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Tripac maintenence Manual

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1. a o na o 5 c3 LEGEND o CODE DISCRIPTION LOCATION m Tm NES e S p ALT ALTERNATOR 6 ml E e ses BATT BATTERY 3 O ES CFM CONDENSER FAN MOTOR 5 Ta 2 oe A CLU COMPRESSOR CLUTCH 8 mm s ree CTS COOLANT TEMP SWITCH ARCTIC OPTION 14 m 3 3 L 05 IDE 2 M EFM EVAPORATOR FAN MOTOR 6 7 E FHM ENGINE HOUR METER OPTION l ENDE n A e FI5 ESW ENGINE SWITCH 3 T FI 5 FUSE 1 5 5 8 22 7 10 e m o E F6 10 FUSE 6 10 2 10 13 14 15 eb RES SS FIL 14 FUSE 11 14 5 16 18 19 TE ES E i E Lu Oo ae 5 FI5 1 FUSE 15 17 4 6 20 Bip FI FIR FIISE 3 aja gt Beo erus d CH 18 20 FUSE 18 20 HOUR METER OPTION 7 11 19 Ta We 304 MOD 8 ee ee FMP FUEL METERING PUMP 21 S P UEL PUMP S 6 ALT FSH FUEL SOLENOID HOLD IN COIL 0 m a FSP FUEL SOLENOID PULL IN COIL 0 E HEATER FUSE FSW FLYWHEEL SENSOR 7 Z RED F4 us gt FT FREEZE THERMOSTAT 8 s 8 a a m 6P1 2 GLOW PLUG 1 2 8 9 gos S HHM HEATER HOUR METER OPTION 9 5
2. O O am lt eS 6 Eu LEGEND Re dE a CODE DISCRIPTION LOCATION MEC z ALT ALTERNATOR 6 zas gj 00 mEnE BATT BATTERY 3 Bos Ee CFM CONDENSER FAN MOTOR 5 Ag gt A CLU COMPRESSOR CLUTCH 8 al X FE CTS COOLANT TEMP SWITCH ARCTIC OPTION 14 Ea j F oc 3 Ee T Ml be CH D OIDE 2 1 i ODE 3 EFM EVAPORATOR FAN MOTOR 6 Ed 4 EHM ENGINE HOUR METER OPTION ar T ES 2 FSW ENGINE SWITCH 3 E Fi 5 FUSE 1 5 8 9 21 6 9 A F6 10 FUSE 6 10 2 10 13 14 15 T C a 5 FIl 14 FUSE 11 14 5 17 18 19 MI FI5 1T FUSE 15 17 4 5 20 cA E wn FI8 20 FUSE 18 20 HOUR METER OPTION 7 11 19 ED E ed F21 23 FUSE21 23 EXTREME ARCTIC OPTION 6 1 7 uM 5 a b HEATER FUSE FMP FUEL METERING PUMP 21 F4 FP FUEL PUMP RED FSH EL SOLENOID HOLD IN COIL 0 2 FSP FUEL SOLENOID PULL IN COIL 0 2 2 E i FSW FLYWHEEL SENSOR 1 Paice FT FREEZE THERMOSTAT 8 S GPI 2 GLOW PLUG 1 2 8 9 Eli HHM HEATER HOUR METER OPTION 9 E iij 252 8 HMI HMI CONTROLLER 2 s 2 82 528 HPCO HIGH PRESSURE CUTOUT SWITCH 8 O E HTS HEATER TEMP SENSOR 26 Q HWTS HIGH WATER TEMP SWITCH 3 E LCS INTERIOR LIGHTS CONNECTION SWITCH 1
3. REVISIONS OPTIONAL l CHANGE ORDER REV DESCRIPTION DATE APPROVED CA 512275 A RELEASED 3 09 07 J IRLBECK FROM I2VDC WHEN e E NUM 518925 B ADDED EXTREME ARCTIC PACKAGE 9 1 12 07 R RAJ TRUCK IGNITION IS ON 7 od do eu IGN E LB gt mE t MER F4 INTERIOR LIGHT STANDBY JAN oe O RED J CONNECTION SWITCH d FROM TRUCH INTERIOR ys pm 2 r ae 7 x LIGHT SOURCE DIA Me A t BEN Cr PP TO TRUCK Fig 1 INTERIOR LIGHTS lev ucc Oe ie ad a ate a e RESET SWITCH Aoo ao ay s 1 Jr Wn if 30 H OL 8x f t ENG NE HEN SB SE c RETURN TEMP Al OUR METER Dn Bride me Cd SENSOR am 2A BAD MA hn ii m E 80 ee pcp LO oc O 5 1A T 8p eo pe Hi ena Nom d PE N c m Mb apo 8D CENT Bee ep SO E BL A iS s 1370 HEATER l pec E ML ES WN Vat DE v oe t RESO ds RE aL 8L2 A d E a a A HOUR METER s UA NM M nton A i FS A 1018 SL ie 18 4 Be one tue Rr i BLK SA ds PE E CH a CH RY R p CONTROLLER CAB SECTION mE c d y FE MOJE qu al Eco X o nn M 100 ret aU LI GRY RED LI RE O Se Ola sess er NOT SAY iO ser S9 pei cd BLK Olie SR ME i ica HO TELA gr ies J i UM D O D 3 J GRM EN qu CH i S SENO sen POWER BOARD gt MY RN cid 4 NET CONTROL BOX SECTION A REEL UM M ES NN RR ER ERE RR RR RR k BATTERY SECTION P D N BAT
4. OPTIONAL A a e RU iS aM dug ee ME quf A 511264 A RELEASED 5 09 06 S WATERS FROM I2VDC WHEN NORMAL FI4 511624 B ADD HOUR METER OPTION 9 20 06 S WATERS TRUCK IGNITION IS ON 7 IGN IGN OES IGN pee SS ato Cp T HEATER PANY POA pa INTERIOR LIGHT ESTAN JAN ALO RED CONNECTION SWITCH 2 p EE FROM TRUCH INTERIOR gp AL pM 2 NOT USED O PW H n LIGHT SOURCE A e re B Peres F 18 TO TRUCK i c FBLA AR E INTERIOR LIGHTS Ar ba JO 8D M L H OF GON aA z GLOW PLUGS E po ere 7 PIMI 204 O PWM 8S OL A RO 8S 1X 5A r ICF 204 O 1CF si I START SOLENOID o mesa oo ENGINE START SIGNAL j 1CL 1 54 O TCL 10o BFET 1 5A 7 lt 0 ENG INE 809 404 O BDP roo So 1 ENGINE SWITCH IE o RETURN TEMP HOUR_METER y BELT O FET TK lt j SENSOR IN ce V HEATER TEMP PCF 10A O PCF cx 1 5 1CL 7 54 e COMPRESSOR CLUTCH E E podes M li SENSOR PCF 10A E TA s TA fo TAT CAR pp ferro BLK a I 80P 40A E BLI OP BL1 o accu UB ES Y NET HEATER 32 OL BL2 80P 404 K a o xm AN HOUR METER 1 A F20 a POPMA ol FUEL SOLENOID ji cn mg Ae RM RED LR 26 IRC BLK g m 82 Or FS 1cLB D gt L 1c18 R E sed N E pom Vau E BLK ICf 204 2 i en iB B pure j CH ev qm 8FET 7 54 CH GRY O RED PCF 10A A HMI CONTROLLER CAB SECTION n s ll a Joo mo PCF 104 0 oe PRE COO
5. Figure 63 82 7 Inspect the oil for contamination See Checking Compressor Oil for Contamination in this chapter for more information 8 Add oil as needed to the compressor See the Specifications chapter in this manual for oil amount See procedure for adding compressor oil in this manual 9 If necessary place a new Thermo King oil label on the compressor Compressor Installation Procedures Installation Precautions Thermo King replacement compressors can be shipped with one of three oil configurations PAG oil POE oil or no oil and a nitrogen holding charge If the oil in the compressor does not match your system it must be changed to the correct type for use in the TriPac system When mounting the compressor take the following precautions 1 Loosen the discharge side connector cap if equipped Slowly release the holding charge Figure 64 Loosen Caps Slowly A CAUTION Do not let oil escape 2 Rotate the armature plate several times to circulate oil that has settled in the cylinders AUA0033 Figure 65 Rotate Armature Plate 3 Verify that the compressor oil type matches the system oil type If not drain the compressor oil and replace it with the oil type in the system Installing the Compressor To install the compressor 1 Mount the compressor 2 Secure the mounting hardware Tighten adjustments as required for proper belt tension See specifications 3 Install
6. gt MLAS 5 u SN i H NA AA N Y Ps US e NES VA Y Number 1 Cylinder Fuel Injection Line Index Mark on Starter Mounting Plate Figure 33 Component Location CAUTION Loosen all of the injection lines at the injection nozzles to prevent the possibility of the engine firing while it is being rotated 1 Remove the injection line for the number 1 cylinder from the delivery valve holder on the injection pump and from the injection nozzle NOTE The number 1 cylinder is the cylinder at the flywheel end of the engine Engine Maintenance 2 Remove the delivery valve spring for the 5 Remove the Starter Fuse F1 from the number 1 cylinder by removing the delivery interface board to prevent the engine from valve holder and the delivery valve spring cranking when the unit is turned On h installing the deli l l qe pa pur ips on 6 Energize the fuel solenoid and the fuel pump y Pree ete by turning the unit On and set the TriPac HMI Remove the cylinder head cover to a setting that will cause the TriPac engine to Place the engine at top dead center of the e S octet j temperature such as 50 F that will cause the compression stroke for the number 1 cylinder Sm HMI to enter an air conditioning cycle and Refer to steps a through d signal an engine start R h ine i irecti a Rotate t e engine in the normal direction 7 Rome Meco backwards of rotation clockwise viewed from the counterclockw
7. NOTE If an engine runs with air trapped in the block the engine may be damaged The high water temperature switch may not protect an engine that has air trapped in the block because the high water temperature switch is designed to protect an engine from overheating due to failures in the cooling system and the loss of coolant A CAUTION Do not start the engine without bleeding the air out of the block l Verify the TriPac OUTLET hand valve is CLOSED tractor inlet next to water pump If this valve is left open coolant will be sitting on top of the TriPac thermostat and not allow the TriPac engine to bleed air 2 Open the TriPac INLET hand valve 3 Place clean container under the TriPac bleed line to catch coolant that is drained 4 Open bleed petcock on the TriPac engine to allow air to bleed out ARA1267 Water Pump Bleeder Bolt Bleed Petcock Figure 29 Water Pump Bleeder Bolt and Bleed Petcock Locations Engine Maintenance NOTE Units built prior to September 2006 have the bleed petcock on the top of the thermostat housing On these units remove the water pump bleeder bolt and bleed the air until there is a steady stream of coolant Then reinstall the water pump bleeder bolt 5 When a steady stream of coolant flows from the bleed line close the bleed petcock 6 Open the TriPac OUTLET hand valve 7 Replace drained coolant from the TriPac back into the truck s radiator 8 Start the TriPa
8. BLUT 6 gt 7I ine 1 SENSOR PRE COOLER PE Maga SEN 80 Da gt L RED FAN FUEL METERING i INS PRE A odo ar 8DP 456 gt WHT PUMP DIAGNOSTIC GRNIRED T4275 71 QS CH gt c BLK THERMOSTAT Leer CONNECTOR Mcd quee 8 gt H CH a IBA LOTT Hs ke FUEL SOLENOID ee 8 cows 2 ee qa Pci ENS a E UM e a u PARRES ee e Vs se AN STANDBY WITH SWITCH OPTION oe cup a ee as ido o a A THERMO KING PROPRIETARY DATA CAD GENERATED DRAWING eae S ZA CUSTOMER SUPPLIED COMPONENT a DO NOT MANU LEN URBI E fA Ingersoll Rand AX OPTIONAL INTERIOR LIGHT CONNECTION CORPORAT MITTED Thermo King BLU ENGINE p AND TRUST AND dign OIL PRESSURE ON OFF SWITCH Z OPTIONAL ARCTIC OPTION BLOCK TEMPERATURE SWITCH TS CONTENTS MAY NOT BE DISCLO D MURPHY 3 22 06 WIRING DIAGRAM SES SWITCH O 8r ET AX STANDBY WITHOUT SWITCH OPTION 2A WIRE IS ABSENT CHER Taan THe purpose CHECKED nS COMPRESSOR 20 8X AND WIRE SBY IS CONNECTED TO F6 ITTEN PERMISSION OF THERMO D MURPHY 3 22 06 Tr Irac E ZN OPTIONAL HEATER TEMPERATURE CONTROL SENSOR do uide ae REF 1636876 m d THERMO KING CORPORATION 1557 ICLB SIZE CODE IDENT NO DWG NO m 2 ZA OPTIONAL ENGINE AND HEATER HOUR METERS ENG APP ESOO game ae MP ri Cd ee wee ee ECL eee ee Und eee ee eA n ON ECT M ee ee 3 22 06 SCALE NONE REF DWG 1E34010 SHEET OF 8 109 TriPac Schematic Diagram
9. COMPRESSOR OILS REFERENCE FOR THERMO KING TRIPAC AIR CONDITIONING SYSTEM OIL VISCOSITY REFRIGERANT EP THERMO USED EP OIL TYPE KING P N R 134a Polyalkylene glycol PAG 100 203 502 A CAUTION Mixing PAG and POE oils will damage the air conditioning system NOTE Because of the many variables in oils particularly in HVAC systems compressors may be delivered with an oil that is not specified for the particular unit it is to be fitted to Unless it is 100 clear it is the correct oil Thermo King recommends the oil be changed to the correct type EN CAUTION With HVAC systems and the use of PAG it is very important that oil mixing does not take place PAG and POE oil CANNOT be mixed Mixing these oils will cause serious system contamination especially with chlorine based refrigerants 23 Specifications Compressor Oil 24 General Description Introduction The Thermo King TriPac Auxiliary Heating amp Cooling Temperature Management System allows drivers to reduce unnecessary truck engine idling conserve diesel fuel and save money TriPac provides truck engine preheating battery charging and truck cab sleeper compartment climate control By using TriPac drivers can reduce fuel cost rest comfortably during stops and comply with local state and federal anti idle laws Reducing unnecessary truck engine idling also reduces engine wear and extends engine maintenance intervals TriPac s own diesel engine uses an automat
10. for hundreds of hours Example for 1 230 hours CLIMATE CONTROL MAIN POWER Figure 13 Engine Hour Meter Display Select Mode of Operation 4 34 Press the HMI Mode Key to select the desired operating mode Select Air Conditioning Heat or air circulation Fan operation DEF is not used When the TriPac is first started the controller will default to the previous setting Press the Mode Key repeatedly to scroll through the selections The operating mode selected will be indicated by an illuminated LED A Monitor Null mode will occur when no LEDs are illuminated If heat is required the TriPac heater may operate while the TriPac APU engine is off and the HMI Fan Speed Key is off no LED illuminated RE THERMO KING Figure 14 Mode Key Select Fan Speed 5 Press the HMI Fan Speed Key to select the desired fan speed Select High Medium or Low speed When the TriPac is first started the HMI Controller will default to the previous setting The fan speed selected will be indicated by an illuminated LED Auto fan speed 1s not currently used The TriPac heater will operate while the Fans are off no fan LED is illuminated fan is in Null If additional air circulation in the truck cab sleeper compartment is desired the fans may be turned on by enabling the APU RE THERMO KING CLIMATE CONTROL AMA566 Figure 15 Fan Speed Key Select Temperature Setpoint 6 Press the HMI Up or Dow
11. llle rn 36 Maintenance Inspection Schedule 5 20 eec exta ex di ee ex ha Re VOR E eo RR s 37 zoe RR TR RENT TT T IL TT rr 37 Engine Oil Change Intervals Change oil and filters hot oooooocoeonooonoo nooo 37 A A A RN A RR REN 38 SI O RN 38 PUSSY SUSI tects o E II A A AA eet ela Sel actin k eens 38 B2 Laa dns dal ee A tse ede Ap a ta ine Aan sh ae Aiki oe ak eae oan gah ei hacen ii ao Cobreloa oda ays 38 Electrical Maintenance 2 033 act ovr ER ew teen Se a e 39 Maintenance Inspection Schedule 2 44 vus Vaden Gnd wena RR 9 RODA YA CRGO EO de Os ewe CERA 39 Alternator Charging System Diagnostic Procedures o o o o ooooooooo er 39 General Information uuu uo egg a E de emere ene ok UU natn UA on do Ene eat en ee d 39 Alterriator AderntllGaloL szert qux dux book dux x ete eg a i oo BOD oe QUE UR AH RC Wei don aci ee 39 Test Equipment for Checking Voltage and Current o o o ooooooooo eee ees 41 Altemar Eoad Tesl utes ue Seal at deat eget A O AR tue Ehe at Sea 41 General Diagnostic and Warranty Evaluation Procedure oo oooocooonoo ee ees 41 Fielg eutrent Test uo deterrere oett Drei dada De dodi blunt Spotted dtu ite ot i end 43 E Mer TT eed 43 High Coolant Temperature Sensor 43 Low Oil Pressure Switch rre 43 Condenser and Pre cooler Axial Fan Motors eee RR s 44 Axial Fan Motor Removal and Installation cce Rs 4
12. 8 9 7CLA TCLA HHM u T ERE 19 i A Fld BLK F20 26 DNS J UGo x 2 eee oo ARS a CH PCFS 5A is VN ae O CH LAT ER YLW YW if 0 DS HA ET a Lo C o BLK op 0A PLANE o RED 2 RECE ici z HMI BLE PT zu RED F3 i EL gb TR RUN en NEE SUR Jie Jg Ji 2 sole EP gm AT E GRY RED Le EF IE ESSET a Dj CRM Z INTERFACE e BRN WHT BRN WHT Jn 2 amp BOARD aa T A P RED UL Aa a a a d d a a A 1 RED 4 IE Bl le BRN WHT l Bl 6 7 3177 GRYIRED HEATER eg TW LW YL 5 RED J BI I i RED YLW YLW HIS DIAGNOSTIC BLK 7 O RED Pvt BRN AA a mod ERES RR Bl 10 23 il Las Mo CH i sic ORIURED BN CH A a CH T es O aa TA TA 29 8 8 HER TCLA ZN STANDBY WITH SWITCH OPTIO 30 ZX CUSTOMER SUPPLIED COMPONENT OPTIONAL INTERIOR LIGHT CONNECTION A L LA MPERA WITCH A ION E ZA OPTIONAL COOLANT TEMPERATURE SWITCH ARCTIC OPTION gt ZX STANDBY WITH QUT SWITCH OPTION 2A WIRE 1S ABSENT 49 AND WIRE SBY 1S CONNECTED TO F6 i O AN OPTIONAL HEATER AND ENGINE HOUR METERS 5 3d N OPTIONAL HEATER TEMPERATURE CONTROL SENSOR m a AN EXTREME ARCTIC OPTION Ol s 5 THIS CONTROLLER HAS AN OPTIONAL STANDBY MODE THAT ALLOWS THE SYSTEM TO BE TEMPORARILY DISABLED E WHEN THE IGNITION SWITCH IS IN THE ON POSITION I2VDC 15 APPLIED TO THE SBY TERMINAL ON THE CONTROL BOARD AND THE SYSTEM GOES INTO STANDBY MODE WHEN THE OPTIONAL DASH MOUNTED SELECTOR SWITCH IS IN THE ST
13. i NOTES gt L GaN RED 4 EE wel o UN NS y e UE i TE A i ZN STANDBY WITH SWITCH OPTION ier eM BLU WT Tec 617 oe et c IX t uc sl i A gt ZA CUSTOMER SUPPLIED COMPONENT PTION TERIOR LIGHT CTI HERMO KING PROPRIETARY DATA CAD GENERATED DRAWING F AN OPTIONAL INTERIOR LIGHT CONNECTION O DOONCT NAMUR CY UPDATE an Ingersoll Rand E AN OPTIONAL ARCTIC OPTION BLOCK TEMPERATURE SWITCH P SUR eM or T Thermo King p SE OIL PRESSURE AX STANDBY WITHOUT SWITCH OPTION 24 WIRE IS ABSENT rei leon rds p MURPHY 10 18 06 mes SWITCH dud M M OME y WHOLE OR IN PART TO OTHERS OF FOHECKED WIRING DIAGRAM COMPRESSOR 20 N OPTIONAL HEATER TEMPERATURE CONTROL SENSOR pelo WRI THEM BERMISSION OF rco D MURPHY 10 18 06 TI D ac CLUTCH ZN OPTIONAL ENGINE AND HEATER HOUR METERS i QI APPROVED REF 1640288 gt 5 1CLB GROUND ISOLATED FROM TRACTOR Dico ME Uo RE d REY u AN EXTREME ARCTIC OPTION ide HE A0e89 E J IRLBECK 10 18 06 SCALE NONE G 1E34010 SHEET 8 E AN
14. Full fielding an alternator can cause increases in alternator output voltage that may damage internal alternator or unit components This damage may not be readily apparent To test the alternator under load Thermo King recommends the use of a clamp on ammeter to monitor output current both on initial startup and under full unit load conditions For example the A PU should be turned on and operating in the A C Mode General Diagnostic and Warranty Evaluation Procedure Complete the following diagnostic procedures before replacing an alternator or the voltage regulator 1 When testing an alternator use accurate equipment such as a Thermo King P N 204 1079 digital multimeter and a Thermo King P N 204 947 amp clamp or an equivalent Electrical Maintenance Make sure the drive belts and pulleys of the charging system are in good condition and are adjusted properly before testing the alternator Be sure the pulleys are the correct size Worn belts loose belts and worn or improperly sized pulleys will lower the output of the alternator Make sure the alternator pulley nut is tight It should be torqued to 50 ft Ib 68 Nem The battery must be charged and in good condition the battery cable connections must be clean and tight and the RED 2 2A sense and D excitation circuits must be connected properly All charging circuit connections must be clean and secure If the battery is questionable a known good jumper bat
15. charge considerations for small compressors 83 check interval for small compressors 84 105 Index checking for contamination in small compressors 85 draining measuring and inspecting in small compressors 84 small compressor oil return procedure 84 type considerations for small compressors 84 oil filter change 48 Operating Instructions 31 P polyolester oil handling procedures 68 pulley and belt alignment on small compressors 89 H refrigerant handling procedures 67 Refrigerant Charge 91 refrigerant recovery 70 refrigeration system charging 91 refrigeration system specifications 18 roadside definition 6 roadside curbside terminology explained 6 S Safety Precautions 13 safety precautions refrigerant service 67 Serial Number Locations 29 specifications 17 I testing system for leaks 77 U Unit Mounting Bolts 103 unit mounting bolts 102 103 unloading timer EUT 45 V valve clearance adjustment 64 W Weekly Pretrip Inspection 34 106 Wiring and Schematic Diagrams Index 1E36877 TriPac Wiring Diagram 1E36876 TriPac Schematic Diagram 1E40289 TriPac Wiring Diagram 1E40288 TriPac Schematic Diagram 107 Wiring and Schematic Diagrams Index 108 TriPac Wiring Diagram 8 Pr REVISTOS SES
16. evacuation hoses Valve 4 V 4 Is in the open position during unit evacuation When closed V 4 isolates the evacuation hoses and the unit from the evacuation system T1 Air Conditioning Maintenance eS oO dete stets ens SE ete ME ess ws Y AS E SA M N RN EX ge d LLL Figure 56 Evacuation Station 72 Air Conditioning Maintenance yA AAA AAA Mas ncs navoisT HAMPTON Vil mia U 5 A S mm gt SP MILLIMETERS OF MERCURY Z 4 0V 4D GAUGE TUBE AEA1638 5 20000 mess 7 8 Calibration Adjustment Screw ul Example Meter needle shown at calibration position when Calibration Standard specifies 0 15 mm Hg Figure 57 Vacuum Gauge 73 Air Conditioning Maintenance Test of Evacuation Equipment NOTE Refer to the illustrations on the two preceding pages while reading the following instructions 1 Connect the evacuation system to a 110 Vac power supply Connect a gauge manifold and refrigerant supply to the fitting above valve V 4 Turn the micron gauge On 2 Close valves V 1 V 3 and V 4 Valve V 2 is open Turn the vacuum pump On 4 Open valve V 1 at the pump The micron gauge needle will move to the left See micron gauge scale diagram previous page NOTE If the vacuum pump is okay and there are no leaks between V 1 and V 3 the micron gauge should show less than 500 microns If not locate and correct the problem 5 With the pump still o
17. range is 50 to 90 degrees 31 Operating Instructions Oxa Fan Speed Key io The HMI Controller Fan Speed O X Low Key is used to select the desired evaporator fan speed When the an TriPac APU system is turned on L the fan speed will default to the setting last used High Medium and Low fan speeds are selected with the Fan Key Auto fan is currently not available APU System Key The HMI Controller APU System Key is used to enable the APU diesel power unit The APU must be ON to provide sleeper compartment air conditioning air circulation truck battery voltage sensing and engine coolant temperature sensing This key also allows access to the diesel engine hourmeter reading The APU does not have to be On to operate the TriPac sleeper compartment heater System Fault Indicator This red indicator illuminates when an alarm condition occurs and an alarm code is displayed SYSTEM O FAULT 32 Operating Modes Air Conditioning Mode If the HMI controller senses that the truck cab sleeper compartment temperature is 5 F above setpoint the APU engine will start 1f not already running and the compressor clutch will engage The A C system will operate for at least 15 minutes after the temperature in the sleeper compartment reaches setpoint This is to ensure that the truck battery is sufficiently charged The APU engine will shut down if the sleeper compartment temperature setpoint and truck battery voltage hav
18. 25 C From 14 4 Vdc to 13 6 Vdc 176 F 80 C From 14 2 Vdc to 13 2 Vdc 42 If the voltage does not increase to the anticipated voltage regulator setting the alternator is defective if there are no problems in the wiring Recheck the wiring before replacing the alternator 16 If the voltage does increase until it reaches the anticipated voltage regulator setting compare the voltage at the B terminal to the voltage between the battery terminals The voltage at the B terminal should be no more than 1 0 Vdc higher than the voltage between the battery terminals If the voltage at the B terminal is no more than 1 0 Vdc higher than the voltage between the battery terminals continue with step 17 If the voltage at the B POS terminal is more than 1 0 Vdc higher than the voltage between the battery terminals clean and check the wires and connections in the 2 and 2A circuits and repeat this check 17 Increase the charging system load as much as possible by running the unit in the A C Mode 18 Monitor the alternator output voltage With the increased load the alternator output voltage should decrease no more than 0 5 Vdc The voltage may increase as much as 1 0 Vdc If the alternator output voltage decreases no more than 0 5 Vdc the alternator 1s good If the alternator output voltage decreases more than 0 5 Vdc the alternator is defective if there are no problems in the wiring Recheck the wiring before replacing the
19. 3 0 2 Starter Motor 90 to 105 cranking anm od Pre Cooler Fan 6 5 to 6 6 Water Temperature switch normally closed fan off Switch opens at 115 F 46 1 C fan on Switch closes at 95 F 35 0 C fan off Evaporator Blower 10 0 to 11 1 HEN Fuel Solenoid Pull In 35 to 45 0 2 to 0 3 NOTE Disconnect components from unit circuit to check resistance 19 Specifications Truck Sleeper Compartment Heater D2 Heat Output 10 7 500 BTU hr Boost 2 2 kW 6 150 BTU hr High 1 8 kW 4 100 BTU hr Medium 1 2 kW 2 900 BTU hr Low 0 85 kW Current at 12v 10 8 3 amps Start 2 8 amps Boost 1 9 amps High 1 0 amps Medium 0 7 amps Low Fuel Consumption 1096 Boost 0 07 gal hr 0 28 liter hr High 0 06 gal hr 0 23 liter hr Medium 0 04 gal hr 0 14 liter hr Low 0 03 gal hr 0 10 liter hr Air Flow 1096 48 cfm Boost 40 cfm High 27 cfm Medium 19 cfm Low Motor Speed 4800 140 RPM Boost 4000 120 RPM High 2800 80 RPM Medium 2000 60 RPM Low 600 20 RPM Adjustment in circulation mode with temperature sensor internal 0 RPM Adjustment in fresh air mode with temperature sensor external 4800 140 RPM Ventilation Operating Voltage Range 10 5 16 vdc Overheat Temperature Shutdown 10 240 F 115 C Resistance Values Glow Plug 0 5 0 05 Ohms Fuel Metering Pump 10 0 5 Ohms Operator Control Unit Set Value Potentiometer 1750 2080 0 5 Ohms 20 Spec
20. 50 Hand Valves Closed to Center Port llli 68 Figure 51 Connecting the Gauge Manifold 0 0 0 rns 68 Figure 52 Balancing the Pressure llle hn 69 Figure 59 Evacualing the System duced sexo ce AA ERES Pade AAA Sad dad b d docs 69 Figure 54 Recoveting Refrigerant sitio ARA E RR DU EA RIA CR AAA ARA RAE E RATE A 69 Figure 55 Liquid Charging the System esiis v S A A A CS OP AAA AAA A AA 69 Flqure 56 Evacuation Sidtion cabro etae orto is AA AA A ele ere 72 Figure 57 Vacuum Gage aod ada aa 73 FIQUEe 59 Leak a2 cana 74 11 List of Figures Figure 59 Figure 60 Figure 61 Figure 62 Figure 63 Figure 64 Figure 65 Figure 66 Figure 67 Figure 68 Figure 69 Figure 70 Figure 71 Figure 72 Figure 73 Figure 74 Figure 75 Figure 76 Figure 77 Figure 78 Figure 79 Figure 80 Figure 81 Figure 82 Figure 83 Figure 84 Figure 85 Figure 86 Figure 87 Figure 88 Figure 89 Figure 90 Figure 91 Figure 92 Figure 93 12 MORTULO we TTC CTI ai olaaa cala ein pela rie ancla dies atada luis pues a 74 Conect Gauge Maniold 2260 04 adds dnt rtm dd ad evade eE 75 Receiver DIG nn E A NN RA 78 Compressor Components 5 as E Ae Ee ns d A A oe AC dt Hp t bees oe bns 81 mislegu ih o CPU rr 82 LOOSEN Caps WB S aoo dodo ts Bebo ope ob Zo a os do mt ath Ses aid rnt RU ah God 82 Holate AMAU Flai vda EE wad LN RC URS oU RR AAA ICH e et a ea
21. 83 Draining the Ol T 84 Armature Plate ROOM sol wach pete wath Meee ACI NL whee eh ewes 84 Small Compressor Oil Fill Procedure 1 0 RR rns 86 Remove Center Bolts cic sere i ee ETIN USERS RUE ANGE kee EN EE EE 86 Remove Armature Plate n ox Da eeu Shade aaa Es 86 Remove Snap Ring and Cover vll eee a ray AT ees 87 REMOVE I UNG dI reper DIPL cdt dire 87 mise 2e tos sn E A wh Gata ca a Hossa ee ee 87 Inspect CltchCOMPONESNIS duit od ate is iS 87 Rc e A E EAE 88 A AAA A O E ARAN 88 Install Cover and Snap BIng x x A eee DR ee A oS eed 88 Install Shims and Drive Plate 2 225 AA ee CCP Qt Rab Kat A db Ces Reda 88 CHECKA GID edoctus tui det eim dS tb cdi dud e dul usd Medi dene 89 Remove Air Heater Cover o 92 Removing COMMON 02 rapera nara rad dra pwede hae ee ele bee ees 92 Heater Casing Disassembly and Glow Pin Removal 2 0 e cece eee eee ees 93 Removing the Glow Plug Support Lining aana aaa cc ne eee eee 93 Removing the overheating sensor flame sensor llle 94 Overheating Sensor and Flame Sensor oooo ooooo lens 94 Installing the overheating flame sensor lille 95 Dismantling the Heat Exchanger and Removing the Combustion Air Blower 96 Removing the Combustion Chamber seras asie saani miai a ana eer 97 Evaporator Cover Removed secsrironatonr dr 101 Evaporator Coil Air Filter n anaana aaea Rr 101 BE E EEEE MP RP LAETI RC RM 102 COnN
22. 86 SN MM RRRM M MM Tr EC E EE 86 A A A AR A E A P PL eae 87 E RAN 88 Pulley and Belt Alignment Engine Driven Compressor 0 000 ee eens 89 Bel Tension drach 2 Bases sacn PTT 89 Table of Contents Sleeper Cab Air Heater Maintenance 0oococccocc ehh hh nnn 91 Maintenance Inspection Schedule o ooooooor ern 91 Sleeper Cab Air Heater Maintenance D2 Shown lille 91 Sleeper Cab Air Heater Service Operations 0oococccccoc hn nnn 92 Remove the Air Heater Cover 92 Removing the Control Unit 2 2 22s Reo oeque 0460 redo en D eoe DoD deeem dac eee et a Seo Goal de 92 Heater Casing Disassembly and Glow Pin Removal o o ooooocooennooo lees 93 Removing the Glow Plug Support Lining o ooooooonoo RR rn 93 Removing the Overheating Sensor Flame Sensor o oooooooooo elles 94 Checking the Overheating Flame Sensor o o oooo eee 94 Overheating Sensor deir OEC ERE ED Ear E Eae aree aea arta aar bs 94 gren dp PELLE 94 Installing the Overheating Flame Sensor o o o oooooooor err 95 Dismantling the Heat Exchanger and Removing the Combustion Air Blower 96 Removing the Combustion Chamber ccc ee rns 97 Optional lPoWerINVerter cimirit dra 99 Opu nalROWer vender 2 rt e ate 99 Stu ctutal Maintenance sacs curia aes or a dd o Po pa abi are un ura 101 Maintenance Inspection Schedule o o ooooooo ees 101 Evaporator
23. Figure 18 Standby Operation 35 Operating Instructions Options Used With Standby Operation Standby Truck Integration When the truck s ignition switch is in the Off or Accessory position the TriPac APU will operate normally if the APU Engine On Off switch and the TriPac HMI Controller Main Power Key are On If the truck s ignition switch 1s in the On position the TriPac HMI Controller will be forced to Standby Mode NORMAL Truck Integration Selector Switch TriPac When the dash mounted Truck Integration Selector Switch 1s in the Normal position the TriPac APU will operate the same as with Standby Truck Integration above However if the dash mounted Selector Switch is in the Standby position the A PU will be forced to Standby mode STANDBY 36 Maintenance Inspection Schedule NOTE Thermo King reserves the right to deny NOTE See the appropriate chapter in this warranty coverage on claims due to lack of maintenance manual for instructions on how to maintenance or neglect Claims in question must correctly perform required maintenance be supported by maintenance records Engine Pre Trip Annual 2 000 Hrs Check condition of or service the following 0 Lb Check engine oil level Inspect belts for condition and proper tension Listen for unusual noises vibrations etc Check air cleaner hose for damage Inspect air cleaner Change as needed or annually Inspect fuel pre filter Change as
24. GO ir M c r PPM 101 Evaporator Coll AI Filer aa dee Uude Geb Roe dod ot bd ot e bib ob he bb ob bd didi 101 Evaborator Drain alVes x ves gd tare 4 mind eS NES 205078 MCI CR RC O RETI a I Re Rod aM SEU ae we 102 Condenser COL utra idu ace dene ds cota des dex eu bs deu dau dls dex dau dau oes 102 ARU MOUNINO BOIS aunar eii a ieee acier rate arco E Sa BELL 102 TriPac System Components Diagram occcccc rh hh nnm 103 Ir prc 105 Wiring and Schematic Diagrams Index 0 0 00 ern nnn 107 10 List of Figures PIQUA Ra CIAL amga dedos ndo tr dora end db de denia od dd deter mn ddr de dedos od dodo do delos no e dde deal oh PI 26 Fidure 2 LHP a6 COPdernSel aras toallita audio 26 Figure 3 TriPac Evaporator and Air Ducts Evaporator installed under sleeper cab bunk 26 FIQUre d Mia calores te bees ere andrade da dvd sd 26 Roures TWMIPRAC HIMEGOnBUVOLGSE A AAA AA AA Leads ed at cade e a i A toy 27 Figure 5 Interface Board xac rac Cd C qct AD c ee dt tJ ret a rosea ut aout CS acne paw T UI amt ATAR 28 Figure 7SEhgihe Reset SWIC 2555 3 9 4 DORADO A dde PE 28 Figure 6 FIM Commoner ia Error ai a dde et redolet O aite doe a ated 31 Figure 9 Early Engine On Off Switch Location 0 0 0 0 0c rns 33 Figure 10 Later Engine On Off Switch Location o o o ooooooonooror RR nns 33 Figure 11 HMI Controller Main Power Key o o oooooooro RR rans 33 Figure 12 APU System Key tere t eee ove EE A A ews 3
25. Hir HMI HM CONTROLLER 22 NE elses 3 SR HPCO HIGH PRESSURE CUTOUT SWITCH 8 amp Spe Sab HTS HEATER TEMP SENSOR 26 27 f 8 e PR HWTS HIGH WATER TEMP SWITCH 3 ee els ice eres end Nex 2 ILCS INTERIOR LIGHTS CONNECTION SWITCH 14 NI rZzz Q Mm LPCO LOW PRESSURE CUTOUT SWITCH 8 Eras MESES INTERFACE OPS OIL PRESSURE SWITCH 2 lt onet 2588 5 BOARD ossw OPTIONAL STANDBY SWITCH 2 heicejesg E 2h F5 TE PCF PRE COOLER FAN 4 L ositssrisl E 10 E NA n bu RR PCFS PRE COOLER FAN TEMP SWITCH 9 E co lse P g eS Ven PHB PREHEAT BUZZER 9 js fajizl E n PR PREHEAT RELAY 8 5 2832532532 D PT PREHEAT THERMISTOR 16 MEENTE eL 19 RR RUN RELAY r Si8sosisii E RSW RESET SWITCH 13 13 A REVISIONS A OSSW RTS RETURN TEMP SENSOR 20 24 sm on i 5112641 DM svosvos SW A D Eo d m BY RELEASED E IRAN len F6 Sp MON pp SR STARTER RELAY 8 c Move ES IA WRAL A SS STARTER SOLENOID 4 5 6 511624 DM 9 1 06 SW B TRUCK IGNITION IS ON TBV THERMOSTAT BYPASS VALVE E ADD HOUR MTR OPTIO 8FET FS ESW ON 3 Ha moto OO 1 5A 2 CTS MT WAT TA TO TRUCK INTERIORA INT CYS pm 4 MATE XE USE c TO TRUCK INTERIOR LIGHTS A ow SEN SEN PeT a 16 BL dj ea BL FSI FSW FS 18 TCLA 1CLA 8 8 mls ICLA 19 TA TA PCFS CH Pug LW 20 RTS Bur FIT BLK BLK 2 3A PE Y Z A 454 J 2 GRY RED de S rey 8 gt SH 3 ET BRN WHT gt RED RED GRY Bl l2 GRY ZA Coro ORINA GRY RED BI 7 HEATER
26. Roadside Curbside Terminology 2 0 cc has 6 Using the Model Tables in About this Uni llli RII 6 tn 6 LISTO PIQUI OS CPC T 11 Satety Precautiolis encre ore eric cine eter eg home Access A E EE opi Ec 13 General P FaelleBs uq ecsoecona allas detur eor adeo won MP Rare wa aes dio won sean oo We so uo oo ae ee dubios le ss 13 RERO Eea MR A RR RAN 13 REI era ION er TTC EMT 13 COW vVolage shine a E ia ca E a aa la ola 14 Model Systems System Designations ooococcccco nnn 15 SBe clHicallOliS outs d E axe dui vae pri FREE RA RE A IEEE qq uS du 17 Trac ENJING MESE ETC EEETE A E DUMP 17 R 134a Air Conditioning System eee aha 18 sii WC a2 6 RC T RR RENE MEX 18 Electrical Control SVSl ell vox dashes verd ave A atre tora ined deri a tre de pd tated S Ld adel aT aate 18 Electrical Components meridia do Rer A cano BAe monto Bae utu eee RAN eee 19 Truck Sleeper Compartment Heater D2 o o ooooooooo hn 20 Truck Sleeper Compartment Heater D4 Option o o o o oooooooconnoo ne 21 Optional PoOWerInVeller apice oi encre roc abate oet b dl ao ce t Rae oe A ois 21 Optional Extreme Arctic Package Components o 22 Specifications Compressor Ollie edo t Lender Er ur a E s ee ML 23 General DescripuOh zx way dns EA LEE ee GE ENNEER AA AA A ER EN 25 NOU MO RR REN ER MEM met 25 Dm Features iria aod ene so x aue bake b ROCA eos AS A ASA bac un edes oen a ofc nen esc A 25 Flac SY SIM da
27. extracted oil for the following Dirt e Color changed to dark brown gray or black e Presence of foreign substances metal shavings etc in the oil Dark brown oil indicates high compressor temperatures Gray oil indicates metal contamination Black oil indicates severe contamination To determine the extent of contamination remove the receiver drier and check the oil color there If the oil 1s contaminated at the receiver drier flush the system with industry approved materials If the oil 1s clean at the receiver drier install a new filter drier and replace the oil with new oil See Adding Compressor Oil Adding Compressor Oil To add oil Verify the correct oil type on the compressor label 2 Verify the correct oil amount See the Specifications chapter in this manual or for replaced components use the chart shown Oil Amounts per Replaced Components Pounds kg Component Replaced Condenser 0 3 9 re Receiver Drier 0 3 9 1 These amounts are approximations Individual systems may vary 3 Add oil to the compressor through the suction port as shown in Figure 68 Use fresh oil taken only from a sealed metal container 4 Turn the armature plate manually several times while adding oil to distribute oil evenly NOTE Replace the system receiver drier if the system was opened for service 85 TM 15 Compressor Maintenance Removal 1 Remove the center armature bolt Use the pulle
28. large Further inspection is required Do not add more refrigerant to the system because it will vent to the atmosphere 1 to 50 PSI Reading Since the system is holding some pressure you can add refrigerant to the system without it being vented to the atmosphere 1 Add refrigerant to the system to increase pressure 2 Add enough refrigerant to raise system pressure up to bottle pressure Keep track of how much refrigerant you add NOTE This refrigerant will be recovered when the leak check is complete You may use refrigerant from a recovery tank to raise pressure 3 Perform a complete and thorough leak check 4 Recover refrigerant from the system Over 50 PSI Reading The low side reading must show at least 50 psig of pressure 1 Using the existing system pressure perform a complete and thorough leak check 2 If noleaks are found but the system has lost some of its refrigerant pressure proceed to the 1 to 50 psi procedure This leak check procedure gives the technician a good opportunity to locate a refrigerant leak Because nothing is lost or vented the procedure is both economical and environmentally friendly 78 Receiver Drier Removal and Installation NOTE It is recommended that the receiver drier be replaced when the system is opened CAUTION Use extreme care when working near the exposed coil fins Coil fins are very sharp and can cause painful lacerations Use gloves when handling c
29. new suction and discharge line O rings Connect the suction and discharge hoses 4 Perform a leak test on the system using the same refrigerant used in the system See Refrigeration Maintenance chapter in this manual for leak testing procedures 5 Evacuate the system using the micron gauge method 6 Charge the system with the correct refrigerant See system charge specification 7 When the system is charged confirm that the system is functioning correctly by operating for several minutes Compressor Oil Caution Statements CAUTION Do not leave a system or oil containers open to the air longer than necessary Compressor oils POE and PAG absorb moisture Moisture contaminated oil will damage system components TM 15 Compressor Maintenance A CAUTION Do not open refrigeration system unnecessarily Doing so increases chances of contamination CAUTION Discard used oil containers These containers are hazardous CAUTION Do not store PAG oil in plastic containers PAG oil absorbs moisture through the plastic container Oil Charge Considerations Most compressors come with a factory oil charge which is listed on the label This oil charge is not necessarily the correct amount See the Specifications chapter in this manual for oil charge information A CAUTION Not using the correct oil charge will damage your system 83 TM 15 Compressor Maintenance Oil Type Considerations Your compressor com
30. pump gear from the gear case you will have to remove the gear case cover to realign the timing marks on the injection pump gear and the idler gear Injection Pump Installation l Place a new O ring on the injection pump and lubricate it with engine oil Place the injection pump in the gear case Rotate the injection pump shaft to mate the key in the shaft with the keyway in the injection pump gear Take care to make sure the key mates with the key way Secure the injection pump to gear case with previously removed hardware Make sure to align the index marks on the injection pump and the gear case like they were in step 1 of Injection Pump Removal NOTE If a different injection pump is being installed see Injection Pump Timing on page 56 to set the timing 59 Engine Maintenance 4 Securethe injection pump gear to the injection 5 Install the injection pump timing cover on the pump shaft with the lock washer and gear case cover and reinstall all components mounting nut Use a shop rag as before to removed previously to facilitate the injection prevent the lock washer or nut from falling pump removal into the gear case Torque the nut to 43 5 to 50 9 ft Ib 59 0 to 69 0 Nem Injection Pump Gear Mounting Nut z Gercme C toc Was OT e pRe Figure 40 Injection Pump Removal and Installation 60 Integral Fuel Solenoid The fuel stop solenoid is located on the end of the
31. test 86 small compressor maintenance 81 small installation guidelines 82 small installing 83 condenser axial fan motor 44 removal and installation 44 condenser coil 102 contamination oil in small compressors 85 contents manual description of 5 crankcase breather 48 curbside definition 6 curbside roadside terminology explained 6 D defrost system 45 E electrical components specifications 19 electrical control system specifications 18 electrical maintenance 39 engine air cleaner 49 engine cooling system 49 engine fuel system water in 56 engine lubrication system 47 engine maintenance 47 engine reset switch 43 engine speed adjustments 65 engine thermostat 52 engine specifications 17 evacuation 71 evacuation procedure 75 evaporator blower motor 45 removal and installation 45 evaporator coil maintenance 101 extreme arctic package components specifications 22 F filter drier removal and installation 78 fuel filter replacement 56 fuel injection pump see injection pump G gauge manifold attachment and purging 70 removal 70 General Display Information 31 glow plugs 43 H high water temperature switch HWT 43 injection pump removal and installation 59 timing 56 L leak testing 77 low oil pressure switch LOP 43 M manual how to use 5 matrix how to use 5 model systems how to use list 5 O oil adding to small compressors 85 amounts replaced components in small compressor systems 85
32. with no compressor movement A CAUTION A belt that is too tight causes severe overload on the compressor and motor bearings This will shorten belt and bearing life Use only approved Thermo King Service Parts replacement belts 89 TM 15 Compressor Maintenance 90 Sleeper Cab Air Heater Maintenance Maintenance Inspection Schedule Pre Trip Annual 2 000 Hrs Check condition of or service the following NENNEN EM Start and run for at least 20 minutes each month Inspect combustion air intake tube and exhaust pipe for restrictions or blockage Inspect ducting air intake screen and air outlet for restrictions or blockage o Remove glow pin and inspect for carbon build up Clean or replace o Remove glow pin screen and inspect for carbon build up Replace E eene epum sen Sleeper Cab Air Heater Maintenance D2 shown CAUTION Use fuel suitable for the climate you operate in see truck engine manufacturer s recommendations Blending used engine oil with diesel fuel is not permitted in the TriPac system It will plug the filters and will not allow the air heater to run properly Thermo King reserves the right to void all warranty on the unit e Remove the glow pin screen and inspect for e Inspect combustion air intake and exhaust for carbon buildup Clean or replace See Air blockage Heater Service Operations chapter P P e Operate heater for a minimum of 20 minutes e Make sure vent ho
33. 2 ls lue a UR ee 56 Irije HOU BEIDE DINING e oda o ditti e oso bv Rods eg o iba Gh e 56 Injection Pump Removal and Installation llli 59 Integral Fuel Solenold sss uacuum aod boe oer beds chr sod oq oe SG RE Sato win Meee ee ws 61 Fuel Solenoid Replacement err ER Eee A Pa RE A RC RO RR RC 63 Valve Clearance Adjustment 64 Engine Spesdg Adjustment ia bs eh oth ua ld Ae Qual an Qu ass utar a ed 65 belt AQUSIMEN o raran 9e bo ROO cate sop led ah aea dia ea A AAA AE 66 Engine Compressor Alternator Belt Tension Adjustment llli 66 Air Conditioning Maintenance 3 9o iaa Esp eue fence pedum exo xem edu n e RR eee eee he a deg 67 Maintenance Inspection Schedule o o o o oooo ens 67 eru AN 67 Refrigerant Service Safety Procedures ills eee 67 General Refrigerant Handling Procedures o o oooooooc n 67 PAG OI Handling Procedures 323 EA EON DCN DR AAA ee 68 Gauge Manifold Conn cllolis i x22 64242468 A DEAE EE RES A E 68 Gauge Manitold Postlofis soma o hturo TOP nt TS PREIS A RT RIS nS WP WP pts 68 aude CONNECIONS oa sodes ho dah ix d robot Ger quce dr Bei De tede Ov ode a ot etat oli roi e b 68 Gauge Manifold Attachment and Purging llli 70 Rice CR 70 Reigerant IRCCOVENY ociosa ele oats a owl eet ox a ew eet ew 70 meu a CT TITULUS 71 TesporEvacuatdon Equipment 2 ta o ta f ARRASTRAN Be aed Cr T d 74 Unit EVaCuUatlon PrOCedUre 22052 2 02 Robes
34. 3 Figure 13 Engine Hour Meter Display o oooooooooror RR IRR rn 34 memo a da io TC M 34 Figure 15 Fan Speed Key 2 os aC arx E A ap OR ab OX ia OR om Ee AA ARA eee ve A eo 34 Figure Te UD and DOWN KEYS 1 1 259 AA o Db ed ARA OA TA TO OA A dd 34 FIgBre T7 9ystem Fault Indicators pcia a ia A CR E ROSTER ir Me Gee de cate de 35 Figure 19 Standby Operation sr vives ere ute ep ebbe EE dhe betes Ir di i4 35 Figure 19 Australian Bosch Alternator Terminal and Component Locations o o o o o ooooooooo 40 Figure 20 Thermo King Alternator Terminal and Component Locations ooo ooooooooo ooo 40 Figure 2 Ie dal Fan MOO a 8 x dosi ts doris ordi A EAS A d atn e dod 44 Figure 22 Evaporator Assembly Cover Removed o o oo o ooooo ens 45 Figure 23 Engine Reser SWIC 22 d eto e Ce AAA ENRICO a KHU S Ear A gout 48 Figure 24 OILEIIGE Pals areen e a AAA HEIC E EIUIE e 48 PIQUE 25 AECI AN uo dod bir iod aecenas del Pes rbi o 49 Figure 26 Engine Cooling System Components Before 10 06 0 eee 50 Figure 27 Engine Cooling System Components 10 06 and After 000 ee 51 Figure 28 Water Pump Assembly and Thermostat llle 52 Figure 29 Water Pump Bleeder Bolt and Bleed Petcock Locations oooocccocccococoo eee 53 Figure 30 Engine Fuel System Rubber Fuel Lines 0 0 ccc eene 54 Figure 31 Engine Fu
35. 4 Evaborator BIOWeF Molor 3 2 25 92 3 3 a pi a A od Gor ca QUA UR aqua ARAS 45 Evaporator Blower Motor Removal and Installation eee ee 45 Engine MainterHantce scrape i o E pa PI xReEE EA 47 Maintenance Inspection Schedule eee 47 Engine Oil Change Intervals Change oil and filters hot llli 47 Engine Lubrication System uos aout e dE X AR ed D REC ed EX de ded reto ERU RO 47 ENnGINes Me Sel OWNGCH a qd om de cued dee teeta peed ee dc d autor a 48 Erigirie OIL Garge 3 n ra Ode SO Ge Sette A p Ope s AAA e eu te EA 48 OIPPIlter Change s ac un RC E ASA AA RUE ERREUR RUE aa OR OR UR Ip E Sr Ae SRL ds om 48 Grankcase Bieatlie 2 Cot aL UC d A a Docet uL er abes ur Cube ue alor iei s Vas RE ne UM EL Eel 48 Engine Air Cleaner a oc outset rane m Bod Ot eR Oa Be ctos oor Gu dh Dah oderit a ida 49 ENGINE COONNG SY SUSI abu uet d uu te aera aie dale oie ei Benen Big ds gine DA a t enu S sra cot ict a ara eee gradita 49 Antifreeze Maintenance Procedures 1 m nee ake ee kee wae A hee de Oe eee ICH x exes 52 TriPac Engine Coolant Maintenance Checks 0 0 0 ee eee eee ees 52 Bleeding the Coolant System eee eee eee eens 53 Table of Contents Engine Maintenance continued EIGN UC OV IERI IT a a ds ada za 54 Bleeding the Fuel SysteM o o ooo cooocoon ll usse ue y ER 3H RR na 55 Water in the FUE Ss vir 64039442944 RN RES ES A a eub d ee eq eA 56 Fuel Filter Replacement 4 2 1
36. 4 rr LPCO LOW PRESSURE CUTOUT SWITCH 8 8 pz H9788 or PH OIL PAN HEATER OPTION 1 s Pifslsiref E der S CPS OIL PRESSURE SWITCH 2 GENER 2 i SSW OPTIONAL STANDBY SWITCH dire E pcr PRE COOLER FAN 1 2 Pazliicta E PCFS PRE COOLER FAN TEMP SWITCH 3 E BESCEE3 I5 7 PHE PREHEAT BUZZER 3 Es rm PR PREHEAT RELAY 8 N Ossi PT PREHCAT THERMISTOR 16 REVISIONS 24 STANDAY l aR RUN RELAY 10 512275 DM aroaro7 JL A 12 D F6 t 2 o ST sg RSW RESET SWITCH 13 13 RELEASED Ji ENG INN Cu AN Ue E a oae JN lA NORMAL DE l RTS ETURN TEMP SENSOR 20 518925 RR 12710707 JI B AT ZN 2 SH SUPPLEMENTAL HEATER OPTION 1 ADDED EXTREME ES OFF l l SHR SUPPLEMENTAL HEAT CONTACTOR OPTION 7 C14 ARCTIC PACKAGE 8 E O larer BEE o g 8X 8 8 LINE 7 14 c 9 F T i SN STARTER MOTOR 4 ADDED GIL PAN ms CTS De ase SR STARTER RELAY 8 HEATER LINE 7 i 1 1 E oE OS Ing E e L ss STARTER SOLENOID Mon ILC z d 4 ro Tauck INTERIOR A int ICES ony AAI Ps as till MER COE ME e en LA cd d fsuRo ZO sa m OY 7X ANS 7 E na OS ae ee OCF Eh PCF PCE CH E PCF Oo De FI XE KF CH SEN SEN sen ee qu l6 El BLI BL EE fe um PANI PHM Ls 2 1 eee pa leu _ BL B2 L m QE MN 7 e PwM jee FSI II 1 FS FSW C S gt TD ib 20A FS2 CLU 18 CLA TOUR Se Fla ic HPCO y PEO soma FT seg Eh s OT C TEL e SEEN OQ O
37. A A a aden E ATAA 75 Charging Procedures cumst as sd a Sw eas a Seas 76 Charging from an Evacuated State ut a m de 76 Charging from a Partially Charged State oo ooooocoooorrr rn 76 Charging Your Air Conditioning System In Cooler Weather llle 77 Testing SYStem1Or Leaks ura CR or rep AAA SA dien de E A doeet 77 Mo o A RR 78 11 10 50 PSI ROAGING ere 625 Sk Hs Goce Bere m 78 Over 50 Pol Reading asirasi id Bee eae Be sm Eee Eee eae ee eee ea dod 78 Receiver Drier Removal and Installation 0 0 0 0 0 eee ee ee etna 78 TM 15 Compressor Maintenance i x2 EE XD bes a Ses E EE 81 Compressor Handling and Storage 1 eee eee teens 82 Removing the Compressor x sua eo ER LR Sae uA pacis o ER ODER RAN ale ewe ext ute ex wate eke 82 Compressor Installation Procedures o o ooooooo ers 82 Installation PRECAUTIONS iii ERES HERES PEE E mad ana 82 Installing te Compressore ur Pi todos ua a etas sc Ss Goto A AAA 83 Compressor Oil Caution Statements ets qaum rud tears ad REPRISE RES ee as ee a 83 Oil Charge CONSID Sl AO NS tiara e dli ket et e dales co aa a ddr od n edd bed aer edd Eee e iai ke ME 83 OU TIPS SON IIA Sd e Roda ted 84 Oil neck interval na apar n e ais la ea a ai ed 84 Oil Check Procedure Draining Measuring and Inspecting the Oil o o ooooooooonooo ooo 84 ot o lo A TTE TIE TITLE TIME 86 CURT E AA e ono O E 86 Clutch Removal Inspection and Installation llle
38. ANDBY POSITION POWER IS APPLIED TO THE SBY TERMINAL ON THE CONTROL BOARD AND THE SYSTEM GOES INTO STANDBY MODE REGARDLESS OF THE INGITION SWITCH POSITION c 34 THE DISPLAY WILL SHOW Sby WHENEVER IN STANDBY MODE O CAUTION STANDBY MODE SHOULD NEVER BE USED TO DISABLE THE SYSTEM WHEN PREFORMING MAINTENANCE 2 PLEASE BE AWARE IN A RETROFIT SITUATION THEIR MAY BE REDUNDANT FUSING FOR CERTAIN 1 0 V YOU SHOULD REFER TO SCHEMATIC 1E34010 FOR FUSES IN PLACE IN THE HARNESS OF THE INTERFACE BOARD O r a a t om x 112
39. Do tt Check condition of engine mounts o A O a Maintain year round anti freeze protection at 30 F 34 C Change coolant every two years or with truck coolant BENE Lo 7 Adjust engine valves Engine Oil Change Intervals Change oil and filters hot Pre Trip Annual 2 000 Hrs Check condition of or service the following 1 000 Hour 1 000 Hour Interval Oil change interval is every 1 000 hours of Intervals operation only when using a Thermo King brand oil filter and Cl 4 or better oil Units with optional DPF require CJ 4 or better oil 500 Hour 500 Hour Interval Oil change interval is every 500 hours of Intervals operation when using any other brand oil filter and Cl 4 or better oil Units with optional DPF require CJ 4 or better oil IMPORTANT Fill the crankcase slowly so oil will not run into the breather thus filling up a cylinder with an open valve Leaving the dipstick out while adding oil will ventilate the crankcase CAUTION Use fuel suitable for the climate you operate in see truck engine manufacturer s recommendations Blending used engine oil with diesel fuel is not permitted in the TriPac system It will plug the filters and will not allow the air heater to run properly Thermo King reserves the right to void all warranty on the unit Engine Lubrication System Oil pressure is affected by oil temperature viscosity and engine speed Subnormal oil pressures usually may be traced to lack o
40. LER FAN inis cue NS M o NE VCL T 9A LL Ol eRIRED N LL qb O us O O bl gd dE l 5A 7O HI l T O ur POWER BOARD i S mh Ici 20K 8 TEN ENS ser O ser Aj IE ASAS T HO oM pron ai O 1D rca HOJ cL c dos a TED PWMI 20A L lt a al i is o Lo ne wo GR S piui 204 1840 EVAPORATOR FAN SEN to SEN E ed MEN D S oc A AU E ML NE oes a TA AAA eee a a a a a S ea A A A ea E Te BATTERY SECTION BATTERY BLK 2voc Es E Red o HO gt TTT AA cR pe ee SA ee es a o nom c E Lu IE uu uc uu ee im CONDENSER CONDENSER Y Y y THERMOSTAT 2 STARTER TriPac A L ICF 1CLB STARTER SOLENOID DE ENGINE SECTION een LA Y IER INIM QE 1CLA E AMET oi COOLANT TEMP SWITCH m ARCTIC OPTION n GROUND 8FET a gt WHT A7 T M MEA BLK El EAN cibus HPCO CH GROUND amp 7 4 ici Sas A cot acme BT ORG ci C PRE COOLER FAN lt EVAPORATOR SECTION OA FAN MOTOR 2VDC CH TEMP SWITCH A o A ee WTA Lwtr LA C OX AA A AA ca A A FUEL SO FUSE l CH BG CH HEATER SECTION SUR RED OX_ 4 SO RED E iu NOT ise pep EO AO RED SSS se HEATER I HIGH WATER BRN CONNECTOR HEATER d TEMP SWITCH ELM MM E FLYWHEEL 20 AAA E cas RED El sped s RED Leo SENSOR Goa TRUCK JURE CEDE ud HIE BLK lt 8 1 CH Er GLOW GLOW FUEL TANK pene n Bn tl HEATER TEMP FS
41. Nem Use the pulley arbor TK No 204 804 to prevent armature plate rotation After tightening the bolt ensure that the pulley rotates smoothly Check the air gap with a feeler gauge The air gap should be 0 016 to 0 031 in 0 4 to 0 8 mm If necessary adjust the air gap by adding or removing shims Adjusting shims are available in the Clutch Hardware Kit ICE No 2530109 Figure 79 Check Air Gap Electrical Connection l Connect the lead wire to the electrical circuit NOTE The stationary field is grounded at the factory therefore it is necessary only to connect the hot lead wire Engage and disengage the clutch several times to check the clutch engagement The armature plate should snap firmly against the pulley TM 15 Compressor Maintenance Pulley and Belt Alignment Engine Driven Compressor The compressor clutch must be perfectly aligned with the engine pulley and any idler or pulley components l Ze Make sure the clutch is installed properly Verify pulley alignment by making sure the belt goes from pulley to pulley in perfect alignment with no indication of a sideward bend Belt Tension l 2 Adjust the belt tension to 95 pounds of force Check belt tension after 36 to 48 hours of initial operation The belt may stretch slightly during the first hours of use Do not overtighten the belt Proper belt tension should allow the belt to be deflected 0 25 in 7 mm at center of span
42. OT settee cect te aul ater LITTERIS OTT RISO IIT 102 TriPac System Components iac eee es RE ER ES AAA 103 Safety Precautions General Practices DANGER Always turn the TriPac Main Power On Off Key on the HMI Controller OFF while refueling the truck Fuel vapors could ignite if they come in contact with TriPac electrical or heater components 1 ALWAYS WEAR GOGGLES OR SAFETY GLASSES Refrigerant liquid refrigeration oil and battery acid can permanently damage the eyes see First Aid under Refrigeration Oil 2 Never operate the unit with the compressor discharge valve closed 3 Keep your hands clothing and tools clear of the fans and belts when the unit is running This should also be considered when opening and closing the compressor service valves 4 Make sure gauge manifold hoses are in good condition Never let them come in contact with a belt pulley or any hot surface 5 Never apply heat to a sealed refrigeration system or container 6 Fluorocarbon refrigerants in the presence of an open flame or electrical short produce toxic gases that are severe respiratory irritants capable of causing death 7 Make sure all mounting bolts are tight and are of correct length for their particular application 8 Do not drill holes in the unit Holes may weaken structural components and holes drilled into electrical wiring can cause fire or explosion 9 Usecaution when working around exposed coil fins The fins c
43. On and set the TriPac HMI to a setting that will cause the TriPac engine to attempt to start NOTE The fuel solenoid must be energized when it is being installed If it is not the plunger and the linkage may not line up correctly and the fuel solenoid will not Fuel Stop Solenoid function proper 6 Place the O ring in the groove in the end of Fuel Injection Pump Groove the fuel injection pump Make sure that the Figure 43 Fuel Solenoid Components O ring is positioned correctly during installation to avoid damage and leaks 7 Install the new fuel solenoid 8 Turn the unit off 9 Reconnect the 20 wire to the reset switch 10 Replace the Starter Fuse F1 in the interface board 63 Engine Maintenance Valve Clearance Adjustment The valve clearance should be checked after every 2000 operating hours maximum It is important that valves be adjusted to the correct specifications for satisfactory engine operation Insufficient valve clearance will result in compression loss and misfiring of cylinders resulting in burned valves and seats Excessive valve clearance will result in noisy valve operation and abnormal wear of the valves and rocker arms The intake and exhaust valves are adjusted with the valve in the closed position NOTE The cylinders these engines are numbered from the flywheel end to the water pump end The number 1 cylinder is next to the flywheel The number 2 cylinder is next to the water pump The t
44. TERY BEK L2VDC A t o Ho III a A O A A o ta te ee E te a 8h d CONDENSER CONDENSER FAN MOTOR SECTION mecs EN J a gt yey THERMOSTAT BeLTCLA STARTER Y TCLB DAA STARTER SOLENOID us E m v v ADA PRE COOLER FAN TEMP SWITCH Ue ENGINE ii LWT RET OT 03 PCr J un GROUND FRAME HABLE CH y GROUND S ORG EVAPORATOR CH FAN MOTOR l WES ES E hd COOLANT TEMP SWITCH F3 ARCTIC OPTION a AE A AE FUEL A Ia ari Pa gt t ir O USE a PUMP HIGH WATER e 1h 28 rpg WHT 0 0 590 Rises zm HEATER SECTION TEMP SWITCH oe A f e RS M E NO USED 20 3 HEATER ds 8 MI mi rs BRN CONNECTOR HEATER CC MT punt m BRN XO BRN BI S i mew aur PEE E amna A gt a E ENGINE 01509 TRUCK OTL SUMP TRUCK IT Ucet BLK 8 imu E GLOW GLOW ON OFF SWITCH i A i AX OIL PAN HEATER i FUEL TANK im I Ese N BRN ec HEATER TEMP cse P OPH wit X i e b a A y p M BLUT XS eL A n Mice T SENSOR EUIS SUPPLEMENTAL HEAT CONTACTOR i FUEL METERING og ay i il yrs 8DP gt 8 E WHT o I l PUM DIAGNOSTIC GRNIRED 5 A poU x oe CONNECTOR Pe VAM E a as A C odo A lo e L eee 2
45. The special tool is included with the glow pin Tighten torque of the glow pin 4 8 ft lb NOTE When the glow pin has been removed check the lining of the support in installed state for any contamination The lining must be replaced if the surface is covered with dirt Sleeper Cab Air Heater Service Operations Removing the Glow Plug Support Lining y L S y x AMA582 AMA583 Special tool with lining 2 Posiion ofreces 00000 s je 5 2 3 Bore 2 7 mm for glow pin ventilation Figure 83 Removing the Glow Plug Support Lining 1 Pull the lining out of the support with pointed pliers Blow out the support with compressed air If necessary carefully pierce with a wire 2 The special tool must be used to install the new lining The special tool is included with the lining Push the lining onto the special tool watching the position of the recess The recess must be positioned at right angles 90 to the axis of the heater NOTE The latest version of the lining is shorter and does not have the recess Therefore it is not necessary to consider its alignment to the axis of the heater when installing the latest version of the lining without the recess 3 Push in the tool with the lining carefully as far as it will go ensuring that the bore 2 7 mm for the glow plug ventilation is free 93 Sleeper Cab Air Heater Service Operations Removing the Overheating Sensor Fl
46. TriPac Auxiliary Heating Cooling Temperature Management System TK 53036 19 MM Rev 1 09 08 Copyright 2005 Thermo King Corp Minneapolis MN USA Printed in USA The maintenance information in this manual covers unit models TriPac 900217 For further information refer to TriPac Operating Manual TK 53035 TriPac Parts Manual TK 53037 TriPac Diagnostic Manual TK 53024 TriPac Installation Manual TK 53120 International Components Engineering ICE Compressor Service Manual ICE No 51068 Diagnosing Thermo King Refrigeration Systems TK 5984 Evacuation Station Operation and Field Application TK 40612 Tool Catalog TK 5955 Electrostatic Discharge Training Guide TK 40282 The information in this manual is provided to assist owners operators and service people in the proper upkeep and maintenance of Thermo King units The above manuals may be purchased from your local Thermo King dealer This manual is published for informational purposes only and the information so provided should not be considered as all inclusive or covering all contingencies If further information is required Thermo King Corporation should be consulted Sale of product shown in this manual is subject to Thermo King s terms and conditions including but not limited to the Thermo King Limited Express Warranty Such terms and conditions are available upon request Thermo King s warranty will not apply to any equipment which has been so repaired or altered outsi
47. a false alarm from a diagnostic controller Testing System for Leaks 1 Use an electronic leak detector to leak test the refrigeration system Carefully inspect the entire system for refrigerant oil leaks which indicate refrigerant leaks component damage and the audible release of refrigerant DANGER Due to environmental concerns and personal safety do not use a Halide torch Using this torch creates a poisonous gas which may cause death NOTE The leak tester must be capable of detecting fluorine based refrigerants NOTE To perform a proper leak check the air conditioning system should be charged with sufficient refrigerant to have a gauge pressure of at least 50 psi 340 kPa when not in operation At temperatures below 59 F 15 C leaks may not be measurable because this pressure may not be reached 2 Install a gauge manifold set 3 Check low side pressure gauge reading The manifold gauge will have a reading that falls into one of three ranges 77 Air Conditioning Maintenance 0 PSI Reading There is no pressure in the system with no obvious signs of a major leak Pressurize the system to 25 psi with refrigerant Monitor system pressure for one minute e Pressure reading does not change or falls slowly The leak is small You may add more refrigerant to this system and know that it will not rapidly vent to the atmosphere Proceed to the 1 to 50 psi procedure e Pressure drops rapidly The leak is
48. alternator Alternator Diode Quick Check This check confirms proper diode function 19 With the unit still running set the digital multi meter connected from the alternator B output to chassis ground for AC volts No more than 1 0 Vac should be present A reading of more than 1 0 Vac indicates damaged alternator diodes 20 Turn the unit off Field Current Test Use this test to determine 1f the alternator can be repaired Perform this test with the unit turned off 1 Attach a clamp on ammeter to the 2A wire near the B terminal on the alternator 2 Energize the field e On the Australian Bosch alternator connect a jumper wire between the F2 terminal on the alternator and a chassis ground e On the Thermo King alternator connect a jumper wire between the F2 terminal and the B terminal Do not connect the F2 terminal to ground or the alternator will be damaged 3 Note the ammeter reading The ammeter reading indicates the field current which should be 2 0 to 5 0 amps at 12 volts e No field current or a low field current indicates an open circuit or excessive resistance in the field circuit Remove the voltage regulator and brush assembly and inspect the slip rings If the slip rings and are acceptable install a new voltage regulator and brush assembly and repeat the test If the brushes are not the problem replace the alternator e High field current indicates a short in the field circuit Replace the r
49. ame Sensor t P ARA AMA584 Cable harness for overheating flame sensor Figure 84 Removing the overheating sensor flame sensor 1 Remove the heater cover 2 Remove the control unit 3 Disconnect both connectors of the overheating flame sensor cable harness from the control unit 4 Unlock clip from sensor 5 Remove overheating flame sensor 94 Checking the Overheating Flame Sensor Observe a maximum temperature of 320 C for checking the sensor Overheating Sensor Special tool Overheating sensor flame sensor Figure 85 Overheating Sensor and Flame Sensor 1 Check the overheating sensor with a digital multimeter If the resistance value is outside the set point indicated in the values in the table then the sensor must be replaced See table on next page Flame Sensor 1 Check the flame sensor with a digital multimeter If the resistance value is outside the set point indicated by the values n the table then the sensor must be replaced See table on next page Temp Temp F C 40 40 4 20 32 0 68 20 104 40 140 60 176 80 212 100 248 120 284 140 320 160 356 180 392 200 Temp Temp F C 40 40 4 20 32 0 68 20 104 40 140 60 176 80 212 100 248 120 284 140 320 160 392 200 464 240 536 280 608 320 680 360 752 400 Resistance k ohms Minimum 1597 0 458 8 154 7 99 3 25 02 11 56 5 782 3 095 1 757 1 050 0 665 0 425 0 285 Resistance
50. an cause painful lacerations 10 Use caution when working with a refrigerant or refrigeration system in any closed or confined area with a limited air supply for example a truck cab cargo or storage compartment or garage Refrigerant tends to displace air and can cause oxygen depletion resulting in suffocation and possible death 11 EPA Section 608 Certification 1s needed to work on refrigeration systems Refrigerant Although fluorocarbon refrigerants are classified as safe refrigerants certain precautions must be observed when handling them or servicing a unit in which they are used When exposed to the atmosphere from the liquid state fluorocarbon refrigerants evaporator rapidly freezing anything they contact First Aid In the event of frost bite the objectives of First Aud are to protect the frozen area from further injury to warm the affected area rapidly and to maintain respiration e EYES For contact with liquid immediately flush eyes with large amounts of water and get prompt medical attention e SKIN Flush area with large amounts of lukewarm water Do not apply heat Remove contaminated clothing and shoes Wrap burns with dry sterile bulky dressing to protect from infection injury Get medical attention Wash contaminated clothing before reuse e INHALATION Move victim to fresh air and use CPR if necessary Stay with victim until arrival of emergency medical personnel Refrigeration Oil Avoid r
51. and Valves Closed to Center Port Gauge Connections e You must leave Schrader valves in access ports although this lengthens the time required for evacuation 68 GC 25 SITE Manufactured Prior to 9 06 Manufactured 9 06 and later R 134a Fittings Figure 51 Connecting the Gauge Manifold Air Conditioning Maintenance 4 kal Hose Looped to Dead Head of Manifold 4 R R le Machine Figure 52 Balancing the Pressure a idis NE ween Figure 54 Recovering Refrigerant Figure 53 Evacuating the System Refrigerant Bottle Figure 55 Liquid Charging the System 69 Air Conditioning Maintenance Gauge Manifold Attachment and Purging NOTE This procedure describes attaching and purging for the gauge manifold set on units without compressor service valves Inspect the gauge manifold for correct hose and fitting connections Clean dirt and moisture from around the service ports 2 Ensure that both gauge manifold hand valves are in the closed front seated position 3 Attach the center gauge manifold hose to the Dead Head Tighten the fitting finger tight 4 Remove the caps from the suction and discharge service ports 5 Attach the high side hose pressure gauge to the discharge service port Tighten the fitting finger tight 6 Attach the low side hose compound gauge to the suction service port Tighten the fitting finger tight 7 Open the gauge manifold hand valves f
52. anual may cover more than one unit Therefore it may contain information not applicable to your unit Contents This manual is organized into the following chapters Safety Precautions Provides detailed safety information You should be familiar with the safety precautions before working on any unit Model Systems and Update These tables list the bills of material and kit options that make up your Matrices unit Use them for the following purposes 1 To determine if you have the right manual for your unit the bill of material B M number on your unit serial plate should match one of the bill of material numbers listed in this publication If you cannot find your unit B M call TK Service for more information 2 To communicate with TK Service Department If you need to call TK Service you must know your model number so that the service representative to help you Specifications Lists unit specifications General Description Gives an overview description of your unit including standard and optional features illustrations and general heating and air conditioning information Operating Instructions Provides unit operating instructions Maintenance Inspection Schedule Table of routine maintenance procedures Maintenance Chapters Provide detailed maintenance procedures required for your unit Electrical Air Conditioning Compressor Engine Structural Wiring and Schematic Diagrams Wiring and Schematic diagrams applicable t
53. any time when the untt switches are On Be sure to turn switches Off before inspecting or working on any part of the unit Engine Compressor Alternator Belt Tension Adjustment 1 The belt adjustment turnbuckle is used to adjust belt tension 2 Rotate the turnbuckle to adjust belt tension a Adjust the belt tension to 95 pounds of force b Check belt tension after 36 to 48 hours of initial operation The belt may stretch slightly during the first hours of use c Do not overtighten the belt Proper belt tension should allow the belt to be deflected 0 25 in 7 mm at center of span with no compressor movement NOTE A belt that is too tight causes severe overload on the compressor and motor bearings This will shorten belt and bearing life Use only approved Thermo King Service Parts replacement belts AMA605 Turnbuckle Flywheel Pulley Figure 48 Belt and Pulley Group 66 Air Conditioning Maintenance Maintenance Inspection Schedule Pre Trip Annual 2 000 Hrs Check condition of or service the following i Tq Check refrigerant level O A a END Check refrigerant lines for rubbing or damage Safety A WARNING Do not use a Halide torch to WARNING Make sure the TriPac can not test for leaks When refrigerants come in A start while servicing the system Turn the contact with a flame a highly toxic gas is APU Engine On Off switch to Off produced This toxic gas is extremely dangerous and may cause deat
54. artially Charged State l Connect a gauge manifold to the system see Gauge Manifold Attachment Purging and Removal Connect a refrigerant supply bottle to the center hose of the gauge manifold Purge all non condensable gases from the hoses and gauge manifold before opening the manifold s service valves Make sure that the refrigerant supply bottle is set to deliver only liquid refrigerant to the gauge manifold Start the unit in Air Conditioning Mode Allow the unit to run for 15 minutes to stabilize the system NOTE Interior temperature should be 70 to 75 F On cool nights or mornings it may be necessary to pre heat the sleeper compartment interior to properly check the charge Check the discharge pressure If the discharge pressure is not above 150 psig 1034 kPa for R 134a systems partially block the condenser air flow to raise the pressure to that level CAUTION Do not turn off the condenser fan Excessive pressures can build up and cause an explosion 5 Crack open the low side gauge valve to allow liquid refrigerant to slowly flow into the compressor suction service valve port No more than 20 psi above running suction pressure 6 Watch the liquid line sight glass Add liquid refrigerant oz at a time until the liquid line sight glass is clear Then close the low side gauge valve 7 Letthe system run for 15 minutes to stabilize 8 Check the liquid line sight glass The liquid line sight gla
55. as much of the residual oil as possible because most of the dirt particles are in the last few quarts of oil that are drained from the oil pan Refill the oil pan refer to the Specifications chapter and check the oil level NOTE Fill the crankcase slowly so oil will not run into the breather and fill up a cylinder with an open valve Leave the dipstick out while adding oil to ventilate the crankcase Run the unit and then recheck the oil level Add oil as necessary to reach the full mark on the dipstick See the Specifications page for the correct type of oil 48 Oil Filter Change The oil filter should be changed along with the engine oil Spin on Filter 1 Remove the filter 2 Apply oil to rubber ring of new filter and install filter 3 Tighten the filter until the rubber ring makes contact then tighten 1 2 turn more Spin on Oil Filter Pressure Valve Nut Oil Pressure Valve Figure 24 Oil Filter Parts Crankcase Breather The crankcase breather system ducts crankcase gases formed in the crankcase directly to the intake Harmful vapors that would otherwise collect in the crankcase and contaminate the oil or escape to the outside are now drawn back into the engine and burned The breather should be inspected yearly to make sure it is not plugged Engine Air Cleaner The air cleaner uses a dry element The air cleaner filters all of the air entering the engine Excessive restriction of the air intake
56. be capable of starting Turn on the HMI and repeat Step 4 to test the engine 55 Engine Maintenance Water in the Fuel System Water in the fuel system can damage the injection pump nozzles and prechamber This damage will subsequently cause more expensive damage to the engine A large accumulation of water in the bottom of the fuel tank will stop a diesel engine Water should be drained off periodically to avoid breakdowns TriPac draws its fuel from the truck s fuel tank Follow the truck manufacturer s procedures for removing water from the truck fuel tank Fuel Filter Replacement 1 Remove the filter and discard 2 Lubricate rubber ring of new filter with fuel 3 Install the filter and tighten until the filter is slightly loose rubber ring not making contact 4 Bleed the air from the filter by operating the electric pump until fuel bubbles appear at the top of filter 5 Tighten the filter until the rubber ring makes contact then tighten 1 2 turn more 56 Injection Pump Timing This timing procedure requires fuel pressure at the injection pump inlet This 1s be accomplished by using the electric fuel pump to supply fuel to the fuel pump inlet CAUTION The cylinders on the engine are numbered from the flywheel end to the water pump end The number 1 cylinder is next to the flywheel and the number 2 cylinder is next to the water pump The timing marks on the flywheel are matched to this system Y
57. ble Figure 74 Inspect Clutch Components 87 TM 15 Compressor Maintenance Installation NOTE Before installing the clutch perform the Inspection procedures described previously 1 Confirm that the felt is installed Gf equipped on the front of the cylinder head 2 Install the coil on the compressor with the lead wire on top At this time confirm that the coil s concave portion is aligned with the felt 1f equipped and then torque the mounting screws to 2 9 to 4 3 ft Ib 4 to 6 Nem 3 Install the lead wire in the wire holder on the compressor E r2 XA op ABHO6 Felt If Equipped Figure 75 Install Coil 4 Install the pulley assembly using the Installer TK No 204 890 and a hand press ABHO07 Figure 76 Install Pulley 88 5 Install the cover if equipped and the snap ring using external ring pliers NOTE The snap ring should be installed with the chamfered inner edge outward facing away from seal Ta A e 4 ee ry CS A ig ABHOS Snap Ring Cover If Equipped Figure 77 Install Cover and Snap Ring 6 Install the driver plate on the drive shaft together with the original shim s Press the drive plate down by hand NOTE If replacement or additional shims are required a clutch hardware kit is available ICE No 2530109 Figure 78 Install Shims and Drive Plate Install the armature bolt and torque it to 8 7 to 10 1 ft Ib 12 to 14
58. c engine and use a non contact thermometer pointed at the water pump bleeder bolt to monitor the coolant temperature The water pump bleeder bolt located next to the bleed petcock on the water pump see Figure 29 CAUTION Do not start the TriPac engine before a partial refrigerant charge has been added or damage to the A C compressor will result 9 When the temperature reaches 170 F 76 C shut off the engine for 2 minutes to allow the thermostat to heat soak and open completely to purge air out of block head and water pump 10 After 2 minutes re start the engine The remaining air in the system will be forced to the truck radiator and the TriPac APU should now be bled of all air 53 Engine Maintenance Engine Fuel System CAUTION Use fuel suitable for the A climate you operate in see truck engine manufacturer s recommendations Blending used engine oil with diesel fuel is not permitted The fuel filter may become plugged and require replacement before the TriPac will operate The fuel system used on the Thermo King TriPac diesel is a high pressure system used in conjunction with a prechamber The components of the fuel system are e Fuel tank the truck fuel tank e Fuel pre filter e Electric fuel pump in line e Fuel filter e Injection pump e Injection nozzles An electric fuel pump pulls fuel from the fuel tank through an in line fuel filter then pushes it to the fuel filter and to the injec
59. cedures found in this manual Run the TriPac and verify proper operation Air Conditioning Maintenance 79 Air Conditioning Maintenance 80 TM 15 Compressor Maintenance NOTE For compressor specifications see the Specifications chapter in this manual 29 i 0 Pin Alignment O ring Body O ring Oil Fill Plug 15 Front Gasket Oil Fill Plug Figure 62 Compressor Components 81 TM 15 Compressor Maintenance Compressor Handling and Storage CAUTION Do not turn the compressor A upside down If the compressor is turned upside down rotate the armature plate several times to circulate oil Store new and rebuilt compressors e With the correct oil charge e Horizontally e With a holding charge of nitrogen to a pressure of 7 to 21 psig 48 to 145 kPa This protects internal parts from moisture and corrosion Removing the Compressor 1 Remove the refrigerant from the unit following procedures in the Refrigeration Maintenance chapter in this manual 2 Remove the hose connections from the compressor manifold 3 Inspect hoses for wear hardness and traces of oil Replace if necessary 4 Remove the compressor from the mount noting the location of all brackets and adjustment bolts 5 Drain and measure the oil from the compressor The correct oil amount 1s listed in the Specifications chapter of this manual Thermo King P N 203 544 6 Consult specifications for correct oil
60. de the manufacturer s plants as in the manufacturer s judgment to effect its stability No warranties express or implied including warranties of fitness for a particular purpose or merchantability or warranties arising from course of dealing or usage of trade are made regarding the information recommendations and descriptions contained herein Manufacturer is not responsible and will not be held liable in contract or in tort including negligence for any special indirect or consequential damages including injury or damage caused to vehicles contents or persons by reason of the installation of any Thermo King product or its mechanical failure Recover Refrigerant At Thermo King we recognize the need to preserve the environment and limit the potential harm to the ozone layer that can result from allowing refrigerant to escape into the atmosphere We strictly adhere to a policy that promotes the recovery and limits the loss of refrigerant into the atmosphere In addition service personnel must be aware of Federal and State regulations concerning the use of refrigerants and the certification of technicians For additional information on regulations and technician certification programs contact your local THERMO KING dealer R 134a and PAG Compressor Oil WARNING Use only PAG based refrigeration compressor oil in the TriPac R 134a air conditioning system See Thermo King Parts Manual for part number WARNING With HVAC system
61. e 1s applied The current draw for the motor is e Condenser fan motor 11 8 to 12 4 amps 10 with 12 5 volts e Pre cooler fan motor 6 5 to 6 6 amps 10 with 12 5 volts Axial Fan Motor Removal and Installation Removal 1 Turn the TriPac unit off 2 Discomnect the motor power plug NOTE Motor is attached to orifice access panel frame 3 Remove fan motor mounting bolts 4 from the orifice access panel 4 Remove axial fan motor from unit Installation 1 Attach the axial fan motor to orifice panel Securely tighten fan motor mounting bolts 4 2 Connect the motor power plug 3 Start the TriPac and verify correct motor operation 4 If the unit 1s operating properly return the TriPac to service A CAUTION Fans are polarity sensitive If not properly connected the fan may run backwards 44 Mounting Holes 4 Power Plug Figure 21 Axial Fan Motor ARA1420 Evaporator Blower Motor A CAUTION Take precautions to ensure the unit will not accidentally start while you are servicing the system The evaporator blower motor is maintenance free If erratic or intermittent operation is observed the current draw of the motor should be measured The current draw for the motor is 10 0 to 11 1 amps at 12 5 volts with a rating tolerance of 10 Evaporator Blower Motor Removal and Installation Removal NOTE The motor and housing are replaced as a unit No repair is pos
62. e been attained and when the optional Arctic Package is installed if the coolant temperature has been attained Heat Mode The air heater controls the sleeper cab temperature to the setpoint entered in the HMI If the APU is enabled the evaporator fans can be on to circulate more air and battery voltage sensing 1s enabled Fan Mode The fans can be turned on for air circulation in the truck cab Fan speed is selected and battery voltage sensing is enabled The APU must be enabled Monitor Null Mode The Monitor Null mode occurs when the HMI controller is on the APU system is enabled and no Mode or Fan LEDs are illuminated fans are off Battery voltage sensing is enabled If the optional Arctic Package is installed coolant temperature sensing is enabled Truck cab temperature sensing is not enabled Engine On Off Switch DANGER Always turn the TriPac Main Power Key on the HMI Controller OFF while refueling the truck Fuel vapors could ignite if they come in contact with TriPac electrical or heater components WARNING The unit may start automatically without warning if the Engine On Off Switch is in the On position WARNING Immediately stand clear when the preheat buzzer sounds This indicates that the engine is preheating If the engine is hot preheat time will only be a few seconds The Engine On Off Switch is located inside the TriPac APU housing on the right side of the frame This switch must be
63. efrigeration oil contact with the eyes Avoid prolonged or repeated contact of refrigeration oil with skin or clothing Wash thoroughly after handling refrigeration oil to prevent irritation First Aid In case of eye contact immediately flush with plenty of water for at least 15 minutes Wash skin with soap and water CALL A PHYSICIAN 13 Safety Precautions Low Voltage Control circuits used in the TriPac unit are low voltage 12 volts dc This voltage potential 1s not considered dangerous but the large amount of current available can cause severe burns if shorted or grounded Do not wear jewelry watches or rings when working on the unit If these items contact an electrical circuit severe burns may result CAUTION Always disconnect power at A the battery before removing or repairing electrical components Failure to do so may result in personal injury or damage to the equipment 14 Model Systems System Designations Thermo King TriPac Auxiliary Heating amp Cooling Temperature Management System System System Pc esso Number POM nest Refrigerant Wiring Diagram Schematic Diagram 1E36877 Rev 1 0 IFB 1E36876 Rev 1 0 IFB 900217 005019 800220 R 134a 1 40288 Rev 1 5 IFB 140289 Rev 1 5 IFB NOTE When calling the dealer or factory for information or parts please have the Bill of Material number for your particular unit handy 15 Model Systems System Designations 16 Specif
64. el System Nylon Fuel Lines 0 0 0 ccc rh 55 Figure 32 Fuel Return Line Banjo Fitting 0 ee III Hn 55 Figure 50 COMPONEN LOCATION sry 64 0 Sets 9 A Seal det Gee Go EAS Cae ELS EN E A 56 Foures MNO MARES 0 or mie s ng i d Noc di a Datos ticos wes alice aie Meant etek Xt t 57 Figure 39 NECHON I TID ax percorsi Sed pod p She dpi dfe reae n a aes a Bee ea 57 Figure 36 Correct Injection Timing Mark Alignment 0 0 0 0 eee eee 58 Figure 37 Correct Injection Timing Mark Alignment With Series Of Injection Timing Marks 58 Figure 39 Index Mark LOCATION cutus A Ca ra a te ADA MET ed a i dk ene Beet ie 59 Figure 39 Index Marc ATO IL 3 5 4 5 oscir AA AAA QC Ao READ GC Ue Cr C A at Caci 59 Figure 40 Injection Pump Removal and Installation llli 60 Figure 41 Integral Fuel Solenoid Components oooo ens 61 Figure 42 Fuel Solenoid Pin Identification o oooooooooooooorer hs 61 Figure 43 Fuel Solenoid Components ees 63 Figure 44 Timing MarkS uu ween case Gu doe atc dos Pek pde Pas wheat do aae Y Vs dew Loc Ado tees 64 Piguresd5 Valve lea all6B ia aida 64 Figure 46 AUSTIN Ya VES ata A AAA AAA ANA e Da er 65 Figure 47 Engine Speed Adjustment 0 o ooooooono esie rss 65 Figure 46 Belt and Pulley Group 6 9 6 vs turo 26nd Vere Bons Verr A a 4 Ed A dd ER durs 66 Figure 49 Hand Valves Opened to Center Port o o o ocococooo eer 68 Figure
65. er Cover Figure 80 Remove Air Heater Cover NOTE The cover must always be removed from the heater for all repair stages You may have to wait for the heater to cool down Unlock both seal plates lift cover and pull to the front 2 The cable harness can exit from the left or right of heater shell 92 Removing the Control Unit Retaining brackets Control unit Figure 81 Removing Control Unit Remove the heater cover 2 Unscrew fastening screw press retaining brackets together lift out control unit 3 Unclip the lines from the holder of the control unit observe the positions of the lines 4 Remove the bushing lower part from the outer case 5 Disconnect the control unit from the controller The control unit can now be removed NOTE When reassembling the control unit ensure that the lines are correctly clipped in the holder of the control unit and that the connectors are plugged into the control unit non interchangeable Heater Casing Disassembly and Glow Pin Removal 3 AS Td AMA581 4 Rubber bushing Connector of glow pin cable harness AMA580 Glow Pin removal tool Figure 82 Heater Casing Disassembly and Glow Pin Removal 1 Remove the heater cover 2 Remove the control unit 3 Disconnect the connector of the glow pin cable harness from the controller 4 Remove the rubber bushing and use the special tool SW 12 to unscrew the glow pin
66. eration system or oil containers e Do not weld or steam clean near A C lines and components Excessive heat builds up dangerous system pressures e Do not expose refrigerant oil to air longer than necessary Refrigerant oil absorbs moisture when exposed to air Use sealed containers e Reinstall refrigerant tank cap after each use when storing refrigerant This provides protection to the valve and safety plug Do not pour oil into another container unless absolutely necessary If you must use another DANGER Breathing refrigerant reduces container make sure it is clean and dry the oxygen level in the blood Inhaling high concentrations of refrigerant vapor is harmful and can cause heart irregularities unconsciousness or death Intentional misuse or deliberate inhalation may cause death e Do not mix different refrigerants Different refrigerants and oils are incompatible 67 Air Conditioning Maintenance PAG Oil Handling Procedures e Do not mix PAG oil with other compressor Oils e Do not use equipment contaminated with Polyolester oils Gauge Manifold Connections Use fittings designed for R 134a refrigerant Gauge Manifold Positions The gauges indicate low and high side pressures Operate one or both hand valves to perform the different service operations Hand Valves Opened to Center Port Figure 49 Hand Valves Opened to Center Port Hand Valves Closed to Center Port Figure 50 H
67. erature falls below 105 F 40 C 49 Engine Maintenance Coolant Temperature Switch Arctic Option 6 Bleed Valve Water Temperature Switch Pre Cooler Fan Pre Cooler Coil Switch Water Pump 8 Pre Cooler Fan 4 Thermostat Ball Valve Coolant Hose Outlet back to truck engine 5 Thermostat Cover 10 Ball Valve Coolant Return Hose Inlet coolant from truck engine Figure 26 Engine Cooling System Components Before 10 06 50 Engine Maintenance A1305 Water Pump 6 Coolant Temperature Switch Arctic Option Thermostat Pre Cooler Coil Thermostat Cover B Pre Cooler Fan 4 Bleed Valve Ball Valve Coolant Hose Outlet back to truck engine 5 Water Temperature Switch Pre Cooler Fan 10 Ball Valve Coolant Return Hose Inlet coolant Switch from truck engine Figure 27 Engine Cooling System Components 10 06 and After 51 Engine Maintenance Antifreeze Maintenance Procedures As with all equipment containing antifreeze periodic inspection on a regular basis is required to verify the condition of the antifreeze Inhibitors become worn out and must be replaced by changing the antifreeze TriPac shares coolant with the truck engine The APU 1s equipped with inlet and outlet coolant fittings Coolant from the APU is routed to the truck engine where it 1s circulated through the engine block and returned back to the APU s pre cooler A coolant hose is routed from the outlet fitti
68. es 220 5 F 104 3 C Opens 190 5 F 88 3 C Coolant Temperature Switch Optional Arctic Package Normally Open Closes 35 11 F 1 6 6 1 C Opens 55 t 11 F 12 7 6 1 C Engine Thermostat 180 to 190 F 82 to 88 C Coolant System Capacity 0 6 quarts 0 6 liters Thermo King synthetic oil is compatible with petroleum lubricants so there is no danger if accidental mixing occurs or if an emergency required addition of petroleum oil Mixing is not recommended however since it will dilute the superior performance properties of the synthetic oil Multi viscosity weight oil with the recommended API classification may be used based on the ambient temperature The above recommendations are written for mineral oil based lubricants Cooling system capacity may vary depending on installation Cooling lines carry additional coolant 0 6 quarts 0 6 liters is engine only 17 Specifications R 134a Air Conditioning System Compressor Model TM 15 HD Refrigerant Charge 1 2 lbs 0 54 Kg minimum 2 0 lbs 0 9 Kg maximum Correct system charge varies Correct charge will depend upon installation and refrigeration line lengths Compressor Oil Charge 8 oz 236 5 ml Compressor Oil Type See Compressor Oil Specifications on following pages Binary Switch Prior To 9 06 High System Pressure Cutout Opens 325 25 psig 2241 172 kPa Cut in Closes 230 20 psig 1586 138 kPa Low System Pres
69. es with an oil charge that may not be compatible with your system Check system decals and operation manual for correct oil type See Compressor Installation Procedures If the oil charge in a new compressor is not compatible with your air conditioning system remove and replace the oil CAUTION Mixing incompatible oils will damage your system Cil Check Interval Check compressor oil e Per maintenance schedule e When the compressor evaporator condenser or receiver drier is replaced e Whenrefrigerant has leaked from the system for example high pressure relief valve discharges e When refrigerant leaks from the compressor Returning Oil to Compressor Recovering Refrigerant and Removing Compressor During operation oil circulates with refrigerant in a system Before checking the oil you must return as much as possible to the compressor Not doing so will result in an incorrect measurement To return oil to the compressor 1 Open the cab doors and windows to raise the interior air temperature to 75 to 80 degrees 25 to 27 C The ambient air temperature should be above 85 degrees F 29 C If not partially block the condenser air flow to raise the compressor discharge pressure above 170 psig 1172 kPa 2 Run the A C system for approximately 20 minutes 3 Turn the A C system off 4 Stop the unit and disconnect the battery for safety 5 Recover the refrigerant See the Refrigeration Maintenance cha
70. ess and in the main wire harness Turn the unit off and reconnect the alternator harness Attach a clamp on ammeter around the RED 2 and 2A wires connected to the B terminal on the alternator All wires connected to the B terminal must pass through the clamp on ammeter Connect a digital multi meter between the B terminal at the alternator and chassis ground Turn the unit on and allow it to start Using the clamp on ammeter check the current flow in the RED 2 and 2A wires A positive reading indicates the alternator 1s charging On unit startup the current flow should momentarily increase to allow for battery current used during preheat and cranking Within a short time the current should fall to normal unit load plus charge current to the battery A reading on the clamp on ammeter at or near 0 amps indicates the alternator is not charging The alternator is defective if there are no problems in the wiring Recheck the wiring before assuming the alternator is defective Check the voltage at the B terminal The voltage should increase until it reaches the anticipated voltage regulator setting as shown in the table below Record the voltage The voltage regulator setting varies inversely with the temperature as shown below Regulator voltage can vary from approximately 15 2 Vdc at 40 F 40 C to approximately 13 2 Vdc at 176 F 80 C Anticipated Regulator Voltage 40 F 40 C From 15 2 Vdc to 14 0 Vdc 77 F
71. eth ce oer te eth an ion a ete eater acs at whee E E A AEE 32 Air Conditioning Mode 3 et is RR Ai DAA a ARG eee Ie 32 FICE MOOS oscar ah a Satna tienen da Coca et acne a a o isa Seat set iron Soe ch Went eater o 32 Fan MOGE cai a Gee eae ee AA EU ae ee Ee EU ee et ee ad etur ee 32 Monitor Nal MOGO 4 2 252 26 cir Se idee er Ro ER Sots od Dot Ro Ge dons dae or c hae Beo Sed ghd dp RC RC ca Noe 32 ENgine On Off SWIC 4 024 pat D IHRER td ey AA LEURS EROR RUN d 8 8 del bee CUR ACER ewes A 33 TriPac HMI Controller Operation 0 0 RR RR rans 33 Press HMI Controller Main Power Key o o o ooocoooor rns 33 Enable AP SVSIGI ya itu tta tr eii A et d o lici Ar ear RAEE a 33 Engine Hourmeter DISplay uu ard ir AAA RANA IC a CC ERE a E e s 34 Select Model Operation 22 95 v IY oe A hA RI be hd Eden ewe aaa ees ds 34 Selech Edi Ded adeo E NT Cua pa Odd ed p ded 34 Select Temperalure SSIPOIAL 2 4 1 92 intet dei die dio muU cod dir dpa ied di epe iud 34 System Fault Ndc 244 2 9 ge oh he o e Boe eoe Doce o od obese ss Nc e ed Xue DET e 35 PAINE OC OS ack cis RT its teste eae eee ae eee ea Pe a Be ee ee a ee ee ee 35 To GleardAlarm COdBS c2 seas eect ce AA nico eae see A ies we alae A woe Ree ne oe 35 Optional Standby Overaiion sia iacet A a 35 Options Used With Standby Operation o o o ooo or har 36 standby Truck Integrati n sicer res a e dat eR UE tere dc C SU on aca oa aa pbi 36 Truck Integration Selector Switch
72. etpoint alarm codes hourmeter reading and other information The LED indicator at lower right will be 1lluminated when the sleeper dempto cab temperature setpoint is displayed The LED indicator at upper left will be illuminated when the inside or outside temperature is displayed Main Power Key The HMI Controller Main Power Key is used to turn the TriPac system on and off from the sleeper compartment The green LED indicator is illuminated when the TriPac system 1s turned on it Ac O 4p DEF OYE HEAT O 36 FAN 6 Up and Down Keys Fan Speed Key 6 APU Key xi mc NM System Fault Indicator Mode Key The HMI Controller Mode Key is used to select the desired operating mode When the TriPac system is turned on the mode will default to the setting last used A C air conditioning Fan and Heat modes are selected by pressing the Mode key DEF is not used A Monitor Null mode will occur when no LEDs are illuminated This allows the unit to monitor the battery voltage and optionally the coolant temperature without monitoring the truck cab temperature Up and Down Keys The HMI Controller Up and Down Keys are used to raise and lower the temperature setpoint in the display Each press of the Up or Down key will raise or lower the setpoint temperature by one degree The display will scroll up or down if the Up or Down key is pressed continuously The HMI Controller setpoint temperature
73. f oil faulty relief valve or worn bearings The use of improper viscosity oil will also produce low oil pressure shutdowns The TriPac diesel engine has a pressure lubrication system Oil is circulated by a trochoid type oil pump driven by the crankshaft timing gear and has several times the capacity required by the engine Oil is picked up through a suction tube with a screened inlet Oil to the rocker arm shaft flows through a tube on the outside of the engine and into the head through a restrictor fitting 47 Engine Maintenance Engine Reset Switch The engine 1s protected by a reset switch Typical causes for an open engine reset switch are low oil pressure high water temperature or an engine start failure The engine reset switch is located on the side of the Interface Board control box enclosure NOTE To check the operation of the engine reset switch ground the 20 circuit to the engine reset switch while the engine is running The engine reset switch should trip open and stop the engine in approximately one minute or less AMA618 Figure 23 Engine Reset Switch Engine Oil Change The engine oil should be changed according to the Maintenance Inspection Schedule Drain the oil only when the engine is hot to ensure that all the oil drains out When changing oil try to make sure that the unit is not tipped away from the direction that the oil is supposed to flow out of the oil pan It is important to drain
74. factory results NOTE Dirty vacuum pump oil or a defective vacuum pump will prevent a low micron reading Hoses and fittings can be isolated individually to identify leaks Unit Evacuation Procedure NOTE Do not attempt to evacuate the unit until the evacuation equipment has been tested and its performance has been verified l Perform all needed service or maintenance 2 Test the system for leaks 3 Prepare the unit for evacuation Recover refrigerant to O psig 0 kPa or EPA equivalent NOTE Federal Regulations may require your recovery machine to pull the system s pressures lower than 0 psig 0 kPa A CAUTION Do not attempt to evacuate a l unit until you are certain that the unit is leak free A unit with less than a full refrigerant charge should be thoroughly leak checked and all leaks must be repaired Connect one hose from the evacuation station valve manifold to a refrigerant supply bottle Keep bottle valve closed Install gauge manifold on the suction and discharge service ports of the TriPac Connect a gauge manifold to the spare access port on valve V 4 Air Conditioning Maintenance Gauge Manifold Connection R 134a Fitting Figure 60 Connect Gauge Manifold Start the vacuum pump and open valves V 1 V 2 V 3 V 4 Evacuate the system to 500 microns After the system reaches 500 microns evacuate for one additional hour After the additional one hour of evacuation cl
75. for Number 1 ee Index ee Mark on Starter Mounting Plate Figure 44 Timing Marks Use a feeler gauge to check the valve clearance on both valves for the number 1 cylinder The valve clearance for both the intake valves and the exhaust valves should be 0 006 to 0 010 in 0 15 to 0 25 mm NOTE Check to make sure that the valve stem cap is in good condition and is positioned squarely on the top of the valve stem Replace the valve stem cap if it shows significant wear Adjust the valves if necessary by loosening the lock nut and turning the adjustment screw until the valve clearance 1s correct AGA148 Adjustment Screw Lock Nut Figure 45 Valve Clearance 5 Hold the adjustment screw in place and tighten the lock nut Em rb Y c RNC y en iC e R vs v k AGA114 gt 3 N 0 gt e QU L Figure 46 Adjusting Valves 6 Recheck the valve clearance 7 Place the engine at top dead center of the compression stroke for the number 2 cylinder a Rotate the engine in the normal direction of rotation counterclockwise viewed from the flywheel end until the top dead center timing mark for the number 2 cylinder on the flywheel lines up with the index timing mark on the starter mounting plate b Check the rocker arms on the number 2 cylinder to see if they are loose c If the rocker arms are loose the engine is at top dead center of the compression stroke
76. for the claw mount or 200 ft Ibs 271 2 Nem for the direct frame mount TriPac System Components Diagram di Nd Tans S31V3H 2 393378 SMONAL El NVINI YA LVAH 9 Adv OvdiMl EU ISNVHX3 MalvsH S ANVL TINA s onul 1 yalvaH v sani dnxold 13N3 oU Jolvsodv 3 OW SNIONS SONAL 6 ala 3013938 C 3909 Y3 LW3H s onal 8 43sN3aNoo ov 1 SLNANOdINOD S WWW TWWYWATWTYWTYAWATYWYWAYWATYAYAYATYAM Sa Figure 93 TriPac System Components AED S VAAANAAANAAANAAAAA 103 TriPac System Components Diagram 104 Index A about this manual 5 alternator 39 field current test 43 general diagnostic and warranty evaluation procedure 41 identification 39 load test 41 antifreeze checking 52 maintenance procedures 52 B belt adjustment 66 belt tension on small compressors 89 belt tension specifications 18 C charging from a partially charged state 76 from an evacuated state 76 charging system diagnostic procedures 39 clutch inspection in small compressors 87 installation 88 pulley and belt alignment on small compressors 89 removal for small compressors 86 test for small compressors 86 components oil amounts in small compressor systems 85 Compressor 92 compressor 27 handling and storage for small compressors 82 labeling small compressors 82 oil specifications 23 removal and installation 92 removing small compressors 82 small compressor belt tension 89 small compressor clutch
77. for the number 2 cylinder d Ifthe rocker arms are tight the engine is at top dead center of the exhaust stroke for the number 2 cylinder Rotate the engine 360 degrees to place the engine at top dead center of the compression stroke for the number 2 cylinder 8 Check and adjust both valves for the number 2 cylinder 9 Replace the cylinder head cover Engine Maintenance Engine Speed Adjustment Compressor Clutch must be engaged l Start the unit and let it run until the engine is warmed up Use the HMI Controller to cause the engine to run if necessary The engine speed should be 1800 25 RPM while the compressor clutch is engaged Engine speed is controlled by the governor lever If the engine speed is not correct loosen the jam nut on the low speed limiting bolt Turn the low speed limiting bolt to change the engine speed Turn the screw in to increase the engine speed Turn the screw out to decrease the engine speed Set the engine speed at 1800 25 RPM and tighten the jam nut Under no load operation the engine speed will be approximately 1850 25 RPM ONG Id IR SY M AS IBS 3 lt a UN NY i 1 I Si R ye NA 7 C sore O IS f NOS Q RP N LLIN RAY IPA AMA613 Low Idling Speed Limiting Bolt Figure 47 Engine Speed Adjustment Y 65 Engine Maintenance Belt Adjustment CAUTION The unit may start A automatically and at
78. fuel injection pump Operation of the TK270 engine is controlled by the operation of the fuel solenoid The fuel solenoid consists of a spring loaded plunger and electro magnetic coil When the engine is OFF spring tension on the plunger maintains the plunger s out position When pushed out this causes the governor linkage to move the injection pump rack to the Fuel Off position When the fuel solenoid is energized current is applied to the coil creating an electro magnetic field When in the pulled in position the plunger releases tension on the governor linkage The governor linkage then moves the fuel injector rack thus controlling the fuel flow and placing it in the Fuel On position Fuel Solenoid Fuel Injection Pump Figure 41 Integral Fuel Solenoid Components Troubleshooting the Integral Fuel Solenoid System NOTE The fuel solenoid pull in coil will require 35 to 45 amps to turn on the fuel The unit s battery must be in good condition If the battery has enough power to crank the engine over it has enough power to energize the fuel solenoid pull in coil Engine Maintenance If you suspect that the engine does not run because the fuel solenoid is not operating correctly use the following procedure l Disconnect the 20 wire from the reset switch so the reset switch will not trip Remove the Starter Fuse F1 from the interface board Disconnect the fuel so
79. h Many service procedures are regulated by federal state and local laws EPA certified technicians must perform regulated refrigeration service procedures using approved equipment and complying with all federal state and local laws e Avoid skin contact with refrigerants Refrigerant contact on skin causes frostbite e Do not breathe refrigerant fumes or vapor Conduct test procedures in areas with good ventilation Refrigeran rvi f efrigerant Service Safety e Do not vent refrigerants to the atmosphere Procedures Recovery of refrigerant is required by most Observe these precautions while performing government regulations Refer to local laws refrigerant procedures for the proper handling of refrigerants and Use the recommended procedures found in refrigerant oils this manual when servicing equipment e Wear the proper clothing when handling Do not apply open flame or heat the tank refrigerants Wear goggles to prevent exposure above 125 F 52 C If needed to charge the from liquid refrigerant to face and eyes Use A C system immerse the tank in 70 F to 80 F butyl lined gloves when handling refrigerants 21 to 27 C water General Refrigerant Handling e Do not fill refrigerant tanks completely Allow Procedures space for liquid expansion To monitor the amount of liquid in a tank weigh the tank before and during the filling operation e Use clean tools to prevent contamination when opening a refrig
80. he closing pressure for the HPCO is 325 psig 2241 kPa Low System Pressure Cutout Switch The Low System Pressure Cutout Switch is a normally closed pressure sensitive switch On models manufactured prior to 9 06 it is part of the binary pressure switch mounted on the receiver drier typically near the TriPac condenser On models manufactured during 9 06 and after a Low Pressure Cutout Switch LPCO is installed at the evaporator coil If the pressure falls below the switch s opening pressure the switch opens the circuit to stop the compressor The opening pressure for the binary switch is 22 5 psig 155 kPa The opening pressure for the LPCO is 5 psig 34 kPa When the pressure rises above the switch s closing pressure the switch closes to allow compressor operation The closing pressure for the binary switch 1s 40 psig 276 kPa The closing pressure for the LPCO is 20 psig 138 kPa 28 Fuse Protection QD os e cnn 0005 00 OL eu 1o Ee O M c 000000 ejeleeeeese Wi Hi L1 CH CH FS FS2 BL2 BLi 7A P E 0000 000 d TN do a 0000000 aB T a gooooooo Oo OU 0000000 LI Y IT AMA723 Figure 6 Interface Board The electrical system is protected by a number of fuses see Fuses on page 18 Most of the fuses are located on the interface board shown above or in the control box near the interface board Engine Reset Switch The engine is protected by a
81. ic start stop feature for additional fuel efficiency TriPac s two cylinder diesel engine is EPA Tier 2 approved An automotive type air conditioning compressor is used for sleeper compartment cooling A fuel fired air heater provides sleeper compartment heat in cold conditions Voltage sensing automatically charges the truck batteries from TriPac s 12 volt alternator Noise dampening construction assures quiet operation Truck engine preheating provides easier cold climate starts by exchanging coolant between TriPac and the truck engine An optional inverter provides 120 volt power to operate on board appliances An optional Arctic package aids truck engine startups in cold weather by sensing low coolant temperature The TriPac is started to heat the coolant as required Unit Features e Easy to operate Human Machine Interface HMI Controller e Truck cab sleeper compartment cooling and heating for driver comfort in all climates e Truck engine preheating for easy starts in cold climates e Truck battery charging with automatic low voltage sensing e 7 5 hp 2 cylinder diesel engine EPA Tier II e Thermo King TM 15 XD compressor for air conditioning e Diesel fuel fired sleeper compartment air heater e 65 amp 12 VDC alternator e Noise dampening construction for quiet operation e Automatic start stop operation for maximum fuel efficiency e Optional Standby Truck Integration e Optional dash mounted Truck Integratio
82. ications TriPac Engine EALE Fuel Type No 2 Diesel fuel under normal conditions Caution Use fuel suitable for the climate you operate No 1 Diesel fuel is acceptable cold weather fuel in see truck engine manufacturer s recommendations Blending used engine oil with diesel fuel is not permitted in the TriPac system It will plug the filters and will not allow the air heater to run properly Thermo King reserves the right to void all warranty on the unit Oil Capacity Crankcase amp Oil Filter 4 5 quarts 4 3 liters w Bypass Oil Filter Fill to full mark on dipstick Fill the crankcase slowly so oil will not run into the breather hose and fill up an open cylinder Leave the dipstick out while adding engine oil to vent the crankcase Oil Type API Type Cl 4 or better multigrade oil API Synthetic Type Cl 4 or better after first 1000 hours optional API Type CJ 4 or better multigrade oil is required for units equipped with the optional DPF Diesel Particulate Filter Oil Viscosity 5 to 104 F 15 to 40 C SAE 15W 40 4 to 86 F 20 to 30 C SAE 10W 30 Engine RPM No Load Operation Compressor Clutch Disengaged 1850 25 RPM Under Load Operation Compressor Clutch Engaged 1800 25 RPM Engine Oil Pressure 50 psig 345 kPa at rated output 18 psig 128 kPa at low idle Low Oil Pressure Switch Normally Closed 15 2 psig 103 14 kPa High Coolant Temperature Switch Normally Open Clos
83. ifications Truck Sleeper Compartment Heater D4 Option Heat Output 10 13 600 BTU hr Boost 4 0 kW 10 200 BTU hr High 3 0 kW 6 800 BTU hr Medium 2 0 kW 3 400 BTU hr Low 1 0 kW Current at 12v 10 8 3 amps Start 3 3 amps Boost 2 0 amps High 1 1 amps Medium 0 6 amps Low Fuel Consumption 10 Boost 0 13 gal hr 0 51 liter hr High 0 10 gal hr 0 38 liter hr Medium 0 07 gal hr 0 25 liter hr Low 0 03 gal hr 0 13 liter hr Air Flow 1096 85 cfm Boost 69 cfm High 50 cfm Medium 30 cfm Low Motor Speed 4400 130 RPM Boost 3600 100 RPM High 2800 80 RPM Medium 1600 50 RPM Low 600 20 RPM Adjustment in circulation mode with temperature sensor internal 0 RPM Adjustment in fresh air mode with temperature sensor external 3600 100 RPM Ventilation Operating Voltage Range 10 5 16 vdc Overheat Temperature Shutdown 10 240 F 115 C Resistance Values Glow Plug 0 5 0 05 Ohms Fuel Metering Pump 10 0 5 Ohms Operator Control Unit Set Value Potentiometer 1750 2080 0 5 Ohms Optional Power Inverter See Manufacturer s Specifications 1800 Watts Specifications Optional Extreme Arctic Package Components Approximate Approximate Current Draw Amps Resistance at 12 5 Vdc Ohms Coolant Heater 800 Watts Supplemental Heater Contactor Coil NOTE Disconnect components from unit circuit to check resistance 22 opecifications Compressor Oil
84. igerant to the gauge manifold Set scale to weigh refrigerant With the unit off open the high side gauge valve to allow liquid refrigerant to flow into the discharge side of the unit When the required amount of refrigerant has flowed into the unit close the high side gauge hand valve If the refrigerant stopped flowing into the unit before the full refrigerant charge was reached close the high side gauge hand valve and proceed to Charging from a Partially Charged State Step 3 Start the APU and allow the unit to run for 15 minutes to stabilize the system NOTE Interior temperature should be 70 to 75 F On cool nights or mornings it may be necessary to pre heat the sleeper compartment interior to properly check the charge Check the discharge pressure If the discharge pressure is not above 150 psig 1034 kPa for R 134a systems partially block the condenser air flow to raise the pressure to that level Check the liquid line sight glass The liquid line sight glass should be full and clear with no bubbles If bubbles are found in the liquid line sight glass proceed to Charging from a Partially Charged State below 9 After confirming the charge close the 10 11 refrigerant supply bottle valve close all service valves remove the manifold gauge set and turn off the engine Replace all service caps Leak check all areas and repair any leaks Release the TriPac back into service Charging from a P
85. iming marks on the flywheel are also numbered this way The timing marks on the flywheel of the two cylinder engines are stamped 180 degrees apart The top dead center marks have the cylinder number stamped next to them The injection timing marks have no identification marks see Figure 44 The index timing mark is stamped on the side of the starter mounting plate that faces the flywheel This index timing mark is on the intake side of the engine 1 Remove the cylinder head cover CAUTION Loosen all of the injection lines at the injection nozzles to prevent the possibility of the engine firing while it is being rotated 2 Place the engine at top dead center of the compression stroke for the number 1 cylinder a Rotate the engine in the normal direction of rotation counterclockwise viewed from the flywheel end until the top dead center timing mark for the number 1 cylinder on the flywheel lines up with the index timing mark on the starter mounting plate b Check the rocker arms on the number 1 cylinder to see if they are loose c If the rocker arms are loose the engine is at top dead center of the compression stroke for the number 1 cylinder 64 d Ifthe rocker arms are tight the engine is at top dead center of the exhaust stroke for the number 1 cylinder Rotate the engine 360 degrees to place the engine at top dead center of the compression stroke for the number 1 cylinder bu 1 Top Dead Center Mark
86. in the On position for the TriPac engine to operate A y J E Mi v 3 LS a D 4 S E e SANA Wi ie m d S i 7 Figure 10 Later Engine On Off Switch Location Operating Instructions TriPac HMI Controller Operation Press HMI Controller Main Power Key 1 Press the Main Power Key The green LED indicator will be illuminated when the HMI Controller is turned on Hi THERMO KING CLIMATE CONTROL Q 36 auto Q 36 HIGH O X MED OX Low Es o Bll 22 1 pi AMA562 Figure 11 HMI Controller Main Power Key Enable APU System 2 The Engine On Off Switch inside the TriPac APU must be on for the engine to run Press the HMI Controller APU Key to enable the diesel power unit and also enable sleeper compartment air conditioning air circulation truck battery voltage sensing and engine coolant temperature sensing The APU Key LED will be illuminated while the APU is enabled When the APU Key is initially pressed the TriPac unit engine hourmeter reading will be displayed See next step RE THERMO KING O X AUTO O 36 HIGH O 36 MED O XK Low JO ove SYSTEM 2 AMA563 Figure 12 APU System Key 33 Operating Instructions Engine Hourmeter Display 3 When the APU Key is initially pressed the TriPac unit engine hourmeter reading will be displayed The display will flash three screens starting with HrS and followed by tX X for thousands of hours and then XXX
87. inder head cover tighten the other injection lines and replace the Starter Fuse F1 in the interface board when finished with the procedure Injection Pump Removal and Installation Injection Pump Removal l Note the alignment of the index marks on the injection pump and the gear case If they are not marked mark them so the injection pump can be returned to the same position when it is reinstalled Ly Index Marks Figure 38 Index Mark Location Index Mark on Injection Pump Index Mark on Gear Case Figure 39 Index Mark Alignment Engine Maintenance Remove the fuel lines wire harness and mounting hardware from the injection pump Remove the injection pump timing cover from the gear case Loosen the injection pump gear mounting nut but do not remove it yet NOTE The injection pump gear assembly is made of two pieces the flange and the gear Do not loosen or remove the four bolts that fasten the gear to the flange because that changes the timing Use a suitable puller to loosen the injection pump gear from the injection pump shaft Remove the injection pump gear mounting nut and lock washer Use a shop rag to prevent the lock washer or nut from falling into the gear case Remove the injection pump from the gear case but leave the injection pump gear in the gear case This keeps the teeth on the injection pump gear aligned properly with the teeth on the idler gear If you remove the injection
88. ise viewed from the water water pump end until the until the top E OAM NE pump end until the injection timing mark or dead center mark for the number 1 l l the 16 degree BTDC mark see Figure 37 is cylinder on the flywheel lines up with the n l o positioned about 1 0 in 25 mm below the index timing mark on the starter mounting M index timing mark on the starter mounting plate plate 8 Use a clean towel to remove the fuel from the 1 top end of the delivery valve holder RE y Injection Timing Mark Top Dead Center Mark for Number 1 Cylinder Index Timing Mark on Starter Mounting Plate Figure 34 Timing Marks b Check the rocker arms on the number 1 Delivery Valve Holder cylinder to see if they are loose Figure 35 Injection Pump c If the rocker arms are loose the engine is 9 Slowly turn the engine in the normal direction at top dead center of the compression stroke for the number 1 cylinder of rotation until you see the fuel rise in the end of the delivery valve holder Stop as soon as d Ifthe rocker arms are tight the engine is at you see the fuel rise top dead center of the exhaust stroke for the number 1 cylinder Rotate the engine 360 degrees to place the engine at top dead center of the compression stroke for the number 1 cylinder 57 Engine Maintenance 10 Check position of the timing marks The injection timing mark on the flywheel should be aligned with the index timing mark on the starter mou
89. k ohms Maximum 1919 0 533 4 175 5 65 84 28 04 13 16 6 678 3 623 2 061 1 256 0 792 0 518 0 351 Values for Overheat Sensor Values for Flame Sensor Resistance ohms Minimum 825 9 903 2 980 0 1056 4 1132 3 1207 8 1282 8 1357 4 1431 5 1505 1 1578 3 1723 4 1866 6 2008 1 2147 7 2285 5 2421 5 Resistance ohms Maximum 859 6 940 0 1020 0 1099 5 1178 5 1257 1 1335 1 1412 8 1489 9 1566 6 1642 8 1793 7 1942 8 2090 0 2235 4 2378 8 2520 3 Sleeper Cab Air Heater Service Operations Installing the Overheating Flame Sensor AMA588 Special tool EIN S Comesoraeen CN AN Figure 86 Installing the overheating flame sensor 1 Mount the special tool on the sensor 95 Sleeper Cab Air Heater Service Operations 96 Place the sensor on the heat exchanger using the special tool The special tool slides on the heat exchanger until the sensor meets the collar installation site of the sensor Lock the sensor in place and remove the purpose made tool It is important to make certain that the sensor sits flat on the heat exchanger If necessary use a mirror and lamp to aid correct assembly Route the cable harness sensor along the clip eyelet to the control unit and connect Dismantling the Heat Exchanger and Removing the Combustion Air Blower p AMA591 AMA596 1 Combustion air blower Heat exchanger 2 a d Tighten the fastening screws in thi
90. le is open Use non each month detergent 10046 volatile carburetor cleaner An air gun will also help Remove loose carbon from the glow pin chamber e Maintain batteries and all electrical connections in good condition The heater will not start with insufficient power Low and e Inspect the ducting the air intake screen and high voltage cutouts will shut the heater down air outlet for restriction or blockage automatically 91 Sleeper Cab Air Heater Service Operations WARNING To prevent personal injury make sure that unit switches are in the Off position before servicing the unit CAUTION Use fuel suitable for the climate you operate in see truck engine manufacturer s recommendations Blending used engine oil with diesel fuel is not permitted NOTE The Cab Air Heater contains an EEPROM that monitors the functions and operating status of the air heater s circuitry inputs amp outputs and components Whenever a fault occurs the air heater EEPROM is programmed to recognize dozens of fault codes The five most recent fault codes are retained in the EEPROM memory Older fault codes are deleted from memory as new fault codes occur Fault codes can be retrieved in chronological order and read using a special Fault Reader TK P N 204 1143 Complete instructions on the use of the fault code reader and resolution of air heater fault codes are found in the TriPac Operating and Diagnostic Manual TK 53024 Remove the Air Heat
91. lem may exist in the RED output circuit from the alternator to the battery Check for an open RED circuit loose connections defective battery cables or dirty battery terminals e The battery must be in good condition and capable of accepting a charge Check for a damaged battery correct electrolyte level and loose or corroded connections e The alternator charging output will be low if the alternator belt or pulleys are defective or the belt is not properly adjusted Be sure the belt is not loose or cracked and the pulleys are the correct size and in good condition The alternator pulley nut must be tight It should be torqued to 50 ft Ib 68 Nem e Theexcitation circuit D circuit must supply voltage to the excite terminal of the alternator e The sense circuit 2A circuit must supply voltage to the sense terminal of the alternator e The alternator must be properly grounded e The unit control circuits or installed accessories may be drawing excessive current e An overcharged battery is usually caused by a defective voltage regulator Alternator Identification Australian Bosch Alternators see Figure 19 were used on these units until the third quarter of 2006 when the units started using Thermo King Alternators see Figure 20 e The word Bosch is present on the rear bearing housing of Australian Bosch Alternators e Thermo King Alternators are painted black NOTE The alternators used on TriPac unit
92. lenoid wire connector from the fuel solenoid Turn the unit On and check the voltage on the 8D pin in the fuel solenoid wire connector from the main wire harness when the run relay energizes during the start sequence Refer to the following illustration to identify the pins in the wire connector and in the fuel solenoid 1 50 inDia 38 1 mm Pull In Coil 8DP Color White Hold In Coil 8D Color Red Common Ground Color Black CH Figure 42 Fuel Solenoid Pin Identification a If battery voltage is not present on the 8D circuit check the 8D circuit for an open or a short b If battery voltage is present on the 8D circuit go to step 5 Check the CH pin in the fuel solenoid wire connector for continuity to a good chassis ground a If there is no continuity between the CH pin in the fuel solenoid wire connector and a good chassis ground check the black CH wire that goes from the fuel solenoid connector to the CH terminal on the throttle solenoid for an open circuit 61 Engine Maintenance 6 8 62 b If this black CH wire is not open check the other CH wire connected to the CH terminal on the throttle solenoid for an open circuit c If there is continuity between the CH pin in the fuel solenoid connector and a good chassis ground go to step 6 Place a jumper wire between the CH pin in the fuel solenoid and a good chassis ground Test the pull in coil by momentarily placing a jumper betwee
93. low 4 Remove excess water and install filter Replace filter 1f necessary 5 Replace and secure filter cover Evaporator Drain Valves AMA624 Evaporator Drain Valve Evaporator Drain Valve Clamp Figure 91 Drain Valves Two evaporator coil drain valves kazoos are accessible under the truck cab sleeper compartment exterior Inspect each evaporator coil drain valve to ensure that they each have a rubber check valve in place Missing or damaged evaporator drain check valves may allow air to be drawn up the drains and prevent evaporator condensate water from draining Also dirt and engine fumes may be drawn up the drains Install new check valves if they are missing Replace them if they are damaged or hardened Loosen and remove the drain valve clamps to replace the drain valves 102 Condenser Coil Clean the coils during scheduled maintenance inspections Remove any debris e g leaves or plastic wrap that reduces the air flow Clean dirty coils with compressed air or a pressure washer Be careful not to bend the fins when cleaning a coil If possible blow the air or water through the coil in the direction opposite the normal air flow Repair bent fins and any other noticeable damage a ET gt 9 AMA550 Figure 92 Condenser APU Mounting Bolts Check during the pretrip inspection for damaged loose or broken parts Torque the unit mounting bolts yearly to 100 ft Ibs 135 6 Nem
94. m then it does clean the refrigerant If you are unsure of this function in your machine read the manual If the machine removes only the refrigerant from the unit to a drum then the air can still be removed by allowing the drum to sit for several hours then venting the air from the top of the drum CAUTION Venting refrigerant may be illegal in your area Check with your local government agencies for definition of venting and your legal responsibilities Measure the drum temperature and pressure then refer to a Temperature Pressure chart to verify that there is only refrigerant in the drum If air is in the drum you may wish to only draw liquid from that drum even after the air has been vented out This precaution ensures that air 1s not put back into the system Since machines are different Thermo King recommends that the manufacturer s instructions are followed exactly Evacuation Evacuation is Important and is Critical to System Performance It has been determined through testing and system analysis that refrigeration systems which contain non condensables such as nitrogen and or air can be overcharged with refrigerant when charged using the sight glass method An overcharge of refrigerant will cause compressor damage Therefore Thermo King recommends that all repairs to the refrigeration system include the removal and recycling cleaning of the refrigerant followed by a thorough evacuation using the proper to
95. m YLW YLW YLW R T lm ED s z pin 2 DIAGNOSTIC HTS Sie ae BEU WIT Fee CONNECTOR 26 BRN GRY BRN Terns ie 2 scs RU RED s BRN CHA BRN BRN T CH CH d gt TA TA 29 8 8 1CLA TCLA AN STANDBY WITH SWITCH OPTIO ZX CUSTOMER SUPPLIED COMPONENT 3 ZA OPTIONAL INTERIOR LIGHT CONNECTION ZX OPTIONAL COOLANT TEMPERATURE SWITCH ARCTIC OPTION LN STANDBY WITH OUT SWITCH OPTION 2A WIRE 1S ABSENT 25 AND WIRE SBY IS CONNECTED TO F6 ZA OPTIONAL HEATER AND ENGINE HOUR METERS THIS CONTROLLER HAS AN OPTIONAL STANDBY MODE THAT ALLOWS THE SYSTEM TO BE TEMPORARILY DISABLED WHEN THE IGNITION SWITCH 1S IN THE ON POSITION 12VDC_1S APPLIED TO THE SBY TERMINAL ON THE CONTROL BOARD AND THE SYSTEM GOES INTO STANDBY MODE WHEN THE OPTIONAL DASH MOUNTED SELECTOR SWITCH IS IN THE STANDBY POSITION POWER IS APPLIED TO THE SBY TERMINAL ON THE CONTROL BOARD AND THE SYSTEM GOES INTO STANDBY MODE REGARDLESS OF THE INGITION SWITCH POSITION 34 THE DISPLAY WILL SHOW by WHENEVER IN STANDBY MODE CAUTION STANDBY MODE SHOULD NEVER BE USED TO DISABLE THE SYSTEM WHEN PREFORMING MAINTENANCE O o ceo lt PROE _DD 110 TriPac Wiring Diagram NENNEN ESO lO E REO AO 222
96. mally connected directly to the truck batteries Inverter features will vary depending upon the brand and model used Typically when the inverter detects an AC load it automatically turns on and converts DC to AC to power onboard 120 Volt devices If the TriPac 1s enabled and the inverter draws truck battery voltage down below the voltage limit established for the installation the TriPac will start and attempt to recharge the truck batteries back to the level specified If the TriPac 1s not enabled the inverter could drain the truck batteries below the level required to start the truck or the TriPac Manufacturer s instructions for the optional inverter are provided separately It is important to read and follow those instructions for proper use of the inverter 99 Optional Power Inverter 100 Structural Maintenance Maintenance Inspection Schedule Pre Trip Annual 2 000 Hrs Check condition of or service the following gt Visually inspect unit for fluid leaks coolant oil refrigerant Visually inspect unit for damaged loose or broken parts Inspect clean and if necessary replace evaporator air filter It may be necessary to check or replace it more often if conditions require it Inspect evaporator drain valves kazoos to ensure that they are in place in good condition and are sealing o Steam clean condenser and APU pre cooler coil Do not bend coil fins Blow out evaporato
97. mber the seal which has been enclosed with the spare part must always be replaced 6 Tighten the fastening screws of the combustion chamber with a torque of 4 8 ft Ib NOTE If the heat exchanger is being replaced the overheating sensor flame sensor must be dismantled and mounted to the new heat exchanger 98 Optional Power Inverter DANGER Do not use an inverter in life A support or health care applications where a malfunction or failure of the inverter could cause failure of a life support device or medical equipment or significantly alter the performance of that equipment DANGER Potentially lethal voltages exist within the inverter as long as the battery supply is connected During any service work the battery supply should be disconnected DANGER Do not connect of disconnect batteries while the inverter is operating from the battery supply Dangerous arcing may result CAUTION Protect against possible A electrical shock hazards If the inverter is operated in wet or damp conditions a user supplied portable GFCI ground fault circuit interruptor must be connected between each inverter receptacle and the equipment it powers CAUTION You may experience uneven performance results if you connect a surge suppressor line conditioner or UPS system to the output of the inverter Optional Power Inverter A 12 volt DC to 120 Volt AC inverter is available as an option for TriPac The inverter is nor
98. n Selector Switch select normal or standby operation e Optional Arctic Package e Optional Extreme Arctic Package e Optional 12 Vdc to 120 Vac 1800 Watt inverter for on board appliances e Optional chrome plated exhaust pipe e Optional stainless steel condenser shroud e Optional Exhaust Diesel Particulate Filter DPF TriPac System The TriPac system includes several major components e An APU auxiliary power unit e Condenser e Evaporator e Heater e HMI Controller 25 General Description MVT y yw Fw 4 IAS III IAN LS LIA IIS ia AMA691 Figure 1 TriPac APU Auxiliary Power Unit The TriPac APU contains the diesel engine air conditioning compressor alternator and engine power switch AMA550 Figure 2 TriPac Condenser Condenser The TriPac Air Conditioning condenser is mounted on the back of the truck cab 26 ARA1421 Alternative Location AMA653 Figure 3 TriPac Evaporator and Air Ducts Evaporator installed under sleeper cab bunk Evaporator The TriPac Air Conditioning evaporator is typically installed under the bunk in the truck cab sleeper compartment Air ducts from the Evaporator carry conditioned air to the sleeper compartment AMA552 Figure 4 TriPac Heater Heater The TriPac heater 1s typically installed under the bunk in the truck cab sleeper compartment It draws fuel from the truck s diesel fuel tank and electric power from the truck s batte
99. n Keys to raise or lower the temperature setpoint Each time an Up or Down Key is pressed the display will increment up or down by one degree If a key is pressed continuously the display will scroll up or down The setpoint will be changed to the value shown in the display The HMI setpoint temperature minimum is 50 degrees and the maximum is 90 degrees The lower right LED in the HMI Display indicates that the sleeper compartment temperature setpoint is displayed RE THERMO KING CLIMATE CONTROL AMA567 Figure 16 Up and Down Keys System Fault Indicator 8 The HMI System Fault red indicator glows any time an alarm condition occurs and an alarm code is displayed RE THERMO KING CLIMATE SYSTEM CONTROL ONUS OX auto 9 wr O HGH APU e O 3 MED O Low AMA568 AMA754 Figure 17 System Fault Indicator Alarm Codes TriPac HMI Controller alarm codes are Eng This code indicates that the that the 8 circuit has a failure This can be caused by an open engine reset switch or the engine compartment On Off Switch is in the Off position Typical causes for an open engine reset switch are low oil pressure high water temperature or a start failure If the unit is equipped with the optional DPF an Eng code can be generated by the Regeneration switch being placed in the Off position or a DPF shutdown code Verify the DPF Regeneration switch is in the On position and check t
100. n in the fuel solenoid The resistance of the hold in coil should be approximately 24 to 29 ohms If the resistance of the hold in coil is not in this range replace the fuel solenoid e Ifthe hold in coil does function properly go to step 9 9 Reconnect the fuel solenoid wire connector to the fuel solenoid 10 Remove the run relay from its socket and make sure the unit is turned ON 11 Check the voltage on the 8D circuit at the 85 terminal in the run relay socket a If battery voltage 1s not present on the 8D circuit check the 8D circuit for an open or a short minimum voltage is 10 volts b If battery voltage is present on the 8D circuit go to step 12 12 Check the voltage on the 2A circuit at the 30 terminal in the run relay socket a If battery voltage is not present on the 2A circuit check the 2A circuit for an open or a short b Ifbattery voltage is present on the 2A circuit go to step 13 13 Reconnect the 20 wire to the reset switch 14 Replace the Starter Fuse F1 in the interface board Engine Maintenance Fuel Solenoid Replacement 1 Disconnect the 20 wire from the reset switch to prevent the reset switch from tripping 2 Remove the Starter Fuse F1 from the interface board 3 Disconnect the fuel solenoid wire connector and remove the old fuel solenoid 4 Connect the fuel solenoid wire connector to the new fuel solenoid 5 Energize the fuel solenoid by turning the unit
101. n the 8DP pin in the fuel solenoid and the positive battery terminal The fuel solenoid should make a definite click when the pull in coil is energized and should click again when the pull in coil is de energized NOTE The pull in coil will draw 30 to 40 amps so do not leave the jumper connected to the 8DP pin for more than a few seconds a If the pull in coil does not energize check the resistance of the pull in coil by placing an ohmmeter between the 8DP pin and the CH pin in the fuel solenoid The resistance of the pull in coil should be 0 2 to 0 3 ohms If the resistance of the pull in coil is not within this range replace the fuel solenoid b If the pull in coil does energize go to step 8 Test the hold in coil a Energize the hold in coil by placing a jumper between the 8D pin in the fuel solenoid and the positive battery terminal b Momentarily energize the pull in coil by placing a jumper between the 8DP pin in the fuel solenoid and the positive battery terminal The fuel solenoid should make a definite click when the pull in coil is energized but should not click when the pull in coil is de energized c De energize the hold in coil by removing the jumper from the 8D terminal The fuel solenoid should make a definite click when the hold in coil is de energized d If the hold in coil does not function properly check the resistance of the hold in coil by placing an ohmmeter between the 8D pin and the CH pi
102. ng of the APU to the inlet side of the water pump located on the truck s engine Another coolant hose is routed from the truck s heater outlet to the APU S pre cooler inlet APU coolant hoses allow shutoff valves to isolate the APU cooling system from the truck s cooling system Engine coolant checks and maintenance should follow the truck engine manufacturer s recommendations See Caution statement below CAUTION Avoid direct contact with hot coolant CAUTION Do not remove the radiator cap while the engine is hot CAUTION Do not mix engine coolant types The original TriPac installation was adapted to the coolant used in the truck engine at the time of installation Before coolant is added or replaced make certain that the coolant type and specifications are correct 52 TriPac Engine Coolant Maintenance Checks e Inspect all the hoses for deterioration and hose clamp tightness Replace if necessary e Loosen the water pump belt Check the water pump bearing for looseness Engine Thermostat For best TriPac engine operation use a 180 F 82 C thermostat in the TriPac engine year round Thermostat Housing Thermostat Water Pump Figure 28 Water Pump Assembly and Thermostat Bleeding the Coolant System Often when a TriPac unit cooling system is refilled air is trapped in the engine block and or under the thermostat Use the following procedure to bleed air out of the block and the cooling system
103. nting plate Repeat steps 7 through 10 to recheck the timing ae Ost Injection Timing Mark Index Timing Mark on Starter Mounting Plate Figure 36 Correct Injection Timing Mark Alignment NOTE Some engines have a series of injection timing marks as shown below The 16 degrees BTDC before top dead center mark is the mark that should be aligned with the index timing mark on the starter mounting plate L pi Y ARA1114 16 Degrees BTDC Mark Correct Timing Mark 25 Degrees BTDC Mark 20 Degrees BTDC Mark 15 Degrees BTDC Mark Index Timing Mark on Starter Mounting Plate Figure 37 Correct Injection Timing Mark Alignment With Series Of Injection Timing Marks 58 4 If the timing is off by more than 1 degree 0 1 in 2 5 mm loosen the mounting nuts on the studs that fasten the injection pump to the engine and rotate the injection pump to change the timing a Pull the top of the injection pump away from the engine to advance the timing SE Push the top of the injection pump toward the engine to retard the timing Tighten the injection pump mounting nuts and recheck the timing Repeat steps 7 through 2 until the timing is correct Install the delivery valve spring for the number one cylinder by removing the delivery valve holder installing the delivery valve spring and then reinstalling the delivery valve holder Install the injection line for the number one cylinder the cyl
104. o see if there are any DPF alarm codes AcS This code indicates that an abnormal air conditioning system condition has occurred Typical causes are high discharge pressure or low system pressure ALt This code indicates that a charging system failure has occurred This code will occur if there is no alternator output after 2 minutes of operation bAt This code indicates that the battery voltage is low Operating Instructions To Clear Alarm Codes Record the alarm code shown in the display To clear an alarm code use the HMI Main Power Key to turn off the TriPac system Then resolve the condition that caused the alarm Check the engine reset switch If the alarm tripped the switch the switch must be reset to allow the TriPac engine to be restarted The engine reset switch is located on the side of the Interface Board control box enclosure Optional Standby Operation The optional TriPac HMI Controller Standby Mode allows the system to be controlled by an external source which is typically the truck s ignition system This is used to disable the TriPac system when the truck s engine is running The display will show Sby when the controller 1s in this mode During Standby mode the controller is temporarily disabled and none of the TriPac systems will operate Voltage sensing and the optional coolant temperature sensing functions are also disabled while in this mode RE THERMO KING CLIMATE CONTROL AMA570
105. o the unit About This Manual Before You Call Thermo King Service Who to call Your Thermo King Service Representative Before you call Thermo King Service have the following information on hand e Bill of Material usually located on the unit serial plate e Model Number found on frame inside the APU unit Blank Pages This manual may contain blank pages at the end of chapters This is normal There is no information missing from the manual Roadside Curbside Terminology Roadside Curbside terminology These terms can be confusing because of differences between North America and Europe Please note The side of the truck to the driver s right when the driver is in his seat and facing forward The side of the truck to the driver s left when the driver is in his seat and facing forward Using the Model Tables in About this Unit The model tables in this section called About this Unit Model Systems and Update Matrices or something similar list important unit information that you will need to communicate with the Thermo King Service Department See the table on the previous page for a description of how to use these tables Table of Contents About This Manual 3 5523 53 esta ba rra Ree radar SRM RES oe en aS BE 5 A nen PETI Lr RE ERE EE ET 5 GIO llo a On 5 Before You Call Thermo King Service o o o oo oooooro rr 6 Bank Pades 29 5 10d dd me Br kG Rota o o emet e e Ba eta e Rare m Remi A AA AAA A 6
106. oil AMA700 Figure 61 Receiver Drier Removal 1 Turn the unit off 2 Recover all refrigerant from the system 3 Disconnect the refrigeration and electrical connections Cap the refrigeration connections to prevent contamination 4 Locate the receiver drier and loosen the mounting hardware NOTE When removing or replacing the fitting nuts on the receiver drier always hold the body of the receiver drier near the fittings to prevent twisting the tubing when the nuts are being loosened or tightened 5 Use two wrenches tubing wrenches recommended to disconnect the connections and remove the receiver drier 6 Discard the old receiver drier Installation NOTE The longer the receiver drier remains open to the air the more moisture it will absorb That moisture shortens the usable life of the receiver drier l Clean all fittings Remove the protective caps from the new receiver drier and oil the threads with the same type of refrigerant oil that is used in the compressor Install the new receiver drier as quickly as possible Tighten the receiver drier mounting hardware Replace refrigerant lines and electrical connections Evacuate the system and check for leaks Repair as needed Recharge the system per procedures recommended in this manual NOTE Whenever a major loss of refrigerant has occurred or when a filter drier is installed additional oil may be required Refer to oil charging pro
107. ols and procedures The primary objective of evacuation 1s to bring the system s pressure to a low micron level to ensure the removal of moisture and non condensables Never attempt evacuation without a micron or vacuum gauge The micron gauge will help determine a Ifthe pump is capable of pulling a deep vacuum b When the vacuum pump oil is contaminated c Ifthe vacuum hoses and valves are leak free d If the unit is leak free e How long you should evacuate the unit f That the unit is still in a deep vacuum before any lines are disconnected or refrigerant is added NOTE These evacuation procedures have been written to be used with the Thermo King Evacuation System see Tool Catalog However the principles of evacuation and the use of a micron gauge during evacuation should always be practiced Air Conditioning Maintenance See the diagram of the Thermo King Evacuation Station and note the location of the valves Valve 1 V 1 Is in the open position when the pump is running to evacuate the hoses and or the unit When V 1 is closed the pump has been isolated from the hoses and or the unit Valve 2 V 2 Is in the open position during unit evacuation In the closed position V 2 isolates the micron gauge and thermistor assembly from the hoses and or the unit Valve 3 V 3 Is in the open position during unit evacuation When closed V 3 isolates the micron gauge and the vacuum pump from the other
108. ontact your local Thermo King dealer for further information 86 4 Remove the cover if equipped MES ii ABHO2 Snap Ring Cover If Equipped Figure 71 Remove Snap Ring and Cover 5 Remove the pulley assembly using the pulley remover TK No 204 806 and the spacer positioned on the cylinder head hub A CAUTION To avoid damaging the pulley groove the pulley claws should be hooked into NOT UNDER the pulley groove 3 Figure 72 Remove Pulley 6 Remove the coil s lead wire from the holder on the top of the compressor 7 Remove the three screws that attach the coil to the compressor and remove the coil NOTE DO NOT hold the coil by the lead wire TM 15 Compressor Maintenance AS apt S y lt Q 1 a Figure 73 Remove Coil Inspection l Armature Plate If the contact surface is scorched the armature plate and pulley should be replaced Pulley Assembly If the pulley s contact surface is excessively grooved due to slippage both the pulley and armature plate must be replaced There should also be no foreign matter such as oil or grit lodged between the armature plate and pulley Thoroughly clean these contact surfaces and the armature plate Coil Inspect the coil for a loose connector or cracked insulation If the insulation is cracked replace the coil Repair or replace the wire or the connector if either is loose or damaged Drive Plate Pulley Assem
109. ose valve V 1 at the pump Turn the pump to Off Observe the reading on the micron gauge after 5 minutes have elapsed The vacuum rise should not exceed 2000 microns If the vacuum level exceeds 2000 microns after 5 minutes a leak is present or additional evacuation time is required If the vacuum level is acceptable start the pump and open valve V 1 to evacuate the pressure rise 5 minutes Close valve V 1 and stop the pump Observe the micron gauge to confirm that the system remains in a deep vacuum Close valve V 4 The unit is ready to charge 75 Air Conditioning Maintenance Charging Procedures A CAUTION When charging with liquid refrigerant do not allow the suction pressure to rise by more than 20 psig 138 kPa above running pressure Some compressor designs are sensitive to larger quantities when charged with liquid refrigerant CAUTION Different refrigerants require different types of oil to operate correctly Do not mix these oils or the refrigerants Consult the compressor oil chart in the front of this manual for additional information Charging from an Evacuated State l 76 Evacuate the system using a vacuum pump and micron gauge following the procedures in this manual See Unit Evacuation Procedure Close both gauge manifold and hand valves Verify that Valve V 4 on the Thermo King evacuation station 1s closed off Open the refrigerant supply bottle valve to deliver liquid refr
110. otor or the alternator Glow Plugs Glow plugs heat the combustion chamber to aid in quick starting The glow plugs are energized when the TriPac system is on and the TriPac controller senses that a startup is required After the glow plugs preheat the TriPac engine will be started If the engine is hot preheat time will only be a few seconds An open glow plug burned out can be detected with an ammeter in the H circuit The ammeter should show 7 0 to 8 5 amps during preheat A current draw of 7 0 to 8 5 amps means the glow plugs are working If the current draw drops below 7 amps during preheat at least one glow plug is bad Electrical Maintenance To isolate an open circuit glow plug remove the H wires and test each glow plug individually with an ohmmeter or a jumper wire and ammeter Each glow plug should have a resistance of 2 3 ohms or a current draw of about 4 3 amps A shorted glow plug will be indicated by the ammeter showing a very high current draw when the TriPac is preheating Check each glow plug A shorted glow plug will have very low resistance High Coolant Temperature Sensor The High Coolant Temperature Sensor will close and trip the reset switch if the coolant temperature is greater than 220 F 104 C Use a continuity tester to check the sensor and use a coolant temperature gauge to check the temperature Remove the 20 wire from the sensor 2 Runthe unit until it reaches normal operating tempe
111. perating open valve V 3 If the micron reading does not return to a level of less than 500 microns locate and correct the problem before continuing 6 With the vacuum pump still operating open valve V 4 The micron level will rise 1 momentarily If the micron reading does not return to a level of less than 500 microns 8 locate and correct the problem before continuing Pressure Rise Time ARA251 Figure 58 Leak 74 10 Isolate the pump from the system by closing the proper valve Watch the movement of the vacuum gauge needle If the needle continues to rise this 1s an indication that a leak exists in the unit or the connecting line The leak must then be located and eliminated Levels Off Pressure Rise Moisture Time ARA250 Figure 59 Moisture Should the needle show a pressure rise but finally level off to practically a constant mark this 1s an indication that the system is vacuum tight but is still too wet requiring additional dehydration and pumping time Evacuate hoses to 100 microns or lowest achievable level below 500 microns Once 100 microns 1s reached close valve V 1 at the pump Turn the vacuum pump Off Observe the micron gauge reading The vacuum rise should not exceed 1500 microns in 5 minutes If the rise is above 1500 microns in 5 minutes check all hoses and connections for leaks Hoses with moisture present will require additional evacuation time to achieve satis
112. pter in this manual 84 6 Remove the compressor from the system See Removing the Compressor on page 82 7 Drain the oil as described Oil Check Procedure Draining Measuring and Inspecting the Cil 1 Perform the Returning Oil to Compressor Recovering Refrigerant and Removing Compressor procedure above 2 Remove the drain plug from the compressor 3 Drain oil from the compressor drain plug and all other ports Figure 66 Draining the Oil 4 Remove remaining oil through the discharge side connector by manually rotating the armature plate until all oil is removed Rotate Armature Plate Several Times Figure 67 Armature Plate Rotation 10 Measure oil in a graduated cylinder or measuring cup e If the oil amount is less than 3 4 of a full oil charge replace with a full charge of new oil e If the oil charge is more than 3 4 of the required oil charge replace only the amount of oil you removed NOTE See the Specifications chapter in this manual for correct oil charge Inspect oil for contamination Replace the oil drain plug and tighten it per specifications see Torque Values in the Specifications chapter If necessary add oil Change the receiver drier See the Air Conditioning Maintenance chapter in this manual for procedure Install the compressor Tighten the mounting bolts TM 15 Compressor Maintenance Checking Compressor Oil for Contamination Inspect
113. r catenae b P e LES LI SIS LUE 25 INE OWE EMAIL 35 9 55 E E Af ELE e eU km dS det s dd e dedo Rec AO ld ask Gk up S Ad dlc 26 eso CC I T 26 Evaporator orestis pasci quoi Dt pde porti ae Dat soit irati Eu Paes a Dates quu oa 26 A o LM PEL MIEL IMPLIES IECUR RE 26 MIST rar TTE OLOR TRITUM 27 Sao nn rn OPC ee eh eee een ere 27 Interface BOSE A A AC a ee a re ae Ae ae AAA M api an f etc 27 COMPressor TN P PAPAE 27 FAG UNE sisi ratio i lade los e en ih lot npa OC RO loll ng Weill nid db ded ab CR eth ied d RR e God d GI a rob 27 High System Pressure Cutout SWILICIY s 42002404 RENE E REGE AE EE RE XX ons bene sen ees 28 Low System Pressure Cutout Switch llle 28 EUSO JPTOTGGUOT a eater pieced ek V A pde aca deeper dw eal a dra dan M deep d act NH apos pan dra 28 miaelechrz cci pe Mr Prec 28 SerabNumb er LOC AMOS uut hara erroe ia E Ear EE 29 Operating INStructiGnS 222v prebere ode dd 31 laico o aM ECTETUR TOURIST ROTUNDIS Tm 31 Tiras FIMIGontroller DesorlpllOLlk 3 xou xt Riu etd br oU Rabe eed ua nd re Xa ei XE Hen 31 HIM oOmrole DISDIAY A RC CRT P BR L BST 31 MaM F OWE ROY dudado eibar atio tut ar daten Roten 31 Meo AA LES IT A O E eae e 31 Seta DOWN CY Sa P 31 Fan Speed KEV c ioo Con e NUR ee aU c egent bar arf ese oe hoe ees 32 APU OVSE KOY versa o dd Ond amp Met oe ad dd as o 32 System anaconda 32 Table of Contents Operating Instructions continued Do RT NOCET TIE T EET tats N
114. r coil and evaporator water drains with air Do not bend coil fins Check APU mounting bolts and brackets for cracks damage and poor alighment Verify tightness and torque to 100 ft lbs 135 6 Nem for the claw mount or 200 ft lbs 271 2 Nem for the direct frame mount A WARNING Take precautions to ensure the unit will not accidentally start while you are servicing the system Evaporator Coil Evaporator Coil Air Filter Clean the coils during scheduled maintenance inspections Remove any debris e g paper or plastic wrap that reduces the air flow Clean dirty coils with compressed air Be careful not to bend the fins when cleaning a coil If possible blow the air or water through the coil in the direction opposite the normal air flow Repair bent fins and any other noticeable damage CAUTION The air pressure should not be high enough to damage coil fins Evaporator Coil Air Filter Air Filter Cover Front of Sleeper Compartment Bunk Evaporator Drain Valve Kazoo Figure 90 Evaporator Coil Air Filter The evaporator coil air filter 1s accessible from inside the truck cab sleeper compartment Unscrew filter cover and remove the filter 2 Using compressed air blow in the direction Figure 89 Evaporator Cover Removed opposite normal air flow to remove accumulated dust 101 Structural Maintenance 3 Wash filter material in warm soapy water Flush water in the direction opposite to normal air f
115. rature approximately 180 F 82 C There should be no continuity from the sensor to ground 3 f you suspect the engine is running hot and the sensor is not closing run the unit until the coolant temperature reaches 220 F 104 C The sensor should have continuity to ground Replace the sensor as necessary Low Oil Pressure Switch The engine oil pressure should rise immediately after the engine 1s started The Low Oil Pressure Switch will trip the engine reset switch and stop the engine if the oil pressure drops below 15 2 psig 103 14 kPa A continuity tester 1s needed to check the Low Oil Pressure Switch Remove the 20 wire from the Low Oil Pressure Switch 2 The continuity tester should indicate a complete circuit between the terminal and ground 3 Start the engine The tester should show an open circuit between the terminal and ground The Low Oil Pressure Switch 1s not repairable It must be replaced if it does not function properly 43 Electrical Maintenance Condenser and Pre cooler Axial Fan Motors NOTE A non repairable plastic fan motor assembly is used If this motor malfunctions it must be replaced A CAUTION Take precautions to ensure the unit will not accidently start while servicing the system The condenser fan and pre cooler axial fan motors are maintenance free If erratic or intermittent operation is observed the current draw of the motor should be measured while proper voltag
116. required or annually Change fuel filter Thermo King brand filter is required Drain water from fuel tank and check vent Check and adjust engine speed Check condition of engine mounts Maintain year round anti freeze protection at 30 F 34 C Change coolant every two years or with truck coolant Adjust engine valves Engine Cil Change Intervals Change oil and filters hot Pre Trip Annual 2 000 Hrs Check condition of or service the following 1 000 Hour 1 000 Hour Interval Oil change interval is every 1 000 hours of operation Intervals only when using a Thermo King brand oil filter and Cl 4 or better oil Units with optional DPF require CJ 4 or better oil 500 Hour 500 Hour Interval Oil change interval is every 500 hours of operation when Intervals using any other brand oil filter and Cl 4 or better oil Units with optional DPF require CJ 4 or better oil IMPORTANT Fill the crankcase slowly so oil will not run into the breather thus filling up a cylinder with an open valve Leaving the dipstick out while adding oil will ventilate the crankcase 37 Maintenance Inspection Schedule Electrical Pre Trip Annual S 1 2 000 Hrs Hrs Check condition of or service the Check condition of or service the following 1 Check operation of protection shutdown devices operation of protection shutdown devices Check alternator voltage Check alternator bearings See Note 1 Inspect batte
117. reset switch When the reset switch opens the engine will shut down Typical causes for an open engine reset switch are low oil pressure high water temperature or an engine start failure The engine reset switch is located on the side of the Interface Board control box enclosure AMA618 Figure 7 Engine Reset Switch Serial Number Locations APU Unit nameplate is located on front lower edge of APU housing frame APU cover must be removed to view the nameplate Engine Nameplate located on the top of the engine The engine is mounted in the TriPac APU housing Compressor Nameplate located on compressor body The engine driven compressor is located in the TriPac APU housing Heater Sticker located on the side of the heater Fabrik No General Description 29 General Description 30 Operating Instructions Introduction The TriPac is operated using an HMI Human Machine Interface Controller which is typically mounted on a wall in the truck cab sleeper compartment The HMI Controller includes a display screen operation keys and indicator LEDs ES O SE AX Dx O 3e AUTO AI Display po we 2 HMI Controller Main Power Key O 4p DEF ni ni ni O 3 HIGH Qj HEAT O 36 MED O a6 FAN zm O 26 LOW aon 2 K O APU SE deer lea AMA553 Figure 8 HMI Controller TriPac HMI Controller Description 2 HMI Controller Display The HMI Controller Display is used to indicate temperature s
118. ries RE THERMO KING CLIMATE SYSTEM CONTROL i icd OX auto O raum O 36 HIGH Oz HEAT Q3 MED O 26 FAN TEMPERATURE SETTING O a6 LOW Neu AMA553 Figure 5 TriPac HMI Controller HMI Controller Human Machine Interface Controller is installed in the truck cab typically on a wall in the sleeper compartment It is easily accessible to the driver and controls TriPac operation Standard typically used operating parameters are enabled in the HMI Controller when TriPac is installed If necessary HMI operating parameters can be adjusted through programming by your Thermo King dealer Control Circuits The control circuits operate on 12V DC supplied by the truck batteries Interface Board The Interface Board is mounted in an enclosure and typically installed in a storage compartment behind or under the truck sleeper compartment The Interface Board accepts instructions from the HMI Controller and operates TriPac components according to those instructions Compressor The TriPac air conditioning compressor is mounted in the TriPac APU and is driven by the TriPac engine Refrigeration lines connect the compressor to the TriPac air conditioning condenser on the back wall of the truck cab and the evaporator usually mounted under the truck cab sleeper compartment bunk General Description Compressor operation is controlled by the TriPac Interface Board The Interface Board receives instructions from the HMI Cont
119. roller The HMI Controller instructs the Interface Board to start the TriPac engine and energize the compressor clutch when cab cooling 1s needed On models manufactured prior to 9 06 the refrigeration system 1s protected by a single binary switch which combines the functions of high pressure and low system pressure cutout switches On models manufactured during 9 06 and after the refrigeration system 1s protected by a high pressure cutout switch HPCO and a low pressure cutout switch LPCO Refrigerant The TriPac uses R 134a refrigerant 27 General Description Protection Devices High System Pressure Cutout Switch The High System Pressure Cutout Switch is a normally closed system pressure sensitive switch On models manufactured prior to 9 06 it is part of the binary pressure switch mounted on the receiver drier typically near the TriPac condenser On models manufactured during 9 06 and after a High Pressure Cutout Switch HPCO is located at the receiver drier If the discharge pressure rises above the switch s Opening pressure the switch opens the circuit to stop the unit and generates an AcS Alarm Code The opening pressure for the binary switch is 325 psig 2241 kPa The opening pressure for the HPCO 1s 400 psig 2758 kPa When the discharge pressure falls below the switch s closing pressure the switch closes to allow compressor operation The closing pressure for the binary switch is 230 psig 1586 kPa T
120. ry terminals Inspect electrical connections Inspect wire harness for rubbing or damage Check electric condenser evaporator and pre cooler fans Note 1 With belt removed spin alternator by hand Listen for noise and ensure that bearings roll freely Structural Pre Trip Annual I 2 000 Hrs Hrs Check condition of or service the Check condition of or service the following Visually inspect unit for fluid leaks coolant oil refrigerant inspect unit for fluid leaks coolant oil refrigerant Visually inspect unit for damaged loose or broken parts Inspect clean and if necessary replace evaporator air filter It may be necessary to check or replace it more often if conditions require Inspect evaporator drain valves kazoos to ensure that they are in place in good condition and are sealing Steam clean condenser and APU pre cooler coil Do not bend coil fins Blow out evaporator coil and evaporator water drains with air Do not bend coil fins Check APU mounting bolts and brackets for cracks damage and poor aligment Verify tightness and torque to 100 ft lbs 135 6 Nem for the claw mount or 200 ft lbs 271 2 N m for the direct frame mount A C System PMP BNI 2000 Hrs neck conationofor service tne folowing 0000 2 000 Hrs Check condition of or service the following Checkrefrigerant level ai iasC lt lt lt Ot eee Heater Pre Trip Ann
121. s have counterclockwise fans When replacing an alternator make sure to use an alternator with counterclockwise fan 39 Electrical Maintenance B Terminal Positive Output RED and 2 Wires B Terminal Negative Ground CH Wire S Terminal Regulator Sense 2A Wire EN W Terminal AC Output 2 L Terminal Regulator Excite D Wire F2 Terminal Voltage Regulator and Brush Assembly 8 Capacitor Figure 19 Australian Bosch Alternator Terminal and Component Locations B Terminal Positive Output RED and 2 Wires F2 Terminal Do Not Ground B Terminal Negative Ground CH Wire EN Voltage Regulator and Brush Assembly S Terminal Regulator Sense 2A Wire W Terminal AC Output L Terminal Regulator Excite D Wire e Figure 20 Thermo King Alternator Terminal and Component Locations 40 Test Equipment for Checking Voltage and Current Always use accurate test equipment such as the Fluke 23 Digital Multi Meter and the Fluke Clamp On Ammeter accessory when checking alternator circuit voltage and amperage See the table below for Thermo King service parts numbers Be sure voltages are measured from the designated terminal to the alternator chassis ground All voltages are DC voltages unless otherwise noted Fluke 23 Digital Multi Meter 204 1079 Clamp On Ammeter for above Meter 204 947 Alternator Load Test Thermo King no longer recommends a full field test for determining the alternator current output
122. s sequence with a tightening torque of 3 3 ft Ib 5 Always replace the seal between combustion air blower and heat exchanger Figure 87 Dismantling the Heat Exchanger and Removing the Combustion Air Blower Remove the heater cover Remove the control unit Remove the flange seal m cou de xem Take the heater out of the outer case lower part 5 Unscrew the 4 fastening screws from the combustion air blower 6 Remove the combustion air blower and the seal from the heat exchanger IMPORTANT When reassembling the combustion air blower a new thermal insulator is always required 7 Tighten the 4 fastening screws of the combustion air blower in the series shown in the drawing with a tightening torque of 3 3 ft Ib Sleeper Cab Air Heater Service Operations Removing the Combustion Chamber AMA592 Combustion chamber Heat exchanger Fastening screws 3 Thermal insulator always replace Figure 88 Removing the Combustion Chamber 1 Remove the heater cover 2 Remove the flange seal 3 Take the heater out of the outer case lower part remove control unit see previous pages remove glow pin see previous pages remove combustion air blower see previous pages 4 Unscrew the 3 fastening screws 5 Pull the combustion chamber out to the front and remove the seal from the heat exchanger 97 Sleeper Cab Air Heater Service Operations NOTE When reassembling the combustion cha
123. s and the use of PAG it is very important that oil mixing does not take place PAG and POE oil CANNOT be mixed Mixing these oils will cause serious system contamination especially with chlorine based refrigerants NOTE When servicing Thermo King R 134a units use only those service tools certified for and dedicated to R 134a refrigerant and PAG compressor oils Residual non HFC refrigerants or oils will contaminate R 134a systems The proper compressor oil is determined by the refrigerant used and specific air conditioning application requirements Verify both serial nameplates on the unit and compressor for correct oil to use in a particular system Because of the many variables in oils particularly in HVAC systems compressors may be delivered with an oil that is not specified for the particular unit it ts to be fitted to Unless it is 100 clear it is the correct oil Thermo King recommends the oil is changed to the correct type PAG oil is very hygroscopic Only use oil taken from a fresh container About This Manual Purpose The purpose of this manual is to provide general maintenance information necessary to maintain the TriPac unit at peak operating standards This includes safety information unit information such as bills of material and kit numbers general unit information maintenance procedures and related information such as wiring and schematic diagrams and some diagnostic and troubleshooting information NOTE This m
124. sible to the motor itself Turn the TriPac unit off 2 Disconnect the power plug from the motor Pi TER Le y Electrical Maintenance 3 Unscrew the screws attaching the motor housing to the evaporator frame and remove the blower housing from the unit Installation 1 Position the motor assembly on the frame 2 Align and replace the motor assembly mounting screws in the frame Securely tighten all the mounting screws 3 Connect the power plug to the motor 4 Start the TriPac and verify correct motor operation 5 If the unit is operating properly return the TriPac to service CAUTION The blower motor is polarity sensitive If not properly connected the blower may run backwards d of y Fr ARA1421 Mounting Screws 2 Figure 22 Evaporator Assembly Cover Removed 45 Electrical Maintenance 46 Engine Maintenance Maintenance Inspection Schedule Pre Trip Annual 2 000 Hrs Check condition of or service the following a Check engine oil level E j ispectbelisforcondiionandpropertension E Listen for unusual noises vibrations etc t Checkaircleanerhose for damage o repeat a ane Grange as needed or annual rset ut prefer Change as required or annual orar oe ter Theme King brand ris equreds poo pp Drain water from fuel tank and check vent o o ot Onekandadustengmespeed
125. ss should be full and clear with no bubbles If bubbles are found in the liquid line sight glass repeat steps 6 through 8 9 After confirming the charge close the refrigerant supply bottle valve close all service valves remove the manifold gauge set and stop the engine 10 Replace all service caps Leak check all areas and repair any leaks 11 Release the TriPac back into service Charging Your Air Conditioning System In Cooler Weather The cool spring and fall weather may make it harder to check and top off the charge of the TriPac air conditioning system More care must be taken to insure that the normal procedure is followed Specific charging procedures are required to place the air conditioning system into an operating mode similar to that seen under normal operation Air Conditioning Maintenance Procedures for R 134a Clear the liquid line sight glass and or float the ball in the receiver tank glass when 1 The compressor discharge pressure is above 150 psig 1034 kPa During other operating conditions refrigerant can collect in coils or tubing and mislead the service technician An over charge condition may result 2 Interior temperature should be 70 to 75 F On cool nights or mornings it may be necessary to pre heat the sleeper compartment interior to properly check the charge Operating conditions other than those listed will not guarantee the proper refrigerant charge for your system and may lead to
126. sure Cutout Opens 22 5 7 5 psig 155 52 kPa Cut in Closes 40 psig 276 kPa High Pressure Cutout HPCO Opens 400 10 psig 2758 69 kPa Closes 325 20 psig 2241 138 kPa Low Pressure Cutout LPCO Opens 5 3 psig 34 21 kPa Closes 20 5 psig 138 34 kPa l Opens 31 1 5 F 0 5 0 8 C Cut in Closes 39 5 1 5 F 4 2 0 8 C When the compressor is removed from the unit oil level should be noted or the oil removed from the compressor should be measured so that the same amount of oil can be added before placing the replacement compressor in the unit Freezestat Cut out Belt Tension Tension New Belt Engine Compressor Alternator Idler Pulley 95 pounds force NOTE A deflection of 0 25 between the alternator and compressor longest free span of belt may be used if a gauge is not available to test tension Electrical Control System Fuses Fuse Number Amp Rating Component Protected Out 18 Specifications Electrical Control System Continued Fase Naber Amp Rating GompewPwoeWTRUR Hourmeter Option 2 Hourmeter Option 8D Hourmeter Option 26 Supplemental Heater Contactor Extreme Arctic Option SHR Supplemental Heater Extreme Arctic Option SH Oil Pan Heater Extreme Arctic Option OPH Fuere Fea r a aoe Yorgo Sorso GI A AA Electrical Components Current Draw Amps Resistance at 12 5 Vdc Ohms Glow Plugs Each 2
127. system affects horsepower fuel consumption and engine life Inspect the element at every oil change At a minimum of once per year inspect for small animal insect nests to ensure full filter element integrity Replace filter if there 1s any evidence of animal ingress Clean by blowing clean dry compressed air from inside filter element Replace air cleaner element as needed or at least every 2 000 hours or 1 year of normal use whichever occurs first The HMI displays TriPac engine operation hours when the APU System key is pressed on APU startup Output Connection to Engine Intake Dry Filter Element Intake Hose Connection Figure 25 Air Cleaner Engine Maintenance Engine Cooling System The engine employs a closed circulating type pressurized cooling system Correct engine temperatures are controlled and maintained by the truck engine cooling system TriPac pre cooler and TriPac engine thermostat The coolant is circulated through the TriPac engine by a belt driven centrifugal pump The pump draws coolant from the truck engine through the pre cooler circulates it through the TriPac engine cylinder block and head and then sends it to back the truck engine block through a coolant hose A thermostat is mounted in the water outlet from the TriPac engine cylinder head to the truck engine The pre cooler fan will turn on if the coolant entry temperature exceeds 120 F 49 C and will turn off when the coolant entry temp
128. tery should be substituted for alternator testing NOTE If the battery is questionable a known good jumper battery should be substituted for alternator testing NOTE Do not perform this test with a battery charger connected to the battery NOTE All voltage readings should be taken between the chassis ground on the alternator and the terminals indicated unless stated otherwise Turn the unit off by placing the TriPac HMI controller Main Power Key and APU System Key in the Off position LEDs should be off not lighted Check and note the battery voltage at the battery with the unit turned off With the unit off check the voltage at the B terminal on the alternator Battery voltage must be present If not check the 2 circuit Disconnect the alternator harness from the voltage regulator by carefully pushing on the spring clip to release the plug lock Turn the unit on by pressing the HMI Main Power Key and APU System Key to turn both On LEDs should be on lighted Check the voltage at the sense circuit 2A circuit Battery voltage should be present If not check the sense circuit 2A circuit in the alternator harness 41 Electrical Maintenance 10 11 17 13 14 15 Check the voltage at the excitation circuit D circuit 10 Vdc or more should be present with the run relay energized fuel pump on If not check the excitation circuit D or equivalent circuit in the alternator harn
129. ther reason HMI Controller code Eng will be displayed if the engine fails to start due to lack of fuel Proceed as follows 1 Open the fuel return line banjo fitting to bleed fuel from the line Engine Maintenance AMA613 Figure 32 Fuel Return Line Banjo Fitting 2 Set the TriPac HMI to a setting that will cause the TriPac engine to attempt to start For example select a temperature such as 50 F that will cause the HMI to enter an air conditioning cycle and signal an engine start NOTE Several repeat attempts may be required to complete this procedure The engine will attempt to start for a maximum of 30 seconds If it does not start the HMI will display fault code Eng and the engine start sequence will end If the procedure describe here is not successful after the third attempt there may not be an adequate amount of fuel present to support an engine start Check the fuel supply in the tank and also inspect fuel lines for leaks 3 The engine will crank The fuel pump will run only when the engine is cranking 4 Repeat Steps 1 and 2 followed by Steps 4 and 5 until an adequate amount of fuel is exiting the fuel return line This indicates that all air has been bled from the line 5 Stop the engine start sequence by turning off the HMI Controller If the Engine Reset Switch trips reset it 6 Close the fuel line banjo fitting and retighten 7 With air bled out of the fuel line the engine should now
130. tion pump The fuel system is relatively trouble free If properly maintained it will usually not require major service repairs between engine overhauls The most common cause of fuel system problems is contamination It cannot be stressed enough that the fuel must be clean fuel tanks must be free from contaminants and the fuel filter must be changed regularly Any time that the fuel system is opened up all possible precautions must be taken to keep dirt from entering the system This means all fuel lines should be capped when open The work should be done in a relatively clean area if possible and the work should be completed in the shortest time possible 54 Figure 30 Engine Fuel System Rubber Fuel Lines Thermo King strongly recommends that any major injection pump or nozzle repairs be done by a quality diesel injection service specialty shop The following procedures can be done under field conditions e Bleeding air from the fuel system e Maintenance involving the fuel tank and filter system e Engine speed adjustment e Electric fuel pump replacement e Injection line replacement e Injection pump timing e Injection nozzle testing adjustment and minor repair Figure 31 Engine Fuel System Nylon Fuel Lines Bleeding the Fuel System The fuel system will have to have the air bled out if the engine runs out of fuel if repairs are made to the fuel system or air gets into the fuel system for any o
131. ual 2 000 Hrs Check condition of or service the following Start and run for at least 20 minutes each month Inspect combustion air intake tube and exhaust pipe for restrictions or blockage Inspect ducting air intake screen and air outlet for restrictions or blockage Remove glow pin and inspect for carbon build up Clean or replace Remove glow pin screen and inspect for carbon build up Replace Change fuel pump screen 38 Electrical Maintenance Maintenance Inspection Schedule Annual 2 000 Hrs Check condition of or service the following neck operation of protection shutdown devices Dcalemaorwag OOOO Dheaemaorberigs SesNoe T EN Inspect sectical connections inspect wire harness for rubbing or damage heck electric condenser evaporator and pre coolerians Note 1 With belt removed spin alternator by hand Listen for noise and ensure that bearings roll freely A WARNING Take precautions to ensure the unit will not accidentally start while you are servicing the system Always turn off the APU Engine On Off Switch when inspecting or servicing any components in the APU enclosure Alternator Charging System Diagnostic Procedures General Information Poor charging performance may not be caused by a bad alternator The following conditions can cause improper battery charging even with a good alternator See Service Bulletin T amp T 388 for more information e A prob
132. ully 8 Loosen the center hose Purge the air from discharge line Tighten the fitting 9 Close front seat the gauge manifold discharge hand valve 10 Loosen the center hose Purge the air from suction line through the center hose Tighten the fitting 11 Close front seat the gauge manifold suction hand valve 12 You are now ready to use the gauge manifold to check system pressures and perform most service procedures 70 Removal NOTE To minimize refrigerant leaks run the system during gauge removal if possible 1 Close front seat the discharge and suction manifold hand valves snugly 2 Ensure the Dead Head fitting is tight CAUTION Air allowed into the system will cause serious damage 3 Quickly remove manifold set from service ports 4 Cap the service ports with the correct sealing caps 5 Leak test service connections and repair all leaks NOTE To minimize refrigerant loss use sealing type quick connectors These fittings restrict flow during evacuation Refrigerant Recovery NOTE There are many recovery machines that remove refrigerant from a system run it through a filter cartridge once and pump it into a refrigerant drum This type of recovery machine will not remove the air from the refrigerant If the recovery machine is capable of circulating the refrigerant and actually running it through a condensing coil and has provisions for venting air from its internal syste
133. y arbor TK No 204 804 to prevent armature plate rotation Figure 68 Small Compressor Oil Fill Procedure E 4 M 2 C E AUA0034 Figure 69 Remove Center Bolt Clutch Procedures Clutch Test 2 Remove the armature plate using the armature plate puller Then remove the shims from 1 Ifthe field coil lead wire is broken replace the either the drive shaft or the drive plate field coil 2 Check the amperage and voltage The amperage range should be 3 6 to 4 2 amps at 12 volts Note the following symptoms and conditions a A very high amperage reading indicates a short within the field coil b No amperage reading indicates an open circuit in the winding 5 AUA0075 c An intermittent or poor system ground E 4 results in lower voltage at the clutch hs Check for tight fit on the coil retaining snap ring or for a good ground at the coil Armature Plate Puller retaining screws Figure 70 Remove Armature Plate 3 Air Gap An incorrect air gap can cause erratic engagement or disengagement and or clutch rattle Check the air gap with a feeler gauge The air gap should be 0 016 to 0 031 in 0 4 to 0 8 mm See Clutch Installation for information about adjusting the air gap 3 Remove the snap ring using external snap ring pliers TK No 204 808 Clutch Removal Inspection and Installation NOTE Make sure the proper tools are available before performing maintenance procedures C

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