 nate the defrost cycle and the unit w
167. ld the control box cover bezel assembly onto the front of the control box Remove the cover and hang it by its tethers be low the control box Remove the wires connected to the SROS Unplug the 14 pin and 60 pin ribbon cables from the display and micro logic boards Loosen the 5 8 32 hex head bots that secure the mi cro logic board Make sure the cover is secured be fore removing the screws because the front 2 hex head bolts hold the cover and display assembly teth ers e Remove the front 2 hex head bolts unhook the teth ers from the standoffs and place the display assembly aside 11 2008 Remove the 4 5mm x 20mm Ig hex head bolts that secure the bezel assembly to the control box g Unplug the 10 pin ribbon cable that attaches the keypad board to the display board Remove the 4 Phillips head screws that attach the display board to the keypad board and place the display board aside Remove the 11 Phillips head screws that attach the keypad and window to the bezel Gently remove the window and keypad from the bezel Discard the old keypad gt NOTE All gaskets must be replaced any time the keypad is removed from the bezel Keypad Installation Short Box CAUTION Do not overtorque screws a Remove both gaskets from the clear window Ensure that the surface is completely free of old gasket ma terial and install the new gaskets NOTE Thetwo window gaskets are
168. le relays provide the microprocessor with a means for switching the unit components to achieve a desired operating mode The control box includes manual switches microprocessor fuses and associated wiring Also the unit can be equipped with an optional remote light bar which mounts separately and can be seen in the mirror from the cab of a truck or on the front of a rail car Standard equipment includes an auto start stop feature This feature provides automatic cycling of the diesel engine which in turn offers an energy efficient alternative to continuous operation of the engine with control of temperature by alternate cooling and heating of the supply air evaporator outlet air 62 10450 2 5 1 Special Features The following special features are incorporated into the Carrier Transicold Advance Microprocessor MessageCenter which clearly displays all information in LCD form Unit Operation and Alarms are displayed in English or codes e UltraFresh 2 e Large LCD display Unit Data and Functional Parameters Programmable Maintenance hourmeters Hourmeters are resettable from the keypad Bright LED alarm light Bright LED mode lights Fully automated Pretrip Auto Start Stop e Automatic Engine Starting Manual engine starting exists in units built before April 2007 Functional Parameter locks e communication link to transmit unit operational data to a remote computer Refer to Section
169. less than 6 0V but greater than or equal to 1 0V It will be off when the battery voltage is less than 1 0V Comm Communication LED The Communication LED will normally be off Two to three blinks per minute indicates DataLink is communicating with micro Ifthe LED comes on steady for 5 6 seconds there is no communications between DataLink and micro Stat Status Power LED The Status Power LED indicates if the DataLink is powered up The LED will be off when power is off or the DataLink is a sleep mode running off the battery The LED will pulse at a rate of 1 second on 1 second off 2 25 2 6 5 Message Trip Comment DataLink has the capability to allow the user to enter comments directly into DataLink The comments havea maximum length of 78 characters Only one comment can be recorded per day In the event that multiple comments are entered only the last will be saved 2 6 6 DataLink Communications a DataLink Retrieval Interrogation Data retrieval from the DataLink can be accomplished with an IBM or Windows compatible computer connected using a Carrier Transicold Download cable P N 22 01737 00 and software program The DataLink Toolbox software DOS program for a computer is supplied on a 3 5 inch floppy disk This software allows downloading screen view of the data and printing The ReeferManager for Windows PC Software Program can also be used to download data 62 10450 B
170. libration will not be performed if the run relay is energized This prevents the operator from calibrating theunit with the sensor in the system The reading ofthe sensor must be at atmospheric pressure 0 psig Bari If the sensor reading is greater than 20 psig 1 36 Bar or less than 13 6inHg it can not be calibrated Once the micro is calibrated the display will readout the actual value 1 Turn power off and remove starter solenoid wire then turn unit back on and let unit fail to start This will de energize run relay 2 Connect wiring to new suction pressure transducer Before installing suction pressure transducer into compressor display the suction pressure via the unit status display While the suction pressure is being displayed press ENTER key for 3 seconds the dis play should read 0 If display reads 0 install suc tion pressure transducer into compressor NOTE If display doesn t indicate zero check suction pressure transducer and micro wiring 2 Install new suction pressure transducer and recon nect starter wire 6 35 UNIDRIVE TORQUE REQUIREMENTS See Figure 6 35 Extensive damage may occur if the proper hardware and procedures are not followed Periodic inspection of hardware and bolt torque is recommended to insure the integrity of the unidrive NOTE Thread locking sealant 3 8 flat washer and 3 8 lock washer must be used on bolts between the compressor mounting flange and the engine bellhou
171. ly true of the integrated circuits found on the truck trailer microprocessor Auto Start Your refrigeration unit is equipped with Auto Start in both Start Stop and Continuous Run modes The unit may start at any time when the Start Run Off Switch SROS is in the Start Run position A buzzer will sound for 5 seconds before the unit is started When performing any check of the refrigeration unit e g checking the belts checking the oil make certain that the SROS is in the OFF position 1 1 Engine Coolant The engine is equipped with a pressurized cooling system Under normal operating conditions the coolant in the engine and radiator is under high pressure and is very hot Contact with hot coolant can cause severe burns Do not remove the cap from a hot radiator If the cap must be removed do so very slowly in order to release the pressure without spray Refrigerants The refrigerant contained in the refrigeration system of your unit can cause frostbite severe burns or blindness when in direct contact with the skin or eyes For this reason and because of legislation regarding the handling of refrigerants during system service we recommend that whenever your unit requires service of the refrigeration system you contact your nearest Carrier Transicold authorized repair facility for service Battery This unit is equipped with a lead acid type battery The battery normally vents small amounts of flammable hydrogen gas
172. matic Defrost severega ai a X RANG RA Re 3 9 3 8 FUNCTIONAL PARAMETERS 3 10 20 UNIT DATA n ccm 3 13 3 10 ALARM DISPLAY AND RESET 3 16 S TOPPINGUNLT CER E Saw DOE heated ETT 3 20 ENGINE AND TEMPERATURE CONTROL 4 1 4 1 AUTO START STOP OPERATION ine dane wale ba 4 1 4 1 1 Start Stop Continuous 4 1 4 1 2 Auto Mode Indicator 4 1 4 1 3 Auto Start rr emt boc ae be 4 1 4 1 4 Auto Start Sequence 2 4 1 4 1 5 Variable Glow TIme nb roni nir A c 4 2 41 6 Minimum Orn TImTIe onere roe etn Fe a eere ORC Fa CR d 4 2 471 7 Minim rmrOffs Time gage deeded see eerie Rede p RA ed eT qu a 4 2 4 1 8 Battery Voltage Paw dee ele Saw eae adele ed Maw ened eee ex eae 4 2 4 1 9 Oil Pressure Signal 4 2 4 110 Maximum OTf TiTie denen ava 4 2 4 2 TEMPERATURE CONTROL cc eed Hiei ar eet lees
173. mon OFF For future use Do nottumon OFF For future use Do nottumon CNFaz OFF Forfuture use Domoumon 62 10450 6 48 Change 11 2008 6 33 SENSOR CHECKOUT An accurate ohmmeter must be used to check resis tance values shown in Table 6 2 Dueto variations and inaccuracies in ohmmeters ther mometers or other test equipment a reading within 2 ofthe chart value would indicate a good sensor If a sen Sor is bad the resistance reading will usually be much higher or lower than the resistance values given in Table 6 2 At least one lead from the sensor RAS terminals D1 and E1 or SAS terminals D2 and E2 must be discon nected from the unit electrical system before any read ing is taken Not doing so will result in a false reading Two preferred methods of determining the actual test temperature at the sensor is an ice bath at 32 F 0 C or a calibrated temperature tester Table 6 2 Sensor Resistance ATS CDT RAS SAS amp WTS ATS RAS SAS amp CDT WTS Resistance Resistance In Ohms In Ohms c 1 653 000 1 178 000 865 000 624 000 463 000 345 000 0 32700 327000 262 000 199 000 153 000 179 000 9 9s 100 000 93 000 73 000 58 000 47 000 38 000 9 150 6 800 3 010 1 860 EA 0 80 90 Change 11 2008 6 49 6 34 SUCTION PRESSURE TRANSDUCER Before installing a new suction pressure transducer it must be calibrated The ca
174. move the plastic cover Permanent dam age to the microprocessor will result a Beforeremovingthe microprocessor turn the SROS to the OFF position and disconnect the negative battery cable Attach a grounded wrist strap CTD P N 07 00304 00 to your wrist and ground it to a good unit frame ground b Open the roadside side door of the unit and loosen the 4 bolts holding the cover display assembly onto the front of the control box Remove the cover and hang it below the control box by its tethers c Remove the wires connected to the SROS Unplug the 2 ribbon cables from the micro but leave them connected to the relay board and display NOTE Microprocessors mounted on the floor of the control box will have a plastic cover over the board Vertically mounted micros do not require a plastic cover Install the correct micro for the unit d Loosen the 5 hex head screws securing the logic board The front 2 screws hold the cover amp display assembly tethers so make sure the cover is secured before removing screws e Remove the front 2 screws and unhook tethers from standoffs Place display to one side f Lift the logic board and pull forward The rear of the logic board will unhook from the standoff pins Lift and remove the board from the control box g Take the new logic board from the anti static bag and install in the control box following steps b to f in reverse order NOTE Logic board is secured at re
175. mum and maximum setpoint to be entered so that only setpoints within that range may be selected Refer to Section 6 32 for more de tailed information on selecting configurations START STOP IAS F IN RANGE HI AIR BOX TEMPERATURE AUTO 5 5 CONTINUOU Press ENTER key when desired setpoint is displayed to lock in new setpoint M NUAL New setpoint will flash and then return to original setpoint if ENTER key is not pressed The setpoint may be changed up or down in whole numbers until the desired setpoint is displayed The display will flash to indicate that the setpoint reading being displayed is a non entered value Each time the UP DOWN Arrow key is pressed the 5 second display timer will be reset Pressing the ENTER key will cause the new displayed setpoint value to become active If the display is flashing and the new value is not entered after 5 seconds of no keyboard activity the display will revert back to the active setpoint NOTE Beginning with software Rev 3 29 changing setpoint from the keypad can be locked out by setting CNF23 to ON Refer to Section 6 32 3 5 62 10450 3 5 START STOP OPERATION START STOP o FAULT STAND BY START STOP 200 4945 SETPOINT BOX TEMPERATURE t 5 UNIT PRETRIP DATA CHECK AUTO S S CONTINUOU MANUAL DEFROST 1 Press the AUTO S S CONTINUOUS toggle key until START STOP is displayed Unit is now in Automatic Start
176. n wo YES YES Are there any alarms Did disconnecting the shutdown in the micro Does the micro options allow the unit to operate power up Repair alarm per this manual Note An oil pressure xm YES NO switch stuck closed can generate an ALT AUX YES alarm Output at the alternator prior to start up can Go to Cond 1 generate an ENG OIL alarm Diagnose fault and re Table pair as required Did you find and correct the condi tion Disconnect shutdown op tions and or telematics sys tem and install J1 jumper Fault is with one of the unit shut down options and or telematics system Diagnose shutdown op tion and repair as required NO Check the F11 amp F12 10 fuses on micro Is a fuse blown Replace the fuse Check No alternat Does the engine starter engage HUP Da and turn the engine over System 0 VDC output I g OK If unit has Manual Glow 12 VDC Remove new alternator and rein Crank Switch try cranking stall old one Alternator is not the the engine Does the en fault Review results with super gine crank visor If necessary go to the be Remove J1 jumper Did you find and cor the tabl d test NO rect the condition Bud S URBS ioi dene andreinstalls
177. n engine adapter Jack adapter from engine flywheel Remove the 2 screws from adapter Insert a pry bar between engine flywheel and adapter Figure 6 16A and slide the adapter sheave toward the compressor enough to change the V belt as shown in Figure 6 16B Re place V belt FLYWHEEL ATTACHING SCREWS Figure A MATCH MARK 5 Pry the adapter back toward the engine flywheel until the bolts will start in the engine flywheel Apply thread sealer Loctite 4262 to the bolts used to secure adapter to flywheel Tighten all bolts evenly and then torque to a value of 28 ft Ib 38 Nm Place V belt on the Gearbox sheave and adjust belt tension as indicated in Table 6 1 Install V belt guard DO NOT START UNIT UNTIL V BELT GUARD IS INSTALLED Reconnect negative battery cable Start unit and run for 15 minutes to allow for belt stretch Turn off unit and then disconnect battery cable Re move belt guard and belt and recheck belt tension Install belt guard NEW BELT ADAPTER FLYWHEEL SLIDE ADAPTER Figure B Figure 6 16 Removing V Belt from Engine Adapter Drive Sheave 62 10450 Change 11 2008 6 12 FANSHAFT ASSEMBLY SEE Figure 6 18 WARNING Beware of V belts and belt driven nents as the unit may start automatically Before servicing unit make sure the Run Stop switch is in the ST
178. n line d Pivot alternator to place tension on belt using hand force only Do not use pry bar or excessive force as it may cause bearing failure For correct belt tension see Table 6 1 Tighten pivot and adjustment bolts e Reinstall negative battery cable Table 6 1 Belt Tension See Figure 6 14 Replacement Belt Replacement Belt Tension After 15 Minutes of BELTS Initial Tension unning Time Lbs Mkg R Us Mg Water Pump Alternator Crankshaft 45 to 55 6 2to 7 6 45 to 55 6 2 to 7 6 bs Gearbox to Fan shaft 70 to 80 9 7 to 11 1 40 Engine to Gearbox 70 to 80 9 7 to 11 1 6 13 62 10450 Gearbox to Fan Shaft Belt Note For units with intake resonator 1 Loosen the pivot bolt 2 Using 1 2 ratchet rotate idler until appropriate tension is obtained 3 Torque pivot bolt to correct tension Upper Belt Idler Gearbox to Fanshaft Torque to 80 ft lbs 108 4 Nm Pivot Bolt Gearbox to Fanshaft Belt Upper Belt Torque Pivot Bolt to 80 ft lbs 108 4 Nm Engine to Gearbox Belt Lower Belt Alternator Lower Belt Idler Engine to Gear box Torque Adjusting Bolt to 15 to 16 ft lbs 20 3 to 21 7 Nm Water Pump Alternator Crank shaft Belt Figure 6 14 V Belt Arrangement 62 10450 6 14 6 11 3 Gearbox Fanshaft And Engine Gearbox a V Belts Gearbox to Fanshaft V Belt Upper Belt 4 WARNING Keep hands and arms away from unit when
179. n top of pistons Compressor not turning freely Starter motor cranks No fuel in tank but engine fails to start Air in fuel system Water in fuel system Drain Sump Plugged fuel filters Replace Plugged fuel lines to injector s Check Fuel control operation erratic Engine Manual Glow plug s defective 6 10 7 Fuel solenoid defective Engine Manual Fuel pump FP malfunction Restricted air filter Problem with ENSCU system Fuel pump screen plugged Starter cranks engages Engine lube oil too heavy but dies after a few seconds Loose connection at battery Poor corroded battery cable ends Compressor not turning freely 5 1 62 10450 INDICATION REFERENCE TROUBLE POSSIBLE CAUSES SECTION 5 1 2 Engine Starts Then Stops Engine stops after several rotations Starter motor will not crank or turns slowly 5 1 3 Starter Motor Malfunction Starter motor turns but pinion does not engage Starter motor does not disengage Glow Crank switch defective If equipped after switch was released Starter motor solenoid defective Pinion does not disengage Defective starter after engine is running Fuel supply restricted No fuel in tank Leak in fuel system Faulty fuel control operation Fuel filter restricted Injector nozzle s defective Injection pump defective Air cleaner or hose restricted Safety device open Check alarms Stop Fuel solenoid defective Fuel pump FP malfunction Problem with ENSCU system Air in fuel system Batt
180. nd the alternator auxiliary has failed For the second and third start attempts the glow time is increased by 5 seconds over the glow time of the first attempt listed below The control allows three consecutive start attempts before the starting is locked out and the start failure alarm is ac tivated REPEAT A 5 Seconds GLOW THIRD ATTEMPT 15 Seconds STOP REPEAT 5 Seconds GLOW SECOND ATTEMPT MAXIMUM 0 Seconds engine temp above 32 F 0 C 15 Seconds STOP FIRST ATTEMPT A VARIABLE 0 to 30 SECONDS GLOW Figure 4 1 Auto Start Sequence NOTE When engine coolant temperature is below 32 F 0 C 62 10450 4 1 5 Variable Glow Time The glow time for the first start attempt will vary in dura tion based on engine coolant temperature and the en gine as follows Table 4 1 Auto Start Glow Time Glow Time in Engine Coolant Temperature Seconds TV F o 10 51 F to 77 F 11 C to 25 Greater than 78 F 26 C The second and third start attempts have a glow time that is 5 seconds greater than the table amount The glow time can be manually overridden through the func tion parameters If the coolant temperature sensor is de fective the control assume a temperature of less than 32 F 0 C for the glow timing 4 1 6 Minimum On Time The on time is 4 or 7 minutes Refer to Section 3 8 1 After the minimum on time the unit will go
181. necessary a Remove rubber check valves Kazoo from drain lines front of refrigerated compartment Remove evaporator bulkhead and back panel then spray coil with a mild detergent solution such as Oakite 164 or any good commercial grade automatic dish washer detergent such as Electrosol or Cascade and let the solution stand for a few minutes and re verse flush opposite normal air flow with clean water at mild pressure A garden hose with spray nozzle is usually sufficient Make sure drain lines are clean Replace evaporator back panel and run unit until de frost mode can be initiated to check for proper drain ing from drain pan Refer to Section 2 b Change 11 2008 6 41 6 30 CONDENSER COIL CLEANING WARNING Personal protection equipment must be utilized when performing coil cleaning Remove all foreign material from the condenser coil by re versing the normal air flow Air is pulled in through the front and discharges over the engine Use an FDA approved cleaning agent whenever possible Com pressed air or water may be used as a cleaning agent It may be necessary to use warm water mixed with any good commercial dishwasher detergent Rinse coil with fresh water if a detergent is used 62 10450 6 31 MICROPROCESSOR CONTROLLER NOTE The erasable programmable read only memory EEPROM chip component on the microprocessor logic board has a label on it listing the revision level of the software
182. ng bolt and lockout on the bracket 6 10 4 Electronic Speed Control ESC Units begin ning with below serial numbers and ALL X2 units Extra KAV90912317 Ultra KAV90910499 Refer to Section 7 for schematic wiring diagram Refer to Section 5 4 for ESC diagnostic alarms and diagnostic trees Figure 6 9 Electronic Speed Control Components Engines with electronic speed control have no speed or fuel solenoids Engine speed is controlled by way of three components the engine speed control unit EN SCU the fuel and speed actuator FSA and the engine speed sensor ENSSN The FSA performs the same function as the solenoids The ENSSN performs the same function as the RPM sensor 62 10450 The ENSCU is mounted on the roadside frame behind the upper door It provides the RPM signal to the micro processor The unit has an alarm LED incorporated within it which is used to diagnose failures within the ESC system Figure 6 10 Frame Mounted Engine Speed Con trol Unit ENSCU The FSA combines the fuel shutoff solenoid and speed control solenoid into one component Engine speed is controlled by varying rod position The ENSSN provides the RPM signal to the ENSCU for speed control 6 10 5 Engine Air Cleaner a Inspection The air cleaner should be inspected regularly for leaks A damaged air cleaner or hose can seriously affect the performance and life ofthe engine The air cleaner is de signed to effectively
183. ngine starts After that time the UR will be de energized and loaded regard less of suction pressure For ambient air temperatures below 110 F 43 the Rear Unloader UR will be de energized regardless of suction pressure while the engine is running High Box Temperature Pulldown Logic NOTE XT and X2 model units REV 3 25 and higher with CNF 19 ON use the suction pressure loading amp unloading chart See Figure 4 2 but also use the following overrides during unit op eration Whenthe unit is running in High Speed 4 Cylinder Cool operation and the suction pressure drops to 10 PSIG 0 68 Bar above the normal cut in point for UF See Figure 4 2 the front unloader is loaded for 15 seconds If the suction pressure drops below the cut in point the front unloader will remain loaded Ifthe suction pressure remains above the cut in point the front unloader will unload after the 15 seconds This cycle will repeat every 2 minutes until either the suction pressure is low enough to load the front unloader or the cycle repeats 10 times Should the front unloader not remain loaded after 10 attempts the cycle will be extended to 30 min ute intervals When the unit is running in High Speed 4 Cylinder Cool operation and the suction pressure drops to 10 PSIG 0 68 Bar above the normal cut in point for UF See Figure 4 2 the front unloader is loaded for 15 seconds If the suction pressure drops below the cut in point the fro
184. nit off and unscrew Dipstick cap dipstick Wipe the dip stick clean and insert the cap into the oil fill tube without threading it into the oil fill tube Remove the dipstick again and check oil level DO NOT add oil ifthe level is in the safe range If needed add oil as indicated by markings on dipstick until level is in the safe range SAFE 2 To Change Engine Oil and Filters After warming up the engine stop engine remove drain plug from oil reservoir and drain engine lube oil Lightly oil gasket on filter before installing Tighten per the filter manufacturer s directions 44 CAUTION When changing oil filters the new filters should be primed with clean oil If the filters are not primed the engine may operate fora period with no oil supplied to the bearings Replace filter s and add lube oil Refer to Section 2 8 Warm up engine and check for leaks 62 10450 6 10 a LUBE OIL amp FUEL FLOW DIAGRAMS Fuel Tank 7 Fuel Bleed Valve Fuel Supply Line 8 Injection Pump Electric Fuel Pump 9 Injector Nozzles Optional 10 Fuel Leak off Line Mechanical Lift Pump 11 Fuel Return Line Fuel Filter Fuel Warmer Optional Figure 6 6 Fuel System Diagram Engine Block Oil Pan Full Flow Oil Filter Bypass Oil Filter Optional Engine Oil Connection Oil Pressure Switch Figure 6 7 Lube Cil Flow Diagram 6 10 3 Servicing the Speed Control Solenoid and Linkage Non ESC eng
185. nloaded 2 2 11 Figure 2 11 Compressor Cylinder Head Loaded 2 12 Figure 2 12 Control Box Short Box Shown 2 15 Figure 2 13 Control Short Box 2 16 Figure 2 14 Control Box Redesigned Tall Box 2 17 Figure 2 15 Logic Board eeni eee ER RO Le el ee ee Le cee PEE ee eA A 2 18 Figure 2 16 Display and 2 19 Figure 221 7 Eight Bar Stee ote UR e Dee ee eda ae ae 2 22 Figure 2 18 Datalink Module lew ele ER acer 2 24 Figure 2 19 DataLink Electrical Schematic 2 26 Figure 2 20 R 404A Refrigerant Circuit Cooling 2 31 Figure 2 21 R 404A Refrigerant Circuit Heating and Defrosting 2 32 Figure 4 1 Auto Start Sequence 4 1 Figure 4 2 SUCTION PRESSURE UNLOADING 4 8 Figure 4 3 UltraFresh Perishable Setpoint Continuous Run Temperature Control 4 9 Figure 4 4 UltraFreeze Start Sto
186. nsducer and the wiring to the high pressure cutout switches HP 1 and HP 2 Identify wiring and switches if necessary See Figure 6 21 l Remove 10 bolts from the engine compressor spacer m Disconnect ground strap from frame n Disconnect suction pressure transducer from com pressor Attach sling or other device to the compressor p Slide compressor enough to clear bell housing of en gine and remove compressor from unit q Once compressor is on table inspect the nylon drive assembly for wear sharp edges Replace if needed See Figure 6 20 Drain from defective compressor before shipping s The original unloader valves must be transferred to the replacement compressor The plug arrangement removed fromthe replacementis installed in the origi nal compressor as a Seal If piston is stuck it may be extracted by threading socket head cap screw into top of piston A small teflon seat ring at bottom of pis ton must be removed t Remove the complete high pressure switch assembly HP 1 and HP 2 See Figure 6 21 and install on new compressor after checking switch settings Remove compressor discharge temperature sensor CDT and install on new compressor Swap the brackets from the old compressor to the new one as needed Use new locknuts v Install compressor in unit by reversing steps 6 18 c through n See Figure 6 35 for torque values Install new gaskets on service valves and tighten bolts un
187. nt unloader will remain loaded Ifthe suction pressure remains above the cut in point the front unloader will unload after the 15 seconds This cycle will repeat every 2 minutes until either the suction pressure is low enough to load the front unloader or the cycle repeats 10 times Should the front unloader not remain loaded after 10 attempts the cycle will be extended to 30 min ute intervals a At ambient temperatures of 90 F 32 2 C or below NOTE The following information applies to all units However the UR and UF in XT and X2 model will operate with the overrides described earlier with a higher priority than this logic When the system is operating at high speed and the suction pressure is greater than 64 PSIG 4 3 Bar both unloader banks are unloaded As the suction pressure drops below 64 PSIG 4 3 Bar rear bank is loaded If the suction pressure drops below 33 PSIG 2 2 Bar the front bank is loaded When the system is operating at low speed and the suc tion pressure is greater than 65 PSIG 4 4 Bar both un loader banks are unloaded As the suction pressure drops below 64 PSIG 4 3 Bar rear bank is loaded If the suction pressure drops below 35 PSIG 2 4 Bar the front bank is loaded b At ambient temperatures of 90 F 32 2 C or higher At ambient temperatures of 90 F 32 2 or higher the unloading suction pressure settings relative to ambient temperatures are a straight line Refer to chart belo
188. o remove only approx 77 83 of refrigerant by this method NOTES 1 It is good practice to place a USED RE FRIGERANT tag on cylinder 2 Install a drier in the charging line when re charging this refrigerant into the system if there is the slightest possibility that mois ture had entered the system 62 10450 6 14 PUMPING DOWN THE UNIT OR REMOVING REFRIGERANT CHARGE NOTE To avoid damage to the earth s ozone layer use arefrigerant recovery system whenever remov ing refrigerant When working with refrigerants you must comply with all local government envi ronmental laws U S A EPA section 608 Whenever the system is opened it must be evacuated and dehydrated Refer to Section 6 16 6 14 1 Pumping Down The Unit In order to service the components downstream of the king valve and back to the compressor the unit can be pumped down in the standard manner a Backseat suction and discharge service valves turn counterclockwise to close off gauge connection and attach manifold gauges to service valves Open valves two turns clockwise Purge manifold gauge lines Frontseat the receiver manual shut off valve king valve by turning clockwise Start unit and run in cool ing mode Place the Run Stop switch in the STOP position when compressor suction pressure ap proaches 1 PSIG 0 07 Bar CAUTION Do not allow suction pressure to go below 0 Psig Bar If the compressor does not
189. o signal from ENSSN for 2 seconds after RPM Two Long One ENSSN or wiring problem is greater than 1 000 RPM for 10 seconds OR for 5 seconds while engine cranking no voltage at pin 18 of ENSCU Actuator FSA wiring disconnected or open cir Te aug eR FSA or wiring problem cuit Coil Resistance Spec 2 8 ohm 10 ENSCU supply voltage is greater than 26V To Lang Senn ENSCU or alternator problem 5 9 62 10450 START HERE Start unit NOTE Ensure the run relay is energized during test With ENSSN unplugged during testing unit will stall amp go through start sequence again Unit will not start This is normal Verify there is at least 11 VDC going into the ENSSN 12V terminal NO Y Check for high resistance or an open between ENSCU terminal 25 amp ENSSN 12V YES gt terminal Did you find and correct the condition Using strobe light 07 00177 01 or equivalent check engine RPM Is RPM equal to or over 2 530 Check for high resistance or an open in the ENSSNG ground circuit Did you find and correct the condition Check high speed mechanical stop on injection pump assembly for loose screws or tampering Are the screws loose Remove new ENSCU and re install old ENSCU back into unit ENSCU is not the fault Review results of above tests with your i Using
190. old without shutoff valves but with valve pads The valve pads should be installed on the re moved compressor prior to return shipping Customer should retain the original capacity control valves for use on replacement compres sor Check oil level in service replacement com pressor Refer to Sections 2 11 and 6 19 If compressor is inoperative and unit still has refrigerant pressure frontseat suction and discharge service valves to trap most of the refrigerant in the unit If compressor runs pump down the unit Refer to Sec tion 6 13 11 If compressor does not operate frontseat both suction and discharge service valves and remove refrigerant charge from compressor Refer to Section 6 13 9 Disconnect the negative battery cable b Slowly release compressor pressure to a recovery system c Verify that all refrigerant has been pumped from com pressor 62 10450 6 30 d Remove the two rear compressor bracket mounting bolts compressor shockmount end e Block up engine f Remove bolts from suction and discharge service valve flanges g Remove oil filter and bracket from O5G compressor where applicable h Loosen lower belt idler and remove belt from gearbox i Remove the 6 bolts that secure the engine drive sheave adapter j Slide the engine drive adapter from the engine Disconnect wiring to unloader valve assemblies compressor discharge temperature sensor CDT suction pressure tra
191. ompressor Unloader Valve Operation Un its With Individual Wires Connected To The Unloaders a With the unit still running in High Speed Cool remove b Using a jumper wire attached to the positive starter or the white positive wire from the unloader coil s Note the suction pressure battery post apply 12 VDC to the front unloader coil terminal The suction pressure should rise noticeably approx 5 10 psig 0 34 0 68 Bar NOTE If no change in suction pressure occurs check the unloader coil ground connection and the coil resistance before making any repairs to the un loader solenoid valve Remove the jumper wire and the suction pressure should drop Repeat steps c amp d to cycle the unloader 3 4 times to verify consistent operation Repeat steps b to e to check the rear unloader See Sections 6 20 2 and 6 20 3 for unloader repair h Reconnect the unloader wires Leave the unit running in High Speed Cool 6 13 3 Compressor Unloader Valve Operation Un its With Unloaders Plugged Into the Wiring Harness With the unit still running in High Speed Cool unplug the unloader coil s from the wire harness Note the suction pressure c Plug the front unloader wires into the coil tester 62 10450 Connect the black test lead to a good ground negat ive connection Momentarily connect the white test lead to the posit ive starter or batt
192. on e Printed in U S A 0308 Carrier A United Technologies Company Carrier Transicold Division Carrier Corporation Truck Trailer Products Group P O Box 4805 Syracuse 13221 0 5 www carrier transicold com
193. operating without belt guard in place Nev er release a unit for service without the belt guard securely tightened in place Disconnect negative battery cable and remove V belt guard DO NOT START UNIT UNTIL V BELT GUARD IS INSTALLED Loosen idler pulley Remove old belt and replace with new belt NOTE Belt tension should be measured at the center of the belt Using a belt tension gauge Figure 6 13 on the belt rotate idler pulley so that the gauge reads the correct tension Refer to Table 6 1 Torque idler retaining bolt See Figure 6 14 NOTE Both belts must be checked and re tensioned after a brief run in period See step 7 Reconnect negative battery cable and install belt guard and operate unit in high speed for 15 minutes Remove guard and disconnect battery Repeat steps 5 and 6 Replace belt guard Reconnect battery cable Change 11 2008 Place gauge here Gearbox to Fanshaft Idler Bolt Figure 6 15 Gauge Placement 62 10450 b Engine To Gearbox V Belt Lower Belt Match mark adapter to engine flywheel Disconnect negative battery cable and remove V belt guard and then loosen idler bolt See Figure 6 164 for ease of assembly Remove six bolts M8 x 1 25 x 20mm 19 securing adapter drive sheave to Figure 6 16A engine flywheel Insert 2 of the six bolts M8 x 1 25 x 20mm lg into the threaded holes jacking holes provided o
194. or a shortto voltage or ground onthe ground circuit Did you find and correct the condition Repair the short to power between the SR Relay L OK and SCS Replace micro and operate system in order to verify repair Did you find and correct the condition Enter hours from old micro into new micro amp verify configurations amp T functional parameter settings No Replace the relay System OK Remove new micro and reinstall old micro Micro is not the fault Review results of above tests with your super visor If necessary go to the be ginning of table amp test again Figure 5 11 Micro Diagnostic Tree Cond 6 Unit will not run in low speed 5 21 62 10450 CONNECTION OK Are the dates for the data on the download screen Data Recorder date amp time may be set wrong Set the correct date amp time Did you find and correct the condi tion Did you have a com munication failure during a download When viewing the download in Reports a specific sensor or event does not show up in the data file Specific sensor and event data is in the data file The Reports data filter settings may be set incorrectly or specific sensors and events may not be recorded Data Recorder is not configured properly Use the Reports Data Filter pull down m
195. or air flow blocked in trailer box Check Debris shrinkwrap cardboard caught in bulkhead Clean Air chute is not in good condition or is attached incorrectly Check Replace 5 7 62 10450 INDICATION REFERENCE TROUBLE POSSIBLE CAUSES SECTION 5 3 10 Expansion Valve Malfunction Low suction pressure and or Low refrigerant charge 6 15 amp 6 17 high superheat External equalizer line plugged Clean Ice formation at valve seat 6 16 Wax oil or dirt plugging valve or orifice 6 23 Broken capillary tube on TXV Replace Power Assy failure or partial loss of element bulb charge Replace Superheat setting too high Defective TXV Replace King valve partially closed Open Filter drier is restricted 6 22 Low superheat and liquid Superheat setting too low 6 23 2 slugging in compressor External equalizer line plugged Open Ice holding valve open 6 16 Foreign material in valve Clean Pin and seat of expansion valve eroded or held open by foreign material 6 23 Heat exchanger is leaking internally Replace Fluctuating suction Improper TXV bulb location or installation 6 23 pressure Low TXV superheat setting 6 23 Incorrect TXV is installed Replace 5 3 11 Solenoid Valve Malfunction Solenoid valve does not No power to valve Check function properly Improper wiring or loose connections Check Coil defective 6 26 Valve improperly assembled 6 26 Coil or coil sleeve improperly assembled 6 26 Movement of plunger restricted due to a Corroded or worn par
196. ounded wrist strap CTD P N 07 00304 00 and ground ittoa good unit frame ground Openthe roadside side door ofthe unit and loosenthe 2 hex slotted head 1 4 20 bolts that hold the control box cover bezel assembly onto the front of the control box Lift the cover and use prop rod to hold cover up Remove the wires connected to the SROS Unplug the 14 pin cable from the display board Loosen the 4 5mm X 20mm hex head bolts that se cure the display board to the control box cover Unplug the 10 pin ribbon cable that attaches the keypad board to the display board Remove the 4 Phillips head screws that attach the display board to the keypad board and place the display board aside Remove the 11 Phillips head screws that attach the keypad and window to the bezel Gently remove the window and keypad from the bezel Discard the old keypad NOTE All gaskets must be replaced any time the keypad is removed from the bezel Keypad Installation Tall Box CAUTION a 6 43 Do not overtorque screws Remove both gaskets from the clear window Ensure that the surface is completely free of old gasket ma terial and install the new gaskets NOTE The two window gaskets are different The gas ket for the window and bezel is notched for clearance around the detents Place the clear window and new keypad on the 3 alignment pins of the bezel Loosely install the 11 Phillips head screws
197. ove retainer if equipped Lift coil from stem See Figure 6 24 b Check unloader coil resistance with an ohm meter Correct resistance should be between 7 5 and 10 5 ohms c Verify coil type voltage and frequency of old and new coil This information appears on the coil housing d Place new coil over enclosing tube and retainer and connect wiring Note When installing 1 coil make sure roll pin is fitted into stem nut and seats properly onto pin to keep it from rotat Use tool torque stem nut to 20 22 ft lbs Torque 3 Bolts to 12 16 ft Ibs 1 Coil Assembly 8 Gasket Valve Body 2 Stem Enclosing Tube 9 Pin Anti Rotation fits Assy into top of stem nut 3 Installation Removal 10 Bolts Valve Body 8 Tool 11 Washers 8 4 Spring Plunger 12 Piston use only with 5 Plunger Assembly hot gas bypass 6 O Ring unloaders 7 Valve Body Figure 6 24 Unloader Solenoid Valve Change 11 2008 6 20 3 Replacing Solenoid Valve Internal Parts See Figure 6 24 a Pump down the unit Refer to Section 6 14 Front seat both service valves to isolate the compressor b Remove coil retaining cap if equipped and coil c Remove enclosing tube assembly item 2 Figure 6 24 using installation removal tool supplied with repair kit item 3 d Check plunger for restriction due to a Corroded or worn parts 5 Foreign material lodged in valve Bent or
198. ove tests with your super visor If necessary go to the beginning of the table amp test again and re install old ENSCU back into unit ENSCU is not the fault Review results of above tests with your supervisor If necessary go to the beginning of the table amp test again Check for open or high resistance on circuit Did you find and correct the condition between FSA and ENSCU Lives NO Review results of above tests with your super visor If necessary go to the beginning of the table amp test again Figure 5 3 ESC Diagnostic Tree 2 Long 3 Short LED Code No Speed Sensor Input To ENSCU 62 10450 5 12 START HERE With the RS switch ON and the ENSCU wire 13 removed from the connector connector plugged in check voltage Replace ENSCU Did you at ENSCU terminal 13 Is Check voltage output at 22 voltage 26 VDC or higher alternator Is voltage 26 find and correct the condition NOTE With connector WDC or higher E unplugged unit will not start but will crank YES Check voltage while unit is cranking To remove gt wire from connector use a pocket screwdriver and push in the rectangular white lock Replace alternator Did you find and correct the condition Starting at terminal NO Remove new ENSCU 13 at the ENSCU and re install old check circuit for l ENSCU ba
199. ow the oil pressure to build up before the microprocessor looks at the input from this switch The switch is located on the front of the engine below the fuel solenoid b Water Temperature Sensor WTS Provides micro with engine coolant temperature information to be displayed and recorded in the DataRecorder The sensor is located on the starter side of the engine near the 4 Injector c Engine Speed Control Unit ENSCU ESC only See Figure 2 8 The ENSCU is mounted on the roadside frame behind the door provides the RPM signal to the microprocessor The unit has an alarm LED incorporated within it which is used to diagnose failures within the ESC system See Section 5 4 for information on diagnosing failures 2 9 Figure 2 8 Frame Mounted Engine Speed Control Unit ENSCU d Fuel and Speed Actuator FSA ESC only The FSA combines the fuel shutoff solenoid and speed control solenoid into one component Engine speed is controlled by varying rod position e Engine Speed Sensor ENSSN ESC only The ENSSN provides the RPM signal to the ENSCU for speed control It is located on the front of the engine in the gear case cover 2 3 2 Alternator Regulator Electrical power for the control system and for charging the battery is provided by the 12 VDC alternator a Alternator Operation 4 CAUTION Observe proper polarity when installing battery Negative battery terminal must be grounded Reverse polarity
200. ower wheel ID slightly Figure 6 18 Evaporator Blower Wheel and Nozzle Cover NOTE To aid in fan shaft alignment install two 3 8 16 x 1 1 2 studs bolts with heads cut off into the fan shaft mounting hub Once the first two fan shaft mounting bolts are loosely installed re move the studs and install bolts 6 12 4 Blower Wheel Installation a Make sure the key is properly placed in the keyway Slide blower wheel and bushing onto shaft b Loosely attach blower wheel to bushing and slide as sembly forward until blower wheel touches pod this will set approximate clearance between blower wheel and pod c Loosely attach the nozzle cover to pod with retaining bolts Install SAS and mounting clamp with at least 1 2 of sensor protruding into the nozzle Re attach the klixon 62 10450 e f d Apply pipe thread sealant to barb fitting and install into vent hole Slide hose vent onto barb fitting Apply caulk to the fan shaft seal and place on the fan shaft Place fan shaft seal ring clamp on seal and torque to 50 ft lbs 68 Nm Slowly and evenly torque blower wheel bolts to 10 11 ft lbs 14 to 15 Nm Position nozzle cover so that blower wheel is cen tered in cover opening Torque nozzle cover bolts to 20 inch Ibs 2 3 Nm Rotate blower wheel and check that clearance is approximately 1 4 Adjust nozzle cover and or blow er wheel if necessary Re install evaporator panel re attach ai
201. p And Continuous Run Temperature Control 4 10 Figure 4 5 Start Stop Perishable Temperature Control Operating Sequence During Minimum Run Time 4 11 Figure 4 6 Start Stop Perishable Temperature Control Operating Sequence After Minimum Run Time 4 11 Figure 5 1 ESC Diagnostic Tree 1 Long 1 Short LED Code Engine RPM is Over 2530 RPM 5 10 Figure 5 2 ESC Diagnostic Tree 2 Long 1 Short LED Code FSA Electrical Failure 5 11 Figure 5 3 ESC Diagnostic Tree 2 Long 3 Short LED Code No Speed Sensor Input To ENSCU 5 12 Figure 5 4 ESC Diagnostic Tree 2 Long 7 Short LED Code ENSCU voltage is over 26 VDC 5 13 Figure 5 5 Micro Diagnostic Tree Cond 1 RS Switch On Micro does not power up 5 15 Figure 5 6 Micro Diagnostic Tree Cond 2 Models with Speed Control Solenoid RS Switch On Engine does not operate 5 16 Figure 5 7 Micro Diagnostic Tree Cond 2 ESC RS Switch On Engine does not operate 5 17 Figure 5 8 Micro Diagnostic Tree Cond 3 RS Switch On Engine Operates But Not Properly 5 18 Figure 5 9 Micro Diagnostic Tree Cond 4 Models with Speed Control Solenoid RS Switch Off Engine tallS to St p ese ar ya eA 5 19 Figure 5 10 Micro Diagnostic Tree Cond 5 Models with Speed Control Solenoid Unit will not run high
202. path that was followed to determine the micro was at fault 62 10450 5 14 NOTE RS switch must be on for remainder of testing Check state of battery charge Check condition and tightness of battery cables at bat tery starter and engine block On older micros check the two small wires coming from the bat tery cable Does the micro power up NO Is the unit equipped with shutdown options and or Disconnect Shutdown SP tions and or telematics sys telematics system remote communication tem and install J1 jumper here Did disconnecting the shut down options allow the unit to operate System OK START HERE The RS Switch is ON Does the mi cro power up Check for voltage at J1 jump er terminal A Voltage should be at least 11 volts Is voltage higher than 11 volts Is there at least 11 volts at RS terminal 3 YES Replace RS switch Did you find and NO correct the Y condition Is the F9 fuse blown Is there at least 11 volts at RS terminal 2 YES NO YES Repair wiring for an open or high resistance between RS terminal 3 and J1 terminal A y YES Fault is one of the unit shutdown op tions and or telematics system Diagnose shutdown option and repair as required
203. per unit designator Degree C or Degree F i e RAS 85 0F The display range is 36 F to 158 F 38 C to 70 C in 0 5 increments Supply Air Temperature The supply air temperature is displayed with the description SAS or CD5 The data is displayed with one decimal place and the proper unit designator Degree C or Degree F i e SAS 85 0F The display range is 36 F to 158 F 38 C to 70 C in 0 5 increments This unit data will be displayed only ifthe SUP PROBE is selected in the controlling probe functional parameter If the probe is bad the display will read for the data Remote Air Temperature The remote air temperature is displayed with the description REM or CD6 The data is displayed with one decimal place and the proper unit designator Degree C or Degree F i e REM 85 0F The display range is 36 F to 158 F 38 C to 70 C IN 0 5 increments This unit data will be displayed only if the REM PROBE is selected in the controlling probe functional parameter If the probe is bad the display will read for the data Ambient Temperature The ambient temperature is displayed with the description ATS or CD7 The data is displayed with one decimal place and the proper unit designator Degree C or Degree F i e ATS 85 0F The display range is 36 F to 158 F 38 C to 70 C 0 5 increments If there is no sensor then the display will read for the data Evaporator Temperature Display The Code
204. perations such as waking up at a specified time requesting information from other modules in the unit taking readings from probes etc Program Flash Cards The program flash cards are used for installing and upgrading DataLink software 2 6 3 Functions a DataLink Power Up The DataLink may power up in any of 3 ways normal DC power by the RTC Real Time Clock because a logging interval has expired or by plugging the Carrier Transicold computer cable P N 22 01737 00 into the downloader port If the DataLink has awakened because the logging interval is up the DataLink will log the appropriate data and power off when it is through It will continue to log data for the next hour 2 minute interval setting or 8 hours all other intervals The DataLink will wake following a unit safety shut down or when the unit is switched off b DataLink Diagnostics The DataLink start up diagnostics processing will occur each time there is a power up or after a hardware reset This processing will test the DataLink hardware for roper operation If any critical test fails then the fault LED will flash the test code three times to indicate what test failed If any of these test fails the module must be replaced 62 10450 2 24 Table 2 3 DataLink Codes TEST Memory Test 1 Memory Test 2 Timer Test 1 Timer Test 2 Timer Test 3 Converter Test 1 6 Trip Start Processing For the user to initiate a Trip Start press
205. plug from the wire harness and reconnect harness to the engine oil safety switch g The unit should be OFF at the end of this step For Units With Unloaders HP 2 and SV 3 Plugged Into the Wire Harness a Unplug the wire harness from the engine oil pressure safety switch and install the bypass jumper plug in the wire harness Unplug the Front Unloader and the HP 2 switch c Unplug the wiring harness from SV 4 and install the coil tester Connect the black wire to a good ground Clip the white wire onto an insulated portion of the black wires so it does not touch any metal Re adjust set point to 20 25 F 11 to 14 C above box temperature high speed heat operation It may be oo to run the unit in COOL prior to this step 62 10450 6 24 e Start the unit Allow the unit to run 30 to 45 seconds The suction pressure should fall to approximately 0 psig and the receiver pressure near or below 200 psig 13 6 Bar Closely monitor both high pressure gauges while connected the wire to the HP 2 switch Compressor discharge pressure will begin to rise Receiver pressure should not rise When the com pressor discharge pressure reaches 390 psig 26 6 Bar shut the engine off using the engine stop lever near the injection pump The microprocessor will re main energized The compressor discharge pres sure will drop off but the receiver pressure should not ch
206. ply Air Sensor SAS Return Air Sensor RAS 8 Nozzle Cover Evaporator Coil Figure 2 7 Evaporator Section Panels and Grille Removed 2 8 2 3 CONDENSING SECTION The condensing section consists of engine compressor drive package condenser fan condenser radiator coil refrigerant controls piping wiring defrost air switch and associated components The drive equipment includes the engine clutch air cleaner muffler coolant overflow bottle and drive belts Refrigeration components mounted in the condensing section include the compressor defrost air switch filter drier and receiver 2 3 4 Engine The diesel engine drives the compressor directly through a nylon drive gear and adapter The adapter also includes a V belt sheave which drives the gearbox The condenser evaporator fan shaft is driven with a V belt from the gearbox The water pump V belt drives the alternator The engine refer to Section 2 8 gives excellent fuel economy and has easy starting characteristics It is equipped with spin on lube oil and fuel oil filters for easier filter changes Engine Transducers and Sensors Pressure Safety Switch OP This normally open switch allows the engine to operate when oil pressure is above 15 PSIG 1 02 0 2 Bars The switch will open and automatically stop the engine 5 seconds after pressure drops below 12 3 3 PSIG 0 84 Bar There is a 15 second delay after the engine starts to all
207. pre heat the combustion chamber The CRANK position of the switch is used to manually engage the engine starter Key Descriptions The keypad has 8 keys which will allow the operator to initiate various functions display operating data and change operating parameters M UP ARROW and DOWN ARROW Keys These keys alow you to change the setpoints or other displayed data of the system They also allow you to scroll through the Unit Data List Function Parameters List Alarm List etc EQUAL Key ENTER The EQUAL key is used for many things including entering a setpoint changing a Functional Parameter clearing alarms and locking the data menu MANUAL DEFROST Key DEFROST The MANUAL DEFROST key is used to initiate a defrost cycle when the proper conditions are met AUTO START STOP CONTINUOUS Key The START STOP CONTINUOUS key is used to change the operating mode from auto start continuous to auto start stop Each push of the key will alternate the operating modes The operating status will be stored in memory and will be retained through power outages The digital display will indicate when stop start is enabled Also See Section 3 5 To start the unit in manual start mode the START STOP CONTINUOUS selection must be in continuous run mode PRETRIP CHECK Key Used to initiate a pretrip given that the proper conditions are met Refer to Section 3 3 UNIT DATA Key The UNIT DATA key is us
208. pressor discharge Refer to Section 3 10 discharge temperature temperature sensor CDT Compressor Discharge microprocessor reset Temperature Alarm 2 29 62 10450 2 14 COMPONENT RESISTANCE amp CURRENT DRAW Table 2 5 Component Resistance amp Current Draw component wms 080 O Fuel solenoid 11 1 Ohms to 13 4 Ohms 0 25 to 2 0 Amps Red Black wires White Black wires Can not be accurately measured with Coil 30 0 to 40 0 Amps Commander in circuit Indicator lights 4 8 0 2 Ohms 62 10450 2 30 2 15 REFRIGERANT CIRCUIT DURING COOLING See Figure 2 20 When cooling the unit operates as a vapor compression refrigeration system The main components of the system are the 1 reciprocating compressor 2 air cooled condenser 3 expansion valve and 4 direct expansion evaporator The compressor raises the pressure and the temperature of the refrigerant and forces it into the condenser tubes The condenser fan circulates surrounding air over the outside of the condenser tubes The tubes have fins designed to improve the transfer of heat from the refrigerant gas to the air This removal of heat causes the refrigerant to liquefy thus liquid refrigerant leaves the condenser and flows through the solenoid valve SV 1 normally open andto the receiver The receiver stores the additional charge necessary for low ambient operation and for the heating and defrost modes The rece
209. probe the heat and cool 60 or 120 second suction pressure tests will be run If both probes are defective none of this logic is executed If the system transitions to heating mode not null not defrost a check that the system is heating properly will be performed This check will start five minutes after the unit transitions to Heat The system will be determined to be heating if SAS is greater than RAS 1 5 C The check will be performed as long as the system continues to operate in Heat If heating is not detected for one minute the system will shut down for 15 minutes and the SYSTEM CK alarm will be ac tivated The engine will be allowed to restart after the 15 minutes expires unless the system has failed to heat three times in which case the STARTFAIL alarm will also be activated Once three successive failures are detected the engine will not be restarted unless alarms are cleared or power is cycled on the control The SYSTEM CK alarm logic will not be active while the unitis in defrost pretrip or anytime the run relay is de energized 62 10450 3 11 STOPPING UNIT 7 FAULT STAND BY SETPOINT BOX TEMPERATURE START RUN e N N OFF 1 To stop the unit place the START RUN OFF switch tin the OFF position The diesel engine will stop and the microprocessor controller will turn off The Microprocessor Main Display and all indicator LE
210. pump down to 1 PSIG 0 07 Bar there may be a problem with the compressor reed valves or other internal compo nents See Section 6 18 Frontseat close by turning clockwise suction ser vice valve and the refrigerant will be trapped between the compressor suction service valve and the manual shut off valve king valve Check the manifold gauge pressure prior to opening the refrigeration system If the pressure rises the dis charge check valve may be leaking refrigerant back into the system Check and replace if necessary See Section 6 21 Before opening up any part of the system a slight positive pressure should be indicated on the pressure gauge When opening up the refrigerant system certain parts may frost Allow the part to warm to ambient temperature before dismantling This avoids internal condensation which puts moisture in the system After making necessary repairs leak test and evacu ate the low side of the refrigeration system Refer to Sections 6 15 and 6 16 6 Backseat manual shut off valve king valve and mid seat suction service valve 62 10450 6 26 h Start the unit in cooling and check for nonconden sibles Check the refrigerant charge Refer to Section 6 17 1 NOTE Store the refrigerant charge in an evacuated container if the system must be opened be tween the compressor discharge valve and re ceiver Whenever the system is opened it must be evacuated and d
211. r chute and bulkhead if equipped 6 12 5 Clutch Installation 44 CAUTION Do not get anti seize oil compound onto clutch contact surfaces Thoroughly clean off oil compound with contact or brake cleaner if this occurs NOTE Starting with the 50 00236 05 clutch the ori entation of the clutch coil MUST be on the bot tom Secure the harness to the lower right fan shaft mounting bolt using the cushion clamp provided Place clutch coil onto fanshaft hub with coil harness on bottom Make sure all original shims are cor rectly positioned on fanshaft pin and then slide coil onto hub so fanshaft pin fits into notch in coil NOTE The fanshaft pin is used to position the coil to properly locate the wire harness to the frame b Install rotor spacer and rotor onto the fanshaft Install the new spanner nut included in mounting ac cessory kit CTD P N 50 00236 21 Use CTD span ner socket 07 00303 02 and torque to 80 85 ft Ibs 108 to 115 Nm NOTE The spanner nut is a LEFT HAND NYLOCK THREAD NUT Slide the armature into place on the fanshaft making sure the key is in place and the keyway lines up cor rectly with the shaft key Change 11 2008 Install the new armature retaining bolt and washer Use spanner wrench P N 07 00396 01 at the 2 o clock position to hold the armature then torque the retaining bolt to 25 to 30 ft Ibs 34 to 41 Nm NOTE The armature retaining bolt is LEFT HAND THREAD BOL
212. r flow if possible Air is pulled in through the front and discharges out the top of the unit Compressed air or water may be used as a cleaning agent It may be necessary to use warm wa ter mixed with any good commercial dishwasher de tergent Rinse coil with fresh water if a detergent is used NOTE Draining the coolant from the engine petcock will leave approximately 1 quart 9 liters of coolant in the block To completely drain the coolant the lower radiator hose must be re moved o Drain coolant Install hose and fill system with clean untreated wa terto which 3 5 of an alkaline based radiator clean er is added 6 oz 151 grams to 1 gallon 3 78 liters of water OR d Close drain cock and fill system with clean untreated water to which three to five percent of an alkaline based radiator cleaner should be added six dry ounces 151 grams to one gallon 3 78 liters of wa ter e Run engine 6 to 12 hours and drain system while warm Rinse system three times after it has cooled down Refill system with water f Run engine to operating temperature Drain system again and fill with 50 50 water anti freeze mixture see Caution Note and Refer to Section 2 8 NEVER POUR COLD WATER INTO A HOT ENGINE how ever hot water can always be added to a cold engine 62 10450 6 10 2 Lube Filters To checkthe engine oil level Run the unit to bring the engine up to operating temperature Cap shut the u
213. re placed on the enclosing tube in proper sequence to avoid premature coil burnout a Replacing the Coil NOTE Coils may be replaced without removing the re frigerant or pumping the unit down 1 Unplug from wiring harness remove coil retainer and coil assembly 2 Verify coil type voltage and frequency This informa tion appears on the coil housing 3 Place new coil over enclosing tube and retainer and connect wiring b Replacing Solenoid Valve Internal Parts See Figure 6 31 Toservicethe liquid line solenoid valve SV 2 or the hot gas solenoid valve SV 4 first pump the unit down Re fer to Section 6 14 Remove and store the refrigerant charge in an eva cuated container Refer to Section 6 14 1 Remove coil retainer and coil assembly from valve Remove enclosing tube assembly and related items 2 Check for foreign material in valve body 3 Install new parts NOTE Rebuild kit P N 14 00150 51 contains both a black neoprene seal and a white teflon seal Use the one that matches seal in existing valve The valve with the teflon seal can be identified by two dimples in the housing See Figure 6 30 DIMPLES Figure 6 30 SV 2 SV 4 MARKING Change 11 2008 4 Tighten enclosing tube assembly according to the fol lowing chart and leak check the valve Refer to Sec tion 6 15 SEAL DESCRIPTION TORQUE VALUE TEFLON WHITE 250 in Ibs 28 Nm 100 in Ibs 11 Nm NEOPRENE
214. regulator Cylinder pressure is approximately 159 9 Bars 2350 PSIG Do not use oxygen in or near a refrigerant sys tem as an explosion may occur See Figure 6 29 WARNING Personal protection equipment must be utilized when performing coil cleaning CAUTION Inspect battery cables for signs of wear ab rasion or damage at every Pre Trip inspec tion and replace if necessary Also check battery cable routing to ensure that clamps are secure and that cables are not pinched or chafing against any components WARNING Keep hands and arms away from unit when operating without belt guard in place Nev er release a unit for service without the belt guard securely tightened in place WARNING Do not start unit without installing the evapo rator panels as unit damage or body harm may result WARNING Do not use a disposable refrigerant tainer to store the charge as an explosion may occur WARNING Never run unit with discharge service valve frontseated Never remove fill plug with pressure in compressor 62 10450 1 2 Observe proper polarity when installing battery negative battery terminal must be grounded Reverse polarity will destroy the rectifier diodes in alternator As a precau tionary measure disconnect positive bat tery terminal when charging battery in unit Connecting charger in reverse will destroy the rectifier diodes in alternator CAUTION Remove D
215. remain closed until the compressor discharge pressure increases to cut out setting Refer to Section 2 12 at which time switch HP 2 opens to de energize the liquid line solenoid valve SV 2 and the valve closes to stop the flow of refrigerant to the expansion valve When the compressor discharge pressure falls to cut in setting Refer to Section 2 12 pressure switch HP 2 closes and in turn energizes the normally closed liquid solenoid valve SV 2 which opens allowing refrigerant from the receiver to enter the evaporator through the expansion valve The function of the hot gas bypass line is to raise the receiver pressure when the ambient temperature is low below 17 8 C so that refrigerant flows from the receiver to the evaporator when needed Defrost Mode only 90 seconds after entering defrost suction pressure is monitored If suction pressure rises higher than 57 psig 3 9 Bar SV1 is opened for 1 second to reduce suction amp discharge pressure and the suction pressure is monitored again after 30 seconds Defrost will continue and does not terminate until the defrost termination thermostat s DTT reach termination temperature and open or the compressor discharge temperature CDT reaches 310 F 154 4 C for 1 minute 2 minutes after defrost initiation At defrost termination SV1 is first opened then SV4 is closed andthe unit shifts to low speed to engage the fan clutch The unit then exits the defrost cycle
216. remove contaminants from the air stream entering the engine An excessive accumulation ofthese contaminants in the air cleaner will impair its op eration therefore a service schedule must be set up and followed The air cleaner filter element requires re placement when dirty b Air Cleaner Service Indicator Optional An optional air cleaner indicator can be connected to the engine air intake manifold and its function is to indicate when the air cleaner requires replacing In operation When plugged air cleaner decreases intake manifold pressure to 20 500 mm WG the indicator moves to the red line The air cleaner should be replaced and the indicator reset by pressing the reset button c Service Procedure 1 Stop the engine and open roadside door 2 Release 2 clips on air cleaner housing and remove bottom cover 3 Remove filter element wipe clean inside of air clean er housing and install new filter element 4 Wipe clean inside of bottom cover and re install 5 Re secure 2 clips on air cleaner housing and close roadside door 62 10450 6 10 6 Engine Crankcase Breather The engine uses a closed type breather with the breath er line attached to the cylinder head cover See Figure 6 11 or Figure 6 12 2 Breather Cover 3 Breather Valve 4 Breather Tube 1 Cylinder Head Cover 5 Breather Oil Shield 2 Breather Cover 6 Bolt 3 Breather Element 7 Breather Assembly 4 Plate 8 O Ring Figure 6 12
217. rify there is at least 11 Check for high resistance or an Verify there is at least 11 open in the VDC going into the ENSSNG ground ENSSN 12 V terminal circuit Did you find and correct the condition Check for high resistance or an open between NO ENSCU terminal a ae Using jumper wire check for Did you find 5 VDC at ENSCU terminal and 10 Do you have 5 VDC at the condition terminal 10 VDC at ENSCU terminal 25 Replace ENSCU Did you find and correct the condition i Remove new ENSCU Check for open or high and re install old resistance on circuit ENSCU back into between ENSSN and ENSCU unit ENSCU is not Did you find and correct the condition the fault Review results of above tests with your supervisor If necessary go to the beginning of the table amp test again Replace ENSSN Did you find and correct the condition Remove new ENSSN and re install old ENSSN back into unit ENSSN is not the fault Review results of above tests with your supervisor If necessary go to the beginning of the table amp test again Figure 5 2 ESC Diagnostic Tree 2 Long 1 Short LED Code FSA Electrical Failure 5 11 62 10450 Go to Condition 2 in microprocessor diagnostic table Figure 5
218. rough the exhaust valves and the exhaust manifold If the air filter is allowed to become dirty the operation of the engine would be impaired 2 11 COMPRESSOR DATA 2 187 Tbs 6216 6 0 pints 21 05G 37 41cfm APPROVED COMPRESSOR OIL R 404A Mobil Arctic EAL 68 2 12 REFRIGERATION SYSTEM DATA Defrost Air Switch 1 40 07 inch Fusible Plug Setting 208 to 220 DAS Initiates Defrost 35 1 8 WG 97 8 to 104 4 Defrost Termination Opens 55 5 F High Pressure Switch Cutout 465 10 psig Temp DTT LOWER 12 8 2 8 C HP1 31 6 0 68 Bar FOR OLDER UNITS Closes 40 7 F Cutin 350 10 psig UPPER AND LOWER 4 4 3 9 C Es FORO 23 8 0 68 Bar Defrost Termination Opens 45 5 F Temp DTT UPPER 7 2 2 8 C OLDER UNITS ONLY Closes 30 7 1 1 3 9 C Expansion Valve Setting 8 to 10 F Refrigeration Charge Refer to Table 2 1 Superheat 4 4 to 5 6 C Gearbox Oil Mobil SHC 75 90W 1502 Setting at 0 0 44 liters 17 8 C box temper Fanshaft Oil Mobil SHC 630 3 202 0 09 ature liters Expansion Valve 55 psig ate Bar Ultra Unit Weight Approximate 1600 Ib 725 kg 60 psig 4 08 Bar Extra Fan Clutch Air Gap 0 015 to 0 150 0 38 to 3 8mm 2 13 SAFETY DEVICES System components are protected from damage is accomplished by the safety devices listed in caused by unsafe operating conditions by automatically Table 2 4 shutting
219. s box temperature battery voltage and engine coolant temperature Once the setpoint is reached the controller will shut off the diesel engine to conserve fuel The controller will not shut off the engine if the battery voltage is not sufficient to restart it The controller will restart the engine if any of the following criteria have been met temperature has moved away from setpoint by 11 F 6 1 C for setpoints in the perishable range and 11 F 6 1 C for setpoints in the frozen range DURING minimum off time temperature has moved away from setpoint by 3 6 2 0 C AFTER minimum off time for setpoints in the perishable range or 0 5 F 0 3 C for setpoints in the frozen range The battery voltage drops below 11 VDC 12 2 VDC for units with EEPROM Rev 3 25 and higher Refer to Section 3 9 1 for unit data engine coolant temperature drops below 34 F 1 C 3 2 MANUAL START GLOW AND IF EQUIPPED 1 Place START RUN OFF switch to the START RUN position If START STOP is 2 Press FUNCTION CHANGE key until AUTO OP or displayed press AUTO S S CONTINUOUS MAN OP is displayed If MAN OP appears unit is in toggle key to place unit in Continuous Run manual start mode Mode o e FAULT STAND BY BOX TEMPERATURE UNIT PRETRIP AUTO S S MANUAL DATA CHECK CONTINUOU DEFROST 3 If AUTO OP appears first press ENTER key then UP or DOWN arrow k
220. s timer will terminate the defrost cycle and allow the unit to heat or cool as needed to maintain temperature control Should the defrost cycle not complete within 45 minutes or if the external defrost signal does not clear at defrost termination the defrost cycle shall be terminated The internal timer will reset for 1 5 hours and the external defrost signal will be ignored for defrost initiation The manual defrost switch will override this mode and start a new 45 minute cycle When defrost override is active the appropriate alarm will be indicated If the run relay is de energized during defrost defrost will be terminated TIP The Manual Defrost Key can be used at any time to start a Defrost Cycle NOTE Refer to Section 4 2 2 for more detailed infor mation on Automatic Defrost 62 10450 3 8 FUNCTIONAL PARAMETERS 1 Press FUNCTION CHANGE key until Function to be changed is displayed 2 Press ENTER key STAND BY DEFROST LER 120H SETPOINT BOX TEMPE ATURE t 5 AUTO 5 5 CONTINUOU 3 Press either UP or DOWN ARROW key until desired Function setting is displayed MANUAL DEFROST NOTE Function changes will change operation of unit 4 Press the ENTER key to lock in new setting NOTE The ability to change functional parameters from the keypad can be locked out using CNF 11 Refer to Section 6 32 for more detailed information The functional parameters
221. self diagnosing test Pre Trip must be monitored by the user to verify the unit operates through all the cycles Did you find and correct the condition OK Check connections at the battery starter engine block and inside the control box Did you find and If micro was correct the condition replaced enter hours from old micro into new micro amp verify If unit is equipped with a DataLink down that configurations load DataLInk amp review unit operation amp functional Did you find and correct the condition parameter settings are correct Refer to SECTION 3 for a description of correct unit operation Did you find and correct the condition Are you sure the unit is not operating properly Operate the system Did you find and correct the condition 4 Y Remove new micro and reinstall old micro Micro is not the fault Review results of above tests with your super Replace micro and operate system in or visor If der to verify repair Did you find and cor necessary go to the beginning rect the condition of table amp test again Figure 5 8 Micro Diagnostic Tree Cond 3 RS Switch On Engine Operates But Not Properly 62 10450 5 18 START HERE The Is the unit RS switch is OFF equipped with shut Does the engine
222. sensor ATS is greater than 120 F 49 the limits are increased to 340 F 171 C for 3 minutes The fault light FL is turned on The compressor discharge temperature sensor is located in the center head of the compressor 62 10450 Discharge Temperature Sensor Alarm The compressor discharge temperature sensor alarm is displayed with the description CD SENSOR or AL13 This alarm is generated if the sensor is open or shorted If the CNF2 is setup for no discharge sensor then the high discharge temperature alarm will be disabled since the discharge temperature determines this alarm SBY Motor Not Applicable This alarm is not applicable for this unit The display is SBY MOTOR or AL 14 Fuse Alarm The fuse alarm is displayed with the description FUSE BAD or AL15 This alarm is generated when the FUSE input is sensed low The fault light FL is turned on The engine will shut down Display Alarm When no communications exist between the main board and the display board for 8 seconds the display alarm is generated and the display is DISPLAY or AL17 Maintenance Hour Meter 1 Alarm The maintenance hour meter alarm 1 is displayed with the description SERVICE 1 or AL18 This alarm is generated when the designated hour meter is greater than maintenance hour meter 1 Maintenance Hour Meter 2 Alarm The maintenance hour meter alarm 2 is displayed with the description SERVICE 2 or AL19 This alarm is generated when
223. sing The recommended sealant is Loc tite screw lock no 262 The following figures show the torque value size and grade of the hardware to be used when reassembling the unidrive assembly 6 35 1 Drive Gear See Figure 6 20 When installing a nylon drive gear always 1 Install with black dot facing steel gear attached to compressor 2 Use new bolts and locking tabs included in drive gear kit 3 Use Locktite or a similar thread locking compound on threads of drive gear bolts 4 DO NOT use never seize or any other lubricating compound on the nylon drive gear or compressor steel gear The gear must be assembled dry 5 Torque the 6 bolt nylon drive gear bolts to 30 ft Ibs 41 Nm 62 10450 3 8 24 x 1 lg Grade 8 28 ft Ibs 38 Nm 1 Bolt DA Na a 28 ft lbs 38 Nm 6 Bolts 3 8 16 x 1 Ig 28 ft lbs 8 Nm 10 Bolts cil 5 8 18 x5 90 ft lbs 122 Nm 4 Bolts Figure 6 35 Unidrive Torque Requirements Non ESC Engine 62 10450 6 50 Change 11 2008 M8 x 1 25 x 20 mm 19 6 Required 28 ft Ibs 38 Nm 3 8 16 x 1 3 4 lg Grade 5 6 Required 30 ft Ibs
224. sure 5 3 6 1 Cooling High discharge pressure Condenser coil dirty 6 30 Condenser fan defective Replace V belt broken or loose 6 11 Discharge check valve restricted or other high side restric Check amp 6 21 tion Noncondensibles in refrigeration system 6 16 Solenoid valve SV 1 malfunction 6 26 2 Refrigerant level is over full 6 13 1 Low discharge pressure Compressor valves s worn or broken 6 20 1 Low refrigerant level 6 15 amp 6 17 Solenoid valve malfunction Replace High suction pressure Compressor valves s worn or broken 6 20 1 Compressor gasket s defective Replace Solenoid or unloader valve malfunction Replace SV 4 defective 6 26 Low suction pressure Suction service valve partially closed Open King valve partially closed Open Filter drier partially plugged 6 22 Low refrigerant level 6 15 amp 6 17 Expansion valve malfunction 5 3 10 No evaporator air flow or restricted air flow 5 3 9 Excessive frost ice on coil Check Solenoid valve SV 2 defective 6 26 Clutch Failure Replace Suction and discharge Compressor valves defective 6 20 1 pressures tend to equalize Compressor drive defective Replace when unit is operating 62 10450 5 6 INDICATION TROUBLE REFERENCE POSSIBLE CAUSES SECTION 5 3 6 2 Heating High discharge pressure Low discharge pressure Low suction pressure Solenoid valves SV 1 SV 2 or SV 4 malfunction V belts broken or loose Noncondensibles in system Head pressure control switch HP 2
225. sure proper oil level 6 20 COMPRESSOR UNLOADER VALVE The compressor unloaders located on the compressor cylinder heads are controlled by relays UFR and URR and the temperature controller Refer to Section 4 5 1 6 20 1 Checkout Procedure a Connect manifold gauges to the compressor suction and discharge service valves and start unit in cooling with the set point within 1 to 2 F 0 6 to1 1 C ofthe refrigerated compartment temperature b Unplug both unloader coils The compressor should be operating with all 6 cylinders Note suction pres sure Use jumper wires connected to the unit battery to en ergize the UF front unloader Note discharge and suction pressures the suction pressure should rise approximately 3 psig 0 2 Bar and the discharge ow drop approximately 5 to 15 psig 0 35 to 1 05 ar Disconnect UF from the jumper wires so that it is de energized and note pressures Suction pressure should drop and discharge pressure should rise by the same amounts they changed in step 3 above e Repeat steps c amp d for UR rear unloader At the end of the test remove jumper wires and plug both unloaders back in to unit harness NOTE If either unloader coil energizes and the suction pressure does not change the unloader as sembly must be checked Change 11 2008 6 20 2 Unloader Coil Replacement NOTE The coil may be removed without pumping the unit down a Disconnect leads Rem
226. t should remain in Defrost for 45 minutes the Fail Safe Defrost Termination logic will stop the Defrost Cycle and put the unit into temperature control mode See sec tion 4 2 2 If the problem corrects itself thermostats opens for ex ample the unit will automatically resume its normal functions The defrost mode may be initiated by three different ways if the evaporator coil is cold enough for one of the defrost klixons DTT to be closed box temperature be low approx 40 F 4 4 C Refer to Section 2 12 These methods are 62 10450 a Defrost Timer Initiation A defrost timer initiation is a keyboard selection Refer to Section 3 8 1 The Defrost Timer runs and accumu lates time when the unit is operating and at least one of the DTTs is closed The timer does not accumulate time during defrost mode during auto start off cycles The de frost timer is reset to zero whenever a defrost cycle is ini tiated or the unit is turned off b Defrost Air Switch Initiation An external defrost signal DA may be supplied as a set of normally open switch contacts closing to initiate the defrost cycle The switch is an air pressure differential switch which measures air pressure differential across the evapora tor coil and initiates the defrost cycle when the air pres sure differential increases enough to close the DA con tacts such as would happen when excessive frost builds up on the evaporator coil surfa
227. t stop operation When in standard multi temp temperature control UltraFreeze is used to control the main compartment if it has a frozen setpoint selected UltraFreeze operates independently of the setting of CNF 15 If UltraFreeze is active the Ultra Fresh 2 unloader cool ing logic is not invoked 4 4 1 Ultra Freeze Offset In continuous run a 3 F 2 4 C offset is added which will force the unit to control to 3 F 2 4 C below set point When the unit demands high speed cool and the high speed is delayed the unit will be allowed to run 6 cyl inder low speed cool 4 4 2 Ultra Freeze Start Stop In start stop operation the unit s control will not have the 3 F offset and will control to setpoint by cycling the unit on and off according to the standard frozen mode start stop startup and shutdown logic The exception to this is when a low battery voltage or low engine coolant tem perature defeats the normal shutdown logic then the UI tra Freeze logic will control to the 3 F below setpoint off set 4 4 3 Default Mode When no controlling probe is available the unit will enter default mode for standard temperature control When in frozen range setpoint is less than or equal to 10 4 F 12 0 the unit will default to low speed loaded When in perishable range setpoint is greater than or equal to 10 4 F 12 0 the unit will shut down 4 13 4 5 OVERRIDES 4 5 1 SPEED SOLENOID OVERRIDES When the ambien
228. t temperature is 120 F 48 9 C or above the unit will operate in Low Speed only 4 5 2 UNLOADER OPERATION OVERRIDES CNF 19 Must be set to ON e When ambient temperature is below 110 F 43 3 the rear unloader UR is forced loaded for pulldown regardless of suction pressure e When ambient temperature is above 125 F 51 7 C the rear unloader UR is allowed to un load and standard unloader logic is applied e When ambient temperature is between 110 F and 125 F 43 3 C and 51 7 C the rear unloader UR will only be allowed to unload during the first 30 seconds of engine run time thereafter it will be forced loaded regardless of suction pressure 62 10450 SECTION 5 TROUBLESHOOTING CAUTION Under no circumstances should anyone attempt to service the microprocessor See Section 6 31 Should a problem develop with the microprocessor contact your nearest Carrier Transicold dealer for replacement INDICATION REFERENCE TROUBLE POSSIBLE CAUSES SECTION 5 1 DIESEL ENGINE 5 1 1 Engine Will Not Start Starter motor will not Battery insufficiently charged Check crank or low cranking speed Battery terminal post dirty or defective Check Bad electrical connections at starter Check Starter motor malfunctions 5 1 3 Starter motor solenoid defective Engine Manual Open starting circuit Incorrect grade of lubricating oil Oil pressure switch contacts closed Voltage at D with engine not running Water or oil o
229. t will operate automatically to maintain the desired temperature within very close limits The control system automatically selects high and low speed cooling or high and low speed heating as necessary to maintain the desired temperature within the trailer The refrigeration compressor used is either a 05G 37cfm or 41cfm depending on unit model see Table 2 1 above equipped with unloaders as standard equipment Unloaders are used as a compressor capacity control to unload the compressor during periods of reduced loads This provides closer temperature control reduces potential for top freezing and reduces power required to operate the compressor thus reducing fuel consumption NOTE Throughout this manual whenever the left or right hand side of the engine is referred to itis the side as viewed from the flywheel end of the engine The auto start stop operation provides automatic cycling of the diesel engine which in turn offers an energy efficient alternative to continuous operation of the engine with control of temperature by alternate cooling and heating of the supply air evaporator outlet air The auto start stop feature 15 standard equipment 8 9 10 11 13 14 King Valve Fuel Filter Hot Gas Solenoid Valve SV 4 Drain Unloader Solenoid Valve Starter Motor High Pressure Cutout Switch HP 1 Lube Oil Fill amp Dipstick and Head Pressure Control Switch HP 2 Lube Oil Filter Discharge Service Valve Oil
230. temperature control reduces potential for top freezing 62 10450 2 10 and reduces power required to operate the compressor thus reducing fuel consumption Major Working Parts e Solenoid and valve system Spring loaded piston type bypass control valve Spring loaded discharge check valve b Unloaded Operation Pressure from the discharge manifold Figure 2 10 item 15 passes through the strainer 9 and bleed orifice 8 to the back of the piston bypass valve 7 Unless bled away this pressure would tend to close the piston 6 against the piston spring 5 pressure With the solenoid valve 1 energized the solenoid valve stem 2 will open the gas bypass port 3 Refrigerant pressure will be bled to the suction manifold 10 through the opened gas bypass port A reduction in pressure on the piston bypass valve will take place because the rate of bleed through the gas bypass port is greater than the rate of bleed through the bleed orifice 8 When the pressure behind the piston has been reduced sufficiently the valve spring will force the piston bypass valve back opening the gas bypass from the discharge manifold to the suction manifold Discharge pressure in the discharge manifold will close the discharge piston check valve assembly 14 isolating the compressor discharge manifold from the individual cylinder bank manifold Theunloaded cylinder bank will continue to operate fully unloaded until the soleno
231. ter has 9 pin serial port DO NOT connectto USB port Did you find and correct the condition Try another computer or check with super visor Figure 5 12 Micro Diagnostic Tree Cond 7 Data Recorder Data Download Problems when using 62 10450 ReeferManager and a download cable 5 22 SECTION 6 SERVICE WARNING WARNING Beware of V belts and belt driven components as the unit may start automatically Before servicing unit make sure the Run Stop switch is in the STOP position Also disconnect the negative battery cable CAUTION CAUTION For units with R404A and POE the use of inert gas brazing procedures is mandatory otherwise compressor failure will occur For more information see Technical Procedure 98 50553 00 Inert Gas Brazing NOTE To avoid damage to the earth s ozone layer use a refrigerant recovery system whenever removing re frigerant When working with refrigerants you must comply with all local government environmental laws 6 1 62 10450 6 1 MAINTENANCE SCHEDULE ACTION SYSTEM OPERATION REFERENCE SECTION a Daily Maintenance Pre Trip Inspection before starting Check Engine Hours Check Engine Oil Level b Every Service Interval or Annually 1 Check unit mounting bolts 2 Check engine and compressor mount bolts 3 Check door latches amp hinges 4 Check gauges switches and electrical connections 5 Check all belt tensions 6 Check control box 7 Check gearbox
232. the UNIT DATA key to display the same data again 62 10450 3 9 1 UNIT DATA The following table has columns for Code and English displays English is the default setting Change Functional Parameter to Code to see Code display format Table 3 2 Unit Data Codes CODE 001 002 CD4 009 Codes 5 amp 6 are variable SAS is displayed when the SUP Probe Function is selected REM is dis played when the REM Probe Function is selected See Functional Parameter List in Section 3 8 1 Suction Pressure The suction pressure is displayed with the description SUCT or CD1 The data is displayed with the proper unit designator P psig or B Bars i e SUCT 25P The display is in inches of mercury for readings below 0 psig The display range is 20 HG to 420 psig 0 7 Bars to 29 4 Bars Engine Hours The number of diesel engine hours is displayed with the description ENG or CD2 The data is displayed with units designator H i e ENG 5040H OR CD2 5040H The display range is 0 to 99999 Engine Temperature The coolant temperature is displayed with the description WT or CD3 The data is displayed with the proper unit designator Degree C or Degree F i e WT 185F or 185F The display range is 58 F to 266 F 50 C to 130 C 62 10450 3 14 Return Air Temperature The return air temperature is displayed with the description RAS or CD4 The data is displayed with one decimal place and the pro
233. to 22 ft Ibs 24 to 30 Nm Condenser Fan Hub Clutch Adapter Rotor Clutch a 416 Torque 4 Bolts 10 to 11 165 14 15 Nm Retaining Bolt Torque 25 to 30 ft Ibs 34 to 41 Nm Left Hand Thread use Service Tool 07 00396 01 for anti rotation of arma ture Clutch Coil orient with harness on bot tom fanshaft pin fits into notch in coil Spanner Nut Torque 80 to 85 ft lbs 108 to 115 Nm Left Hand Thread use Service Tool 07 00303 02 Figure 6 19 Condenser Fan and Clutch 62 10450 6 20 6 13 CHECKING THE REFRIGERATION SYSTEM This refrigeration troubleshooting procedure is de signed to test the major components used in this Carrier Transicold trailer refrigeration unit This procedure de signed primarily to test the system s mechanical compo nents can also point out many electrical problems A sound knowledge of electrical and refrigeration funda mentals and Carrier Transicold heat cool and defrost cycle operations is essential to perform this procedure NOTE The following troubleshooting procedures are designed to test the major components used in trailer refrigeration units using R 404a The fol lowing rules MUST be followed to ensure accu rate results a All directions for each step must be read through and thoroughly understood by the service technician be fore beginning that step Each step
234. trol the refrigeration system It is located behind the condenser grille c Compressor Discharge Temperature Sensor Transducer CDT Provides micro with discharge temperature information to be displayed recorded in the DataRecorder and used to control the refrigeration system It is located on the center cylinder head of the compressor It will shut the unit down if center compressor head discharge temperature reaches 310 F 154 C for three minutes or 350 F 177 C If ambient temperature sensor AAT is at 120 F 49 C or higher the CDT limits are increased to 340 F 171 C for three minutes 2 4 EVAPORATOR SECTION The evaporator fits into a rectangular opening in the upper portion of the trailer or rail car front wall When installed the evaporator section is located inside this box and the condensing section is outside The evaporator assembly consists of an evaporator coil evaporator fan expansion valve two defrost thermostats termination switches The location of the thermostats is shown in Figure 2 7 The return air sensor is also shown in Figure 2 7 2 4 1 Thermal Expansion Valve The thermal expansion valve is an automatic device which controls the flow of liquid to the evaporator ac cording to changes in superheat to the refrigerant leav ing the evaporator The thermal expansion valve maintains a relatively constant degree of superheat in the gas leaving the evaporator regardless of suction pressure Th
235. ts 6 26 b Foreign material lodged in valve 6 26 c Bent or dented enclosing tube 6 26 Defective HR 1 2 3 Replace Solenoid valve closes but Foreign material lodged under seat Clean refrigerant continues to flow Defective seat Replace 5 4 Electronic Speed Control Troubleshooting Table 5 1 ENSCU LED Fault Chart See following pages for troubleshooting trees The following diagnostic tables are intended to assist technicians in diagnosing problems with Electronic Speed Control Engine Units These tables are not intended to replace a good technician s knowledge of the control and electrical systems but to supplement it It is important to verify the reported LED alarm and then correctly identify the appropriate table for that condition When using these tables do not skip any steps The tables are formatted in a logical troubleshooting sequence and skipping around the tables will most likely lead to errors in diagnosis A few testing procedures call for the use of a jumper wire This is necessary due to the tight fit of the pins when seated in the connecter Crimp female terminal CTD P N 22 50098 61A to one end of a 2 piece of wire and leave the other end of the wire bare in order to check for proper voltages and resistances as outline in the tables 62 10450 5 8 LED display pat Failed component MH 5 L 1 Engine Over Speed more than 2 530 RPM One Long One ENSSN or mechanical engine Short problem N
236. ts except XT and X2 models XT and X2 units Rev U3 3 23 amp higher 20 OFF Unlocked Note4 F C Locked CNF19 Change 11 2008 6 47 NOTES These settings are optional and can be set to cus tomer specifications or left at default values All oth er settings not marked with MUST be set as shown for proper unit operation 1 CNF1 determines the length ofthe glow cycle which varies depending on the type of engine in the unit When CNF 25 is ON the CNF1 setting is not used 2 CNF9allows selection of how the unit will reactunder an Out Of Range condition An Out Of Range condition is de scribed as the box temperature having arrived at setpoint then drifting away from setpoint With this CNF in the OFF position once the box temperature has been Out Of Range for 15 minutes the ALARM light will be turned on and the alarm display OUT RANGE will be dis played alternately with the default dis play ofthe setpoint and boxtemperature With this CNF in the ON position once the box temperature has been Out Of Range for 45 minutes the unit will shut down and the same alarms as described above will be displayed CNF3 amp CNF11 Standard Function Lock allows the Func tion Key and the Start Stop Continuous Run Key to be locked so that no changes can be made Modified Function Lock is the same as Standard Function Lock except that with the setpoint at or between 32 and
237. ttern the display could initially show the snowflake display for a few seconds and then display the same data that was being displayed at the time the unit was turned off For example if an alarm was being displayed it may be displayed again Temperature display is right justified with unused digits blank A negative sign will be displayed for all setpoint and box temperatures below zero The resolution for box temperature in both Centigrade and Fahrenheit is one tenth degree Indicator LEDs The display has two LEDs across the top to indicate operation status These indicators are Fault Indicates there is an alarm e Stand By Unit running on Stand by Not applicable for X series units 62 10450 2 20 Switch Descriptions RUN STOP RUN STOP Switch YX When placed in the RUN position this switch provides power to the microprocessor The microprocessor performs self test all OFF segments of display are illuminated Then setpoint and Box Temperature are displayed To stop the unit or remove power from the microprocessor move the run stop switch to the STOP position GLOW CRANK Switch MGC Re moved From Units Built after April 2007 The GLOW CRANK switch is located on the side of the control box CRANK GLOW IS 27 The manual glow crank switch when held in the GLOW position energizes approximately 7 5 amps per plug at 12 vdc the glow plugs in the engine to
238. us the valve has a dual function automatic expansion control and prevention of liquid return to the compressor 2 4 2 Heat Exchanger The heat exchanger is of the tube in tube type con nected in the main suction line and liquid line Within the heat exchanger the cold suction gas is used to cool the warm liquid refrigerant This results in greater system capacity and efficiency 2 4 3 Evaporator Coil The unit evaporator is a tube and fin type The operation of the compressor maintains a reduced pressure within the coil At this reduced pressure the liquid refrigerant evaporates at a temperature sufficiently low enough to absorb heat from the air Heating is accomplished by circulating hot gas directly from the compressor to the evaporator coil Solenoid valves control the refrigerant circuit to operate the heating cooling system Automatic evaporator coil defrosting is initiated by either sensing the air pressure drop across the coil with a differential air switch or with the defrost timer in the microprocessor 2 5 SYSTEM OPERATING CONTROLS AND COMPONENTS The temperature controller is a Carrier Transicold controller Refer to Sections 2 5 2 and 3 1 Once the controller is set at the desired temperature the unit will operate automatically to maintain the desired temperature within very close limits The microprocessor that is shown on the electrical schematic interfaces with unit components Plug in interchangeab
239. utput atthe alternator prior to start up can generate an i ENG OIL alarm Diagnose fault and repair as re down options and or telematics quired Did you find and correct the condition System Diagnose shutdown op Replace the relay tion and repair as required eview results o Note START FAIL alarm must be cleared to continue P YES Fault is with the unit shut above tests with diagnostic table Check for battery voltage at F11 amp 12 your supervisor If terminal B side closest to relay Do you have battery necessary go to voltage the beginning of the NO table and test again Does the engine starter engage YES Check NI turn the engine over Remove J1 jumper If unit has Manual Glow alternat Crank Switch try cranking or D Remove new alternator rein YES andreinstallshutdownoptionsand the engine Does the en output stall old one Alternator is not the or telematics system 2 fault Review results with super gine crank 12 VDC visor necessary go to the be Does the engine start amp NO NO ginning of the table and test stall after few 1 y Replace alternator again seconds System Check RS switch SSR Did you find and cor OK lay starter solenoid
240. ve HR2 will turn off 2 se conds later closing SV4 The defrost relay will de ener gize 5 seconds after HR1 to engage the clutch If the temperature control requires high speed there will be a 2 second delay after the defrost relay is de energized g High Ambient Defrost Ambient air temperature is Greater Than 80 F 26 7 C When the ambient is greater than 80 F 26 7 C the fol lowing stages are performed for defrost Refer to Table 4 3 e Stage 1 Pump Down runs for a minimum of thirty seconds and then checks the suction pressure When the suction pressure is less than 10 PSIG it will continue to stage 2 The total time in stage one cannot be greater than 330 seconds If 330 seconds is reached stage two will automatically be entered regardless of suction pressure Stage 2 is defrost HR1 will be energized to close the SV1 valve HR2 will energize to open the SV4 valve and turn off the Cool Light and turn on the Heat Light 8 light bar HR4 will energize to allow HP2 to control SV2 valve opening and closing DR is energized turn on the Defrost Light 8 light bar to de energize the clutch to stop the evaporator fan and prevent hot air circulation to the load SR will be energized to put the engine into high speed Stage 3 Defrost Termination is the termina tion of defrost Defrost will terminate when the microprocessor senses both defrost ter mination thermostats DTT s have reached termination temperature and
241. w 62 10450 R 404A REFRIGERATION SYSTEM DIESEL OPERATION SUCTION PRESSURES UNLOADING SUCTION PRES 40 SURE PSIG 80 90 100 110 120 130 AMBIENT TEMPERATURE F UF FRONT UNLOADER UR REAR UNLOADER ABOVE THE LINE UNLOADED BELOW THE LINE LOADED 62 10450 Figure 4 2 SUCTION PRESSURE UNLOADING 4 8 The following temperature control operating sequence diagrams are after pulldown and do not show rides RISING BOX High Speed TEMPERATURE 6 Cylinder Cool 3 6 F 2 0 C 3 2 1 8 Low Speed 4 Cylinder Cool 2 7 1 5 2 3 1 3 C Low Speed 6 Cylinder Cool 41 8 F 1 0 C 1 4 F 0 8 C Low Speed 2 Cylinder Null Cool Null Pulses Low Speed 2 Cylinder Null Null Heat Pulses 1 4 F 0 8 C 1 8 F 1 0 C Low Speed 4 Cylinder Heat 2 3 F 1 3 2 7 F 1 5 C Low Speed 6 Cylinder Heat 3 2 F 1 8 C 3 6 F 2 0 C High Speed FALLING BOX 6 Cylinder Heat TEMPERATURE Note The unit follows the temperature control sequence shown in this diagram AFTER pulldown The sequence does not include any speed or unloader overrides Figure 4 3 UltraFresh Il Perishable Setpoint Continuous Run Temperature Control 4 9 62 10450 RISING BOX TEMPERATURE High Low Speed 6 Cylinder Cool 0 6 F 0 3 0 2 F 0 1 Low Speed Setpoint Auto S S Control Point 6 Cylinder Cool 0 3
242. will control selected operating features of the unit These parameters can be displayed by pressing the FUNCTION CHANGE key All functional parameters are retained in memory The following sections describe the list of functions which can be modified via the keypad A description of the function will be displayed on the left side with the corresponding data on the right side The function parameter list can be scrolled through by pressing the FUNCTION CHANGE key or by using the UP DOWN Arrow keys With each FUNCTION CHANGE key push the list will be advanced one If the function key is 62 10450 pressed and held for one second the list will be advanced one item at a time This list will be circular meaning once the end ofthe list is reached the list will go to the first entry While the functional parameter is displayed the data can be changed by pressing ENTER then pressing either the UP or DOWN Arrow keys Ifthe value is changed the displayed data will then flash to indicate that the value has not been entered If the new value is not entered in 5 seconds the display will revert back to the last entered value If the ENTER key is pressed the display will stop flashing to indicate that the value has been entered The new value will continue to be display for 5 seconds before reverting back to the default display Each time a key is pressed the 5 second delay will be reset To select a different functional parameter the FUNCTION CHANGE
243. wires for open or high resistance between J1 terminal B and terminals 45 amp 59 on micro cable for loose con nections Did you find and correct the condition Remove new micro and reinstall old micro Micro is not the fault Review results of above tests with your supervisor If necessary go to the beginning of the table and test again Replace micro ribbon cable Did you find and cor rect the problem Remove new micro ribbon cable and reinstall old cable Code 1 Replace micro and operate system in order to verify re pair Do not install micro hours atthis time Did you find and correct the condition YES Remove J1 jumper and reinstall shutdown options and or telematics system Enter hours from old micro into new micro and verify configura tions amp functional parameter set tings Ribbon cable is not the fault Review results of above tests with your supervisor If ne cessary go to the beginning of the table and test again Figure 5 5 Micro Diagnostic Tree Cond 1 RS Switch On Micro does not power up 5 15 62 10450 NOTE RS switch must be on for re START HERE The RS mainder of testing Is the unit equipped switch is ON Does the en with shutdown options and or telemat YES gine run ics system remote communicatio
244. wnward direc tion d Tighten fitting on drier e Secure clamp f Check drier connections for leaks g Check refrigerant level 6 23 THERMOSTATIC EXPANSION VALVE The thermostatic expansion valve TXV is an automat ic device which maintains constant superheat of the re frigerant gas leaving the evaporator regardless of suc tion pressure The valve functions are a automatic re sponse of refrigerant flow to match the evaporator load and b prevention of liquid refrigerant entering the com pressor Unless the valve is defective it seldom requires any maintenance 6 23 1 Replacing Expansion Valve amp Screen a Pump down the unit by closing the king valve Refer to Section 6 14 b Remove insulation Presstite from expansion valve bulb and then remove bulb from suction line c Remove Presstite from the expansion valve power head d Cut TXV from system tubing close to TXV body NOTE Use a wet rag to prevent system tubing from overheating whenever brazing e Unsolder TXV stubs from piping f Inspect strainer for debris Clean if possible Replace if strainer is torn Install new strainer with cone of screen pointing into liquid line at inlet to the valve g Position new valve h Wrap valve with wet rags to keep TXV cool whenever brazing and clean all tube stubs in system tubing so new valve fits easily i Solder valve in place and cool connections with wet rag j Pressure test braze joints
245. xcept for safeties if the engine stalls Continuous Run operation is normally used for perishable loads 3 7 Start Stop and Continuous operation may be tied to the setpoint ranges for frozen and perishable loads and the START STOP CONTINUOUS key may be locked out using and CNF11 Refer to Section 6 32 The unit will remain in low speed for 5 minutes after engine start up when the Continuous Run setpoint is below 10 F 12 C 62 10450 3 7 MANUAL DEFROST DEFROST Indicator o FAULT STAND BY DEFROST 200 4345 F SETPOINT 1 Check that box temperature is 40 F 4 4 C or lower BOX TEMPERATURE MANUAL DEFROST 2 Press the MANUAL DEFROST key to initiate Manual Defrost NOTE Defrost cannot be started when the Evaporator Coil temperature is above 40 F 4 4 C The defrost mode may be initiated in three different ways if the evaporator coil is below 40 F 4 4 C 1 Defrost is initiated automatically at preset intervals by the defrost timer in the microprocessor Defrost is initiated by the defrost air switch The defrost mode may be manually initiated by pressing the Manual Defrost Key 62 10450 3 8 The defrost mode terminates when the evaporator temperature is higher than 55 F 12 8 C Should the defrost cycle not complete within 45 minutes the defrost cycle is terminated After the 45 minute termination the controller will wait 1 5 hours before attempting another
246. ximum pressure of the MOP setting of the TXV e If the suction pressure does not rise it could indicate arestricted or blocked liquid line or TXV valve Check to be sure that the SV 2 is energized and open NOTE This step does not check the superheat setting or the MOP of the expansion valve Superheat must be done separately as outlined in Section 6 23 f The unit should be OFF at the end of this step 6 13 6 HP 2 and SV 2 for Cycling During Heat and Defrost For Units With Individual Wires Connected To the Unloaders and SV 2 a Disconnect the white positive wire from the unload ers b Adjust setpoint to 77 F 25 or higher and start the unit The unit will run in low speed for 15 seconds then go into High Speed Heat It may be necessary to placethe unit in High Airflow so that the engine will run in high speed c Connect a voltmeter to the positive terminal of SV 2 refer to wiring schematic if necessary Refer to Sec tion 7 leaving all wires to both HP 2 and SV 2 con nected Observe the voltmeter and compressor dis charge gauge readings The compressor discharge pressure will rise because SV 1 should be closed with only SV 4 open When the discharge pressure rises to 300 psig 20 4 Bar the HP 2 switch contacts will open causing SV 2 to close This can be seen by the voltmeter reading dropping to O VDC and the compressor discharge pressure decreasing When the discharge pressure drops to 200 psig 13 6 B
247. y free water and formation of acids resulting in metal corrosion 6 16 2 Preparation Evacuate and dehydrate only after pressure leak test Refer to Section 6 15 b Essential tools to properly evacuate and dehydrate any system include a good vacuum pump 5 cfm 8m3H volume displacement P N 07 00176 11 and a good vacuum indicator such as a thermocouple vacuum gauge vacuum indicator P N 07 00414 00 NOTE Do not use a manifold gauge because of its in herent inaccuracy c Keep the ambient temperature above 60 F 15 6 C to speed evaporation of moisture If ambient temper ature is lower than 60 F 15 6 C ice might form be fore moisture removal is complete Heat lamps or al ternate sources of heat may be used to raise system temperature 6 16 3 Procedure for Evacuation and Dehydrating System NOTE Standard service hoses are not suitable for evacuation purposes a Remove refrigerant using a refrigerant recovery sys tem Change 11 2008 6 27 b The recommended method to evacuate dehy drate the system is to connect three evacuation hoses as shown in Figure 6 19 to the vacuum pump and refrigeration unit Also as shown connect an evacuation manifold with evacuation hoses only to the vacuum pump electronic vacuum gauge and refrigerant recovery system With the unit service valves closed back seated and the vacuum pump and electronic vacuum gauge valves open start the pump and

caution - Sunbelt Transport Refrigeration

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