OPERATION AND

SERVICE MANUAL

TRAILER REFRIGERATION UNIT

Phoenix Advantage,
Phoenix Xtra and
Phoenix Multi-Temp
NDA–79/89

62 ---02426 $6.00

NOTE: THIS ART REVERSES OUT OF PMS -- 1788 RED ORANGE

 TABLE OF CONTENTS

Section Page

1 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1--- 1
1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1---1
1.2 Engine Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1---7
1.3 Refrigeration System Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1---7
1.4 Safety Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1---8
1.5 Engine Screw Threads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1---8
1.6 Engine Air System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1---8
1.7 Lube Oil And Fuel Flow Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1---8
1.8 Compressor Unloaders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1---9
1.9 Battery Charging Alternator System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1---11
1.9.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1---11
1.9.2 Alternator Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1---11
1.9.3 Integral Voltage Regulator Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1---11
1.10 Microprocessor Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1---12
1.10.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1---13
1.10.2 Controls And Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1---13
1.10.3 Status Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1---14
1.10.4 Caution Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1---14
1.10.5 Digital Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1---14
1.10.6 Defrost Mode Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1---15
1.10.7 Controller Interface Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1---15
1.10.8 Remote Monitoring --- Microlink(Optional) . . . . . . . . . . . . . . . . . . . . . . . . . 1---18
1.11 Auto Start Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1---18
1.12 Switches And Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1---21
1.12.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1---21
1.12.2 Control Panel And Related Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1---21
1.12.3 Location Of Engine Safety Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1---22
1.13 Condenser Shutters And Covers (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1---22
1.14 Refrigerant Circuit During Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1---23
1.15 Refrigerant Circuit During Heating And Defrosting . . . . . . . . . . . . . . . . . . . . . . . . . . . 1---24

2 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--- 1
2.1 Pre---Trip Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2---1
2.2 Starting And Stopping Instructions --- Engine Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . 2---1
2.3 Starting And Stopping Instructions --- Auto Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2---2
2.4 Control Circuit Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2---2
2.4.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2---2
2.4.2 Engine Preheat And Start---Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2---2
2.4.3 Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2---3
2.4.4 Heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2---3
2.4.5 Defrost . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2---4

3 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3--- 1
3.1 Diesel Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3---1
3.1.1 Engine Will Not Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3---1
3.1.2 Engine Starts Then Stops . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3---1
3.1.3 Starter Motor Malfunction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3---2
3.1.4 Malfunction In The Engine Starting Circuit . . . . . . . . . . . . . . . . . . . . . . . . . 3---2

i
 TABLE OF CONTENTS (CONT’D)

Section Page

3 TROUBLESHOOTING (CONT’D) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3--- 1

3.2 Alternator (Automotive Type) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3---2
3.3 Refrigeration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3---3
3.3.1 Unit Will Not Cool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3---3
3.3.2 Unit Runs But Has Insufficient Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3---3
3.3.3 Unit Operates Long Or Continuously In Cooling . . . . . . . . . . . . . . . . . . . . . 3---3
3.3.4 Unit Will Not Heat Or Has Insufficient Heating . . . . . . . . . . . . . . . . . . . . . . 3---3
3.3.5 Defrost Cycle Malfunction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3---4
3.3.6 Abnormal Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3---4
3.3.6.1 Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3---4
3.3.6.2 Heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3---5
3.3.7 Abnormal Noise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3---5
3.3.8 Solid State Control System Malfunction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3---5
3.3.9 No Evaporator Air Flow Or Restricted Air Flow . . . . . . . . . . . . . . . . . . . . . 3---5
3.3.10 Expansion Valve Malfunction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3---6
3.3.11 Solenoid Valve Malfunction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3---6
3.3.12 Condenser Shutter Malfunction (OPTIONAL) . . . . . . . . . . . . . . . . . . . . . . 3---6

4 SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4--- 1
4.1 Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4---1
4.1.1 Daily Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4---1
4.1.2 First 400 Hour Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4---1
4.1.3 Every 1000 Hour Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4---1
4.1.4 Every 3000 To 6000 Hour Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4---1
4.2 Priming The Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4---2
4.3 Engine Service And Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4---2
4.3.1 Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4---2
4.3.2 Lube Oil Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4---2
4.3.3 Run Solenoid Linkage Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4---2
4.3.4 Servicing The Speed Control Solenoid And Linkage . . . . . . . . . . . . . . . . . . 4---3
4.3.5 Engine Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4---3
4.3.6 Engine Crankcase Breather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4---4
4.3.7 Servicing Fuel Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4---4
4.3.8 Servicing Glow Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4---5
4.4 Servicing The Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4---5
4.4.1 Preliminary Checks And Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4---5
4.4.2 Test Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4---5
4.4.3 Problem Area Determination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4---5
4.4.4 In---Unit Alternator/Regulator Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4---6
4.4.5 Alternator Brush Test Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4---7
4.4.6 Slip Ring Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4---7
4.4.7 Alternator Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4---7
4.5 Servicing And Adjusting V---Belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4---7
4.5.1 Belt Tension Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4---7
4.5.2 Water Pump V---Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4---8
4.5.3 Driveshaft To Jackshaft And Jackshaft To Evaporator/Condenser Fans . . . 4---8
4.6 Pumping The Unit Down Or Removing The Refrigerant Charge . . . . . . . . . . . . . . . . 4---9

ii
 TABLE OF CONTENTS (CONT’D)

Section Page

4 SERVICE (CONT’D) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4--- 1

4.7 Refrigerant Leak Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4---10
4.8 Evacuation And Dehydration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4---11
4.8.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4---11
4.8.2 Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4---11
4.8.3 Procedure For Evacuation And Dehydrating System . . . . . . . . . . . . . . . . . . 4---11
4.9 Adding Refrigerant To System (Full Charge) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4---12
4.10 Adding Refrigerant To System (Partial Charge) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4---12
4.11 Purging Noncondensibles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4---12
4.12 Replacing The Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4---12
4.13 Checking The Compressor Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4---13
4.14 Compressor Unloader Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4---14
4.15 Servicing The Check Valve --- Serviceable Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4---16
4.16 Checking And Replacing Filter---Drier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4---16
4.17 Checking And Replacing High Pressure Cutout Switch . . . . . . . . . . . . . . . . . . . . . . . . . 4---16
4.17.1 Replacing High Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4---16
4.17.2 Checking High Pressure Switch (HP---1 Or HP---2) . . . . . . . . . . . . . . . . . . . . 4---16
4.18 Replacing Receiver Sight Glass Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4---17
4.19 Servicing Solenoid Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4---17
4.19.1 Solenoid Valves SV2 --- Alco . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4---17
4.19.2 Solenoid Valve SV1/SV3 --- Sporlan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4---17
4.20 Solenoid Valve SV---1 Checkout Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4---18
4.21 Checking Defrost Or Heating Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4---18
4.22 Checking Calibration Of The Defrost Air Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4---19
4.23 Replacing The Condenser/Evaporator Fan Shaft Or Bearing . . . . . . . . . . . . . . . . . . . . 4---19
4.24 Servicing Defrost Damper Solenoid (DDS) Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 4---20
4.25 Evaporator Coil Cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4---22
4.26 Thermostatic Expansion Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4---22
4.27 Microprocessor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4---23
4.28 Controller Air Sensor Checkout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4---24
4.29 Suction Pressure Transducer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4---24
4.30 Servicing Condenser Shutter (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4---24
4.31 Unidrive Torque Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4---26

5 ELECTRICAL SCHEMATIC WIRING DIAGRAM

5.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5---1

6 MULTI--- TEMP OPERATION AND SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6--- 1

6.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6---1
6.2 Electrical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6---1
6.3 Safety Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6---1
6.4 Refrigerant Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6---2
6.5 Remote Compartment Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6---3
6.6 Servicing The Remote Evaporator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6---3
6.7 Servicing Liquid Solenoid Valve (LSV) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6---4
6.8 Evaporator Pressure Regulating Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6---4
6.9 Adjusting The Evaporator Pressure Regulating Valve . . . . . . . . . . . . . . . . . . . . . . . . . . 6---4
6.10 Replacing Or Adjusting Generator Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6---5

iii
 LIST OF ILLUSTRATIONS
Figure Page
1---1 Curbside . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1---2
1---2 Roadside . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1---2
1---3 Front View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1---3
1---4 Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1---4
1---5 Control Box --- Door Open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1---5
1---6 Evaporator Section --- Panels And Grille Removed . . . . . . . . . . . . . . . . . . . . . . . . 1---6
1---7 Lube Oil Flow Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1---8
1---8 Fuel System Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1---8
1---9 Compressor Cylinder Head (Unloaded) Suction Cutoff . . . . . . . . . . . . . . . . . . . 1---10
1---10 Compressor Cylinder Head (Loaded) Suction Cutoff . . . . . . . . . . . . . . . . . . . . . 1---10
1---11 Alternator Schematic Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1---11
1---12 Alternator And Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1---11
1---13 Microprocessor Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1---12
1---14 Auto Start Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1---19
1---15 Refrigerant Circuit --- Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1---23
1---16 Refrigerant Circuit --- Heating And Defrosting . . . . . . . . . . . . . . . . . . . . . . . . . . . 1---24

4---1 Speed And Run Control Solenoids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4---3

4---2 Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4---3
4---3 Engine Crankcase Breather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4---4
4---4 Mechanical Fuel Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4---5
4---5 Electric Fuel Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4---5
4---6 Open Diode---Trio Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4---6
4---7 Open Regulator Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4---6
4---8 Alternator Output Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4---7
4---9 Alternator Brush Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4---7
4---10 Belt Tension Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4---8
4---11 V---Belt Arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4---8
4---12 Alternator, Jackshaft And V---Belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4---9
4---13 Engine Adapter Drive Sheave To Jackshaft V---Belt . . . . . . . . . . . . . . . . . . . . . . . 4---9
4---14 Vacuum Pump Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4---11
4---15 Compressor Drive Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4---13
4---16 Pressure Switches HP---1 And HP---2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4---13
4---17 Compressor --- Model O5G . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4---14
4---18 Compressor Unloader Valve --- Suction Cutoff . . . . . . . . . . . . . . . . . . . . . . . . . . . 4---15
4---19 Unloader Solenoid Valve --- Suction Cutoff . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4---16
4---20 Check Valve --- Serviceable Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4---16
4---21 Typical Setup For Testing High Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . 4---17
4---22 Solenoid Valves SV2 --- Alco . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4---17
4---23 Solenoid Valves SV1/SV3 --- Sporlan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4---18
4---24 Defrost Air Switch Test Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4---19
4---25 Evaporator/Condenser Fan Shaft Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4---21
4---26 Defrost Damper Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4---21
4---27 Thermostatic Expansion Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4---22
4---28 Thermostatic Expansion Valve Bulb And Thermocouple . . . . . . . . . . . . . . . . . . . 4---23
4---29 Tightening Sequence for Microprocessor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4---24
4---30 Condenser Shutter Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4---25
4---31 Unidrive Torque Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4---26

iv
 LIST OF ILLUSTRATIONS (CONT’D)

Figure Page
5---1 Electrical Schematic Wiring Diagram --- Dwg. No. 62---03833 . . . . . . . . . . . . . . . 5---2

6---1 Refrigerant Circuit --- Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6---2

6---2 Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6---3
6---3 Remote Control Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6---3
6---4 Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6---5
6---5 Electrical Schematic Wiring Diagram Dwg. No. 62---03815 Rev B . . . . . . . . . . . . 6---7
6---6 Electrical Schematic Wiring Diagram Dwg. No. 62---03816 Rev D . . . . . . . . . . . 6---9

LIST OF TABLES

Table Page
1---1 Model Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1---1
1---2 Safety Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1---9
1---3 Alternator And Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1---11
1---4 Keypad LED, Digital Display Troubleshooting Messages . . . . . . . . . . . . . . . . . . . 1---12
1---5 Battery Voltages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1---19
1---6 Pre---Trip Sequence Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1---22

2---1 Electrical Control Positions (Engine) --- Below +10_F (---12.2_C) . . . . . . . . . . . 2---5
2---2 Electrical Control Positions (Engine) --- Above +10_F (---12.2_C) . . . . . . . . . . . 2---6

4---1 Belt Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4---8

4---2 Sensor Resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4---27
4---3 R---502 Pressure --- Temperature Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4---27

6---1 Safety Devices --- Remote Evaporator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6---1

v/vi
 r

OPERATION AND
SERVICE MANUAL
TRAILER REFRIGERATION UNIT

NDA–79/89
Phoenix Advantage,
Phoenix Xtra and
Phoenix Multi-Temp

Carrier Transicold Division, Carrier Corporation, P.O. Box 4805, Syracuse, N.Y. 13221

E Carrier Corporation 1992 S Printed in U. S. A. 0492

 P

SECTION 1
DESCRIPTION
1.1 INTRODUCTION It is mounted separately on the front roadside corner of
WARNING the trailer.
Beware of V--- belts and belt driven components The temperature controller is a microprocessor solid
as the unit may start automatically. Before state controller (Refer to section 1.10). Once the control-
servicing unit, make sure the start--- run stop ler is set at the desired trailer temperature, the unit will
switch is in the OFF position. Also disconnect operate automatically to maintain the desired tempera-
the negative battery cable. ture within very close limits. The control system automat-
ically selects high and low speed cooling or high and low
The model NDA configuration is a one piece, self--- speed heating as necessary to maintain the desired tem-
contained, fully charged, pre---wired, refrigeration--- perature within the trailer.
heating “nosemount” diesel powered unit for use on
insulated trailers to maintain cargo temperatures from The refrigeration compressor used is a Carrier Mod-
---20_F to +80_F (---28.9 to +26.7_C). The model/serial el O5G equipped with Varipowr as standard equipment.
number plate is located inside of the unit on the rear Varipowr is used as a compressor capacity control to un-
frame as shown in Figure 1---1. load the compressor during periods of reduced loads.
This provides closer temperature control, reduces poten-
The evaporator fits into a rectangular opening in the tial for top freezing and reduces power required to oper-
upper portion of the trailer front wall. When installed, ate the compressor; thus reducing power consumption.
the evaporator section is located inside the trailer; and
the condensing section is outside and on the front of the For power, Carrier Transicold Model CT4---134, die-
trailer. sel engine is used. The engine gives excellent fuel econo-
my and has easy starting characteristics. The engine is
The condensing unit consists of an engine---compres- equipped with spin---on lube oil and fuel filter for easier
sor drive package, condenser fan, condenser/radiator filter changes.
coil, control panel, control box, refrigerant controls, pip-
ing, wiring, defrost air switch, and associated compo- NOTE
nents. Throughout this manual, whenever the “left” or
The evaporator assembly consists of an evaporator “right” hand side of the engine is referred to, it is
coil, evaporator fan, expansion valve, two defrost ther- the side as viewed from the flywheel end of the
mostats (termination switches), defrost damper, heat ex- engine.
changer (Advantage only) and a damper solenoid. The The diesel engine drives the compressor directly
location of the thermostats are shown in Figure 1---6. The through a nylon drive gear and adapter. The adapter also
return air sensor is also shown in Figure 1---6. includes a V---belt sheave which drives the jackshaft. The
Heating is accomplished by circulating hot gas direct- condenser/evaporator fanshaft is driven with a V---belt
ly from the compressor to the evaporator coil. Three elec- from the jackshaft. A separate V---belt from the jackshaft
tric solenoid valves control the refrigerant circuit to drives the alternator.
improve the operating reliability of the heating system. Electrical power for the control system and for charg-
Automatic evaporator coil defrosting is initiated by ing the batteries is provided by the 12 vdc alternator.
either sensing the air pressure drop across the coil with a Also, on the model NDA, the auto start/stop feature
differential air switch or with the built---in timer in the mi- is standard equipment.
croprocessor.
The auto start/stop operation provides automatic
The control box and panel include manual switches, cycling of the diesel engine, which in turn offers an energy
microprocessor with light emitting diodes (LED), amme- efficient alternative to continuous operation of the en-
ter, fuses, and associated wiring. Also, the model NDA is gine with control of temperature by alternate cooling and
equipped with a remote light bar as standard equipment. heating of the supply air (evaporator outlet air).

Table 1--- 1. Model Chart

Model Refrigerant Engine Engine Engine

High Speed Low Speed

NDA ---791 Phoenix Advantage R---502 CT4---134---DI 1900 rpm 1350 rpm
NDA ---799 Phoenix Advantage R---502 CT4---134---TV 1900 rpm 1350 rpm
NDA ---899 Phoenix Xtra R---502 CT4---134---TV 2200 rpm 1400 rpm

1---1
 P

1 2

TOP VIEW 3

1. Condenser Pressure Control 1. Radiator Fill Neck Location

Solenoid Valve (SV ---1) 2. Evaporator Section
2. Bypass Check Valve 3. Defrost Air Switch
3. Hot Gas Solenoid Valve (SV ---3) 4. Radiator Overflow Reservoir
4. Receiver 5. Control Panel
5. Receiver Sight Glass 6. Microprocessor
6. Receiver Manual Outlet Valve
7. Filter---Drier Figure 1--- 2. Roadside
8. Engine Air Cleaner
9. Battery
10. Model/Serial No. Location

Figure 1--- 1. Curbside

1---2
 P

1. Liquid Line Solenoid Valve (SV ---2) 12. Fuel Filter

2. Discharge Service Valve 13. Oil Pressure Switch
3. Unloader Solenoid Valve 14. Injection Pump
4. Discharge Line Check Valve 15. Fuel Bleed Valve
5. High Pressure Cutout Switch (HP---1) 16. Lube Oil Fill
and Head Pressure Control Switch (HP---2) 17. Starter Motor
6. Suction Service Valve 18. Oil Drain
7. Suction Pressure Transducer (SPT) 19. Full Flow Lube Oil Filter
8. Alternator and Regulator 20. Bypass Lube Oil Filter (Optional)
9. Speed Control Solenoid 21. Compressor Sight Glass
10. Run Solenoid 22. Compressor
11. Mechanical Fuel Pump 23. Battery

Figure 1--- 3. Front View

1---3
 P

9
1
8

2
7

6 3

1. Pre---Trip Switch
2. Air Flow Switch
3. Microprocessor
4. Start ---Run---Stop Switch
5. Glow Switch
6. Engine --- Auto Start Switch
7. Ammeter
8. Defrost Test Points
9. Off---Time Switch

Figure 1--- 4. Control Panel

1---4
 P

10 9 1 2

3
4

1. Diode --- Relay Board

2. Defrost Relay
3. Speed Relay
4. Heat Relay (HR1)
5. Run Relay
6. Heat Relay (HR2)
7. Fuses
Top Fuse (F2 --- 30 Amp)
Second Fuse (F3 --- 20 Amp)
Third Fuse (F4 --- 5 Amp)
Bottom Fuse (F8 --- 20A)---Optional
8. Fuse (F1 --- 80 Amp)
9. Starter Solenoid Relay
10. Glow Plug Relay

Figure 1--- 5. Control Box --- Door Open

1---5
 P

8
3

2 4

7 6 9
NDA---79 Phoenix Advantage
8

4
2

7 5

NDA---89 Phoenix Xtra

1. Expansion Valve and Bulb Location 6. Return Air Sensor

2 Damper Actuator Solenoid 7. Defrost Termination Thermostats
3. Damper 8. Supply Air Sensor (Optional)
4. Evaporator Fan 9 Heat Exchanger
5. Hot Gas Line (Evaporator Drain Pan)
Figure 1--- 6. Evaporator Section --- Panels and Grille Removed

1---6
 P

1.2 ENGINE DATA Lube Oil Viscosity:

CT4---134DI / TV (V2203DI / V2203TV): Outdoor Temperature
a. Bore/Stroke
3.43 in. (87mm) /3.64 in. (92.4 mm) Fahrenheit Centigrade SAE
b. Compression Ratio Below 32_ 0_C 10W or 10W30
CT4---134DI (V2203DI) 20.5 : 1 32_ to 77_F 0_ to 25_C 20 or 10W30
CT4---134TV (V2203TV) 22 : 1 Over 77_F Over +25_C 30 or 15W40
c. Cooling System
Oil Change Intervals:
Capacity:
First 400 hours, thereafter as listed below.
10 U.S. quarts (9.46 liters)---includes 1 quart
(0.95 liter) in coolant recovery bottle. CAUTION
(Refer to section 4.3.1) The maximum oil change interval is 1 year (for
Type of Anti---Freeze: either approved oil). The only approved
Ethylene Glycol 5 quarts (4.73 liters) synthetic lube oil is Mobil Delvac 1. The normal
Water 5 quarts (4.73 liters) oil change intervals (listed below) should be
(Refer to section 4.3.1) reduced if the equipment is operated under
extreme conditions such as in dirty
Thermostat: environments.
Starts to Open 177 to 182_F (80 to 83_C)
Fully Open 203_F (95_C) Engine Unit API MOBIL
d. Cylinders (Number) Features Class CD DELVAC 1
(Hours) (Hours)
Four
e. Displacement CT4-- 134TV Oil Bath 1000 2000
134 cu. in. (2.2 liters) Air Cleaner w/o
Bypass Oil Filter
f. Firing Order
1---3---4---2 Dry Type 1500 3000
Air Cleaner
g. Fuel w/Bypass Oil Filter
Winter Diesel No. 1
Summer Diesel No. 2 CT4-- 134DI Oil Bath 1500 3000
Air Cleaner w/o
h. Glow Plug Amperage Bypass Oil Filter
7.0 amps per plug at 10.5 vdc (nominal) Dry Type 2000 4000
i. Horsepower Air Cleaner
CT4---134DI 33.0 hp @ 1900 rpm w/Bypass Oil Filter
CT4---134DI 25.0 hp @ 1350 rpm
1.3 REFRIGERATION SYSTEM DATA
CT4---134TV 36.0 hp @ 2200 rpm
CT4---134TV 34.0 hp @ 1900 rpm a. Compressor
CT4---134TV 25.0 hp @ 1350 rpm Model: O5G (41 cfm)
j. Injection Setting Number of Cylinders: 6
CT4--- 134DI 3250 to 3400 psi (228.5 to 239.0 kg/cm@) Maximum Number of Unloaders: 2
CT4--- 134TV 1991 to 2133 psi (140 to 150 kg/cm@) Weight (Less Service Valves): 137 lb (62 kg)
k. Valve Clearance (Cold): b. Compressor Oil Charge
(Intake and Exhaust): 8 U.S. Pints (3.8 litres). (Refer to section 4.12 for
0.0071 to 0.0087 inch service replacement compressor.)
(0.18 to 0.22 mm)
c. Approved Compressor Oils
l. Weight (Dry): with Accessories: Shrieve---Zerol Refrigeration Fluid 150 (synthetic)
417.8 lb (189.5 kg)
d. Compressor Oil Sight Glass
m. Lubrication System
Oil level should be between bottom to 1/4 of sight glass
19 U.S. quarts (18 liters) with the compressor in operation.
(Includes 1 U.S. quart = 0.95 liter) (Refer to section 4.13)
Oil Pressure: e. Defrost Air Switch
40 to 60 psig (2.8 to 4.2 kg/cm@) Initiates Defrost:
(Engine in high speed)
1.40 (¦ .07) inch (35 ¦ 1.8 mm) WG
Oil Pressure Safety Switch Setting Closes:
15 ( ¦ 3) psig (1.05 kg/cm@)

1---7
 P

f. Solid State Defrost Timer ton draws clean fresh air down into the cylinder for the
Optional Setting: compression and power strokes. As the engine goes
through its exhaust stroke, the upward movement of the
1---1/2, 3, 6, or 12 hours
piston forces the hot exhaust gases out of the cylinders
g. Defrost Thermostats through the exhaust valves and the exhaust manifold. If
Opens: 50 ¦ 5_F (10 ¦ 3_C) the air filter is allowed to become dirty, the operation of
Closes: 40 ¦ 5_F (4.4 ¦ 3_C) the engine would be impaired.
h. Expansion Valve Superheat
1.7 LUBE OIL AND FUEL FLOW DIAGRAMS
Setting at 0_F (---17.8_C) box temperature:
12 to 14_F (6.7 to 7.8_C) 1 6
i. Fusible Plug Setting
208 to 220_F (97.8_F to 104.4_C)
j. Head Pressure Control Switch (HP--- 2) 2
5
Cutout: 350 ¦ 10 psig (26 ¦ 0.7 kg/cm@)
Cut---in: 235 ¦ 10 psig (16.5 ¦ 0.7 kg/cm@) 4
k. High Pressure Switch (HP--- 1) 3
Cutout: 428 ¦ 10 psig (30 ¦ 0.7 kg/cm@)
Cut---in: 320 ¦ 10 psig (22.5 ¦ 0.7 kg/cm@) 1. Engine Block 5. Engine Oil
l. Refrigeration Charge R--- 502 2. Oil Pan Connection
3. Full Flow Oil Filter 6. Oil Pressure Switch
29 lb (13.2 kg) 4. Bypass Oil Filter
m. Weights (Approximate)
Figure 1--- 7. Lube Oil Flow Diagram
Unit:
1690 lb. (767 kg) --- Advantage
1720 lb. (780 kg) --- Xtra 5,6
Battery: 3
Dry: 35 lb (16 kg)
Wet: 50 lb (22.7 kg)
Integral Fuel Tank: 2
Capacity: 33.5 gal. (126.8 litre)/ 285 lb (129 kg)
1 4
Draw: 30 gal. (113.6 litres)/ 255 lb (115.7 kg)
1.4 SAFETY DEVICES
System components are protected from damage
caused by unsafe operating conditions by automatically
shutting down the unit when such conditions occur. This
is accomplished by the safety devices listed in Table 1---2.
11
1.5 ENGINE SCREW THREADS
All threads used on the diesel engine are metric ex- 10
9 8
cept the oil drain plug which is American Standard Pipe
Thread (NPT).
1.6 ENGINE AIR SYSTEM
7
The air cleaner is put on the engine to prolong its life
and performance by preventing dirt and grit from getting 1. Fuel Tank 6. Fuel Warmer
into the engine causing excessive wear on all operating 2. Fuel Supply Line (Optional)
parts. However, it is the responsibility of the operator to 3. Fuel Pump 7. Fuel Bleed Valve
give the air cleaner equipment regular and constant 8. Injection Pump
(Optional)
attention in accordance with the instructions. (Refer to 9. Injector Nozzles
section 4.3.5) 4. Mechanical
Lift Pump 10. Fuel Leak ---off Line
Clean air is supplied to the engine through the air 5. Fuel Filter 11. Fuel Return Line
cleaner (See Figure 1---1). The air is necessary for com-
plete combustion and scavenging of the exhaust gases. As Figure 1--- 8. Fuel System Diagram
the engine piston goes through the intake stroke, the pis-

1---8
 P

Table 1--- 2. Safety Devices

Unsafe Conditions Safety Device Device Setting

1. Low engine lubricating oil 1. Oil pressure safety 1. Opens below 15 ¦ 3 psig
pressure switch (OP) --- automatic reset (2.1 ¦ 1.2 kg/cm@)
2. High engine cooling 2. Water temperature 2 Opens above
water temperature sensor (microprocessor) 230 ¦ 5_F (110 ¦ 3_C)
3. Excessive current draw 3. Fuse (F1) 3. Opens at 80 amps
by glow plug circuit
4. Excessive current draw 4. Fuse (F2) 4. Opens at 30 amps
by control circuit and
starter solenoid (SS)
5. Excessive current draw by 5. Fuse (F3) 5. Opens at 20 amps
control circuit
6. Excessive current draw by 6. Fuse (F4) 6. Opens at 5 amps
microprocessor
7. Excessive compressor 7. High pressure cutout switch 7. Refer to Section 1.3.l. for
discharge pressure (HP---1) --- automatic reset switch settings

1.8 COMPRESSOR UNLOADER ing, unloader relay (UFR ) energizes to unload compres-
The compressor is equipped with unloaders for ca- sor bank (compressor in four cylinder operation).
pacity control. This consists of a self---contained, suction b. Major Working Parts
cut---off arrangement which is electronically controlled 1. Solenoid and valve system
by the temperature controller.
2. Unloader piston assembly
The capacity controlled cylinders are easily identi-
fied by the solenoid which extends from the side of the 3. Spring and cover plate
cylinder head. When the solenoid energizes, cylinders c. Unloaded Operation
unload, preventing suction gas from being drawn into the
cylinder(See Figure 1---9). The unloaded cylinders oper- When the unloader valve solenoid energizes, the ca-
ate with little or no pressure differential, consuming very pacity control valve port opens (item 3, Figure 1---9). This
little engine power. A de---energized solenoid reloads the allows the discharge gas behind the unloader piston as-
cylinders as shown typically in Figure 1---10. sembly (item 4) to vent back to the suction side. The un-
loader valve spring (item 7) at this point, can move the
NOTE unloader valve body to the left, blocking the unloader
There is a delay of 30 seconds between suction port. The cylinder bank is now isolated from the
de---energizing one set of unloaders to compressor suction manifold to unload these two cylin-
de---energizing the other set of unloaders. ders. No refrigerant is allowed into the cylinders and no
compression takes place.
a. Temperature Control Within 2.7_F (1.5_C)
of Set Point d. Loaded Operation
1. Cool light (CL) or heat light (HL) illuminated When the unloader valve solenoid de---energizes, the
(depending on mode of operation). capacity control valve port closes (item 3, Figure 1---10).
This allows discharge pressure to build---up behind the
2. If in low speed cooling, unloader relays (UFR & unloader piston assembly. A high enough pressure will
URR) energize to unload compressor banks (compressor compress the unloader valve spring, opening the un-
in two cylinder operation). loader suction port. Suction gas can now be drawn into
3. The heat mode forces the rear unloader (UR) to the cylinders, running the bank fully loaded.
a loaded condition (de---energized). In low speed heat-

1---9
 P

2 3 4 5 6

1
7

8
16
15
14

SUCTION PRESSURE 13 12 11 10 9

DISCHARGE PRESSURE

1. Solenoid Valve 6. Unloader Valve Body 12. Discharge Valve

2. Coil 7. Unloader Valve Spring 13. Discharge Manifold
3. Capacity Control Valve 8. Cover Plate 14. Valve Plate
(Open) 9. Suction Manifold 15. Strainer
4. Unloader Piston Assembly 10. Suction Valve 16. Bleed Orifice
5. Unloader Head 11. Piston

Figure 1--- 9. Compressor Cylinder Head (Unloaded) Suction

Cutoff

2 3 4 5 6

1
7

8
16
15
14

SUCTION PRESSURE 13 12 11 10 9

DISCHARGE PRESSURE

1. Solenoid Valve 6. Unloader Valve Body 12. Discharge Valve

2. Coil 7. Unloader Valve Spring 13. Discharge Manifold
3. Capacity Control Valve 8. Cover Plate 14. Valve Plate
(Closed) 9. Suction Manifold 15. Strainer
4. Unloader Piston Assembly 10. Suction Valve 16. Bleed Orifice
5. Unloader Head 11. Piston
Figure 1--- 10. Compressor Cylinder Head (Loaded)
Suction Cutoff

1---10
 P

1.9 BATTERY CHARGING ALTERNATOR enough to warrant a sealed unit. The system is tempera-
SYSTEM ture compensated to permit the ideal charging rate at all
1.9.1 Introduction temperatures.
Table 1--- 3. Alternator and Manuals The regulator is an electronic switching device. It
senses the voltage appearing at the auxiliary terminal of
Prestolite Prestolite Amps the alternator and supplies the necessary field current for
Alternator No. Manual No. maintaining the system voltage at the output terminal.
The output current is determined by the load.
8EM2012NA 25---197 65 3
2
1
It is recommended that the applicable manual (see
chart above) be obtained from Prestolite Electric, 7585
10
Empire Drive, P.O. Box 6210, Florence, Kentucky, 41042,
4
U.S.A., for complete overhaul and service information of
the alternator, and regulator, if required.
9
The mechanical construction of the alternator differs
from the d---c generator in that the field rotates and the
(armature) generating windings are stationary. The field 5
current necessary to control the output of the alternator 8
is supplied from the solid---state regulator. This integral
voltage regulator, which incorporates an IC, all silicon 6
semiconductor and thick---film construction, controls the
current feed to the field via the brushes and rotor slip 7
rings.
Two completely sealed ball bearings support the ro-
tor in the front and rear housing.
1. 12vdc Test Lamp 6. AC Tap
CAUTION Terminal (D+) 7. Rotor (Field)
2. Diode Trio 8. Stator
Observe proper polarity when installing battery, 3. Positive Output(B+) 9. Integral Regulator
negative battery terminal must be grounded. 4. Rectifier 10. Excite
Reverse polarity will destroy the rectifier diodes 5. Ground
in alternator. As a precautionary measure,
disconnect positive battery terminal when Figure 1--- 11. Alternator Schematic Diagram
charging battery in unit. Connecting charger in
reverse will destroy the rectifier diodes in 1 2
alternator.
7 3
1.9.2 Alternator Operation
The alternator converts mechanical and magnetic
energy to alternating current (A.C.) and voltage, by the 6
rotation of an electromagnetic field (rotor) inside a three
phase stator assembly. The alternating current and volt- 5
age is changed to direct current and voltage, by passing
A.C. energy through a three phase, full---wave rectifier
system. Six silicon rectifier diodes are used. (See
Figure 1---11)
4
1.9.3 Integral Voltage Regulator Operation
(12 volts d--- c)
1. AC Tap 5. Excite
The regulator is an all---electronic, transistorized de- 2. Back Cover 6. Ground
vice. No mechanical contacts or relays are used to per- 3. Positive Output(B+) 7. 12vdc Test Lamp
form the voltage regulation of the alternator system. The 4. Integral Regulator Terminal (D+)
electronic circuitry should never require adjustment and Figure 1--- 12. Alternator and Regulator
the solid state active elements used have proved reliable

1---11
 P

1.10 MICROPROCESSOR CONTROLLER

ENTER

MANUAL
DEFROST SETPOINT ENGINE
ENTER * HOURS

ALTERNATING PROBE COOLANT

DISPLAY TEMP TEMP
ON/OFF
* *
DEFROST
INTERVAL
(HR)
Carrier
TRANSICOLD
SUCTION
PRESSURE
(PSIG)

Figure 1--- 13. Microprocessor Control Panel

Table 1--- 4. Keypad LED, Digital Display Troubleshooting Messages

Failed Failure Panel Digital

Component or Mode LED Display
Circuit Indication Readout

Oil Pressure Switch Open Low Oil Pressure On None (Normal)

Oil Pressure Switch Closed None None (Normal)
Water Temperature Sender Shorted High Coolant
Temperature On 266 Flashing*
Water Temperature Sender Open High Coolant
Temperature Flashing ---4 Flashing*
Control Probe RAS or SAS** Open Cool LED Flashing ---36 Flashing
Control Probe RAS or SAS* Shorted Cool LED Flashing 100 Flashing
DA Shorted Defrost LED Flashing None (Normal)
DT Shorted Defrost LED Flashing None (Normal)
Automatic Restart Failure to Start Auto Start/Stop
on LED Flashing None (Normal)
Out of Range If set point has not Out of Range
(Pulldown) been reached since LED On None (Normal)
unit was started
Out of Range ¦6_ deviation from Out of Range
from set point for LED Flashing None (Normal)
15 minutes

* Appropriate function must be accessed on keypad to display reading.

** If programmed for dual control only.

1---12
 P

1.10.1 General NOTE

The microprocessor controller is housed in the con- When changing the set point, always remember
trol panel on the lower roadside corner of the unit. This to ENTER the set point.
controller consists of three printed circuit boards: a mi- To change set point, press the SETPOINT key. Then
croprocessor/display, analog interface (or option board) use the up/down arrows to adjust the set point to the de-
and a relay board. The microprocessor/display and ana- sired setting. Press the ENTER key to enter the new val-
log interface board are mounted directly to the key pad. ue into memory. It is a good practice to always verify the
Most outputs to control the operation of the unit are set point after changing it by pressing the SETPOINT
switched through the relay board which connects to the KEY.
analog interface board through a ribbon cable. The relay
board has five interchangeable relays that may be re- b. Up/Down Arrows
placed. The microprocessor is totally self---contained and The up and down arrows are used to change the val-
does not contain any serviceable components. ues of set point and defrost interval. Also the up and
When the microprocessor wants to energize a specif- down arrows are used to select ambient or discharge tem-
ic relay, it will internally complete the ground path perature, refer to Probe Temperature Key.
through the ribbon cable to the relay. This process will be c. Enter Key
referred to in this manual as “pulling the relay coil low.” The ENTER key is used to enter new values of set
For example when the controller wants to energize the point and defrost interval into memory. This key is also
run relay (RR), it will “pull pin JJ1 low.” used to access other microprocessor functions as de-
CAUTION scribed herein.
Under no circumstances should anyone attempt d. Manual Defrost Key
to service the microprocessor!(see section 4.27) To initiate a manual defrost, press the MANUAL
Should a problem develop with the DEFROST and ENTER keys simultaneously.
microprocessor, contact your nearest Carrier
Transicold dealer for replacement. e. Alternating Display On/Off
Press the ALTERNATING DISPLAY ON/OFF key
The Carrier Transicold microprocessor controller in-
to have the display alternate between box temperature
corporates the following features:
and set point at three second intervals. To terminate al-
--- Display box temperature ternating display, press key again.
--- Display controller set point and adjustment f. Defrost Interval Key
--- Display alternating between box temperature and
controller set point The microprocessor controller is equipped with a
--- Defrost interval timer solid state defrost interval timer. Defrost intervals of 1.5,
--- Manual defrost initiation switch 3, 6, and 12 hours may be selected. To display the current
--- Display Remote probe temperature (optional) defrost interval in memory, simply press the DEFROST
--- Display of supply and return air temperatures INTERVAL key.
(optional) NOTE
--- Display of engine and standby operating hours
Always remember to ENTER the new value
--- Display of engine coolant temperature and
protective shutdown device when changing the defrost interval.
--- Display of suction pressure To change the defrost interval, press the DEFROST
--- Out---of---range detector INTERVAL key. Use the up/down arrows to obtain the
--- Diagnostic display of protective shutdown devices desired setting. Once the desired setting is obtained,
--- Auto---start/stop operation press the ENTER key to enter the value into memory.
--- Communicate unit operating data to a satellite g. Probe Temperature Key
1.10.2 Controls and Display (See Figure 1--- 13) The Probe Temperature Key is used to display probes
RAS and SAS temperature.
a. Setpoint Key
When this key is selected, the active (controlling)
To display set point, press the SETPOINT key. The probe temperature will be displayed. On units equipped
set point in memory will be displayed for five seconds. with dual probes for supply and return air control, press
When set point is displayed, the set point light emitting the PROBE TEMP and ENTER keys simultaneously to
diode (LED) will also be illuminated. The display will re- display the inactive probe temperature. If a second probe
vert to displaying box temperature if no other keys are is not present, “EEE” will be displayed.
pressed.

1---13
 P

h. Engine Hours Key h. Auto Start/Stop--- On LED Flashing

Pressing the ENGINE HOURS key will display the Indicates the engine has not started after three
number of accumulated engine operating hours. Note successive auto start attempts or unit has failed to run a
that the microprocessor will retain this value if power is minimum of seven minutes, three consecutive times.
removed from the unit (such as battery removal). Operat- Check starting system.
ing hours over 9,999 must be recorded manually as the
processor will revert back to zero hours and begin count- 1.10.4 Caution Indicators(Light Emitting Diodes)
ing again. (See Figure 1--- 13)
i. Coolant Temperature Key a. Out--- Of--- Range LED
Press COOLANT TEMP key to display engine cool- Active probe temperature is outside of the tolerance
ant temperature. band of ¦ 3_F (1.7_C) of set point. Unit on initial
j. Suction Pressure Key pulldown.
Suction pressure may be displayed by pressing the b. Out--- Of--- Range LED Flashing
SUCTION PRESSURE key. Active probe temperature is outside of the tolerance
k. Set point Light Emitting Diode (LED) band of ¦ 6_F (3.3_C) of set point for 15 minutes after
unit was in---range. For set points below +10_F
The set point light illuminates whenever set point is
(---12.2_C) (frozen range) the unit is only considered
being displayed.
out---of---range for temperatures above set point.
l. Box Temperature (LED)
For example --- with the controller set point at ---10_F
The box temperature light illuminates whenever box (---23.3_C), a box temperature of ---20_F (---28.9_C)
temperature is being displayed. would not be considered out---of---range. But, if the box
temperature was 0_F (---17.8_C), this would be out---of---
1.10.3 Status Indicators (Light Emitting Diodes) range.
(See Figure 1--- 13)
c. High Coolant Temperature LED
a. Cool LED Engine coolant temperature excessive. Unit has
Indicates the unit is operating in cool mode. shutdown to prevent engine damage.
b. Cool LED Flashing d. High Coolant Temperature LED Flashing
Indicates a defective temperature probe. On units Indicates a defective coolant temperature sensor.
equipped with supply and return air probes, control of The unit will continue to operate normally. This condi-
unit would automatically be changed to the other probe. tion should be corrected immediately as the protective
In the event of probe failure on a single probe unit, the shutdown is not functional.
unit would be controlled as follows. e. Low Oil Pressure LED
1. If the set point temperature is greater than 10_F Engine oil pressure low. Unit has shutdown to pre-
(12.2_C), the unit would stop. vent engine damage.
2. If the set point temperature is less than 10_F f. High Discharge Temperature LED
(12.2_C), the unit would operate in low speed
The high discharge temperature LED is NOT
cool (compressor fully loaded).
APPLICABLE for these units.
c. Heat LED
Indicates the unit is operating in heat mode. 1.10.5 Digital Display
d. Defrost LED a. Introduction
Unit is operating in defrost mode. During defrost, A four---digit liquid crystal display (LCD) is incorpo-
both heat and defrost LEDs are illuminated and “dF” ap- rated on the processor. The following parameters may be
pears on the display. displayed:
e. Defrost LED Flashing --- Box temperature
Indicates a defrost mode failure. Unit is operating on --- Set point temperature
override timer. Check defrost system. Refer to --- Defrost interval setting
section 1.10.6 for defrost mode failure. --- Remote probe temperature
f. Fuel Miser--- On LED --- Supply/return air temperature
--- Engine/standby operating hours
Unit is operating in fuel saving mode with compres- --- Engine coolant temperature
sor unloaded. --- Suction pressure
g. Auto Start/Stop--- On LED
Unit is operating in auto start/stop mode.

1---14
 P

b. Other Display Functions ber. Thus, the designation JC---3 would refer to a wire
(Display Message/Description) from the 3 pin on connection block JC.
--- dF--- b. Connection Block Descriptions
Indicates unit is operating in defrost. Display may be (See Figure 1--- 5 and 5--- 1)
over ridden by any keypad function. (1) Relay Board
PPPP
JA Relay board inputs and outputs
Indicates unit is operating in pretrip mode. Display
may be overridden by any keypad function. JB Relay board inputs and outputs
c. Diagnostics (2) Analog interface Board
In addition to the above, the LCD is also used as a
diagnostic interface with the operator to troubleshoot JC Main connections to analog interface board
problems. Diagnostic messages are shown below: (mostly inputs)
--- SP--- (during self--- test)
JD Return air sensor input
Indicates a valid set point has not been entered.
--- Lb--- JE Supply air sensor input
Indicates a low battery condition (Refer to section JF Auto---start connections (inputs and outputs)
1.11).
--- Hb--- JG Connection for external switches (pretrip,high
Indicates a high battery or over voltage condition airflow, continuous run, test board and door
(Refer to section 1.11). switches)
EEEE (when reading alternate probe) JH Option inputs/outputs for heat lockout, out---
Indicates alternate probe not present or defective. of---range and electric heat
--- 36 (Flashing)*
JJ (Ribbon cable connection from analog interface
On single probe units, probe has failed open. On dual board to relay board.) This cable controls
probe units, both probes have failed open. functioning of the relay coils on the relay board.
100 (Flashing)*
On single probe units, probe has failed closed JK (Ribbon cable connection from microprocessor
(shorted). On dual probe units, both probes have failed display board to analog interface board)
closed. c. Connection Descriptions
*Note: When probe failure occurs, cool LED will
also flash. JA--- 1 Output to heat light on remote light bar
Err1, Err2 or Err3 (during self--- test) JA--- 2 Connection point for the electric fuel pump
Indicates processor logic errors. The processor is
nonfunctional and must be replaced. JA--- 3 Not used
1.10.6 Defrost Mode Failure
JA--- 4 Connection point for the starter solenoid relay.
The microprocessor controller monitors operation Note that the unit must be in “MANUAL” mode
of the defrost termination switch and defrost air switch to to manually crank starter motor.
prevent the possibility of damaging a load due to the fact
that the unit is “stuck” in defrost. JA--- 5 Connection point for fuel heater relay
Defrost mode failure is indicated by a flashing de-
frost LED as stated in section 1.10.3.e. JA--- 6 Main ground connection for relay board
During defrost mode failure, the unit is allowed to JA--- 7 Output to the exciter circuit on the alternator
defrost for a maximum of one hour. After this period, the voltage regulator
unit is allowed to function normally in order to maintain
load temperature for one hour. The unit is then placed JA--- 8 Output to HP2 switch
back in defrost for one hour. This cycle repeats until the
problem is corrected. Also, should the problem be cor- JA--- 9 Not used
rected at any time, the unit returns to normal operation.
1.10.7 Controller Interface Connections JA--- 10 Common with T3
(See Figure 5--- 1)
a. Connection Terminology JA--- 11 Open Not Used
Connections to the analog interface and relay boards JA--- 12 Connection point for SSR7 and arc suppression
have terminal connections labeled “JA” thru “JK”. Pin diode D53.
numbers are called out after the connection block num-

1---15
 P

JA--- 13 Not used JC--- 2 Pin 2 provides the microprocessor with an input
indication that the unit is being glowed for
JA--- 14 Not used start---up.

JA--- 15 Input to the positive side of the run relay. Input NOTE
is present whenever HP1 is closed and Oil pressure is not checked for 15 seconds after
the start---run---stop switch is in the run position. release of glow switch. For the run relay to
energize for starting, the following conditions
JA--- 16 Not used must be met: (a) coolant temperature must be
less than 230_F (111_C), (b) HP1 must be
JB--- 1 (common with JB---2) closed, (c) battery voltage must be within
specified minimum/maximum levels, (d) one
JB--- 2 Output to rear unloader (UR) probe must be functional and (e) a valid set point
must be entered. If the above conditions are met,
JB--- 3 Not used the run relay is energized when the glow plug
switch is energized.
JB--- 4 Output to TP2 which is common with the defrost
air switch and defrost termination thermostats JC--- 3 Provides microprocessor with an input voltage
for suction pressure transducer.
JB--- 5 Input indicating the defrost termination ther-
mostats are closed (common with JJ---3). JC--- 4 Main ground connection pin for microprocessor
NOTE and analog interface boards
Every time the defrost is initiated, a one hour JC--- 5 Input connector pin for water temperature
clock is started in the microprocessor. After one sensor. This sensor provides six functions: (a)
hour the processor looks at the state of the used to display coolant temperature, (b) used to
defrost termination thermostats (DT). If the shut down unit if coolant temperature is exces-
thermostats (DT) are still closed, the processor sive, (c) used to illuminate LED if high coolant
assumes that the thermostats have failed closed temperature exists, (d) used to determine prop-
and the unit is placed in the defrost override er glow time on auto start unit, (e) used to start
mode. unit on auto start if coolant temperature drops
Input is also used to start the timing function on below 32_F (0_C) and (f) used to determine
the solid state defrost timer. when engine can be placed in high speed after
starting.
JB--- 6 Not used
Sensor operates on an inversely proportional
JB--- 7 Output to defrost light on remote light bar relationship. If coolant temperature is high, a
low resistance reading will appear across sensor.
JB--- 8 Not used (common with T7 ) To test unit for proper shutdown if coolant
temperature is excessive, short sensor wire to
JB--- 9 Output to the front unloader coil UF ground.

JB--- 10 Not used JC--- 6 Not used

JB--- 11 Not used (common with T6 ) JC--- 7 Power supply to suction pressure transducer (5v)
JB--- 12 Output to SV1 --- Refer to JJ---5 JC--- 8 Alternator auxiliary input connection. This in-
put serves three functions: (1) used to terminate
JB--- 13 Output to SV2 cranking in the auto start mode; (2) signals the
start of the 15 second oil pressure delay in
JB--- 14 Output to SV2/HP2; common with JB---13
manual and auto start modes; and (3) used for
JB--- 15 Output to cool light on remote light bar charging indicator for auto start shutdown.

JB--- 16 Output to SV3

JC--- 1 Main input to microprocessor. Power (12 vdc)

should be present whenever the start---run---stop
switch is in the run position. Also used to
monitor battery voltage.

1---16
 P

NOTES JF--- 5 5 vdc input to the processor to indicate a 30

If the above signal (12 vdc) is not present after minute minimum off time is requested on auto
starting: start/stop. Fifteen minute minimum off time is
the default value (no voltage at JF---5).
1. Unit will shut down in approximately 30
seconds with manual operation. JF--- 6 Common 5 vdc output to the off time switch

2. In auto start, the starter will be engaged for CAUTION

the maximum cranking time (10 seconds) Never apply 12 vdc to JD, JE, JF, or JG terminal
and the unit will continue to run without 12 blocks. These four items are low voltage (2.5 or
vdc at JC---8, but will not shut down 5.0 vdc). Damage to the microprocessor will
automatically. result. (Refer to Note 4, Figure 5--- 1)

JG--- 1 Common output (2.5 vdc) to high airflow.

JC--- 9 Defrost switch input. If this pin has 12 vdc and
Pre---trip and board test.
the defrost termination switches (DT) are
closed, the unit will initiate a defrost. The JG--- 2 Not used
controller also senses this input when the defrost
termination switches open. If the input still JG--- 3 Not used
exists directly upon termination of defrost, the
controller assumes the air switch is defective JG--- 4 Input (2.5 vdc) to the controller indicating the
(stuck closed) and places the unit in defrost high airflow option is desired. In this mode the
override. On override, the unit is alternately unit is prevented from running in low speed if the
placed in defrost and normal control at one--- set point is set above 10_F (---12.2_C). Unload-
hour intervals. ers will function normally.
JC--- 10 Not used JG--- 5 Input (2.5 vdc) indicating pre---trip mode is
desired. (Refer to section 1.12.2.e.4)
JD--- 1 Return air sensor input connection
JG--- 6 Oil pressure switch connection used to shutdown
JD--- 2 Return air sensor input connection unit if low oil pressure exists. Also controls the
low oil pressure LED.
JD--- 3 Ground for suction pressure transducer
JH--- 2/JH--- 3 Not used
JE--- 1 Supply air sensor input connection (optional)
JH--- 4 Input for out---of---range light.
JE--- 2 Supply air sensor input connection (optional)
JH--- 5 Output for remote out---of---range light.
JE--- 3 Not used
NOTE JJ--- 1 (Ribbon cable) If controller places potential at
pin 1, run relay will not energize. If pin is pulled
Connections JF---1 through JF---6 are for auto
low, run relay will energize.
start.

JF--- 1 Pin 1 is an input to the microprocessor indicating JJ--- 2 (Ribbon cable) Input (12 vdc) to the processor
indicating electric standby mode is requested
that the unit should be operating in auto
(not available)
start/stop mode.

JF--- 2 Pin 2 output controls the functioning of the JJ--- 3 (Ribbon cable) Input (12 vdc) to the processor
starter solenoid relay during auto start opera- indicating a closed defrost klixon
tion. To energize the relay, the pin is pulled low JJ--- 4 (Ribbon cable) Pin 4 controls the operation of
by the microprocessor. heat relay HR2. HR2 controls the functioning of
JF--- 3 In auto start ,the glow plug relay is controlled by SV3 and the heat light on remote bar light. Pin 4
is pulled low to energize the relay.
output from pin 3. The pin is pulled low by the
microprocessor to energize the relay. JJ--- 5 (Ribbon cable) Pin 5 controls the operation of
JF--- 4 Output (12 vdc) for a remote bar mounted heat relay HR1. HR1 controls the functioning of
restart failure light. SV2, SV1 and the cool light on a remote bar
light. Pin 5 is pulled low to energize the relay.

1---17
 P

NOTES d. Relay Board 1/4 Inch Connections

1. When the unit changes from cool to heat, T1 Main 12 vdc power into the relay board.
heat relays HR1 and HR2 are energized Supplies potential to the relay coils, defrost
simultaneously. Solenoid valve SV1 closes, circuit and T3 protected by fuse F3 (20 amp).
SV3 opens, SV2 closes (if HP2 is open), the
remote cool light de---energizes and the T2 Main 12 vdc power into the relay board.
remote heat light is illuminated. Supplies potential to most of the relay contacts
controlling load devices such as SV1, SV3, DDS,
2. When the unit changes from heat to cool, etc., protected by fuse F2 (30 amp).
heat relay HR2 de---energizes two seconds
after heat relay HR1. This allows solenoid T3 Common with T4 on diesel units.
valve SV1 to open two seconds before SV3
closes. Also, note that on a remote light bar, T4 Connection common with JA---2,JA---3,
the cool and heat lights will be on at the same JA---4,JA---5 (to electric fuel pump) and T5 .
time for this two---second period. Cool and
heat LEDs on the processor will change T5 Output terminal (12 vdc) to run solenoid (RS).
immediately when HR1 de---energizes.
T6 Output terminal (12 vdc) to speed control
JJ--- 6 (Ribbon cable) Pin 6 controls the operation of solenoid (SCS). This terminal is energized to
the unloader front relay (UFR). Pin 6 is pulled place the engine in high speed .
low to energize the (UFR). The (UFR) is
soldered into the relay board and is not replace- T7 Output terminal (12 vdc) to defrost damper
solenoid (DDS).
able.

JJ--- 7 (Ribbon cable) Pin 7 controls the operation of

the unloader rear relay (URR). Pin 7 is pulled
low to energize the (URR). The (URR) is
soldered into the relay board and is not replace-
able. 1.10.8 Remote Monitoring --- Microlink(Optional)
The microprocessor controller is equipped with
JJ--- 8 (Ribbon cable) Controls the functioning of the RS232 communication port. This port can be used to
speed relay. Note: Speed relay is now energized communicate unit operating data to a mobile satellite
for high speed operation. transmitter. This information will then be relayed back to
the office via a modem to a computer.
JJ--- 9 (Ribbon cable) Controls the functioning of the
defrost relay. Again, pin 9 would be pulled low to 1.11 AUTO START OPERATION
energize the relay. The automatic start/stop system is used to automati-
cally cycle the engine off and on to save fuel, reduce wear,
JJ--- 10 (Ribbon cable) Interconnection for arc suppres- and, thus reduce operating costs. The system is contained
sion diodes. (Connects the relay drivers on the in the analog interface board of the controller. It utilizes
processor to the relay coils on the relay board.) the controller sensors, glow plug and starter solenoid re-
NOTE lays which are also used for normal operation.

Main power for outputs is supplied to the relay This auto start system also has many of the same fea-
board on the two 1/4 inch spade connections. tures as the original system such as minimum run time,
These spade connections are independently low engine temperature protection, minimum off time,
fused and are labeled T1 & T2 . and three start attempts.

1---18
 P

a. Variable Glow Time Short cycling is also prevented by the minimum off
During auto start/stop operation, glow time is auto- time switch found on the control panel. (Refer to section
matically selected based on engine coolant temperature 1.12.2.e.6)
as follows: c. Coolant Temperature Override
The unit is prevented from stopping if coolant tem-
Engine Coolant Temperature Glow Time perature is below 32_F (0_C). Likewise, if the unit has
cycled off and coolant temperature drops below 32_F
SECONDS FOR (0_C), the engine is automatically started. This feature
DI TV insures proper engine starting even in cold ambient envi-
ronments.
Less than 33_F (1_C) 30 15
33_F to 50_F (1_C to 10_C) 20 10 d. Battery Voltage Protection
51_F to 77_F (11_C to 25_C) 10 5 The microprocessor controller continuously moni-
Greater than 78_F (26_C) 5 0 tors battery voltage and will automatically start and stop
the unit to maintain a proper voltage level. Shown in
b. Minimum Operating Time Table 1---5 is a summary of how this system operates.
A minimum operating time of seven minutes is pro- e. Start Sequence
grammed into the controller to prevent short cycling and One of the features of the auto start system is the
ensure that air flows for a sufficient time to sample load variable glow time before cranking. The glow time before
temperature and prevent hot spots. In order to save fuel, cranking is dependent on the engine coolant temperature
if temperature requirements are not satisfied after this as sensed by the water temperature sensor. (Refer to
seven minute operating time, the controller automatical- paragraph a)
ly operates the unit as follows: High speed loaded cool for
set points less than +10_F (---12.2_C). The controller The engine cranking period is now a maximum of 10
locks unit in high speed loaded cool until set point is seconds. If the engine starts before 10 seconds has
reached. Low or high speed loaded cool or heat for set elapsed, the alternator auxiliary signal will cause the pro-
points greater than +10_F (---12.2_C). cessor to de---energize the starter solenoid relay.

Table 1--- 5. Battery Voltages

Condition Message Voltage Description

Display Level

Low battery ---Lb--- Less than 10 Unit is automatically stopped in manual or auto
start/stop mode to prevent control error.

Intermediate battery ---No Display--- 11.0---13.4 If the unit has cycled off in auto start/stop
mode and battery voltage drops to11.0
volts, the unit is automatically started to charge
battery. Unit will operate until a battery voltage
of 13.4 volts is obtained at which level unit will
stop if temperatures are satisfied.
High battery ---Hb--- Greater than 17 Unit is automatically stopped in manual or auto
start/stop mode to prevent damaging
components.

VARIABLE MAXIMUM
0-- 30 SECONDS 10 SE-
CONDS
GLOW CRANK
15 SECONDS REPEAT 15 SE- REPEAT
GLOW STOP CONDS
“A” STOP “A”

FIRST ATTEMPT “A” SECOND ATTEMPT THIRD ATTEMPT

Figure 1--- 14. Auto Start Sequence

1---19
 P

If the engine fails to start, after a 15 second stop peri- There are two conditions which can override the off
od, a second start attempt identical to the first will begin. time and trailer temperature for immediate restart. They
If this attempt fails, the processor will allow a third and are:
final attempt to start. After the third failure, the proces- 1) Coolant temperature below 32_F (0_C)
sor will lock out unit operation and cause the AUTO
START/STOP---ON LED to flash. The remote restart 2) Battery voltage drops to 11.0 volts
failure light will also energize. An attempt should then be Whenever the engine restarts, it must satisfy all shut-
made to manually start the unit. It should be noted that a down conditions before it can again shut off.
restart failure indication will also be given if the unit fails
to run for the 7 minute run time on three successive start To start the unit automatically, the engine auto start
attempts. switch (EAS, Figure 5---1, coordinate H4 and P14) must
be placed in AUTO position and start---run---stop switch
Once the unit has started automatically, the unit (SRS, D2 and Q14) placed in the RUN position.
must run for a minimum of 7 minutes before it can consid-
er shutting off. This minimum run time is to prevent short This gives the microprocessor full control of unit op-
cycling and ensure adequate air flow through the load so eration. Most of the auto start inputs/outputs to the pro-
that the controller can accurately sense load tempera- cessor are made through pins on the JF plug connector
ture. It also prevents hot spots in the trailer. During the (E4).
minimum run time, the microprocessor will respond as Most of the preheat and cranking circuits are the
required to bring trailer temperature to the desired set same as manual starting except the way the glow plug and
point. starter solenoid relays (G4 and O13) are energized with
After the minimum run time (7 minutes) the micro- automatic starting.
processor will look at the remaining conditions that must The processor receives 12 vdc from SP4 (G3) to
be satisfied to allow a shutdown. These are: power up, and an input signal from the EAS switch at pin
1) Battery Condition --- Battery voltage must be JF1 (E5) indicating that auto start operation is re-
above 13.4 volts (measured at JC---1). quested. If the trailer temperature is out---of---range, the
processor will energize the glow plug relay (GPR) and run
2) The trailer temperature must be within +1/2_F relay (RR) coils (located at G4 and K3) by pulling pins
(0.3_C) of set point for both frozen and perishable range JF3 and JJ1 low (E5 and K2).
set points.
The GPR will energize to preheat the engine. The
3) Engine coolant temperature must be above 32_F run relay will also energize to provide voltage to the re-
(0_C). maining control circuits.
4) Alternator must be charging (12V at JC---8). After 0 to 30 seconds, depending on engine type and
If ALL of the above four conditions are not satisfied, temperature, the processor will energize the SSR coil
the engine will continue to run until they are. After the (O13) by pulling pin JF2 (E4) low to energize the engine
minimum run time, in order to save fuel and achieve a cranking circuit. The cranking period can last for a maxi-
rapid shutdown, the microprocessor will only allow the mum of 10 seconds. If the engine starts sooner, a 12 vdc
unit to run in the modes as detailed in paragraph b (mini- signal from the alternator auxiliary (ALT AUX) terminal
mum operating time). at terminal JC8 (D5) will cause the processor to de---en-
ergize the SSR coil and terminate cranking.
When all the shutdown conditions are satisfied, the
processor breaks the run relay ground path at JJ---1. It The GPR will de---energized after cranking stops.
also blanks the status LEDs to prevent battery drain. The If the unit fails to start after 3 successive attempts,
display and caution LEDs remain activated. the remote restart failure light will turn on and the AUTO
Once the engine has cycled off, it will remain off for START/STOP---ON LED will flash.
15 or 30 minutes, depending upon the position of the off It should also be noted that a restart failure indica-
time switch. This prevents the engine from rapid cycling tion will also be given if the unit fails to run for the 7 min-
due to changes in air temperature. Air temperature in the ute run time after three start attempts.
trailer can change rapidly, but it takes time for the prod-
uct temperature to change. When all the shutdown conditions have been
This auto start system does not include a 2 minute off achieved, the processor will stop the engine by opening
time test position. The reason for this is that all timing the ground circuit for the run relay. This removes the
functions of the microprocessor and the auto--- start sys- voltage from all the load circuits that are supplied by ter-
tem are checked during the controller self---test when the minals T1 and T2 (L7 and M5) on the relay board. The
unit is started. processor also blanks the status LED’s to conserve bat-
tery power.
After the off time is complete, the processor looks at
the active probe temperature (trailer temperature). It During the off cycle, the processor continues to re-
must be at least 6_F (3.3_C) away from set point (out--- ceive voltage from SP4 (G3) to JC1 and JF1 (E5). This
of---range) for a restart to be initiated. allows the controller sensors, i.e. water temperature

1---20
 P

(WTS) and trailer temperature (SAS or RAS) to remain teries), battery charging alternator and the voltage regu-
active to monitor conditions for restart. The minimum lator.
off time timer is also timing. If the off time switch (D4) is d. Sensor
in the 30 minute position as shown in Figure 5---1, 12 vdc
will be placed at pin JF5 (D4). This input tells the proces- 1. Water Temperature Sensor (WTS)
sor to prevent starting for 30 minutes. If the off time This device senses engine water temperature and
switch is in the 15 minute position, no voltage will be pres- transmits a signal to the microprocessor. (Refer to JC---5)
ent at JF5. The unit will then look at trailer temperature
e. Switches
after 15 minutes has elapsed.
NOTE 1. Engine Auto Start Switch (EAS)
This unit is not equipped with a 2 minute off time The switch is used to select automatic cycling of
test position because the processor verifies the engine, or normal continuous run operation. With the
proper timer function during initial self test. Start---Run---Stop (SRS) switch in the RUN position and
the engine auto---start switch (EAS) in the AUTO posi-
After the off time has elapsed, the engine will restart
tion, the unit will start and stop as required to maintain
when the trailer temperature deviates more than 6_F
cargo temperature (provided all conditions are met).
(3.3_C) from set point. In the frozen range, this must be a
(Refer to section 1.11)
rise in temperature.
The unit may be switched to continuous run by
An immediate restart can occur for the following
placing the EAS switch in the MANUAL position after
conditions:
the unit has started.
1. Battery voltage drops below 11.0 volts
2. Glow---Plug Switch (GPS)
2. Engine coolant temperature drops to 32_F
The glow---plug switch (momentary contact
(0_C)
type), when held in the UP position (glow) permits bat-
The above two items are called restart override tery current (approximately 7.5 amps per plug at 12 vdc)
conditions and are safeties to make sure that the unit will to flow to the glow plugs in the engine to pre---heat the
always be able to restart during automatic operation. combustion chamber. The glow plugs are located under
1.12 SWITCHES AND CONTROLS the fuel injectors. When starting engine, it is necessary to
continue to hold the glow---plug switch in the UP position
1.12.1 Introduction until the engine has developed sufficient oil pressure to
Components required for monitoring and control- close the oil pressure safety switch (OP). (Refer to sec-
ling the diesel engine --- refrigeration system are located tion 2.4.2)
in the control box and control panel. The water tempera- 3. Normal --- High Air Flow Switch (NHS)
ture sensor is located on top of the engine.
1.12.2 Control Panel and Related Components When hauling sensitive products that require
(See Figure 1--- 4 and Figure 1--- 5) constant high airflow, the high airflow switch may be se-
lected. This switch prevents the unit from running in low
a. Air Filter Service Indicator --- Optional With Dry
Type Filter speed in the perishable temperature range (set point
greater than +10_F = ---12.2._C). Unloaders will func-
The air filter indicator is connected to the engine air tion normally.
intake manifold and its function is to indicate when the
air filter element requires replacing. In operation: When 4. Pre---Trip Switch (PTS)
a plugged air cleaner element decreases intake manifold This switch is used to check the controller oper-
pressure to 20” (45 cm) WG, a red signal shows in the in- ating sequence through all modes of operation.
dicator. The filter element should be replaced and the in-
dicator reset by pressing the reset button. While the unit is running, place the switch in the
UP position; this will initiate the pre---trip cycle through
b. Defrost Test Points (TP1--- TP2) its modes as described in Table 1---6.
These terminals are used to bypass defrost termina- NOTE
tion thermostats (DTT) to allow defrost or pre---trip
modes of operation when the evaporator temperature is To initiate PRE---TRIP, one defrost termination
above 35_F. thermostat (DTT) must be closed (box
temperature must be below 40_F =4.4_C) or a
Located on the front of the control panel (see jumper placed between defrost test points
Figure 1---4), place bar across the two studs (TP1---TP2) (TP1---TP2) on the control panel. Then you
to test defrost circuitry. After testing be sure to remove must visually witness each mode and verify its
bar or the unit will remain in defrost and activate the de- proper operation as the controller will not
frost fault circuits. record any occurring problems.
c. Gauges 5. Off---Time Switch (OTS)
1. Ammeter Gauge (A)
During auto start/stop operation, off time of fif-
The d---c ammeter indicates the rate of charge or teen (15) minutes or thirty (30) minutes may be selected
discharge of the battery charging system (including bat- with this bar. (See Figure 1---4)

1---21
 P

6. Start---Run---Stop Switch (SRS) switch opens, the run relay (RR) coil is de---energized
and the RR contacts open to de---energize the run sole-
When placed in the RUN position, this switch
noid (RS); thus stopping the engine.
provides power to the processor. A self---test is initiated
whenever power is first supplied to the controller. During b. Water Temperature Sensor (WTS)
self---test, (1) all display segments will light and show This sensor, set to open at 230 ¦ 5_F (110 ¦ 3_C),
“888.8” and (2) all LED indicators will illuminate. will automatically stop the engine upon high water tem-
The controller is also checked internally. After perature. The sensor is located near the thermostat hous-
five seconds, the controller will display the current set ing in the cylinder head. When the sensor opens, the run
point entered in memory for five seconds. Box tempera- relay (RR) coil is de---energized and the RR contacts
ture will then appear. open to de---energize the run solenoid (RS); thus stop-
ping the engine.
To stop the unit or remove power from the pro-
cessor, place the stop---run---start switch in the STOP For auto start/stop mode see section 1.11.c.
position. The START position of the switch is used to 1.13 CONDENSER SHUTTERS AND COVERS
manually crank the engine. (Refer to section 2.2) (Optional)
If the switch is left in the RUN position, the run The primary function of the shutters and covers is to
relay and status LEDs will be de---energized to prevent maintain higher condenser pressures for the refrigera-
accidental draining of the battery. The display and cau- tion unit heating and defrost cycles when the unit is oper-
tion lights will remain functional. The controller can be ating in low ambient temperatures.
reactivated by energizing the glow plug switch.
The shutters and covers also help to maintain a warm
1.12.3 Location of Engine Safety Devices engine. A thermal device located inside the top shutter
a. Oil Pressure Safety Switch (OP) (right hand side) controls the opening and closing of the
shutters. The front and top shutters open or close simul-
This switch, set to open below 15 ¦ 3 psig (1.0 ¦ 0.2 taneously at a preset temperature. The shutters start to
kg/cm@), will automatically stop the engine upon loss of open at 70_F (21_C) condensing air temperature and are
oil pressure. See Figure 1---3 for location. When the fully open at 90_F (32_C). (Refer to section 4.30)

Table 1--- 6. Pre--- Trip Sequence Chart

Time Duration Display Status

Mode (Seconds) Message* LED’s

High Speed Cool 30 PPPP---20 seconds Cool

Suction Pressure/10 seconds
Low Speed Loaded Cool 30 PPPP Cool
Low Speed Unloaded Cool 30 PPPP Cool, Fuel Miser
Low Speed Unloaded Heat 30 PPPP Heat, Fuel Miser
Low Speed Loaded Heat 30 PPPP Heat
High Speed Heat 30 Coolant Temperature Heat
High Speed Cool 30 Defrost Interval Cool
Defrost Variable** ---dF--- Heat, Defrost

* The display message can be overridden at any time by depressing any keypad functions.
** When defrost has been initiated, it will remain in defrost until the defrost termination thermostats open or the
jumper wire is removed from the defrost test points (TP1 and TP2).

1---22
 P

1.14 REFRIGERANT CIRCUIT DURING On the Xtra model the refrigerant then flows
COOLING (Refer to Figure 1--- 15) through the subcooler. The subcooler occupies a portion
When cooling, the unit operates as a vapor compres- of the main condensing coil surface and gives off further
sion refrigeration system. The main components of the heat to the passing air.
system are the (1) reciprocating compressor, (2) air--- The liquid then flows to an externally equalized ther-
cooled condenser, (3) expansion valve, and (4) direct ex- mostatic expansion valve which reduces the pressure of
pansion evaporator. the liquid and meters the flow of liquid refrigerant to the
The compressor raises the pressure and the tempera- evaporator to obtain maximum use of the evaporator
ture of the refrigerant and forces it into the condenser heat transfer surface.
tubes. The condenser fan circulates surrounding air over The refrigerant pressure drop caused by the expan-
the outside of the condenser tubes. The tubes have fins sion valve is accompanied by a drop in temperature; thus,
designed to improve the transfer of heat from the refrig- the low pressure, low temperature fluid that flows into
erant gas to the air. This removal of heat causes the re- the evaporator tubes is colder than the air that is circu-
frigerant to liquefy; thus liquid refrigerant leaves the lated over the evaporator tubes by the evaporator fan.
condenser and flows through the solenoid valve SV---1 The evaporator tubes have aluminum fins to increase
(normally open) and to the receiver. heat transfer; therefore heat is removed from the air cir-
The receiver stores the additional charge necessary culated over the evaporator. This cold air is circulated
for low ambient operation and for the heating and defrost throughout the trailer to maintain the cargo at the de-
modes. The receiver is equipped with a fusible plug which sired temperature.
melts if the refrigerant temperature is abnormally high The transfer of heat from the air to the low tempera-
and releases the refrigerant charge. ture liquid refrigerant causes the liquid to vaporize. This
The refrigerant leaves the receiver and flows through low temperature, low pressure vapor passes through the
the manual receiver shutoff valve (King valve) and “suction line---liquid line” heat exchanger where it ab-
through a filter---drier where an absorbent keeps the re- sorbs more heat from the high pressure high temperature
frigerant clean and dry; the refrigerant then flows liquid and then returns to the compressor.
through the electrically controlled liquid line solenoid
valve (SV---2) which starts or stops the flow of liquid re-
frigerant.

EXTERNAL EQUALIZER EXPANSION VALVE FUSIBLE

PLUG
EXPANSION
VALVE BULB SHUT--
EVAPORATOR OFF
VALVE RECEIVER

LIQUID
VAPOR LINE BYPASS FILTER
CHECK SOLE-
DRIER NOID
VALVE
VALVE
HEAT EX- (SV2), NC
CHANGER

HOT GAS LINE

VIBRASORBER LIQUID LINE
DISCHARGE
* SUBCOOLER
SERVICE SUCTION
HOT GAS
VALVE SERVICE
VALVE
SOLE- CONDENSER
NOID
(SV3), NC

COMPRESSOR DIS- CONDENSER PRES-

CHARGE SURE
STRAINER CHECK CONTROL SOLE-
VALVE NOID (SV1), NO
VIBRASORBER

HP-- 1 HP-- 2

* NOTE: SUBCOOLER ON XTRA ONLY

Figure 1--- 15. Refrigerant Circuit --- Cooling

1---23
 P

1.15 REFRIGERANT CIRCUIT DURING sor enters the evaporator. Also the liquid line solenoid
HEATING AND DEFROSTING valve (SV---2) will remain energized (valve open) as the
(Refer to Figure 1--- 16) head pressure control switch (HP---2) will remain closed
The unit will only heat when the controller is set until the compressor discharge pressure increases to 350
above +10_F (---12.2_C) as the heat relays are electroni- psig (24.6 kg/cm@).
cally locked out with set points below +10_F (---12.2_C). Switch HP---2 opens to de---energize the liquid line
When vapor refrigerant is compressed to a high pres- solenoid valve (SV---2) and the valve closes to stop the
sure and temperature in a reciprocating compressor, the flow of refrigerant to the expansion valve.
mechanical energy necessary to operate the compressor When the compressor discharge pressure falls to 235
is transferred to the gas as it is being compressed. This en- psig (16.45kg/cm@), pressure switch (HP---2) closes and in
ergy is referred to as the “heat of compression” and is turn energizes the normally closed solenoid valve
used as the source of heat during the heating cycle. (SV---2) which opens, allowing refrigerant from the re-
NOTE ceiver to enter the evaporator through the expansion
valve.
Solenoid valve (SV---2) remains open during
heating or defrosting to allow additional When in engine operation and the discharge pres-
refrigerant to be metered into the hot gas cycle sure exceeds pressure settings detailed in section 1.3.l.,
(through the expansion valve) providing pressure cutout switch (HP---1) opens to de---energize
additional heating capacity until de---energized the run relay coil (RR). When the RR coil is de---ener-
by head pressure control switch HP---2. gized, the RR contacts open to de---energize the run sole-
noid (RS); thus stopping the engine. The function of the
When the controller calls for heating, hot gas sole- condenser coil bypass line is to raise the receiver pressure
noid valve (SV---3) opens and the condenser pressure when the ambient temperature is low (below 0_F =
control solenoid valve (SV---1) closes. The condenser coil ---17.8_C) so that refrigerant flows from the receiver to
then fills with refrigerant, and hot gas from the compres- the evaporator when needed.

FUSIBLE
EXTERNAL EQUALIZER EXPANSION VALVE PLUG
EXPANSION
VALVE BULB SHUT--
EVAPORATOR OFF
VALVE RECEIVER

LIQUID
VAPOR LINE BYPASS FILTER
CHECK SOLE-
DRIER NOID
VALVE
VALVE
HEAT EX- (SV2), NC
CHANGER

HOT GAS LINE

VIBRASORBER LIQUID LINE
DISCHARGE
* SUBCOOLER
SERVICE SUCTION
HOT GAS
VALVE SERVICE
VALVE
SOLE- CONDENSER
NOID
(SV3), NC

COMPRESSOR DIS- CONDENSER PRES-

CHARGE SURE
STRAINER CHECK CONTROL SOLE-
VALVE NOID (SV1), NO
VIBRASORBER

HP-- 1 HP-- 2

* NOTE: SUBCOOLER ON XTRA ONLY

Figure 1--- 16. Refrigerant Circuit --- Heating and Defrosting

1---24
 SECTION 2
OPERATION
2.1 PRE--- TRIP INSPECTION 7. Observe any signs of lube or fuel oil leaks.
a. Before Starting Engine 8. Check radiator hoses for leaks.
1. Drain water and foreign objects from fuel tank 9. Check refrigerant level. (Refer to section 4.9.f)
sump. Then fill tank with diesel fuel. (Refer to
10. Check manual defrost operation. (Refer to
section 1.2.g)
section 2.4.5)
2. Check radiator coolant level. (Add pre---mixed 11. Check operation --- determine if unit responds
50/50 permanent antifreeze---water as re- properly to setting of controller, cycling from
quired.) USE ETHYLENE GLYCOL ONLY. heat to cool, and high to low speed. (Refer to
(Refer to section 1.2.c) section 2.4)
3. Check condenser coil for cleanliness. (Refer to 12. Feel filter---drier. Excessive temperature drop
section 4.3.1) across drier indicates restriction. (Refer to
4. Check engine lubrication and fuel oil filter cases, section 4.16)
oil lines, and connections for leaks. (Tighten 2.2 STARTING AND STOPPING
connections and/or replace gaskets.) INSTRUCTIONS --- ENGINE DRIVE
5. Check engine lubrication oil level. (Refer to a. Starting Instructions (Manual Starting)
section 1.2.m) WARNING
6. Check V---belts for proper tension, fraying or Under no circumstances should ether or any
cracks. Adjust belt or replace. other unauthorized starting aids be used in
7. Check jackshaft bearings for excessive play. conjunction with the glow plugs.

8. Check battery liquid level. (Fill per battery

NOTE
instructions.)
Whenever starting the engine, in order to reduce
9. Check battery terminals for cleanliness and starter cranking and engine loads, the
securement. Clean and coat with a mineral type microprocessor always starts and operates in low
grease (such as vaseline). speed, unloaded cool for the first 15 seconds.
10. Check condenser/evaporator fan shaft bearing Upon completion of this period, the
for excessive play. microprocessor will allow the unit to operate
normally, providing the coolant temperature is
11. Check engine air cleaner for cleanliness and above 77_F (26_C). In order to prolong engine
condition of air cleaner hose. life, the microprocessor will prevent operation in
12. Check oil level in compressor sight glass. high speed until coolant temperature reaches
this temperature.
13. Check defrost drain pan hoses. (Should be clear
of debris.) 1. Place engine auto start switch (EAS) in MANU-
14. Check evaporator and condenser coil for cleanli- AL position.
ness. 2. Place start---run---stop switch in RUN position.
A self---test sequence will begin. All display
15. Check defrost air switch tubes and connections
segments and lights will illuminate for five
for breaks or air leaks.
seconds. The current set point will then be
16. Check defrost damper blade and bearings. displayed for five seconds.
b. After Starting Refrigeration Unit 3. Place the glow plug switch in GLOW position as
follows:
1. After start---up, check control panel for caution
light (LED).
Ambient Temperature Glow Time
2. Check water temperature. (Should be 170 to
210_F = 77 to 99_C.) Below 0_F (---17.8_C) 30 seconds
0 to 32_F (---17.8 to 0_C) 20 seconds
3. Check ammeter. (Should indicate 2 to 10 amps Above 32_F (0_C) 10 seconds
after start---up.)
4. Check engine speed. (Refer to section 4.3.4) 4. While holding glow plug switch in GLOW, place
5. Listen for abnormal noises. (Refer to section the start---run---stop switch in START. After
starting, release start switch, then the glow plug
3.3.7)
switch. If the engine does not start after cranking
6. Check compressor oil level. (Refer to section 15 seconds, release start switch and repeat
4.13) starting procedure.

2---1
 5. Set controller at desired set point. Make sure to NOTE
depress ENTER key.
To make it easier to locate the schematic
6. Check defrost interval by pressing DEFROST components referred to in the written text, the
INTERVAL key. Adjust as desired. schematic in this manual has map coordinates
added to the margins. For example, to locate the
b. Stopping Instructions ammeter (A) on the schematic, it would follow
the component designation by the designation
Place start---run---stop switch (SRS) in the STOP (E2). This would indicate that it is closest to lines
position. E and 2 on the schematic. These locations have
also been added to the legend.
2.3 STARTING AND STOPPING
INSTRUCTIONS --- AUTO START 2.4.2 Engine Preheat and Start--- up
To preheat the engine, the start---run---stop switch
a. Starting Instructions must be placed in the RUN position. This allows current
to flow from the battery (figure 5---1), coordinates G2,
1. Place engine auto start switch in AUTO. through the fusible link, ammeter, 30A fuse and the 5A
fuse to the start---run---stop switch (figure 5---1, D2).
2. Place start---run---stop switch in the RUN posi-
tion. During auto---start---stop operation, unit When the SRS is in the run position, voltage is placed
will automatically start and stop in response to at splice point SP4 (G3). From SP4, current is fed to ter-
changing box temperature. (With engine auto minal JC---1 (E5) on the processor. This is the main power
start switch in MANUAL, unit will operate input to the controller. The main processor ground connec-
continuously after starting.) tion is made from pin JC---4 (E6). The processor will now
go through a 5 second self---test to check logic circuits and
b. Stopping Instructions timing functions.
Place start---run---stop switch in the STOP position. If any problems exist within the processor, it will not
allow the unit to start. An error message will then be dis-
2.4 CONTROL CIRCUIT OPERATION played. (Refer to section 1.10.5.)

2.4.1 Introduction Splice point SP4 also supplies potential through HP1
(O---11) to JA---15 (O---11). From JA---15 it passes
The electrical schematic (figure 5---1) for units through a printed circuit containing diode D68 (K4) to
equipped with the microprocessor controller is basically the run relay coil (RR, K3). The processor will allow the
the same as other Carrier Transicold equipment. The run relay to energize when the glow plug switch is ener-
schematic is read from top to bottom and left to right, gized, providing the following conditions are met:
with switches on the left and load devices on the right. 1. Engine coolant temperature is below 230_F
There are several exceptions to this, however, due to the (110_C).
layout of the controller. The controller boards shown on
the schematic that interface with unit components are the 2. The controller probe is functional.
analog interface or processor board on the left and the
3. Battery voltage is within prescribed limits (see
relay board on the right.
table 1---5).
Connections to these boards are made through sev- Placing the glow plug switch (GPS, located at F5) in
eral multiple---pin plug connectors. These connectors are the GLOW position completes a ground path for the glow
labeled JA to JJ. JA and JB are located on the relay board plug relay coil (GPR, also located at F5). The coil ener-
while JC to JJ are on the analog interface board. gizes and the GPR normally open (N.O.) contacts (B2)
close supplying voltage to the glow plugs (G3).
The analog interface board connections are mainly
inputs and outputs for control switches, temperature sen- When the run relay (K3) energizes, the normally
sors, safety, and auto start functions that control the op- open RR contacts (L6, L8, and M10) close, supplying po-
eration of the unit. The processor board also controls the tential to the remaining refrigeration and engine control
operation of the relay board through the ribbon cable circuits. Voltage is supplied to the heat, unloader, and
connected to the JJ plug connection. speed relays through diode D54 (L4) on the relay board.
The processor will allow only the unloader relays to
The relay board, which contains five plug---in inter- energize by pulling terminals JJ---6 & JJ---7 (L2) low (al-
changeable relays provides the microprocessor with a lowing a ground path). This enables the unit to start in
means for switching the unit components to achieve a de- low speed unloaded cool to reduce engine loading. Volt-
sired operating mode. On the relay board, the heavy lines age is also supplied through printed circuits to terminals
represent printed circuit traces, not actual wires. Most JB---13 and JB---15 (N4) to energize SV---2 and the re-
circuits will be traced on the relay board from left to right. mote cool light.
The main 12 vdc power for all outputs enters the board at
spade terminals T1 and T2. All relay outputs through the The same circuit also supplies power to test point
plug connectors JA and JB leave from the right of the TP2, defrost air switch and the defrost termination ther-
board to the appropriate load device. mostats.

2---2
 This in turn supplies voltage to terminals JB---1, JB---2 &
Through the second set of RR contacts (L8), current JB---9. Both unloaders (UF and UR) energize to unload
will flow through diode D58 (M11) and JA---7 to the volt- the compressor (compressor in two cylinder operation,
age regulator. It will also flow to JA---10 and to T3 , T4 , center bank loaded).
T5 and JA---5 to energize the run solenoid, fuel pump
and to supply voltage to the starter solenoid relay coil For set points above +10_F (12.2_C) and with de-
(SSR) circuit (O---13). creasing temperature, the unit will shift to low speed un-
loaded heat.
To start the engine, placing the start---run---stop Unit will remain in various stages of heating until the
switch (D2, momentary contact) in the START position box temperature increases enough to place the unit in the
completes the ground path for the starter solenoid relay low speed unloaded cool mode. As the box temperature
coil which energizes. The normally open (N.O.) SSR con- increases, the unit will shift to low speed loaded cool, and
tacts (F1) close to energize the starter solenoid (located then to high speed cool mode (speed relay energizes).
in the starter). When the solenoid pulls in, its N.O. con- 2.4.4 Heating
tacts (G2) close to energize the starter motor.
Refer to section 1.15 for description on heating cycle
Once the engine has started, the start and glow plug and to JJ---5 connection in section 1.10.7.c.
switches can be released.
The unit will only heat when the controller is set
For the unit to remain running, the engine must above +10_F (---12.2_C) as the heat relays are electroni-
maintain at least 15 psig (1.0 kg/cm@) oil pressure. cally locked out with set points below +10_F (---12.2_C).
The microprocessor will always place the unit in low The controller automatically selects the mode(s)
speed unloaded cool for 15 seconds after starting. necessary to maintain box temperatures at set point. The
heating modes are as follows with descending tempera-
2.4.3 Cooling
tures:
The controller automatically selects the mode(s)
(a) Low speed unloaded heating, (b) low speed
necessary to maintain box temperature at set point. The
loaded heating, and, (c) high speed loaded heating.
modes are as follows with descending temperatures:
The controller will shift the unit into low speed un-
(a) High speed loaded cool, (b) low speed loaded loaded heat if the trailer temperature falls toward set
cool, (c) low speed unloaded cool, (d) low speed un- point (compressor in four cylinder heating). The micro-
loaded heat, (e) low speed loaded heat, and, (f) high processor pulls terminals JJ---4, JJ---5 and JJ---7 (L2) low
speed loaded heat. to complete the ground paths for the heat relays (HR1
If the unit is in high speed loaded cool, the micropro- and HR2, located at L3) and unloader rear relay (URR,
cessor will pull terminal JJ---8 (M2) low to energize the also at L3). When these relays energize, several things
speed relay (M3). A set of normally open contacts (SR, happen. HR1 will open the two normally closed (N.C.)
N7) close to energize the speed control solenoid (SCS, lo- HR1 contacts (M4) to the cool light and solenoid valve
cated at O7). The engine will be in high speed. (SV2). SV2 now operates in conjunction with the head
pressure control switch (HP2 located at P5). (Refer to
When the unit is running in high speed loaded cool section 1.15)
and with the evaporator coil temperature below 35_F
(1.7_C) to close at least one defrost termination thermo- Also, HR1 closes a set of normally open contacts
stat (O3) , a pretrip may be initiated at this time by de- (M7) to energize solenoid valve SV1 to close the con-
pressing the pretrip switch (PTS, F9). The operator now denser outlet line.
may verify the pretrip sequence. When the unloader front relay (UFR at L3) ener-
(Refer to table 1---6) gizes, a set of N.O. contacts (UFR at N9) close to energize
As the trailer temperature falls toward set point, the the compressor front unloader (UF, located at O8). Com-
microprocessor will place the unit in low speed loaded pressor will be in four cylinder heating.
cool (compressor in six cylinder operation). The temper- Energizing HR2 closes two sets of N.O. contacts
ature at which this occurs is not fixed but depends upon (JB---16 and JA---1, located at N8 and N9). Solenoid SV3
the rate at which the trailer temperature is approaching energizes and mechanically opens to supply hot refriger-
set point. ant vapor to enter the evaporator (section 1.15). The oth-
The speed relay (SR, located at M3) de---energizes to er set of HR2 contacts supply power to the heat light.
open the circuit to the speed control solenoid (SCS, lo- If more heating capacity is required, the unit will shift
cated at O7). Engine speed decreases from high speed to to low speed loaded heating. The microprocessor will
low speed and the compressor remains in six cylinder op- break the ground path to JJ---7 to de---energize the un-
eration. loader relay (M3), which in turn, de---energizes the com-
If the trailer temperature falls closer to set point, the pressor unloaders (compressor shifts from four cylinder
controller will shift the operation from low speed loaded to six cylinder operation).
cool to low speed unloaded cool to further reduce cooling When maximum heating capacity is required, the
capacity. To do this, the microprocessor will pull termi- unit will shift to high speed loaded heat. The micropro-
nals JJ---6 & JJ---7 (M2) low, completing the ground path cessor energizes the HR1, HR2, and speed relay (SR)
for the unloader relays (UFR & URR, located at M3). coils. Terminals JJ---4, JJ---5 and JJ---8 (L2) will be pulled
The coils energizes to close the UFR & URR contacts. low. The only change from the low speed loaded heat

2---3
mode is that the speed relay is now energized. (SR con- The third means of defrost initiation is by the defrost
tacts at N6 close to energize the speed control solenoid air switch (DA). The switch (located at P2) is a differen-
(SCS). The engine will be in high speed. tial pressure air switch which measures differential air
pressure across the evaporator coil and initiates the de-
NOTE frost cycle when the air pressure increases enough to
close the DA contacts, such as would happen when exces-
Whenever the unit shifts to heat or defrost, HR1 sive frost builds up on the evaporator coil surface. (Refer
and HR2 energize simultaneously. When to section 1.3.e.)
switching from heat (or defrost) to cool, HR1
de---energizes 2 seconds before HR2. This allows When the air switch contacts close, a 12 vdc potential
time for SV---1 to open and clear the condenser to terminal JC---9 (E6) on the microprocessor. The pro-
of liquid before SV3 closes. This will eliminate cessor looks for voltage at terminal JJ---3 (N2). Voltage at
any high pressure buildup which could occur. JJ---3 indicates that at least one defrost termination ther-
During this time, only on the remote light bar, mostat (O3) is closed. The unit will shift to the defrost
the heat and cool lights will be on together. The mode if voltage is present at JJ---3.
heat and cool LED on the control panel change If both thermostats (klixons) are open (no voltage at
immediately. JJ---3), defrost cannot be initiated by any means.
2.4.5 Defrost In defrost the processor pulls terminals JJ---4, JJ---5,
Refer to sections 1.10.2.f and 1.15 for the heat and and JJ---8 low (L2 & M2) to shift the unit into high speed
defrost cycle. heat. The processor also pulls terminal JJ---9 (N2) low to
energize the defrost relay coil (N3). This closes the de-
frost relay contacts (two sets of N.O. contacts JB---7, and
NOTE T7 ) to energize the damper solenoid (DDS) and the de-
The unit will be in high speed in the defrost frost light on the remote light bar. The defrost and heat
mode. light emitting diodes (LED) will also be illuminated.

The defrost mode may be initiated by three different

ways if the evaporator coil is below 35_F (1.7_C). (Refer The unit will remain in defrost until both defrost ter-
to section 1.3.) mination thermostats (O3) open to remove voltage from
the defrost relay. If the thermostats fail to open in one
Method one to initiate defrost is by pressing the hour, the processor will terminate defrost and shift be-
MANUAL DEFROST and ENTER keys simultaneous- tween normal control and defrost at one hour intervals.
ly. This will also occur if the defrost air switch is stuck closed.
Method two is that defrost may be initiated automat- Also, refer to JC---9 and JJ---3 in section 1.10.7.c.
ically at preset intervals by the defrost timer built into the If the problem corrects itself, (thermostats or damp-
controller. (Refer to section 1.10.2.f). The manual de- er opens for example), the unit will automatically resume
frost key and defrost timer are part of the microprocessor its normal functions and the DEFROST LED will stop
and are not shown on the schematic. flashing (on STATUS board).

2---4
 Table 2--- 1. Electrical Control Positions --- Set Point Below +10_F (--- 12.2_C)

HIGH LOW LOW HIGH

CONTROL CIRCUIT SPEED SPEED SPEED SPEED DEFROST
COOLING COOLING HEATING HEATING

Compressor Unloaders De---energized See Note 1 Not Not De---energized

(UF & UR) Applicable Applicable

Condenser Pressure Control De---energized De---energized Not Not Energized

Valve (SV ---1) Applicable Applicable

Defrost Relay (DR) and De---energized De---energized Not Not Energized

Solenoid (DDS) Applicable Applicable

Heat Relay (HR1 and HR2) De---energized De---energized See See Energized
Note 2 Note 2

Hot Gas Solenoid Valve De---energized De---energized Not Not Energized

(SV ---3) Applicable Applicable

Light Emitting Diodes (LED)

Cool (CL) ON ON OFF OFF OFF

Heat (HL) OFF OFF Not Not ON

Applicable Applicable

Defrost (DL) OFF OFF OFF OFF ON

Liquid Line Solenoid Valve Energized Energized Not Not See

(SV ---2) Applicable Applicable Note 3

Speed Control Solenoid Energized De---Energized Not Not Energized

(SCS) Applicable Applicable

Speed Relay (SR) Energized De---energized Not Not Energized

Applicable Applicable

NOTES: 1. Unit will operate with energized or de---energized unloaders. (Refer to section 1.8)
2. The heat relay is prevented from energizing with set points below +10_F (---12.2_C).
3. Solenoid Valve SV ---2 opens or closes in response to head pressure control switch HP---2
(Refer to section 1.15)

2---5
 Table 2--- 2. Electrical Control Positions --- Set Point Above +10_F (--- 12.2_C)

HIGH LOW LOW HIGH

CONTROL CIRCUIT SPEED SPEED SPEED SPEED DEFROST
COOLING COOLING HEATING HEATING

Compressor Unloaders De---energized See Note 1 See Note 1 De---energized De---energized

(UF & UR)

Condenser Pressure De---energized De---energized Energized Energized Energized

Control Valve (SV ---1)

Defrost Relay (DR) and De---energized De---energized De---energized De---energized Energized

Solenoid (DDS)

Heat Relay (HR1 and HR2) De---energized De---energized Energized Energized Energized

Hot Gas Solenoid Valve De---energized De---energized De---energized Energized Energized

(SV ---3)

Light Emitting Diodes (LED)

Cool (CL) ON ON OFF OFF OFF

Heat (HL) OFF OFF ON ON ON

Defrost (DL) OFF OFF OFF OFF ON

Liquid Line Solenoid Valve Energized Energized See Note 2 See Note 2 See Note 2
(SV ---2)

Speed Control Solenoid Energized De---energized De---energized Energized Energized

(SCS)

Speed Relay (SR) Energized De---energized De---energized Energized Energized

NOTES: 1. Unit will operate with energized or de---energized unloaders. (Refer to section 1.8)

2. Solenoid Valve SV ---2 opens or closes in response to head pressure control switch HP---2
(Refer to section 1.15)

2---6
 SECTION 3
TROUBLESHOOTING
CAUTION
Under no circumstances should anyone attempt to service the microprocessor!(see section 4.27) Should a
problem develop with the microprocessor, contact your nearest Carrier Transicold dealer for replacement.
3.1 DIESEL ENGINE

INDICATION/ REFERENCE
TROUBLE POSSIBLE CAUSES PARAGRAPH

3.1.1 Engine Will Not Start

Starter motor will not Battery insufficiently charged Check
crank or low cranking speed Battery terminal post dirty or defective Check
Bad electrical connections at starter Check
Starter motor malfunctions 3.1.3
Starter motor solenoid defective Engine Manual
Open starting circuit 3.1.4
Incorrect grade of lubricating oil 1.2.m

Starter motor cranks No fuel in tank 1.2.g & 1.3.n

but engine fails to start Air in fuel system 4.2
Water in fuel system Drain Sump
Plugged fuel filter Replace
Plugged fuel lines to injector (s) Check
Fuel control operation erratic 4.3.3
Glow plug(s) defective 4.3.8
Run solenoid (RS) defective 4.3.3
Fuel pump (FP) malfunction 4.2

Starter cranks, engages, Engine lube oil too heavy 1.2.m

but dies after a few seconds Voltage drop in starter cable(s) Check

3.1.2 Engine Starts Then Stops

Engine stops after Fuel supply restricted Check
several rotations No fuel in tank 1.2.g
Leak in fuel system Check
Faulty fuel control operation 4.3.3
Fuel filter restricted Replace
Injector nozzle(s) defective Engine Manual
Injection pump defective Engine Manual
Air cleaner or hose restricted 4.3.5
Safety device open 1.4
Open wiring circuit to run solenoid (RS) Check
Fuel pump (FP) malfunction 4.2

3.1.3 Starter Motor Malfunction

Starter motor will not Battery insufficiently charged Check
crank or turns slowly Battery cable connections loose or oxidized Check
Battery cables defective Replace
Starter brushes shorted out Engine Manual
Starter brushes hang up or have no contact Engine Manual
Starter solenoid damaged Engine Manual
Start ---Run---Stop switch defective Replace
Engine lube oil too heavy 1.2.m

3---1
INDICATION/ REFERENCE
TROUBLE POSSIBLE CAUSES PARAGRAPH

3.1.3 Starter Motor Malfunction (CONTINUED)

Starter motor turns Pinion or ring gear obstructed or worn Clean both,
but pinion does not engage remove burrs,
or replace;
apply grease

Starter motor does not disengage Start ---Run---Stop switch defective Replace
after switch was depressed Starter motor solenoid defective Engine Manual

Pinion does not disengage Defective starter Engine Manual

after engine is running

3.1.4 Malfunction In the Engine Starting Circuit

No power to starter Battery defective Check
motor solenoid (SS) Loose electrical connections Tighten

Run solenoid (RS) Battery defective Check

does not energize or does Loose electrical connections Tighten
not remain energized Oil pressure safety switch (OP) defective Replace
Run relay (RR) defective Replace
Water temperature safety switch (WT) open 1.2.c
Water temperature sensor (WTS) defective Replace
Run solenoid (RS) defective 4.3.3
Start ---Run---Stop switch (SRS) defective Replace

3.2 ALTERNATOR (AUTOMOTIVE TYPE)

Alternator fails to charge Limited charging system operating time Check
Battery condition Check
Alternator belt loose/broken 4.5
Loose, dirty, corroded terminals, plugs or
broken leads Check/Repair
Excessively worn, open or defective brushes 4.4.5
Open blocking diode Check D58
Regulator faulty 4.4.4
Open isolation diode 4.4.4
Open rotor (field coil) Replace

Low or unsteady charging rate Alternator belt loose 4.5

Loose, dirty, corroded terminals, plugs or
broken leads Check/Repair
Excessively worn, sticky or intermittent brushes 4.4.5
Faulty regulator 4.4.4
Grounded or shorted turns in rotor 4.4
Open, grounded or shorted turns in stator Replace

Excessive charging rate Regulator leads loose, dirty, corroded Clean/Repair

(as evidenced by battery terminals, plugs or wires broken or Replace
requiring too frequent Defective regulator 4.4.4
refilling) or charge indicator shows
constant “charge with engine idling”

Noisy alternator Defective or badly worn V ---belt 4.5

Worn bearing(s) Replace
alternator
Misaligned belt or pulley 4.5
Loose pulley Tighten

3---2
INDICATION/ REFERENCE
TROUBLE POSSIBLE CAUSES PARAGRAPH

3.3 REFRIGERATION
3.3.1 Unit Will Not Cool
Diesel engine Malfunction(s) 3.1

Compressor malfunction Compressor drive defective 4.12

Compressor defective 4.12

Refrigeration system Defrost cycle did not terminate 3.3.5

Abnormal pressure 3.3.6
Solenoid valve malfunction 3.3.11

3.3.2 Unit Runs But Has Insufficient Cooling

Compressor Compressor valves defective 4.12
Unloader malfunction 4.14

Refrigeration system Abnormal pressure 3.3.6

Unloader malfunction 4.14
Expansion valve malfunction 3.3.10
No or restricted evaporator airflow 3.3.9

Engine does not Speed control linkage 4.3.4

develop full rpm Engine malfunction 3.1

3.3.3 Unit Operates Long or Continuously in Cooling

Container Hot Load Allow time to
pull down
Defective box insulation or air leak Correct

Refrigeration system Abnormal pressure 3.3.6

Temperature controller malfunction 3.3.8

Compressor Defective 4.12

3.3.4 Unit Will Not Heat or Has Insufficient Heating

Refrigeration Head pressure control switch (HP---2) defective 4.17
Abnormal pressure 3.3.6
Temperature controller malfunction 3.3.8
Condenser shutter malfunction 3.3.12
Solenoid valve malfunction 3.3.11
1/4” check valve (bypass) defective 4.15

Compressor Compressor drive defective 4.12

Compressor defective 4.12

Engine does not develop Speed control linkage 4.3.4

full rpm Engine malfunction 3.1

3---3
INDICATION/ REFERENCE
TROUBLE POSSIBLE CAUSES PARAGRAPH

3.3.5 Defrost Cycle Malfunction

Will not initiate defrost Defrost air switch (DA) out of calibration 4.22
automatically Defrost thermostats open or defective 4.21
Defrost air switch (DA) defective 4.21 & 4.22
Loose terminal connections Tighten
Damper solenoid relay (DDS) defective 4.24
Air sensing tubes defective or disconnected Check

Will not initiate defrost manually Manual defrost switch defective Replace
Loose terminal connections Tighten
Damper solenoid relay (DDS) defective Replace
Defrost thermostats (DT) open or defective Replace

Initiates but does not defrost Solenoid valve malfunction 3.3.11

Defrost relay (DR) defective Replace
Defrost damper solenoid (DDS) or linkage defective 4.24
Damper open or defective 4.24

Frequent defrost Defrost air switch (DA) out of adjustment 4.21 & 4.22
Wet load Normal

Damper blade does not close Defrost damper solenoid (DDS) defective 4.24
Damper defective 4.24

Does not terminate or Defrost damper linkage disconnected 4.24

cycles on defrost Defrost thermostats (DT) shorted closed 4.21
Manual defrost switch shorted closed Replace
Head pressure control switch (HP---2) defective 4.17
Low refrigerant charge 4.10
Defrost air switch (DA) out of adjustment 4.21 & 4.22

3.3.6 Abnormal Pressure

3.3.6.1 Cooling
High discharge pressure Condenser shutter malfunction 3.3.12
Condenser coil dirty 4.3.1
Condenser fan defective 4.23
V ---belt broken or loose 4.5
Discharge check valve restricted 4.15
Noncondensibles or refrigerant overcharge 4.11
Solenoid valve (SV ---1) malfunction 4.20

Low discharge pressure Compressor valves(s) worn or broken 4.12

High suction pressure Compressor valves(s) worn or broken 4.12

Compressor gasket(s) defective 4.12

Low suction pressure Suction service valve partially closed Open

Receiver outlet valve partially closed Open
Filter---drier partially plugged 4.16
Low refrigerant charge 4.10
Solenoid valve (SV ---2) defective 4.19
Expansion valve malfunction 3.3.10
No evaporator air flow or restricted air flow 3.3.9
Excessive frost on coil 4.21

Suction and discharge Compressor valves defective 4.21

pressures tend to equalize
when unit is operating

3---4
INDICATION/ REFERENCE
TROUBLE POSSIBLE CAUSES PARAGRAPH

3.3.6.2 Heating
High discharge pressure Solenoid valves (SV ---1 or SV ---3 ) malfunction 3.3.11
Condenser fan defective 4.23
V ---belts broken or loose 4.5
Noncondensibles in system 4.11
Head pressure control switch (HP---2)
defective (closed) 4.17
Condenser shutter malfunction 3.3.12

Low discharge pressure Compressor valve(s) worn or broken 4.12

Head pressure control switch (HP---2) defective(open) 4.17
Solenoid valve (SV ---1) malfunction 3.3.11
Low refrigerant charge 4.10
Condenser shutter malfunction 3.3.12

Low suction pressure Refrigerant shortage 4.10

Solenoid (SV ---1) open 3.3.11
Defective HP---2 4.17

3.3.7 Abnormal Noise

Compressor Loose mounting bolts Tighten
Worn bearings 4.12
Worn or broken valves 4.12
Liquid slugging 3.3.10
Insufficient oil 4.13

Condenser or Loose or striking shroud Check

evaporator fan Bearings defective 4.23
Bent shaft 4.23

Jackshaft Bearings defective 4.5

V ---belts Cracked or worn 4.5

3.3.8 Solid State Control System Malfunction

Will not control Sensor defective 4.28
Relay(s) defective Check
Microprocessor malfunction 4.27

3.3.9 No Evaporator Air Flow or Restricted Air Flow

Evaporator coil blocked Frost on coil 4.21
Dirty coil 4.3.1

No or partial evaporator V ---belt broken or loose 4.5

air flow Jackshaft defective Replace
Evaporator fan loose or defective 4.23
Evaporator fan rotating backwards 4.5
Evaporator air flow blocked in trailer (box) Check
Defrost damper in the closed position 4.24

3---5
INDICATION/ REFERENCE
TROUBLE POSSIBLE CAUSES PARAGRAPH

3.3.10 Expansion Valve Malfunction

Low suction pressure with Low refrigerant charge 4.7/4.10
high superheat External equalizer line plugged Clean
Ice formation at valve seat 4.8
Wax, oil or dirt plugging valve or orifice 4.26
Broken capillary 4.26
Power assembly failure or partial Replace
Loss of element/bulb charge Replace
Superheat setting too high 4.26.c

Low superheat and liquid Superheat setting too low 4.26.c

slugging in compressor External equalizer line plugged Open
Ice holding valve open 4.11
Foreign material in valve 4.11
Pin and seat of expansion valve eroded or
held open by foreign material 4.26

Fluctuating suction Improper bulb location or installation 4.26

pressure Low superheat setting 4.26.c

High superheat Broken capillary 4.26

3.3.11 Solenoid Valve Malfunction

Solenoid valve does not No power to valve Check
function properly Improper wiring or loose connections Check
Coil defective 4.19
Valve improperly assembled 4.19
Coil or coil sleeve improperly assembled 4.19
Movement of plunger restricted due to:
a. Corroded or worn parts 4.19
b. Foreign material lodged in valve 4.19
c. Bent or dented enclosing tub 4.19

Solenoid valve closes but Foreign material lodged under seat Clean
refrigerant continues to flow Defective seat Replace

3.3.12 Condenser Shutter Malfunction (OPTIONAL)

Shutters will not Bearing(s) seized 4.30.e & f
open Shutters seized 4.30.c & f
Element (thermostat) malfunction 4.30.a
Linkage disconnected 4.30.c

Shutters will not Return springs broken Replace

close Linkage disconnected 4.30.c
Bearing(s) seized 4.30.e & f

Air leakage Linkage out of adjustment 4.30.c

Vane seals worn 4.30.d
Improper shutter installation 4.30.b

3---6
 U
L W

SECTION 4

SERVICE

WARNING
Beware of V--- belts and belt driven components as the unit may start automatically. Before servicing
unit, make sure the start--- run stop switch is in the OFF position. Also disconnect the negative battery
cable.

NOTE
To avoid damage to the earth’s ozone layer, use a refrigerant recovery system whenever removing
refrigerant.
4.1 MAINTENANCE SCHEDULE

Unit Reference
ON OFF Operation Section

4.1.1 Daily Maintenance

X 1. Pre---Trip Inspection --- before starting 2.1.a
X 2. Pre---Trip Inspection --- after starting 2.1.b
X 3. Check engine hours Run 10 min.

4.1.2 First 400 Hour Maintenance

X 1. Pre---Trip Inspection --- before starting 2.1.a
X X 2. Change lube oil and filter 4.3.2
X 3. Pre---Trip Inspection --- after starting 2.1.b
4. Check engine hours Run 10 min.

4.1.3 Every 1000 Hour Maintenance (Normal Operating Conditions)

X X 1. Complete 400 Hour Maintenance (Refer to paragraph 1.2.m. for
oil change intervals) 4.1.2
X 2. Tighten engine, compressor and unit mounting bolts None
X 3. Tighten all electrical connection in control box Tighten
X 4. Calibrate defrost air switch 4.22
X 5. Clean air cleaner, check hose and connections 4.3.5
X 6. Check water pump bearing end play None
X 7. Check alternator slip rings and brushes 4.4.5/4.4.6
X 8. Clean evaporator and condenser coils 4.3.1/4.26
X 9. Check fuel pump (FP) filter 4.3.7
X 10. Replace fuel filter 4.3.7

4.1.4 Every 3000 to 6000 Hour Maintenance

X X 1. Complete a 1000 Hour Maintenance 4.1.3
X 2. Clean crankcase breather 4.3.6
X X 3. Clean and flush cooling system 4.3.1
X 4. Replace all V ---belts 4.5
X 5. Check engine compression Engine Manual
X 6. Check starter condition Engine Manual
X 7. Check and adjust injector nozzles Engine Manual

4---1
 U W

4.2 PRIMING THE FUEL SYSTEM agent. It may be necessary to use warm water mixed with
any good commercial dishwasher detergent. Rinse coil(s)
a. Mechanical Fuel Pump with fresh water if a detergent is used.
The unit is equipped with a mechanical fuel lift b. Drain coolant completely by opening drain---
pump, it is mounted on the engine next to the injection cock and removing radiator cap.
pump.(also see section 4.3.7) This pump has a manual
plunger for bleeding fuel when the fuel tank has been run CAUTION
dry.
Use only ethylene glycol anti--- freeze (with inhib-
Since the unit employs a closed fuel circuit, it is rec- itants) in system as glycol by itself will damage
ommended to use the following steps: the cooling system.
Always add pre--- mixed 50/50 anti--- freeze and
1. Turn bleed valve (Red) counter---clockwise until water to radiator/engine. Never exceed more
fully opened (See Figure 1---3). than a 50% concentration of anti--- freeze. Use a
low silicate anti--- freeze meeting GM specifica-
2. Turn the top of the manual plunger counter---
tions GM 6038M or equal.
clockwise to unlock it. (See Figure 1---3) Then, rapidly
hand pump the manual plunger until a positive pressure c. Close drain---cock and fill system with clean, un-
(resistance) is felt, which will indicate fuel flow. treated water to which three to five percent of an akal-
ined based radiator cleaner should be added (six ounces
3. Depress and turn the top of the manual plunger --- dry 151 grams to one gallon = 3.78 litres) of water.
clockwise to lock in place.
d. Run engine 6 to 12 hours and drain system while
4. Start engine. (Refer to section 2.2 and 2.3) warm. Rinse system three times after it has cooled down.
5. When engine is running properly, turn bleed Refill system with water.
valve clockwise until fully closed. e. Run engine to operating temperature. Drain sys-
b. Electrical Fuel Pump (Optional) tem again and fill with treated water/anti---freeze. (see
Caution Note and refer to section 1.2.c) NEVER POUR
If the unit is equipped with electrical fuel pumps, COLD WATER INTO A HOT ENGINE, however hot
they are mounted on the fuel tank mounting brack- water can always be added to a cold engine.
et.(also see section 4.3.7) It is recommended to use the
following steps: 4.3.2 Lube Oil Filters
1. Open bleed valve located on top of the injection After warming up the engine, stop engine, remove
pump. (See Figure 1---3) drain plug from oil reservoir and drain engine lube oil.
Lightly oil gasket on filter before installing.
2. Energize the fuel pump by holding glow plug
switch in the PREHEAT position. This will complete the CAUTION
circuit to the fuel pump.
When changing oil filters, the new filters should
3. Start engine. (Refer to section 2.2 and 2.3) be primed with clean oil. if the filters are not
primed, the engine may operate for a period with
4. When engine is running properly, turn bleed no oil supplied to the bearings.
valve clockwise until fully closed.
Replace filter(s) and add lube oil. (Refer to section
4.3 ENGINE SERVICE AND COMPONENTS 1.2.m) Warm up engine and check for leaks.

4.3.1 Cooling System 4.3.3 Run Solenoid Linkage Adjustment

The condenser and radiator assembly is designed a. Remove spring from injection pump run lever
with the radiator located alongside of the condenser coil. (items 8 and 10, Figure 4---1).
Air flows through the radiator by using the condenser fan.
The condenser and radiator may be cleaned at the same b. Loosen the solenoid mounting bolts.
time.
c. Holding the run lever (item 10) against the full
The radiator, externally and internally, must be clean open stop, slide the solenoid (item 1) as far toward the le-
for adequate cooling. The condenser fan belt must be ad- ver as the linkage (item 6) will allow and tighten the
justed periodically to provide maximum air flow. (Refer mounting bolts. DO NOT ADJUST SAFETY SCREW
to section 4.5.3) as it is factory set.
Do the following to service the cooling system: d. Connect run control spring (item 8).
a. Remove all foreign material from the radiator--- e. Energize run solenoid and check for approxi-
condenser coil by reversing the normal air flow. (Air is mately 1/8 inch clearance between the run control lever
pulled in through the front and discharges over the en- and the stop. If clearance is in excess of 1/8 inch, repeat
gine.) Compressed air or water may be used as a cleaning the above steps.

4---2
 U
L W

f. Set controller at trailer temperature and then

12 start engine. Engine should be in low speed (Refer to
4 Table 1---1). Set the controller 10_F (5.5_C) below trailer
3 temperature. Engine should be in high speed (Refer to
3 Table 1---1). If engine speed is not correct (pump lever
11
1 against stop), loosen mounting hardware and move sole-
5 noid toward the pump lever (bracket has slotted holes).
9 g. If adjustment is not achieved by doing step f, stop
3 engine and remove linkage from solenoid. Remove boot
2 8 (item 11) from solenoid and pull solenoid shaft out (far
enough to loosen jam nut on solenoid shaft). Energize so-
lenoid for maximum force (pull) and then turn shaft
clockwise to shorten.
NOTE
It may be necessary to apply heat to adjusting “I”
10 bolt to be able to turn it because Loctite is used .
3 h. De---energize solenoid, tighten shaft jam nut and
2 11 replace boot. Connect linkage and repeat steps 5 and 6.
7
6 4.3.5 Engine Air Cleaner (See Figure 4--- 2)
3
4 8 10 1

SAFETY SCREW
DO NOT ADJUST
6
R
U
1 N 2
1/8’’

1. Solenoid 7. Clip 3
2. Capscrew 8. Spring (Run Control) 4
3. Flat Washer 9. Linkage
4. Locknut, 1/4---20 (Speed Control) 5
5. Solenoid Bracket 10. Run Control Lever
6. Linkage 11. Boot 1. Air Inlet Hood 4. Inner Cup(Oil bath)
(Run Control) 12. Cotter Pin 2. Air Cleaner Body 5. Oil or Dust Cup
Figure 4--- 1. Speed and Run Control Solenoids 3. Clamp
Figure 4--- 2. Air Filter
4.3.4 Servicing the Speed Control Solenoid and a. Inspection
Linkage The oil bath or dry type air cleaner should be in-
a. Disconnect linkage arm (item 9, Figure 4---1) spected regularly for leaks. A damaged air cleaner or
from solenoid. Disconnect wiring to solenoid. Remove hose can seriously affect the performance and life of the
mounting hardware from solenoid and then remove sole- engine. The air cleaner is designed to effectively remove
noid. contaminants from the air stream entering the engine.
An excessive accumulation of these contaminants in the
b. Install replacement solenoid and mounting air cleaner will impair its operation, therefore, a service
hardware. Do not tighten at this time. schedule must be set up and followed. Remember that the
c. Attach linkage to solenoid and install the clip to air cleaner cleans the air, but the air cleaner requires
the linkage rod. Push injection pump speed lever coun- cleaning. The following simple service steps are easily
terclockwise (away from solenoid) until lever rests made while the engine is being serviced in the field.
against pump stop and hold in this position (high---speed The simple service steps are as follows:
position). Solenoid plunger should bottom out.
1. Watch all connections for mechanical tightness.
d. Tighten solenoid mounting hardware. Connect Be sure cleaner outlet pipe is not fractured.
wiring to solenoid. 2. If cleaner has been dented or damaged, check all
e. Check engine speed. With the engine stopped, connections immediately.
place a mark on the crankshaft sheave (white paint for ex- 3. In case of leakage and if adjustment does not
ample). Speed may be verified by a Strobette model 964 correct the trouble, replace necessary parts or gaskets.
(strobe---tachometer) Carrier Transicold P/N 07---00206. Swelled or distorted gaskets must always be renewed.

4---3
 U W

b. Service Procedure (Oil Type) ly. Check all connections between the air cleaner and the
engine to be certain that they are tight and leak---free.
CAUTION
Always cover the engine inlet tube while the air 4.3.6 Engine Crankcase Breather
cleaner is being serviced. The engine uses a closed type breather with the
1. Oil Cups breather line attached to the cylinder head cover. (See
Figure 4---3)
When to Service:
The breather assembly should be cleaned once a year
Remove the oil cup at regular intervals. Initially in- or at every 3000 hours maintenance interval (whichever
spect daily or as often as conditions require. Never allow comes first).
more than 1/2 inch (12.7 mm) of dirt deposit in either cup.
More than 1/2 inch accumulation could result in oil and
dirt to carry over into the engine causing accelerated en- 7
gine wear. Heavily contaminated oil will not allow the air
cleaner to function properly.
How to Service: 8

Stop the engine and remove the oil cup from the air
cleaner. Remove the oil from the oil cups. Remove the
inner cup from the oil cup and clean both cups of sludge.
Reassemble and fill both oil cups to the indicated level
with SAE #10 oil for temperatures below freezing or
SAE #30 for temperatures above freezing. It is generally 1
a recommended practice to use the same oil as required 2
in the engine crankcase. (Refer to section 1.2.m) 3
CAUTION 4
5
Do not underfill or overfill the cups. Overfilling 6
of cups means loss of capacity and underfilling
means lack of efficiency. 1. Cylinder Head Cover 5. Breather Oil Shield
2. Body Assembly 2. Breather Cover 6. Capscrew
3. Breather Element 7. Breather Assembly
When to Service: 4. Plate 8. O---Ring
The lower portion of the fixed element should be in- Figure 4--- 3. Engine Crankcase Breather
spected each time the oil cup is inspected or serviced. If
there is any sign of contaminant buildup or plugging, the 4.3.7 Servicing Fuel Pump
body assembly should be removed and back flushed. At a. Mechanical Pump (See Figure 4--- 4)
least one a year or at regular engine service periods re-
move the entire air cleaner and perform the following: Due to foreign particles in the fuel and wax as a result
of using the wrong grade of fuel or untreated fuel in cold
(a) Remove oil cup. Check and clean center weather. The fuel filter may become plugged or re-
tube. DO NOT USE GASOLINE. stricted, and the engine will loose capacity. The filter
(b) Pump solvent through the air outlet with suf- must be cleaned on a regular schedule such as unit pre---
ficient force and volume to produce a hard, even stream trip or when the oil and fuel filters are changed (Refer to
out the bottom of the body assembly. Reverse flush until section 4.1).
all foreign material is removed. 1. Turn nut counter---clockwise to loosen and re-
c. Service Procedure (Dry Type) move (item 1).
1. Stop the engine, remove and clean the dust cup. 2. Remove banjo fitting (item 2) and let it hang
Check for damage or if plugged. Remove the dirty ele- loose, making sure to keep copper rings (item 4) for re-
ment (filter) from the air cleaner.(Refer to section 4.1.3) placement.
Install new element. 3. Turn filter (item 3) counter---clockwise and re-
2. Reinstall dust cup, making sure it seals 360_ move. Check and clean.
around the air cleaner body and tighten wing nut secure- 4. To install reverse steps 1 through 3.

4---4
 U
L W

4.3.8 Servicing Glow Plugs

The glow plugs, when energized, draw a nominal 7.0
amps at 10.5 vdc. When servicing, the glow plug is to be
fitted carefully into the cylinder head to prevent damage
3 to glow plug. Torque value for the glow plug is 14 to 18 ft---
lb (1.9 to 2.5 mkg).
Checking for a Defective Glow Plug
a. One method is to remove the injector and then
1 energize the glow plug. The glowing tip may then be ob-
served.
b. Another method is to place an ammeter (or
4 clip---on ammeter) in series with each glow plug and ener-
2 1 gize the plugs. Each plug (if good) should show amperage
draw.

1. Nut 3. Filter 4.4 SERVICING THE ALTERNATOR

2. Banjo 4. Copper Rings 4.4.1 Preliminary Checks and Tests
NOTE
Figure 4--- 4. Mechanical Fuel Pump Before starting the actual electrical test
b. Electrical Pump (See Figure 4--- 5)(Optional) procedure, the charging system, battery and
wiring should be checked to eliminate possible
1. To Check or Replace Filter problem areas. Figure 1---12 identifies the
terminals on the rear of the alternator.
Place box wrench on hex portion of cover, item 1, a. Check the condition and adjustment of belts.
Figure 4---5 and rotate cover counterclockwise (the mag-
net and gasket, items 2 and 3, should stay with the cover). 1. Check belt adjustment
Remove filter for inspection or replacement. (Refer to section 4.5).
2. Replace any worn or glazed belts.
2. To Replace Spring
b. Check to see that all terminals, connectors and
Using your finger, depress check valve assembly, plugs are clean and tight.
item 8. With a screwdriver, snap wire retaining clip out of 1. Loose or corroded connections cause high
the two holes in the check valve housing. Slowly release resistance and this could cause overcharging, under-
spring pressure and remove items 6 through 13. charging or damage to the charging system.
3. To Install 2. Badly corroded battery cables could prevent
the battery from reaching a fully charged condition.
Reverse steps 1 and 2.
c. Check battery condition and charge if necessary.
A low or discharged battery may cause false or misleading
13 12 11 10 9 7 6
readings when conducting in---unit tests.
4.4.2 Test Tools
A list of the following tools is provided to perform
tests on the alternator and its components.
8 a. Volt---ohm meter
5 4 3 2 1 b. Single---pole, single throw switch
c. 12 vdc lamp
d. Insulated 12 gauge stranded wire
e. Alligator clamp terminals
4.4.3 Problem Area Determination
1. Cover 8. Check Valve Assy.
2. Gasket 9. Seat CONDITIONS: Engine running for all tests
3. Magnet 10. Plunger (unless otherwise specified).
4. Filter 11. Plunger Spring a. Battery Undercharged
5. Retainer Clip 12. Retainer 1. Perform open diode---trio test. (Refer to section
6. Flat Washer 13. Spring --- 10 psi 4.4.4)
7. O---Ring (0.7kg/cm@)
2. Perform regulator tests. (Refer to section 4.4.4)
Figure 4--- 5. Electric Fuel Pump (Optional) If regulator is O.K., the cause is probably an open field
circuit, and alternator must be removed for repair.

4---5
 U W

3. Further investigation requires alternator remov- Test No. 2 --- Open Regulator Test
al and repair (diodes).
12vdc
b. Battery Overcharged TOGGLE TEST LAMP
SWITCH (D+,ind lite or aux)
1. Perform alternator output test.
+ POS + OUTPUT
(Refer to section 4.4.4) BATTERY (B+)
A
2. Regulator shorted. Replace regulator.
B
GROUND
FIELD
4.4.4 In--- Unit Alternator/Regulator Tests INTEGRAL
REGULATOR JU1
Test No. 1 --- Open Diode--- Trio Test EXCITE
(TO OIL PRESSURE
SWITCH OR
12vdc TOGGLE SWITCH )
TOGGLE TEST LAMP
SWITCH (D+,ind lite or aux)
+ ---
POS + OUTPUT VOLTS BATTERY
+ + ---
(B+) BLACK
BATTERY
A RED
B
GROUND STEP TEST POINT INDICATION
1* A (B+) BATTERY
INTEGRAL VOLTAGE
JU1
REGULATOR
BATTERY VOLTAGE
EXCITE 2* B (REG) WITH TEST LAMP OFF
(TO OIL PRESSURE
SWITCH OR JUMPER ATTACHED.
TOGGLE SWITCH ) 3 B (D+) 1.5 TO 3.0 VOLTS.
TEST LAMP ON
+ ---
VOLTS BATTERY * JUMPER NOT ATTACHED
+ ---
BLACK
Figure 4--- 7. Open Regulator Test
RED
CONDITIONS: Engine stopped (start---run---stop
STEP TEST POINT INDICATION switch in the RUN position) and voltmeter set---up as
1 * A (B+) BATTERY shown in Figure 4---7.
VOLTAGE
2 * B (REG) 1.5 TO 3.0 VOLTS NOTE
WITH TEST LAMP Before performing test, removal of back cover is
ON required. To remove, disconnect wires from
3 A (B+) 13.5 TO15.0 VOLTS terminals extending through back cover.
(JUMPER ATTACHED Remove back cover (two screws) and reconnect
ENGINE RUNNING) all wires.
* JUMPER NOT ATTACHED a. With jumper not attached, check for battery volt-
age at terminals A and B. Test lamp will be off.
Figure 4--- 6. Open Diode--- Trio Test b. Add jumper JU1 between field and ground. (See
Figure 4---7) If 1.5 to 3.0 volts is present at terminal B
CONDITIONS: Start---run---stop switch (SRS) in and the test lamp is on, the regulator is open. Alternator
RUN position and engine stopped (after proper hook--- should be removed for repair.
up is made and test leads connected). No electrical loads.
Test No. 3. Alternator Output Test
a. With jumper not attached. Check for battery CONDITIONS: Engine running (after voltmeter is
voltage at terminal A and for 1.5 to 3.0 volts at terminal B. connected as shown in Figure 4---8).
(See Figure 4---6) a. Start unit and run engine with load. With the unit
b. Add jumper JU1 between terminals A and B. operating (placing a load on charging circuit) check for
Start engine and run with no load. If the test lamp now nominal system output voltage of between 13.8 --- 14.8
volts for a properly operating charging system. (Voltages
goes off, and charging voltage is present at terminal A
may vary a few tenths of a volt, higher or lower, due to am-
(more than battery voltage), the diode---trio is open. Al-
ternator should be removed for repair. If the voltmeter bient temperature variations.)
indication is not in this range, remove the jumper and b. If the alternator output voltage does not fall
proceed to the regulator test within the proper range, the alternator should be re-
(test no. 2). moved for further inspection and tests. (refer to Motoro-
la manual)

4---6
 U
L W

TOGGLE
12vdc
TEST LAMP
D B
SWITCH (D+,ind lite or aux)
POS + OUTPUT
+
BATTERY (B+)

GROUND A
INTEGRAL
REGULATOR
EXCITE
(TO OIL PRESSURE C
SWITCH OR
TOGGLE SWITCH ) Figure 4--- 9. Alternator Brush Assembly
+ ---
VOLTS BATTERY 4.4.6 Slip Ring Servicing
+ ---
BLACK
Clean brush contacting surfaces with fine crocus
RED POS + OUTPUT
cloth. Wipe dust and residue away.
13.8 TO 14.8V If surfaces are worn beyond this restoration, replace
entire rotor assembly.

Figure 4--- 8. Alternator Output Test 4.4.7 Alternator Installation

a. Make sure negative battery terminal is discon-
4.4.5 Alternator Brush Test Procedure nected.
b. Place V---belt on alternator sheave and then
NOTE install alternator with two bolts loosely in position.
Before performing test, removal of back cover is c. Check the center alignment of the jackshaft driv-
required. To remove, disconnect wires from ing pulley and alternator pulley, to ensure proper drive.
terminals extending through back cover. Pulley misalignment will create excess belt wear and limit
Remove two screws securing back cover to rear alternator bearing life. The center line of the alternator
housing and remove cover. sheave, and the driving sheave must be in line.
a. Removing Brush Set d. Pivot alternator to place tension on belt using
hand force only. Do not use pry bar or excessive force as it
1. Remove two locknuts securing brush holder and
may cause bearing failure. For correct belt tension see
remove brush assembly. table 4---1. Tighten pivot and adjustment bolts.
2. Check brush assembly for cracked, chipped or oil e. Connect wiring to alternator.
soaked brushes. Remaining brush length should be at
least 3/16 inch (4.76 mm) long. f. Connect battery cable. Start unit and check for
output per section 4.4.4.
3. Check slip rings for carbon build---up.
4.5 SERVICING AND ADJUSTING V--- BELTS
4. Using a 12 vdc test lamp or ohmmeter, test brush WARNING
assembly for continuity and insulation (See Figure 4---9)
Replace brush assembly if necessary. Beware of V--- belts and belt driven components
as the unit may start automatically.
b. Brush Continuity Check (See Figure 4--- 9)
4.5.1 Belt Tension Gauge
Using a 12 vdc test lamp or ohmmeter, test brush as-
It is recommended using a belt tension gauge (tester)
sembly for continuity and insulation as shown. Remove
P/N 07---00253, shown in Figure 4---10 whenever V---belts
brush assembly if necessary.
are adjusted or replaced.
A belt tension gauge provides an accurate and easy
CONTINUITY CHECK method of adjusting belts to their proper tension. Proper-
ly adjusted belts give long lasting and efficient service.
Continuity A to B OK Too much tension SHORTENS belt and bearing life, and
Continuity C to D OK too little tension causes slippage and excessive belt wear.
No Circuit A to C OK It is also important to keep belts and sheaves free of any
No Circuit A to D OK foreign material which may cause the belts to slip.
No Circuit B to C OK
No Circuit B to D OK The belt tension gauge can be used to adjust all belts.
The readings which we specify for Carrier Transicold
units are applicable only for our belts and application, as

4---7
 U W

the tension is dependent on the size of the belt and dis-

tance between sheaves. When using this gauge, it should
be placed as close as possible to the midpoint between
1
two sheaves. (See Figure 4---11)

The V---belts must be kept in good condition with the

2
proper tension to provide adequate air movement across
the coils. TO
ALTERNATOR
Table 4--- 1. Belt Tension (Part No. 07--- 00253)
(See Figure 4--- 10)
3
Initial Tension (New Belt) Retention Value

Water pump to Crankshaft 65---75 65---75 4

Jackshaft to Fanshaft 140 80---90
Jackshaft to Compressor * 65---75
Jackshaft to Alternator 65---75 65---75 ENGINE

* This tension will automatically be set when the jackshaft

to fanshaft belt is tensioned. Tension will be approxi- COMPRESSOR
mately the same as the jackshaft to fanshaft belt.
1. Evaporator/Condenser
Fan Shaft Sheave
2. Midpoint of Belt
3. Jackshaft
4. Frontside Idler
Figure 4--- 11. V--- Belt Arrangement
5. Using a belt tension gauge (Figure 4---10) on the
upper belt, rotate frontside idler so that the gauge reads
Figure 4--- 10. Belt Tension Gauge correct tension. (Refer to Table 4---1) Lower belt will au-
(Part No. 07--- 00253) tomatically be tensioned to approximately the same val-
ue.
6. Tighten frontside idler, carriage bolt, and
4.5.2 Water Pump V--- Belt capscrews.
NOTE
The water pump V---belt is driven by a sheave on the Both belts must be checked and retensioned, if
engine crankshaft. Frayed, cracked or worn belts must be necessary, after a brief run--- in period. (see step
replaced. Adjustment is achieved by altering the position 7)
of the frontside idler.
7. Operate unit in high speed for 5 to 10 minutes.
When replacing V---belt, avoid excessive force when Repeat steps 5 and 6. And then rotate idler as necessary
applying tension to the V---belt to prevent damage to the to adjust upper belt to a tension indicated in Table 4---1.
water pump bearings. (Refer to Table 4---1) Once again, lower belt will be automatically tensioned to
approximately the same value.
8. Repeat step 6 and then replace belt guard.
4.5.3 Driveshaft to Jackshaft and Jackshaft To b. Driveshaft to Jackshaft
Evaporator/Condenser Fans
1. Remove V---belt guard and then loosen frontside
a. Jackshaft to Fan Shaft V--- Belt idler bolt.
2. Match mark adapter to engine flywheel (See
To Replace V---belt: Figure 4---13A) for ease of assembly.
3. Remove six bolts (5/16---18 x 1 lg) securing adapt-
1. Remove V---belt guard. (See Figure 4---12)
er drive sheave to engine flywheel, Figure 4---13A.
2. Loosen capscrews (5) and carriage bolt (3) so 4. Insert three of the six bolts (5/16---18 x 1 lg) into
that swing arm (4) is free to move. three threaded holes (jacking holes) provided on engine
adapter. Jack adapter from engine flywheel. Remove the
3. Loosen frontside idler (7). three screws from adapter. Insert a pry bar between en-
gine flywheel and adapter, Figure 4---13A and slide the
4. Note direction of upper belt twist. Remove old adapter---sheave toward the compressor enough to
belt and replace with new belt in exactly the same way. change the V---belt as shown in Figure 4---13B. Replace
(See Figure 4---11) V---belt.

4---8
 U
L W

6. Place V---belt on the jackshaft sheave and adjust

belt tension as indicated in Table 4---1. Install V---belt
5 guard. DO NOT START UNIT UNTIL V---BELT
GUARD IS INSTALLED.
4
7. Start unit and run for 10 minutes to allow for belt
3 stretch.

8. Turn unit off and recheck belt tension.

8 2
1 4.6 PUMPING THE UNIT DOWN OR
REMOVING THE REFRIGERANT CHARGE

NOTE
6
To avoid damage to the earth’s ozone layer,
7 use a refrigerant recovery system whenever
removing refrigerant.

a. Pumping the Unit Down

To service the filter---drier, liquid line solenoid valve

1. Alternator Pivot Bolt
(SV---2), expansion valve, or evaporator coil, pump most
2. Alternator Adjustment Bolt
of refrigerant into condenser coil and receiver as follows:
3. Carriage Bolt
4. Swing Arm 1. Backseat suction and discharge service valve
5. Capscrews (turn counterclockwise) to close off gauge connection
6. Drive V ---Belt and attach manifold gauges to valves.
7. Frontside Idler
8. Alternator V ---Belt 2. Open valves two turns (clockwise). Purge gauge
Figure 4--- 12. Alternator, Jackshaft and V--- Belts line.

PRY BAR DRIVE 3. Close valve at the receiver outlet by turning

SHEAVE clockwise. Start unit and run in high speed cooling. Place
BOLTS (6) start---run---stop switch in the STOP position when unit
reaches 1 psig (0.1 kg/cm@).
MATCH MARK
4. Frontseat (close) suction service valve and the
refrigerant will be trapped between the compressor suc-
ENGINE ADAPTER tion service valve and the receiver manual shutoff valve.
DRIVE SHEAVE
SPACER 5. Before opening up any part of the system, a
Figure A slight positive pressure should be indicated on the pres-
sure gauge. If a vacuum is indicated, emit refrigerant by
cracking receiver outlet valve momentarily and opening
V-- BELT REMOVAL
the liquid solenoid valve electrically to build up a slight
positive pressure. Place the start---run---stop in the RUN
position and place the glow plug switch in the GLOW
position for the solenoid valve SV---2 to energize.

6. When opening up the refrigerant system, certain

parts may frost. Allow the part to warm to ambient tem-
perature before dismantling. This avoids internal con-
densation which puts moisture in the system.
Figure B
Figure 4--- 13. Engine Adapter Drive Sheave to 7. After repairs have been made, be sure to per-
Jackshaft V--- Belt
form a refrigerant leak check, section 4.7, and to evacuate
5. Pry the adapter back toward the engine flywheel and dehydrate the system, section 4.8.
or use 5/16---18 x 2---1/2 lg bolts (3) in every other hole of
adapter and take up evenly on the bolts until the 5/16---18 8. Start the unit in cooling and check for noncon-
x 1 lg bolts will start in the engine flywheel. Apply thread densibles. (Refer to section 4.11)
sealer (Loctite #262) to the bolts used to secure adapter
to flywheel. Take up on all bolts evenly and then torque to 9. Check the refrigerant charge. (Refer to section
a value of 28 ft---lb (3.87 mkg). 4.9.f)

4---9
 U W

b. Removing the Refrigerant Charge (e) Midseat receiver outlet valve. (Starting
from the fully backseated position, turn valve in four or
NOTE
five turns.)
Store the refrigerant charge in an evacuated
container if the system must be opened between (f) Run the unit in high speed cooling with the
the compressor discharge valve and receiver. condenser coil completely blocked off. Head pressure
will quickly rise. Stop the unit when it reaches 260 psig (18
Whenever the system is opened, it must be
kg/cm@). This will take three or four minutes in a 70 to
evacuated and dehydrated. (Refer to section
80_F (21to 27_C) ambient.
4.8)
WARNING (g) Fully open cylinder valve. Liquid refrigerant
will flow from receiver into cylinder and head (discharge)
Do not use a disposable refrigerant container to
pressure will drop.
store the charge as an explosion may occur.
1. Equipment Required NOTE
(a) Appropriate returnable refrigerant cylin- Refrigerant will flow from system into cylinder
der, preferably 125 lb (57 kg) net capacity. Also, a 50 lb until system pressure is equivalent to container
(23 kg) capacity returnable cylinder may be used. Refrig- temperature. For example, if cylinder is at 90_F
erant removal will be faster and more complete with the (32.2_C), given a system containing R---502 the
larger cylinder. system pressure reaches 187 psig (13 kg/cm@) no
(b) Refrigerant service gauge manifold. further transfer will take place. (For this reason,
it is possible to remove more than 77 to 83
(c) Vacuum pump, preferably 5 cfm (8 m#H), percent of refrigerant by this method if the
P/N 07---00176---01. refrigerant cylinder can be cooled such as by
(d) Weight scales (0---300 lb = 0 to 91 kg range, packing in ice.)
minimum).
(h) Monitor head pressure and weight of refrig-
(e) A 12---foot length of 3/8 inch (I.D.) evacua- erant cylinder to determine how much refrigerant is be-
tion hose or 3/8 inch copper tubing with 3/8 inch female ing removed. (Assuming a trailer unit properly charged
flare adapter on each end. Do not use hose or tubing of with refrigerant, 77 to 83 percent of refrigerant will drain
smaller diameter or the removal process will take consid- into cylinder in four to five minutes).
erably longer.
Shut off cylinder valve when the head pressure holds
2. Procedure
steady (unit and cylinder pressures have equalized). At
To service the condenser coil, receiver, solenoid this time, all the refrigerant that can be removed quickly
valves SV---1, SV---3, and check valves, store the refriger- is in the cylinder.
ant in an evacuated container as follows:
(i) Connect a refrigerant recovery system to the
(a) Evacuate and dehydrate returnable refrig- unit to remove remaining charge.
erant cylinder to 29 inches (74 cm) Hg vacuum (mini-
mum). A 5 cfm (8 m#H) vacuum pump will pull down the (j) After repairs have been made, be sure to
cylinder in three to five minutes. After cylinder has been perform a refrigerant leak check, section 4.7, and to evac-
evacuated, close cylinder valve, shut off vacuum pump, uate and dehydrate the system, section 4.8, before re-
and remove pump. charging refrigerant as detailed in section 4.9.
(b) Backseat compressor service valves and con-
nect a gauge manifold. Tighten connections at compres- NOTE
sor service valves. Attach lines loosely to manifold. Be
1. It is good practice to place a USED
sure manifold valves are frontseated. One at a time, crack
REFRIGERANT tag on cylinder.
open compressor service valves to purge lines with refrig-
erant and tighten connections at manifold. Midseat ser-
vice valves after purging. 4.7 REFRIGERANT LEAK CHECKING
(c) Connect evacuated refrigerant cylinder to
the manual receiver outlet valve. Tighten line at receiver a. If system was opened and repairs completed,
valve and attach loosely to cylinder valve. Crack open re- leak check the unit.
ceiver outlet valve to purge line with refrigerant and
b. The recommended procedure for finding leaks
tighten connection at cylinder.
in a system is with a halide torch or electronic leak detec-
NOTE tor. Testing joints with soapsuds is satisfactory only for lo-
If cylinder has two valves, be sure to connect cating large leaks.
drain line to liquid valve.
c. If system is without refrigerant, charge system
(d) Place evacuated refrigerant cylinder on with refrigerant to build up pressure between 30 to 50
scales and note weight of empty cylinder. Leave cylinder psig (2.1 to 3.5 kg/cm@). Remove refrigerant drum and
on scales. leak check all connections.

4---10
 U
L W

NOTE f. Remove refrigerant using a refrigerant recovery

It must be emphasized that only the correct system.
refrigerant drum be connected to pressurize the g. Repeat steps d, e and f one time.
system. Any other gas or vapor will contaminate
the system which will require additional purging h. Evacuate unit to 500 microns. Close off vacuum
and evacuation of the high side (discharge) of pump valve and stop pump. Wait five minutes to see if
the system. vacuum holds. This checks for residual moisture and/or
d. Remove refrigerant using a refrigerant recovery leaks.
system and repair any leaks. Evacuate and dehydrate the i. With a vacuum still in the unit, the refrigerant
unit. (Refer to section 4.8) Charge unit with refrigerant. charge may be drawn into the system from a refrigerant
(Refer to section 4.9) container on weight scales. The correct amount of refrig-
erant may be added by observing the scales. (Refer to sec-
4.8 EVACUATION AND DEHYDRATION tion 4.9)
4.8.1 General
Moisture is the deadly enemy of refrigerant systems.
The presence of moisture in a refrigeration system can
have many undesirable effects. The most common are 10
copper plating, acid sludge formation, “freezing---up” of
metering devices by free water, and formation of acids,
resulting in metal corrosion.
4.8.2 Preparation 8
a. Evacuate and dehydrate only after pressure leak 11
test. (Refer to section 4.7) 12
b. Essential tools to properly evacuate and dehy-
drate any system include a good vacuum pump (5 cfm =
8m#H volume displacement, P/N 07---00176---01) and a
good vacuum indicator such as a thermocouple vacuum 7 9
gauge (vacuum indicator). (Available through Robinair
Manufacturing, Montpelier, Ohio, Part Number 14010.)
NOTE
It is not recommended using a compound gauge 13
because of its inherent inaccuracy.
c. Keep the ambient temperature above 60_F
(15.6_C) to speed evaporation of moisture. If ambient
temperature is lower than 60_F (15.6_C), ice might form
before moisture removal is complete. Heat lamps or al-
ternate sources of heat may be used to raise system tem-
perature. 4 5 6
3
4.8.3 Procedure for Evacuation and
Dehydrating System
a. Remove refrigerant using a refrigerant recovery
system. 2 1
b. The recommended method to evacuate and de-
hydrate the system is to connect three lines (3/8” OD cop- 1. Refrigerant Recovery Unit
per tubing or larger) to manifold. Attach one line to the 2. Refrigerant Cylinder
receiver, compressor suction and discharge service 3. Evacuation Manifold
valves. (See Figure 4---14) 4. Valve
c. Connect lines to unit and manifold and make 5. Vacuum Pump
sure vacuum gauge valve is closed and vacuum pump 6. Vacuum Gauge
valve is open. 7. Receiver Outlet Valve
8. Receiver
d. Start vacuum pump, open all valves half way.
9. Condenser
Then open vacuum gauge valve. Evacuate unit until vacu-
10. Evaporator
um gauge indicates 2000 microns. Close vacuum gauge
11. Discharge Valve
valve, vacuum pump valve and stop vacuum pump.
12. Suction Valve
e. Break the vacuum with clean dry refrigerant. 13. Compressor
Use refrigerant that the unit calls for. Raise system pres- Figure 4--- 14. Vacuum Pump Connection
sure to approximately 2 psig.

4---11
 U W

4.9 ADDING REFRIGERANT TO SYSTEM 4.11 PURGING NONCONDENSIBLES

(FULL CHARGE)
A leak in the suction side of a system operating in a
a. Dehydrate unit and leave in deep vacuum. (Re- vacuum will pull air into system. The presence of noncon-
fer to section 4.8) densibles in the system is usually indicated by excessive
head pressure. The noncondensibles accumulate at the
b. Place drum of refrigerant on scale and connect top of the condenser coil or receiver because they are
charging line from drum to receiver outlet valve. Purge lighter than refrigerant vapor.
charging line at outlet valve. WARNING
Do not purge unit without protection for face and
c. Note weight of drum and refrigerant.
eyes. Refrigerant charge should not be released
to the atmosphere.
d. Open liquid valve on drum. Open receiver outlet
valve half way and allow the liquid refrigerant to flow into a. Perform a low side pumpdown to isolate noncon-
the unit until the correct weight of refrigerant has been densible gases in the condenser side of system. (Refer to
added as indicated by scales. Correct charge will be found section 4.6.a)
in section 1.3.m.
b. Allow system to sit for a minimum of fifteen min-
utes for gases to separate.
NOTE
c. Open purge cock located on top of condenser
It is possible that all liquid may not be pulled into coil for ten to fifteen seconds and then close tightly.
the receiver, as outlined in step d. In this case,
frontseat the receiver outlet valve (king valve) d. Backseat receiver outlet valve and run unit. If
and the liquid will be pulled into the system. Unit discharge pressure is still abnormally high, repeat proce-
must be operating in the cooling mode. dure one more time.
e. If discharge pressure is still high, remove refrig-
e. When drum weight (scale) indicates that the cor- erant from system to empty charging cylinder. (Refer to
rect charge has been added, close liquid line valve on section 4.6.b) Evacuate and charge system following
drum and backseat the receiver outlet valve. directions in section 4.9.

f. Start unit in cooling mode. Run approximately 4.12 REPLACING THE COMPRESSOR
ten minutes. Partially block off air flow to condenser coil
so discharge pressure rises to 230 psig (16 kg/cm@). If compressor is inoperative and unit still has refrig-
erant pressure, frontseat suction and discharge service
Refrigerant should appear at center line of lower re- valves to trap most of the refrigerant in the unit.
ceiver sight glass. If charge is inadequate, add refrigerant If compressor runs, pump down the unit. (Refer to
charge (per section 4.10). section 4.6.a)
a. Remove the two rear compressor bracket
4.10 ADDING REFRIGERANT TO SYSTEM mounting bolts (compressor shockmount end).
(PARTIAL CHARGE) b. Block up engine.
a. Place drum of refrigerant on scale and note c. Slowly release compressor pressure.
weight. Backseat suction service valve and connect charg- d. Remove bolts from suction and discharge service
ing line between suction valve port and drum. Open VA- valve flanges.
POR valve on drum and purge charging line.
e. Remove oil filter and bracket from compressor.
b. Run the unit in cooling for ten minutes and then f. Disconnect wiring to unloader valve assemblies,
partially block off air flow to condenser coil so discharge suction pressure transducer and the wiring to the high
pressure will rise 10 psig (0.7 kg/cm@). Refrigerant should pressure cutout switches (HP---1 and HP---2). Identify
appear at center line of the lower receiver sight glass . If wiring and switches if necessary. (See Figure 4---16)
charge is inadequate, add refrigerant charge with con-
denser coil still blocked. (Refer to section 4.10.c) g. Remove four bolts from the two engine---com-
pressor spacers.
c. Open suction service valve three turns. Add h. Disconnect ground strap from frame.
charge until level appears at center line of the lower re-
ceiver sight glass (white pill will be floating). i. Disconnect suction pressure transducer from
compressor .
d. Backseat (open) suction service valve. Close va-
j. Attach sling or other device to the compressor.
por valve on refrigerant drum, noting weight. Vent charg-
The O5G compressor weighs 137 pounds (62 kg).
ing line and replace all caps.
k. Slide compressor enough to remove spacers.
e. Start unit and check for noncondensibles. (Refer Then slide compressor enough to clear nylon drive gear,
to section 4.11) Figure 4---15, and remove compressor from unit.

4---12
 U
L W

ft/lb (6.4 mkg). Install new gaskets on service valves and

1 tighten bolts uniformly.
2 p. Attach two lines (with hand valves near vacuum
pump) to the suction and discharge service valves. Dehy-
drate and evacuate compressor to 500 microns (29.90”
Hg vacuum = 75.9 cm Hg vacuum). Turn off valves on
7 8 both lines to pump.
q. Fully backseat (open) both suction and discharge
3 service valves.

4 r. Remove vacuum pump lines and install manifold

5 gauges.

2 s. Start unit and check for noncondensibles. (Refer

6
to section 4.11)
t. Check refrigerant level (section 4.10.b.)
1. Compressor 5. Nylon Drive Gear
2. Spacer 6. Drive Sheave Bolts u. Check compressor oil level. (Refer to section
3. Compressor Drive 7. Jackshaft V ---Belt 4.13) Add oil if necessary.
Gear 8. Engine adapter---Drive v. Check compressor unloader operation. (Refer
4. Locking Tab Sheave to section 4.14)
Figure 4--- 15. Compressor Drive Assembly
w. Check refrigerant cycles. (Refer to section 2)
l. Drain oil from defective compressor before ship-
ping. (Oil drain plug is located at the bottom plate, oil 4.13 CHECKING THE COMPRESSOR OIL
pump end of compressor.) (See Figure 4---17) LEVEL
m. The original unloader valves must be transferred a. To Check the Oil Level in the Compressor:
to the replacement compressor. The plug arrangement 1. Operate the unit in high speed cooling for at
removed from the replacement is installed in the original least 20 minutes.
compressor as a seal. If piston is stuck, it may be extracted
by threading socket head cap screw into top of piston. A 2. Check the oil sight glass on the compressor to en-
small teflon seat ring at bottom of piston must be re- sure that no foaming of the oil is present after 20 minutes
moved. of operation. If the oil is foaming excessively after 20 min-
utes of operation, check the refrigerant system for
NOTES flood---back of liquid refrigerant. Correct this situation
The service replacement compressor is sold before performing step a.3.
without shutoff valves (but with valve pads). 3. Check the level of the oil in the front sight glass
Customer should retain the original capacity with the compressor operating. The correct level should
control valves for use on replacement be between bottom and 1/4 of the sight glass. If the level is
compressor. Check oil level in service above 1/4, oil must be removed from the compressor. To
replacement compressor. If none add 8 U.S. remove oil from the compressor, follow step d. If the level
Pints (3.7 Litres).(Refer to sections 1.3.c, and is below sight glass, add oil to the compressor following
4.13.c) step b.
n. Remove the complete high pressure switch as- b. Adding Oil with Compressor in System
sembly (HP---1 and HP---2) (See Figure 4---16) and install Two methods for adding oil are the oil pump method
on new compressor after checking switch settings. Re- and closed system method.
move suction pressure transducer and install on new
compressor. Install compressor frame to new compressor 1. Oil Pump Method
(if removed with defective compressor). One compressor oil pump that may be purchased is a
Robinair, part no. 14388. This oil pump adapts to a one
COMPRESSOR HEAD U.S. gallon (3.785 litres) metal refrigeration oil container
and pumps 2---1/2 ounces (0.0725 litres) per stroke when
connected to the suction service valve port. Also there is
HP---1 no need to remove pump from can after each use.
When the compressor is in operation, the pump
check valve prevents the loss of refrigerant, while allow-
HP---2 ing servicemen to develop sufficient pressure to over-
come the operating suction pressure to add oil as neces-
Figure 4--- 16. Pressure Switches HP--- 1 and HP--- 2 sary.
o. Install compressor in unit by reversing step Backseat suction service valve and connect oil charg-
4.12.c through n. It is recommended using new locknuts ing hose to port. Crack the service valve and purge the oil
when replacing compressor. Torque bolts to a value of 46 hose at oil pump. Add oil as necessary.

4---13
 U W

2. Closed System Method d. To remove oil from the compressor:

In an emergency where an oil pump is not available, 1. Close suction service valve (frontseat) and pump
oil may be drawn into the compressor through the suction unit down to 2 to 4 psig (0.1 to 0.3 kg/cm@). Frontseat dis-
service valve. charge service valve and slowly bleed remaining refriger-
ant.
CAUTION
2. Remove the oil drain plug on the bottom plate of
Extreme care must be taken to ensure the man- the compressor and drain the proper amount of oil from
ifold common connection remains immersed in the compressor. Replace the plug securely back into the
oil at all times. Otherwise air and moisture will compressor.
be drawn into the compressor.
3. Open service valves and run unit to check oil lev-
Connect the suction connection of the gauge man- el, repeat as required to ensure proper oil level.
ifold to the compressor suction service valve port, and im-
merse the common connection of the gauge manifold in 4.14 COMPRESSOR UNLOADER VALVE
an open container of refrigeration oil. Crack the suction The compressor suction cutoff unloaders (located on
service valve and gauge valve to vent a small amount of the compressor cylinder heads) are controlled by relays
refrigerant through the common connection and the oil UFR,URR and the temperature controller. (Refer to
to purge the lines of air. Close the gauge manifold valve. section 1.8)
With the unit running, frontseat the suction service a. Checkout Procedure
valve and pull a vacuum in the compressor crankcase. 1. Connect manifold gauges to the compressor suc-
SLOWLY crack the suction gauge manifold valve and oil tion and discharge service valves and start unit in cooling
will flow through the suction service valve into the com- with the container temperature at least 5_F (2.8_C)
pressor. Add oil as necessary. above set point and the compressor will be fully loaded
1 2 (both unloader coils are de---energized). Note suction
11
pressure.
10 2. Remove wiring from the front unloader coil.
3
9 Place electrical tape over wire terminals.
8 3. Set controller upscale (cooler to warmer). This
mechanically simulates falling temperature. Approxi-
mately 2_F (1.1_C) below box temperature the unloader
coils will energize, but only the rear unloader valve will
unload. Note suction pressure, a rise of approximately 3
psig (0.2 kg/cm@) will be noted on the suction pressure
7 gauge.
4
4. Reconnect wiring on the front unloader. The
6 front unloader will retract and an additional 3 psig (0.2
5 kg/cm@) rise on the suction gauge will be noted. Compres-
sor is now fully unloaded and only the top bank is loaded
1. High Pressure Switch Connection
(two cylinders).
2. Suction Pressure Transducer Connection
3. Suction Service Valve 5. Reverse the above procedure to check out com-
4. Oil Fill Plug pressor loading. Suction pressure will drop with this test.
5. Bottom Plate NOTE
6. Oil Drain Plug If either unloader coil energizes and the suction
7. Oil Level Sight Glass pressure does not change, the unloader assembly
8. Oil Pump must be checked. (Refer to section 4.14.b)
9. Unloader Solenoid
10. Discharge Thermistor Connection b. Replacing the Unloader
11. Discharge Service Valve WARNING
Figure 4--- 17. Compressor --- Model O5G Make sure power to unit is OFF and negative
c. Adding Oil to Service Replacement battery cable is disconnected before servicing
Compressor the compressor unloader.
NOTE 1. Close off suction and discharge service valve to
The correct oil charge is 8 U.S. Pints (3.8 litres). trap most of the refrigerant in the unit (this will prevent
moisture from entering the system and save most of the
Service replacement compressors may or may not be refrigerant charge).
shipped with oil.
2. Slowly release compressor pressure through the
If compressor is without oil: service valve gauge ports.
Add oil, (section 1.3.c) through the suction service 3. Remove cylinder head and unloader from com-
valve flange cavity or by removing the oil fill plug (See pressor. Have on hand valve plate gasket, cylinder head
Figure 4---17) gasket, suction and discharge service valve gaskets.

4---14
 U
L W

4. Proceed to step 11 if not rebuilding unloader at

this time. 1
2
CAUTION

Care must be exercised when handling valve

body and enclosing tube as a dent in the enclos- 3
ing tube could mean failure to unload the com-
pressor. 4

5
5. Remove valve body and enclosing tube assembly
and gasket. (Items 1, 2, and 3, Figure 4---18).

6. Remove cover and gasket (items 9,10 & 11) from

bottom of cylinder head. Then remove spring and valve
body (items 7 and 8).

7. From the top of the cylinder head, push piston

(item 6) out of piston cavity.
6
8. On the replacement piston, place ring seal in
position on piston by positioning in place (using two
thumbs). Make sure seal is firmly in place. 7

9. From bottom of cylinder head, insert seal and 8

piston in cylinder head. Using piston driver, push piston
into cylinder head cavity.
9
10. Re---assemble rest of unloader.
10
11. Install new valve plate gasket and cylinder head
gasket before installing cylinder head. 11

12. After installing cylinder head, torque bolts to a 1. Valve Body and 6.Piston and Ring Seal
value of 35 to 40 ft/lb (4.84 to 5.53 mkg). Enclosing Tube 7.Valve Body
2. Capscrew and Gaskets 8.Spring
13. Place unloader coil and snap cap on unloader 3. Gasket 9.Cover Gasket
valve enclosing tube. 4. Strainer 10.Cover
5. Cylinder Head 11.Capscrews
14. Install compressor and mounting plate in unit.
Figure 4--- 18. Compressor Unloader Valve ---
15. Install new gaskets on service valves and then Suction Cutoff
install mounting bolts in service valves and torque to a c. Solenoid Coil Replacement
value of 16 to 20 ft/lb (2.21 to 2.77 mkg).
NOTE
16. Attach two lines (with hand valves near vacuum The coil may be removed without pumping
pump) to the suction and discharge service valves. the unit down.
Dehydrate and evacuate compressor to 500 microns (75.9 1. Disconnect leads. Remove snap cap. Lift off coil.
cm = 29.90 inches Hg vacuum). Turn off valves on both (See Figure 4---19)
lines to pump. 2. Verify coil type, voltage and frequency of old and
new coil. This information appears on the coil housing.
17. Fully backseat (open) both suction and discharge
service valves. d. Replacing Solenoid Valve Internal Parts
(See Figure 4--- 19)
18. Remove vacuum pump lines. 1. Pump down the unit. Frontseat both service
valves to isolate the compressor.
19. Start unit and check refrigerant charge. (Refer 2. Remove coil snap cap, and coil.
to section 4.9.f)
3. Remove enclosing tube collar (item 4,
20. Check system for wetness. Change filter---drier if Figure 4---19) using installation/removal tool supplied
necessary. (Refer to section 4.16) with repair kit (item 3).
4. Check plunger for restriction due to: (a) Cor-
21. Check compressor oil level per section 4.13.a. roded or worn parts; (b) Foreign material lodged in valve;
Add oil if necessary. (Refer to section 4.13.b.) (c) Bent or dented enclosing tube.

4---15
 U W

a. To replace check valve, store the refrigerant into

1 an evacuated container. (Refer to section 4.6)
2 b. Replace necessary parts.
3 c. Evacuate and dehydrate unit. (Refer to section
4.8)
4 d. Add refrigerant charge. (Refer to section 4.9)
5
6 4.16 CHECKING AND REPLACING
7 FILTER--- DRIER
12
8 To Check Filter---Drier
13 Check for a restricted or plugged filter---drier by feel-
9
10 ing the liquid line inlet and outlet connections of the drier
cartridge. If the outlet side feels cooler than the inlet
11 side, then the filter---drier should be changed.
To Replace Filter---Drier
a. Pump down the unit per section 4.6. Remove
1. Snap Cap 7. Plunger Spring U---bolt and nuts from clamp, then replace drier.
2. Coil Assembly 8. Plunger Assembly
3. Installation/Removal 9. Gasket b. Check refrigerant level. (Refer to section 4.10.b)
Tool 10. Valve Body
4. Enclosing Tube 11. Gasket 4.17 CHECKING AND REPLACING HIGH
Collar 12. Capscrew PRESSURE CUTOUT SWITCH
5. “O” Ring 13. Gasket, Capscrew
4.17.1 Replacing High Pressure Switch
6. Enclosing Tube
Figure 4--- 19. Unloader Solenoid Valve --- a. Pump down the unit. (Refer to section 4.6.a)
Suction Cutoff Frontseat both suction and discharge service valves to
isolate compressor. Then slowly release compressor re-
5. Install new parts. Do not overtighten enclosing frigerant charge.
tube assembly. Torque to a value of 100 inch pounds (1.15 b. Disconnect wiring from defective switch. The
mkg). high pressure switches are located on the top cylinder
6. Remove supplied installation/removal tool. head. (See Figure 4---17)
Install coil, voltage plate, and snap cap. c. Install new cutout switch after verifying switch
7. Evacuate and dehydrate the compressor. (Refer settings. (Refer to section 4.17.2)
to section 4.12.p through 4.12.w.) d. Evacuate and dehydrate the compressor. (Refer
to section 4.12.p through 4.12.w)
8. Start unit and check unloader operation (Refer
to section 4.14.a). 4.17.2 Checking High Pressure Switch
(HP--- 1 or HP--- 2)
4.15 SERVICING THE CHECK VALVE --- WARNING
SERVICEABLE TYPE
Do not use a nitrogen cylinder without a pres-
The check valve allows the hot gas to travel in one sure regulator. Cylinder pressure is approxi-
direction only. mately 2350 psi (165 kg/cm@).Do not use oxygen
The function of the condenser coil bypass is to raise in or near a refrigerant system as an explosion
the receiver pressure when the ambient temperature is may occur.
low so that refrigerant can flow from the receiver to the (See Figure 4--- 21)
evaporator when the unit is in heating or defrost. a. Remove switch as outlined in section 4.17.1.
b. Connect ohmmeter or continuity light across
switch terminals. Ohmmeter will indicate resistance and
1 continuity light will be lighted if switch closed after reliev-
5 2 ing pressure.
3 c. Connect switch to a cylinder of dry nitrogen.
4
(See Figure 4---21)
d. Set nitrogen pressure regulator higher than cut-
1. Cap 4. Brass/Teflon Seat out point on switch being tested. Pressure switch cutout
2. Copper Washer 5. Body and cut---in points are shown in sections 1.3.k. and 1.3.l.
3. Spring e. Close valve on cylinder and open bleed---off
Figure 4--- 20. Check Valve --- Serviceable Type valve.

4---16
 U
L W

f. Open cylinder valve. Slowly close bleed---off 2. Verify coil type, voltage and frequency. This in-
valve and increase pressure until the switch opens. If light formation appears on the coil housing.
is used, light will go out and if an ohmmeter is used, the
3. Place new coil over enclosing tube, snap cap and
meter will indicate open. Open pressure on gauge. Slowly
open bleed---off valve (to decrease pressure) until switch connect wiring.
closes (light will light or ohmmeter will move). b. Replacing Solenoid Valve Internal Parts
1 (See Figure 4--- 22)
4
1
5 1. Cylinder Valve
2 2
and Gauge
2. Pressure Regulator
3. Nitrogen Cylinder
4. Pressure Gauge
(0 to 400 psig = 3 1. Snap Cap
3 6
0 to 28 kg/cm@) 2. Coil Assembly
5. Bleed---Off Valve 3. Enclosing Tube Assembly
6. 1/4 inch Connection 4. Plunger Assembly
5. Gasket
4 6. Piston Assembly
5 7. Body
8. Bracket Adapter
Figure 4--- 21. Typical Setup for Testing High
Pressure Switch 6

4.18 REPLACING RECEIVER SIGHT GLASS 7

ASSEMBLY
8
NOTE
There are two types of receiver sight glasses.
One is the floating ball type (P/N 14---00111), Figure 4--- 22. Solenoid Valves SV2 --- Alco
and the second is the prism type (P/N
14---50023---00); both are interchangeable. The liquid line solenoid valve (SV2) may be serviced
a. Store the refrigerant in an evacuated container. by pumping the unit down. (Refer to section 4.6.a)
(Refer to section 4.6.b) 1. Remove coil snap cap and coil assembly from
b. Unscrew the sight glass assembly. Spread some valve. Remove enclosing tube assembly and related
sealing compound on pipe threads of new sight glass as- items.
sembly and install. 2. Check for foreign material in valve body.
c. Leak check receiver sight glass per section 4.7. 3. Install new parts. Do not completely tighten en-
d. After leak checking unit, evacuate and dehy- closing tube down. Purge line by emitting small amount of
drate as outlined in section 4.8. refrigerant per section 4.6.a.5.
e. Add refrigerant charge. (Refer to section 4.9) 4. Tighten enclosing tube assembly to a torque val-
ue of 200 inch pounds (2.3 mkg) and leak check the valve.
f. Check for noncondensibles. (Refer to section (Refer to section 4.7)
4.11)
5. Install coil assembly and snap cap.
4.19 SERVICING SOLENOID VALVES 6. Start unit and check refrigerant charge per sec-
4.19.1 Solenoid Valves SV2 --- Alco tion 4.9.f.
CAUTION 7. Check refrigeration cycles.(Refer to section 2)
Do not damage or overtighten the enclosing tube
assembly. Torque to 200--- inch pounds (2.3 4.19.2 Solenoid Valve SV1/SV3 --- Sporlan
mkg). Also make sure all parts are placed on the a. Replacing the Coil
enclosing tube in proper sequence to avoid pre-
mature coil burnout. NOTE
a. Replacing the Coil The coil may be replaced without removing the
refrigerant or pumping the unit down.
NOTE
1. Remove top locknut, spacer cup and nameplate
The coil may be replaced without removing the (SV1). For SV3, remove screw and nameplate.
refrigerant or pumping the unit down.
2. Disconnect wiring and remove coil.
1. Disconnect leads, remove coil snap cap and coil
assembly. 3. Replace coil by reversing steps 1 and 2.

4---17
 U W

b. Replacing Internal Components 10. Dehydrate and evacuate the system. (Refer to
(See Figure 4--- 23) section 4.8) Charge unit with refrigerant per sections 4.9
1 and 4.10.
1
11. Start unit and check operation. (Refer to section
2 3 2)
3
4.20 SOLENOID VALVE SV--- 1 CHECKOUT
4 PROCEDURE
4
To obtain proper heating and defrost, the normally
open (N.O.) SV---1 solenoid valve must energize and
5 close tightly during the heat and defrost cycles. If the
6
valve does not close tightly due to physical damage, for-
6 7 eign material or wear, refrigerant leakage through the
valve can reduce heating capacity.
7 8 a. During normal heat or defrost cycles the follow-
ing conditions will be observed when the valve is operat-
8 ing properly:
11
(1) Receiver refrigerant level will drop quickly
9 at the initiation of heating or defrost mode.
9
(2) Suction pressure will rise slowly to 25---30
psig (1.8 to 2.1 kg/cm@).
10 10 (3) Discharge pressure will drop quickly, but be-
gin to rise to a minimum of 250 psig (17.5 kg/cm@) within
SV---1 SV---3 15 to 20 minutes.
1. Locknut/Screw 7. Enclosing Tube b. If suction and discharge pressures remain low
2. Spacer Cup 8. Gasket and the receiver level does not drop, the valve may be in-
3. Nameplate 9. Seat Disc operative and can be checked by the following method.
4. Coil 10. Body (1) Verify the solenoid coil has proper voltage
5. Spacer 11. Stem and
and is energized in heating and defrosting.
6. Enclosing Tube Plunger
Locknut (2) Connect a discharge pressure gauge to the
Figure 4--- 23. Solenoid Valves SV1/SV3--- Sporlan compressor discharge service valve and connect a gauge
to the liquid line valve (king valve) leaving the receiver
1. Remove and store the refrigerant charge in an tank.
evacuated container. (Refer to section 4.6.b)
(3) With the trailer temperature at 35_F
2. Remove the top locknut, spacer cup, nameplate, (1.7_C) or lower, operate the unit in high speed cool and
coil assembly and spacer (SV1). For SV3, remove screw remove or disconnect the “hot” wire leading to the SV---1
and nameplate. coil.
3. Using a 12 point, 1---3/8 inch box wrench, loosen (4) With a separate 12 vdc positive voltage, en-
the enclosing tube locknut and bleed off remaining re- ergize SV---1 with the unit in high speed cooling and ob-
frigerant. serve the discharge and receiver pressures. If the valve is
closing properly, compressor discharge pressure will be-
4. Remove enclosing tube and locknut assembly.
gin to rise and the receiver pressure will remain the same
The gasket is inside the enclosing tube. or begin to drop slowly. If the valve is not seating proper-
5. Remove seat disc from inside of body and check ly, both discharge and receiver pressure will rise slowly or
for obstructions and foreign material. remain the same.
6. Place the seat disc into the valve body with the Operate the unit until discharge pressure reaches
smaller diameter end facing up. 200 psig (14 kg/cm@) and disconnect jumper wire to SV---1
valve. Discharge and receiver pressure should be within 5
7. For SV3 install stem and plunger (item 11, to 15 psig (0.4 to 1.0 kg/cm@) of each other.
Figure 4---23)
8. Place the enclosing tube locknut over the enclos- 4.21 CHECKING DEFROST OR HEATING
ing tube. Install spacer over enclosing tube making sure it CYCLE
is seated properly in the enclosing tube locknut. Tighten NOTE
enclosing tube locknut to a torque value of 20 ft---lb (2.78
mkg). Do not overtighten. The evaporator temperature must be 35_F
(1.7_C) (approximately 40_F = 4.4_C box
9. Install coil assembly, nameplate and top locknut temperature) or lower, before any checks can be
or screw. made.

4---18
 U
L W

a. Hot Gas Solenoid Valve (SV--- 1 & SV--- 3)

Heating and Defrosting
2
1. Connect a discharge pressure gauge to the re-
ceiver outlet valve and another gauge to the compressor 5
discharge service valve. Connect a gauge to the compres-
sor suction service valve.
2. Start unit with controller set at least 10_F =
5.5_C below indicated box temperature to obtain high 3
speed cooling. Press the manual defrost and ENTER 6
keys simultaneously to initiate defrost. (Box temperature 4
1
must be below 40_F = 4.4_C.) The hot gas solenoid valve
(SV3) will energize and the hot gas line will be hot to
touch on either side of the valve. The condenser pressure 1. Ohmmeter or Continuity Device
control solenoid (SV1) closes and suction pressure will 2. Adjustment Screw (0.050 socket head size)
rise approximately 10 to 15 psig (0.70 to 1.05 kg/cm@) af- 3. Low Side Connection
ter 15 to 20 minutes on unit operation. Refer to section 4. Pressure Line or Aspirator Bulb
4.20 if unit does not heat properly. (P/N 07---00177---01)
The unit will remain in defrost until coil temperature 5. Magnehelic Gauge (P/N 07---00177)
increases to 50_F (10_C) where the defrost thermostats 6. High Side Connection
open and the unit resumes automatic operation. Figure 4--- 24. Defrost Air Switch Test Setup
b. Defrost Air Switch (DA) NOTE
Use a hand aspirator (P/N 07---00177---01), since
1. To check air switch, run unit in high speed cool- blowing into tube by mouth may cause an
ing and jump across the air switch terminals. This will incorrect reading.
start the defrost cycle as it simulates the action of the de-
frost air switch. Bypassing the switch in this manner oper- e. With the gauge reading at zero, apply air pres-
ates all components involved in defrost. sure very slowly to the air switch. An ohmmeter will indi-
cate continuity when switch actuates.
2. Unit should remain in defrost until evaporator f. Refer to section 1.3.e for switch settings. If
coil temperature reaches 50_F (10_C). At this point one switch fails to actuate at correct gauge reading, adjust
of the two defrost thermostats should open to terminate switch by turning adjusting screw clockwise to increase
the defrost cycle. Replace the defrost thermostats if unit setting or counterclockwise to decrease setting.
fails to terminate defrost.
g. Repeat checkout procedure until switch actuates
3. If the above test indicates satisfactory operation, at correct gauge reading.
test defrost air switch (DA) settings using a Dwyer Mag-
nehelic gauge (P/N 07---00177) or similar instrument. h. After switch is adjusted, place a small amount of
(Refer to section 4.22) paint or glycerol on the adjusting screw so that vibration
will not change switch setting.
c. Solid State Defrost Timer
4.23 REPLACING THE CONDENSER/
Refer to section 1.10.2.f. for description. EVAPORATOR FAN SHAFT OR BEARING
WARNING
4.22 CHECKING CALIBRATION OF THE Beware of unannounced starting of the evapora-
DEFROST AIR SWITCH tor and condenser fan.
a. Make sure magnehelic gauge is in proper cal- a. To Remove the Fan Shaft
ibration.
1. Remove two screws securing split tapered bush-
NOTE
ing to condenser fan hub (items 12 and 13, Figure 4---25).
The magnehelic gauge may be used in any Place the two screws in the threaded holes of the fan hub
position, but must be re---zeroed if position of and use screws as jacking bolts to remove bushing from
gauge is changed from vertical to horizontal or fan.
vice versa. USE ONLY IN POSITION FOR 2. Remove V---Belt. (Refer to section 4.5.3.)
WHICH IT IS CALIBRATED.
3. Remove tapered bushing and sheave (items 10
b. With air switch in vertical position, connect high and 11, Figure 4---25). Turn the two socket head screws
pressure side of magnehelic gauge to high side connec- (7/32 hex wrench) counterclockwise until the bushing
tion of air switch. (See Figure 4---24) clears the sheave and then remove sheave. At this time
c. Install tee in pressure line to high side connec- reassemble sheave and bushing by placing bushing into
tion. Tee should be approximately half---way between sheave and aligning the two half---moons of the bushing
gauge and air switch or an improper reading may result. to the sheave. Place socket head screws in sheave and
turn them in enough to catch the inner edge of bushing.
d. Attach an ohmmeter to the air switch electrical Rotate bushing 90_ and then the assembly is ready for
contacts to check switch action. installation.

4---19
 U W

4. Remove four 3/8---18 x 1 lg capscrews and wash- 19. Locate the fan and key so that 1/3 of the con-
ers (items 14, 15 and 16) from the bearing housing (item denser fan extends beyond the leaving edge of the fan
8, Figure 4---25). shroud. Secure fan and hub to shaft.
5. Remove evaporator panels. 20. Install evaporator fan venturi ring. Then install
tapered hub and blower wheel loosely. Adjust blower
6. Remove two screws securing split tapered bush- wheel and tighten.
ing, to blower wheel (items 1 and 2, Figure 4---25). Place
the two screws in the threaded holes of the fan hub and 21. Install evaporator panels.
use screws as jacking bolts to remove bushing from blower WARNING
wheel.
Do not start unit without installing the evapora-
7. Remove venturi ring (item 3, Figure 4---25) by tor panels as unit damage or body harm may re-
removing six 1/4---20 x 3/4 long capscrews. sult.
8. Remove the shaft and bearing housing. 22. Start unit and check refrigeration cycle.

9. If necessary to replace bearings; remove locking 4.24 SERVICING DEFROST DAMPER

collar from bearing (item 6, Figure 4---25). Remove fan SOLENOID (DDS) ASSEMBLY
shaft from bearing housing and then, using a bearing pull-
er, remove bearings. Bearings cannot be driven through WARNING
housing. Beware of unannounced starting of the evapora-
10. Inspect housing for casting number. The tor and condenser fan.
48---00228---00 and 48---00228---02 casting use different a. Replacing Solenoid or Adjusting Linkage
bearings. Refer to your parts manual. (See Figure 4--- 26)
11. Inspect inner housing for rust or signs of water. 1. Remove six 1/4---20 capscrews securing evapora-
Immediately discard any housing which cannot be reused tor panel to unit.
after average cleaning in a “parts washer”. Insure that 2. Disconnect wiring to solenoid.
housing is completely dry with no solvent residue before
reusing. 3. Remove rod linkage clip (item 4, Figure 4---26)
securing linkage rod (item 2).
12. Coat inside of bearing housing and outer bearing
race with Beacon 325, or Mobil SHL 460 grease (or other 4. Remove four 1/4---20 capscrews and locknuts se-
lithium base equivalent --- do not use WD---40 motor oil curing solenoid.
or other product which may have a solvent action). 5. Install new solenoid.
13. Lubricate “O” ring with Beacon 325 or lithium 6. Install linkage and clip.
base grease and install in grooves on shaft.
7. Connect solenoid wiring.
14. Press new bearings into housing and install shaft
with the long keyway on the condenser side. The shaft ex- 8. Energize the damper solenoid to close shutter
tends 6 inches (152 mm) from the face of the bearing blade.
housing. Place locking collars on bearings and torque set 9. If damper does not seal, remove boot (item 3)
screws to 6 foot/pounds. from solenoid and pull solenoid shaft out (far enough to
CAUTION loosen jam nut on solenoid shaft). Energize solenoid for
maximum force (pull) and then shorten shaft by turning
Install one bearing into housing taking care to clockwise. De---energize solenoid, tighten shaft jam nut
press bearing evenly into housing using both in- and replace boot. Connect linkage and energize solenoid.
ner and outer race. DO NOT press against the
seals. Install shaft with “O” ring into bearing. NOTE
Install 2nd bearing onto shaft to complete as- It may be necessary to apply heat to adjusting “I”
sembly. “O” ring damage can be caused by sharp bolt to be able to turn it because Loctite is used .
set screw holes in locking collar if shaft is in-
serted in a different manner. b. Replacing Bushings or Damper Blade
15. Install bearing housing assembly into unit secur- 1. Remove damper return spring from damper
ing with four 3/8---16 x 1 inch long screws. (item 10, Figure 4---26).

16. Install sheave with key and split taper bushing. 2. Remove clip and cotter pin from linkage rod
The center line of the sheave is located 1---1/32 inch (33 (items 2, 4, and 6, Figure 4---26).
mm) from the face of the bearing housing. 3. Remove mounting hardware from damper plate
assembly (item 7, Figure 4---26). Remove blade and bush-
17. Install V---belt per section 4.5.3.
ing. Replace parts as necessary.
18. Install tapered hub on condenser fan loosely.
4. Reassemble parts by reversing steps 1 through 3.
Fan rotation is clockwise when viewing from front of unit.
Air is pulled through the coil and discharges over the en- 5. Check linkage by following section 4.24.a. steps 8
gine. and 9.

4---20
 U
L W

5
9
5

6
5 13
12

3 11

8 10
2
14 15 16
7
1 4 4 6,7 11

1. Split Tapered Bushing---2---1/2 Dia. 10. Sheave

2. Blower Wheel 11. Split Tapered Bushing---1---13/16 Dia.
3. Venturi Ring 12. Condenser Fan
4. Shaft 13. Condenser Fan Hub
5. Key 14. Flat Washer, 3/8
6. Bearing 15. Lock Washer, 3/8
7. O---Ring (Used with old style bearings) 16. Capscrew, 3/8---16 x 1 lg
8. Bearing Housing
9. V ---Belt
Figure 4--- 25. Evaporator/Condenser Fan Shaft Assembly

6
7
8
1 5

2 9

10

1. Solenoid 5. Linkage Adapter 9. Damper Blade Assembly

2. Linkage Rod 6. Cotter Pin --- 1/16 Dia. 10. Return Spring
3. Solenoid Boot 7. Damper Plate Assembly
4. Clip, Linkage Rod 8. Bushing
Figure 4--- 26. Defrost Damper Assembly

4---21
 U W

4.25 EVAPORATOR COIL CLEANLINESS 5. The thermal bulb is located below the center of
the suction line (4 or 7 o’clock position). This area must
The use of recycled cardboard cartons is increasing be clean to ensure positive bulb contact. Strap thermal
across the country. The recycled cardboard cartons bulb to suction line and insulate both with Presstite.
create much more fiber dust during transport than ”new”
cartons. The fiber dust and particles are drawn into the 6. Install new gaskets and insert cage assembly and
evaporator where they lodge between the evaporator install power assembly.
fins. If the coil is not cleaned on a regular basis, some- 7. Fasten equalizer tube to expansion valve.
times as often as after each trip, the accumulation can be
great enough to restrict air flow, cause coil icing, repeti- 8. Evacuate by placing vacuum pump on suction
tive defrosts and loss of unit capacity. Due to the ”wash- service valve.
ing” action of normal defrost the fiber dust and particles 9. Open receiver outlet valve and then check refrig-
may not be visible on the face of the coil but may accumu- erant level. (Refer to section 4.10.b)
late deep within.
10. Check superheat. (Refer to section 1.3.h)
It is recommended to clean the evaporator coil on a
regular basis, not only to remove cardboard dust, but to
remove any grease or oil film which sometimes coats the
fins and prevents water from draining into the drain pan. 1 4
Cardboard fiber particles after being wetted and
dried several times can be very hard to remove. There-
fore, several washings may be necessary.
a. Remove rubber check valves (Kazoo) from drain 2 5
lines (front of trailer).
b. Spray coil with a mild detergent solution such as
Oakite 164 or any good commercial grade automatic dish
washer detergent such as Electrosol or Cascade and let 3
the solution stand for a few minutes and reverse flush 6
(opposite normal air flow) with clean water at mild pres-
sure. A garden hose with spray nozzle is usually sufficient. 7
Make sure drain lines are clean.
c. Run unit until defrost mode can be initiated to
1. Power Assembly 5. Cage Assembly
check for proper draining from drain pan. (Refer to sec-
2. Body Flange Gaskets 6. Body Flange
tion 2)
3. Seat Gasket 7. Body Flange Screws
4. Bulb
4.26 THERMOSTATIC EXPANSION VALVE Figure 4--- 27. Thermostatic Expansion Valve
The thermal expansion valve is an automatic device b. Alternate Method
which maintains constant superheat of the refrigerant gas
leaving the evaporator regardless of suction pressure. 1. Pump down the unit by closing the receiver out-
The valve functions are: (a) automatic response of refrig- let valve and then closing the suction service valve
erant flow to match the evaporator load and (b) preven- 2. Remove insulation (Presstite) from expansion
tion of liquid refrigerant entering the compressor. Unless valve bulb and then remove bulb from suction line.
the valve is defective, it seldom requires any mainte-
nance. 3. Loosen flare nut and disconnect equalizer line
from expansion valve.
There are two methods of replacing the expansion valve.
4. Remove flange screws and lift off power assem-
a. Preferred Method bly. Then remove the cage assembly. Check for foreign
material in valve body.
Refer to section b. for alternate method.
5. The thermal bulb is located below the center of
1. Pump down the unit by closing the receiver out- the suction line (4 or 7 o’clock position). This area must
let valve. (Refer to section 4.6.a) be clean to ensure positive bulb contact. Strap thermal
bulb to suction line and insulate both with “Presstite.”
2. Remove insulation (Presstite) from expansion
valve bulb and then remove bulb from suction line. 6. Install new gaskets and insert cage assembly.
Install power assembly with flange screws loosely.
3. Loosen flare nut and disconnect equalizer line
from expansion valve. 7. Fasten equalizer tube to expansion valve.
8. Tighten flange screws on expansion valve and
4. Remove flange screws and lift off power assem-
then check the refrigerant charge per section 4.10.b.
bly. Then remove the cage assembly. Check for foreign
material in valve body. 9. Check superheat. (Refer to section 1.3.h)

4---22
 U
L W

c. Checking Superheat 5. Run unit until stabilized. Set controller 10_F

(5.5_C) below box temperature.
NOTE 6. From the temperature/pressure chart, deter-
It is not recommended adjusting internal mine the saturation temperature corresponding to the
adjustable valves unless absolutely necessary. evaporator outlet pressure.
7. Note the temperature of the suction gas at the
If the valve came from the factory with the proper
expansion valve bulb.
setting and the setting has changed, a mechanical mal-
function has occurred and adjusting superheat will not Subtract the saturation temperature determined in
correct the malfunction. Step 6 from the average temperature measured in Step 7.
The difference is the superheat of the suction gas.
If a replacement valve has the wrong superheat set-
ting, the valve may be adjusted if you do not have another e. Adjusting Superheat
replacement valve on hand. Due to the time involved in 1. Pump the unit down and remove the two bolts
adjusting the superheat, replace the valve rather than ad- holding the valve body together. (Refer to sections 4.26.a
justing it. or 4.26.b)
d. To Measure Superheat 2. Remove the cage assembly and rotate the adjust-
ing nut to increase or decrease the superheat. Turning the
NOTE nut to compress the valve spring will increase the super-
heat and decrease refrigerant flow through the valve. De-
The expansion valve and bulb location are shown compressing the spring will decrease the superheat and
in Figure 1---6. increase the refrigerant flow through the valve.
1. Remove evaporator panel from rear of unit and 3. Reassemble the valve and then start the unit.
then remove Presstite from expansion valve bulb and suc-
tion line. 4. When the unit has stabilized operation for at
least 20 minutes, recheck superheat setting.
2. Loosen one TXV bulb clamp and make sure area
under clamp (above TXV bulb) is clean. 5. If superheat setting is correct, remove gauge and
thermocouple. Insulate bulb and suction line.
3. Place thermocouple above (parallel) TXV bulb
and then secure loosened clamp making sure both bulbs 4.27 MICROPROCESSOR
are firmly secured to suction line as shown in
NOTE
Figure 4---28.
The erasable, programmable, read only memory
(EPROM) chip (component U9 on the
microprocessor display board) has a window on
it which is covered with a label listing the revision
level of the software. The window is used to erase
3 4 the chip’s memory with the use of ultraviolet
2 light. the label prevents light from entering the
5 chip and erasing the memory. Under NO
1 circumstances should this label be removed.
CAUTION
1. Suction Line (end view) Under no circumstances should a technician
2. TXV Bulb Clamp electrically probe the processor at any point,
3. Nut and Bolt (clamp) other than the connector terminals where the
4. Thermocouple harness attaches. Microprocessor components
5. TXV Bulb operate at different voltage levels and at ex-
Figure 4--- 28. Thermostatic Expansion Valve Bulb tremely low current levels. Improper use of volt-
and Thermocouple meters, jumper wires, continuity testers, etc.
could permanently damage the processor.
NOTE As mentioned above, some microprocessor inputs
operate at voltage levels other than the conventional 12
When conducting this test the suction pressure vdc. Connector points and the associated approximate
must be 6 psig (0.4 kg/cm@) below expansion voltage levels are listed below for reference only. Under
valve maximum operating pressure (MOP). For no circumstances should 12 vdc be applied at these con-
example: R---502 units use an expansion valve nection points.
with a 30 MOP. The recommended test pressure
should be below 24 psig(1.69 kg/cm@). Grounded wrist cuffs are available at most radio,
computer and electronic supply stores. It is recom-
4. Connect an accurate gauge to the 1/4” port on mended that these be worn whenever handling a micro-
the suction service valve. processor.

4---23
 U W

It is absolutely imperative that whenever a Micro-

CONNECTION POINT
processor is removed from a unit for any reason, that the
Connection Point Approximate Voltage old Key Board gasket be removed, and a new one be
Range installed.
JG1, JG3, JG4, JG5 2.5 vdc The tightening sequence shown below should be ad-
NHS1, NHS2,CRS2, hered to when tightening the retaining bolts or nuts. The
CRS1 PTS1,and PTS2 recommended torque for securing nuts or bolts is 20
JD1, JD2, JE1, JE2, 2.5 vdc (Variable) inch---lbs. Over tightening the nuts or bolts, or using a
RAS, SAS tightening sequence other than the one shown, may cause
warping of the Key Board.
JF5, JF6, OTS1, OTS2 5.0 vdc
JC5, WTS 2.5 vdc (Variable)
5 1 7
JC6, CDT 2.5 vdc (Variable)

CAUTION 3 4
Most electronic components are susceptible to
damage caused by electrical static discharge 8 2 6
(ESD). In certain cases, the human body can
have enough static electricity to cause resultant
damage to the components by touch. This is es- Figure 4--- 29. Tightening Sequence for
pecially true of the integrated circuits found on Microprocessor
the truck/trailer microprocessor. 4.28 CONTROLLER SENSOR CHECKOUT
Although there is less danger of electical static dis- An accurate ohmmeter must be used to check resis-
charge ESD damage in the outdoor environment, where tance values shown in Table 4---2.
the processor is likely to be handled, proper board han-
dling techniques should always be stressed. Boards Due to variations and inaccuracies in ohmmeters,
thermometers or other test equipment, a reading within
should always be handled by their edges, in much the
same way one would handle a photograph. This not only 2% of the chart value would indicate a good sensor. If a
precludes the possibility of ESD damage, but also lowers sensor is bad, the resistance reading will usually be much
the possibility of physical damage to the electronic com- higher or lower than the resistance values given in
ponents. Although the microprocessor boards are fairly Table 4---2.
rugged when assembled, they are more fragile when sepa- At least one lead from the sensor (RAS, terminals
rated and should always be handled carefully. JD1 and 2 or SAS, terminals JE1 and 2) must be discon-
nected from the unit electrical system before any reading
During emergency situations, the five switch test is taken. Not doing so will result in a false reading. Two
board may be used to keep a unit running and prevent a preferred methods of determining the actual test temper-
critical load from spoiling. Since the microprocessor is to- ature at the sensor, is an ice bath at 32_F (0_C) or a cali-
tally disconnected from the unit, it cannot monitor the brated temperature tester.
engine’s safety switches for oil pressure and coolant tem-
perature. Since the engine is running unprotected when the 4.29 SUCTION PRESSURE TRANSDUCER
five switch board is used, it is imperative that should a
problem develop with the microprocessor, it be replaced Before installing a new suction pressure transducer it
immediately. The five switch board is intended to be a must be calibrated.
trouble---shooting tool only. 1. Connect wiring to new suction pressure trans-
ducer. Before installing suction pressure transducer into
When using the five switch board to troubleshoot, compressor, press SUCTION PRESSURE key on con-
the unit should be started in low speed, unloaded cool in trol panel. If display reads “0” on control panel install
the same way as the processor would start the unit. Good suction pressure transducer into compressor. If it does
judgment should also be used when cycling any unit with the not reads “0” go to step 2.
five switch board. Rapid cycling should be avoided.
2. Press Carrier Transicold oval, SUCTION PRES-
When welding is required on the unit frame, or on SURE and ENTER keys at the same time to calibrate
the front area of the trailer, ALL wiring to the Micropro- suction pressure transducer. Display should read “0”.
cessor MUST be disconnected. When welding is per- (See Figure 1---13)
formed on other areas of the trailer, the welder ground
connection MUST be in close proximity to the area being 4.30 SERVICING CONDENSER SHUTTER
welded. It is also a good practice to remove both battery (OPTIONAL)
cables before welding on either the unit frame or the trail- a. Replacing the Vernatherm Power Unit
er to prevent possible damage to other components such (Element)
as the alternator and voltage regulator.
The Vernatherm power unit assembly (item 1,
Should damage to the Key Board of the Micropro- Figure 4---30) is pre---set and will start to open at 70_F
cessor occur, it is possible to replace only the Key Board. (21_C) condensing air temperature. It is not adjustable

4---24
 U
L W

for various temperature settings. The temperature must

be below 68_F (20_C) when replacing the Vernatherm 6
power unit (element).
1
To replace power unit (item 1), remove old power 2
unit (item 1) and jam nut (item 2). Assemble jam nut to 7
new power element. Turn power element into body cast-
ing until the push pin (item 3) is firmly positioned against
the push rod (item 6). Then tighten jam nut.
5
b. Air Leakage 4

With the shutter closed and unit running, place a

piece of paper on the surface of the shutter. If the paper is 6
held in place by fan suction, the shutter is improperly ad-
justed. Air leakage may be caused by one or more of the 4
following:
3
1. Bearings (Refer to section 4.30.e.)
1. Vernatherm Power Unit 5. Lock Nut
2. Jam Nut 6. Push Rod
2. Shutters need adjusting. (Refer to section
3. Actuating Lever 7. Push Pin
4.30.c.)
4. Control Rod
Figure 4--- 30. Condenser Shutter Adjustment
3. Vernatherm power unit needs adjusting. (Refer
to section 4.30.a.) Replacing Vane Seals
1. Remove shutters from unit and disconnect shut-
4. Worn vane seals (Refer to section 4.30.d.) ter return spring from both shutters. Shutter may now be
opened.
5. Improper shutter installation on unit. (There 2. When replacing seals, do not let them extend be-
must be an air---tight seal all around shutter to ensure that yond the vanes. This will eliminate any possibility of bind-
air enters the shutter only.) ing of the shutter. Use a soap solution in the vane channel
and stretch the seal when assembling to the channel. The
c. Shutter Linkage Adjustment seal, being elastic, will return to its natural shape.
e. Bearing Seizure
Check condition of vane seals before making adjust-
ments to the shutter linkage (Refer to section 4.30.d.) When shutters are not adjusted correctly and suffi-
Also, the temperature must be below 68_F (20_C) and cient air leakage through the vanes occur, the shutters
the vanes firmly closed before making adjustments. will not operate and will stay in a static position (partially
opened). This will, in some instances, especially where
salt conditions exist, cause the vane pins and bearings to
If the vane seals appear to be in good condition, place
seize, making the shutters inoperative.
a piece of cardboard, or feeler gauge, approximately .015
inch (0.381 mm) thick between the vanes. If there is a When this occurs, remove the shutter from the unit
drag on the gauge when removing, the adjustment is cor- and apply liberal amounts of penetrating oil to all bearing
rect. If the gauge is loose between the vanes, the shutter surfaces, including the control bar and let stand for a peri-
must be adjusted by doing the following: od of time. Disconnect the return spring and then, oper-
ate the vanes by hand, until they move freely. Remove ex-
1. Loosen lock nuts (item 5) on both control rods. cess oil with a solvent.
The shutters will be held closed by the return springs and f. Lubrication
the vanes should now be sealing properly.
Lubricate all pivot points with rust inhibitor and lu-
bricant, LPS---2 or equal.
2. Press actuating lever (item 3) and shaft assembly
to its full “in” position. 1. Run unit until shutters open (warm weather op-
eration). Attach applicator (plastic tube) to aerosol can
and lubricate all pivot points. Do not spray directly into
3. Tighten lock nuts (item 5) on both control rods.
radiator and condenser coil.
When adjustment is completed, the push rod (item 6)
must be against Vernatherm push pin (item 7). 2. If shutters are seized or do not open because of
low ambient temperature:
d. Checking and Replacing Vane Seals Remove shutters from unit and disconnect shutter
return spring from both shutters. Lubricate all pivot
To inspect the vane seals, start unit and when shutters points and manually move shutters until satisfactory op-
open, check seals for damage or a worn condition. eration is achieved.

4---25
 U W

4.31 UNIDRIVE TORQUE REQUIREMENTS

(See Figure 4--- 31)
Extensive damage may occur if the proper hardware
and procedures are not followed. Periodic inspection of
hardware and bolt torque is recommended to insure the
integrity of the unidrive.
NOTE
Earlier units used locking tabs to retain the bolts
between the compressor mounting flange and
the adapter spacers. If the locking tabs are not
replaced, or on new units without locking tabs, a
thread locking sealant, 5/16 flatwasher and 5/16
lockwasher must be used. The recommended
sealant is Loctite screw lock no. 262.
The figure below shows the torque value, size and
grade of the hardware to be used when reassembling the
unidrive assembly.

M12 x 1.25 x 25 mm lg M10 x 1.25 x 25 mm lg 3/8---16 x 1---1/4 lg Grade 5 (4 Req’d)

(3 Req’d) 70 ft ---lbs (9.68 mkg) (1 Req’d) 47 ft ---lbs (6.5 mkg) 30 ft ---lbs (4.15 mkg)

3/8---24 x 1.00 lg Grade 8

30 ft ---lbs (4.15 mkg)

FLYWHEEL

5/16---18 x 1.00 lg Grade 8

(6 Req’d) 28 ft ---lbs (3.87 mkg)
M12 x 1.25 x 25 mm lg
DIRECT DRIVE (4 Req’d) 70 ft ---lbs (9.68 mkg)

Figure 4--- 31. Unidrive Torque Requirements

4---26
 U
L W

Table 4--- 2. Sensor Resistance (RAS and SAS)

Temperature Resistance Temperature Resistance Temperature Resistance
_F _C In Ohms _F _C In Ohms _F _C In Ohms
---20 ---28.9 165,000 +14 ---10.0 55,300 +48 + 8.9 21,000
---18 ---27.8 154,000 +16 --- 8.9 52,100 +50 +10.0 19,900
---16 ---26.7 144,300 +18 --- 7.8 49,100 +52 +11.1 18,900
---14 ---25.6 134,400 +20 --- 6.7 46,300 +54 +12.2 18,000
---12 ---24.4 126,100 +22 --- 5.5 43,600 +56 +13.3 17,000
---10 ---23.3 118,300 +24 --- 4.4 41,100 +58 +14.4 16,100
--- 8 ---22.2 110,500 +26 --- 3.3 38,800 +60 +15.6 15,300
--- 6 ---21.1 103,700 +28 --- 2.2 36,600 +62 +16.7 14,500
--- 4 ---20.0 97,100 +30 --- 1.1 34,600 +64 +17.8 13,800
--- 2 ---18.9 91,000 +32 0 32,700 +66 +18.9 13,200
0 ---17.8 82.800 +34 + 1.1 30,800 +68 +20.0 12,500
+2 ---16.7 80,200 +36 + 2.2 29,200 +70 +21.1 11,800
+4 ---15.6 75,300 +38 + 3.3 27,600 +72 +22.2 11,300
+6 ---14.4 70,800 +40 + 4.4 26,100 +74 +23.3 10,600
+8 ---13.3 66,500 +42 + 5.5 24,700 +76 +24.4 10,300
+10 ---12.2 62,500 +44 + 6.7 23,400 +78 +25.6 9,800
+12 ---11.1 58,800 +46 + 7.8 22,100 +80 +26.7 9,300

Table 4--- 3. R--- 502 Pressure --- Temperature Chart

TEMPERATURE PRESSURE TEMPERATURE PRESSURE
_F _C Psig Kg/cm@ Bar _F _C Psig Kg/cm@ Bar

---40 ---40 4.1 .29 .28 28 --- 2 62.8 4.42 4.33

---35 ---37 6.5 .46 .45 30 --- 1 65.6 4.61 4.52
---30 ---34 9.2 .65 .63 32 0 68.4 4.81 4.72
---28 ---33 10.3 .72 .71 34 1 71.3 5.01 4.92
---26 ---32 11.5 .81 .79 36 2 74.3 5.22 5.12
---24 ---31 12.7 .89 .88 38 3 77.4 5.44 5.34
---22 ---30 14.0 .98 .97 40 4 80.5 5.66 5.55
---20 ---29 15.3 1.08 1.05 45 7 88.7 6.24 6.12
---18 ---28 16.7 1.17 1.15 50 10 97.4 6.85 6.72
---16 ---27 18.1 1.27 1.25 55 13 106.6 7.49 7.35
---14 ---26 19.5 1.37 1.34 60 16 116.4 8.18 8.03
---12 ---24 21.0 1.48 1.45 65 18 126.7 8.91 8.74
---10 ---23 22.6 1.59 1.61 70 21 137.6 9.67 9.49
--- 8 ---22 24.2 1.70 1.67 75 24 149.1 10.48 10.28
--- 6 ---21 25.8 1.81 1.78 80 27 161.2 11.33 11.11
--- 4 ---20 27.5 1.93 1.90 85 29 174.0 12.23 12.00
--- 2 ---19 29.3 2.06 2.02 90 32 187.4 13.18 12.92
0 ---18 31.1 2.19 2.14 95 35 201.4 14.16 13.89
2 ---17 32.9 2.31 2.27 100 38 216.2 15.20 14.91
4 ---16 34.9 2.45 2.44 105 41 231.7 16.29 15.98
6 ---14 36.9 2.59 2.54 110 43 247.9 17.43 17.09
8 ---13 38.9 2.73 2.68 115 46 264.9 18.62 18.26
10 ---12 41.0 2.88 2.83 120 49 282.7 19.88 19.49
12 ---11 43.2 3.04 2.98 125 52 301.4 21.19 20.78
14 ---10 45.4 3.19 3.13 130 54 320.8 22.55 22.12
16 --- 9 47.7 3.35 3.29 135 57 341.2 23.99 23.52
18 --- 8 50.0 3.52 3.45 140 60 362.6 25.49 25.00
20 --- 7 52.5 3.69 3.62 145 63 385.0 27.07 26.54
22 --- 6 54.9 3.86 3.89 150 66 408.4 28.71 28.16
24 --- 4 57.5 4.04 3.96 155 68 432.9 30.44 29.85
26 --- 3 60.1 4.23 4.14 160 71 458.7 32.25 31.63

4---27
 SECTION 5
ELECTRICAL SCHEMATIC WIRING DIAGRAM
5.1 INTRODUCTION
This section contains Electrical Schematic Wiring Diagram covering the Models listed in Table 1---1. The following
general safety notices supplement the specific warnings and cautions appearing elsewhere in this manual. They are
recommended precautions that must be understood and applied during operation and maintenance of the equipment
covered herein.
WARNING
Beware of V--- belts and belt driven components as the unit may start automatically. Before servicing unit, make
sure the start--- run stop switch is in the OFF position. Also disconnect the negative battery cable.
WARNING
Beware of unannounced starting of the evaporator and condenser fan.
WARNING
Make sure power to unit is OFF and negative battery cable is disconnected before servicing the compressor
unloader.
WARNING
Do not use a disposable refrigerant container to store the charge as an explosion may occur.
WARNING
Under no circumstances should ether or any other unauthorized starting aids be used in conjunction with the
glow plugs.
CAUTION
Under no circumstances should anyone attempt to service the microprocessor! Should a problem develop with
the microprocessor, contact your nearest Carrier Transicold dealer for replacement.
CAUTION
Under no circumstances should a technician electrically probe the processor at any point, other than the
connector terminals where the harness attaches. Microprocessor components operate at different voltage levels
and at extremely low current levels. Improper use of voltmeters, jumper wires, continuity testers, etc. could
permanently damage the processor.
CAUTION
Never apply 12 vdc to JD, JE, JF, or JG terminal blocks. These four items are low voltage (2.5 or 5.0 vdc). Damage
to the microprocessor will result. (Refer to Note 4, Figure 5--- 1)
CAUTION
Observe proper polarity when installing battery, negative battery terminal must be grounded. Reverse polarity
will destroy the rectifier diodes in alternator. As a precautionary measure, disconnect positive battery terminal
when charging battery in unit. Connecting charger in reverse will destroy the rectifier diodes in alternator.

5---1
 LEGEND

Figure 5--- 1. Electrical Schematic Wiring Diagram --- Dwg. No. 62--- 03833
(Sheet 1 of 2)

5---2
 A B C D E F G H I J K L M N O P Q

10

11

12

13

14

15

16

Figure 5--- 1. Electrical Schematic Wiring Diagram --- Dwg. No. 62--- 03833
(Sheet 2 of 2)

5---3/5---4
 SECTION 6
MULTI---TEMP OPERATION AND SERVICE
6.1 INTRODUCTION 6.2 ELECTRICAL DATA
a. System a. Generator (5kw)
The Phoenix Multi---Temp multiple compartment re- Wattage 5000 Watts
frigeration system offers the versatility of two or three Volts 230 v---ac
compartment temperature control. The Multi---Temp Phase 1
allows the shipper to ship frozen and perishable commo- Speed 3600 rpm at 60 hz
dities in the same load under separate refrigeration con- Rotation either direction
trol. b. Remote Evaporator Fan Motor
The Phoenix Multi---Temp unit is comprised of the Volts 12 v---dc
basic Phoenix diesel nosemount unit with one or two re- Horsepower 1/8 hp
mote evaporators for rear compartments . Speed 3000 rpm
Rotation Clockwise when viewed from shaft end
The unit also is equipped with a 5---kilowatt, single
phase, 230 v---ac generator in the nosemount to power c. Remote Evaporator Defrost Heaters
the electric heaters in the rear evaporators. 1. Two Compartments
b. Remote Evaporator and Control Box Number 2
The rear compartments of the Multi---Temp system is Voltage 240 v---ac/1 ph/60hz
equipped with a separate evaporator and remote Wattage 2500 watts each
mounted control box.
The remote evaporators can be wall or ceiling 2. Three Compartments
mounted and includes evaporator coil and heaters, drain Number 2
pan, evaporator fan and motor (12v---dc), defrost ter- Voltage 240 v---ac/1 ph/60hz
mination thermostat, liquid line solenoid, expansion Wattage 1250 watts each
valve, air switch and evaporator pressure regulator.
The control box includes a solid state controller, indi- 6.3 SAFETY DEVICES
cating lights, switches, circuit breakers and relays. CB4 is
a circuit breaker which protects the evaporator fan motor Safety Devices for protection of the Remote Evapo-
and CB5 protects the control power circuit. rator are listed in Table 6---1.

Table 6--- 1. Safety Devices --- Remote Evaporator

Unsafe Conditions Safety Device Device Setting

1. Excessive current draw by 1. Circuit breaker (CB4) 1. Trips at 30 amps

remote evaporator fan motor automatic reset

2. Excessive current draw by 2. Circuit breaker (CB5) 2. Refer to Wiring Diagram

remote evaporator control circuit automatic reset

3. Excessive current draw by 3. Fuse (F6, F7) 3. Opens at 30 amps

5 KW generator

6---1
6.4 REFRIGERANT CIRCUIT
The Multi---Temp refrigerant circuit is the same as
the Phoenix but with the addition of a remote evapora-
tor.
The remote evaporator refrigerant flows through
the electrically controlled liquid line solenoid valve
(LSV) which starts or stops the flow of liquid refrigerant.
The remote evaporator is fitted with an evaporator
pressure regulating valve. This valve will automatically
throttle flow from the evaporator in order to maintain the
preset minimum evaporator pressure.

EVAPORATOR PRES-
SURE REMOTE
EVAPORATOR EXPANSION VALVE
REGULATING VALVE LIQUID
SOLE-
NOID
VALVE
(LSV)

EXTERNAL EQUALIZER EXPANSION VALVE

EXPANSION
SHUT--
VALVE BULB
EVAPORATOR OFF
VALVE

LIQUID
VAPOR LINE BYPASS RECEIVER
CHECK SOLE-
VALVE NOID
VALVE
HEAT EX- (SV2), NC
CHANGER

HOT GAS LINE FILTER

VIBRASORBER DRIER
LIQUID LINE
DISCHARGE
SUCTION
HOT GAS
SERVICE SERVICE
VALVE VALVE
SOLE- CONDENSER
NOID
(SV3),
NC
COMPRESSOR DIS- CONDENSER PRES-
CHARGE SURE
STRAINER CHECK CONTROL SOLENOID
VALVE (SV1), NO
VIBRASORBER

HP-- 1 HP-- 2

Figure 6--- 1. Refrigerant Circuit --- Cooling

6---2
6.5 REMOTE COMPARTMENT OPERATION
a. To start remote evaporator, place the remote 3
compartment switch in the ON position (See
Figure 6---2). Set desired temperature using the dial on 4
2
the remote control box (See Figure 6---3).
b. The manual defrost switch and function lights 1 5
for each compartment are on the remote control box.
c. Turn remote compartment switch OFF when re-
mote evaporator is not required.
NOTE 6
For starting instructions on the nosemount unit
refer to section 2.2.
7

1 1. Power Light
2. Cool Light
2 3. Heat Light
4. Defrost Light
5. Manual Defrost Switch
6. Thermometer
7. Temperature Selector
Figure 6--- 3. Remote Control Box
6.6 SERVICING THE REMOTE EVAPORATOR
WARNING
BEFORE SERVICING THE REMOTE
EVAPORATOR, REMOVE NEGATIVE
BATTERY CABLE AND TAG NOSEMOUNT
START--- RUN--- STOP SWITCH TO PREVENT
STARTING.
a. Fan Motor or Blade Replacement
1. Remove front panel.
1. Third Compartment ON---OFF Switch (3ST)
2. Second Compartment ON---OFF Switch (2ST) 2. Remove fan guard, loosen fan hub set screw
(#10---32 x 1/2 lg --- cone point) and remove fan. Remove
Figure 6--- 2. Control Panel fan motor hardware and fan wiring (if required).
3. Replace fan motor and fan blade before tighten-
ing fan setscrew, align fan with 1/3 of the fan blades ex-
tending beyond the leaving edge of the housing. Replace
fan guard and front panel, test fan operation.
b. Replacing Tubular Heaters
1. Remove front panel.
2. Disconnect heater wiring from junction block
and spiral wrap.
3. Release spring tension on heater and remove
from attaching clip.
4. Replace and rewire heater. Reinstall front panel
and test heater operation.

6---3
6.7 SERVICING LIQUID SOLENOID VALVE (LSV) 1. Connect gauge to evaporator pressure regulat-
NOTE ing valve (EPR) access valve. Remove the cap from the
EPR.
The liquid solenoid valve (LSV) is the same
valve as (SV2). Refer to section 4.19 for NOTE
servicing. To adjust valve, place 1/4” hex wrench size in
adjustment screw. A clockwise rotation
6.8 EVAPORATOR PRESSURE REGULATING increases the valve setting while a
VALVE
counterclockwise rotation decreases the setting.
Evaporator pressure regulating valves offer an effi- To obtain the desired setting, a pressure gauge
cient means of balancing the system capacity and the load should be utilized so the effects of any
requirements during periods of low loads and maintain- adjustment may be observed.
ing different evaporator conditions on multi---tempera-
ture systems. The primary function of this type of valve is 2. Set front and rear compartment controllers to
to prevent the evaporator pressure from falling below a above settings and start unit. When the front compart-
predetermined value at which the valve has been set. ment suction Pressure reaches l0 to 12 Psig (0.7 to 0.8 kg/
cm@) , set rear evaporator EPR. valve at 17 Psig 1.2 kg/
The valves will automatically throttle the vapor flow cm@ ) . This setting will satisfy the operating
from the evaporator in order to maintain the desired requirements for most 2 compartment applications.
minimum evaporator pressure. As the load increases, the
evaporating pressure will increase above the valve setting 3. However, if the front compartment does not pull
and the valve will open further. down to 0_F (---l7.8_C) within 2 hours, adjust the rear
evaporator EPR to a higher pressure setting, increasing
Operation
by 2 psig (0.1 kg/cm) increments. (Adjustment screw
Evaporator pressure regulating valves respond only turned in a clockwise direction. ) Allow temperature to
to variations in their inlet pressure (evaporator pres- stabilize after each new valve adjustment until the set
sure). The outlet pressure is exerted on the underside of compartment temperature is reached.
the bellows and on top of the seat disc. Since the effective
area of the bellows is equal to the area of the port, the 4. Conversely, if the front compartment reaches
outlet pressure cancels out and the inlet pressure acting controller setting of 0_F (---17.8_C) but the rear compart-
on the bottom of the seat disc opposes the adjustable ment does not pull down to 35_F (l.7_C) within 1 hour,
spring force. These two forces are the operating forces of adjust the rear evaporator EPR. counterclockwise in 2
the valve. When the evaporator load changes, the valve psig (0.1 kg/cm@) increments until the set rear compart-
opens or closes in response to the change in evaporator ment temperature is reached. Allow stabilization of tem-
pressure. perature after each new adjustment is recommended.
An increase in inlet pressure above the valve setting EPR adjustments should be made when the ambient
tends to open the valve. If the load drops, less refriger- temperature is near summer maximum Adjustments
ant is boiled off in the evaporator and the evaporator made in cooler ambients may require resetting when the
pressure will decrease. The decrease in evaporator pres- summer maximum is reached.
sure tends to move the valve to a more closed position
For other temperature and respective valve pressure
which in turn keeps the evaporator pressure up. The net
settings, contact Carrier Transicold.
result is that the evaporator pressure does change as the
load changes. b. Service
The operation of a valve of this type is improved by Since these valves are hermetic and cannot be disas-
an anti---chatter device built into the valve. Without this sembled for inspection and cleaning, they usually must be
device, the valve would be susceptible to compressor replaced if they become inoperative. However, if the
pulsations that can greatly reduce the life of a bellows. valve fails to open, close properly, Or won’t adjust, it is
This feature allows the valve to function at low load probably due to solder or other foreign materials lodged
conditions without chattering or other operating difficul- in the port. It is sometimes possible to dislodge these ma-
ties. terials. by turning the adjustment screw all the way out
with the system running.
6.9 ADJUSTING THE EVAPORATOR PRESSURE
REGULATING VALVE If the valve develops a refrigerant leak around the
a. Adjustment spring housing, it probably has been overheated during
installation or the bellows has failed due to severe com-
0_F (---17. 8_C) Front and 35_F (1. 7_C) Rear Compart- pressor pulsations. In either case the valve must be re-
ment Operation placed.

6---4
6.10 REPLACING OR ADJUSTING GENERATOR
BELT
a. Loosen generator support bracket rear pivot
bolts (Item 6, Figure 6---4). Loosen jam nut on adjusting
screw (Item 3) and take up on locknut enough to clear
generator V---belt from the sheave.
b. To remove generator V---belt from driveshaft,
follow instructions in section 4.5. (See Figure 4---13)
c. After replacing belt, take up on jam nut and lock-
nut on adjusting screw until belt does not slip.

1 4

2
5

1. V ---Belt
2. Generator 5kw
3. Adjusting Screw
4. Jam Nut
5. Locknut
6. Pivot Bolt
Figure 6--- 4. Generator

6---5
6---6
 Figure 6--- 5. Electrical Schematic Wiring Diagram
Dwg. No. 62--- 03815 Rev B

6---7
6-- 8
 Figure 6--- 6. Electrical Schematic Wiring Diagram
Dwg. No. 62--- 03816 Rev D

6-- 9