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Carrier X4 7300 - Service Manual

Carrier X4 7300
282 pages
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Trailer & Rail Refrigeration
BYPASS
CHECK
VA LV E
RECEIVER
FUSIBLE
PLUG
FILTER-DRIER
SV1
N/O
SV4
CONDENSER
N/C
OPERATION & SERVICE MANUAL
For The
X4 7300 & X4 7500
Trailer and Rail Refrigeration Units
62-11637 Rev B

Table of Contents

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Carrier X4 7300 Specifications

General IconGeneral
BrandCarrier
ModelX4 7300
CategoryUtility Vehicle
LanguageEnglish

Summary

SECTION 1 - SAFETY PRECAUTIONS

1.1 SAFETY PRECAUTIONS

General safety guidelines for installation and servicing, emphasizing caution with moving parts and electrical components.

1.2 SPECIFIC WARNING, CAUTION, AND NOTICE STATEMENTS

Explains hazard symbols (Danger, Warning, Caution, Notice) and specific safety directives for unit operation and maintenance.

1.3 SAFETY DECALS

Displays various safety decals with warnings and precautions in multiple languages.

SECTION 2 - UNIT DESCRIPTION

2.2 GENERAL DESCRIPTION

Describes the unit as a self-contained, nosemount diesel-powered refrigeration/heating unit for insulated compartments.

2.3 CONDENSING SECTION

Details the components of the condensing section, including the engine, power train, and associated systems.

2.3.3 Engine Controls

Explains the function and operation of engine control components like FSA, ENSSN, RPS, ENOPS, and ENCT.

2.4 EVAPORATOR SECTION

Describes the evaporator section, its components, and its role in cooling the refrigerated compartment.

2.4.2 Evaporator Expansion Valve (EVXV)

Details the function of the EVXV in controlling refrigerant flow and maintaining superheat.

2.5 SYSTEM OPERATING CONTROLS AND COMPONENTS

Covers the APX control system, its features, and component descriptions and locations.

2.5.4 Component Description And Location

Lists and describes key APX control system components like PCM, MM, SVM, ENCU, and DM.

2.10 COMPONENT RESISTANCE & CURRENT DRAW

Provides electrical specifications for various unit components, useful for troubleshooting.

2.11 SAFETY DEVICES

Explains the safety devices that protect the system from high pressure and unsafe operating conditions.

2.12 REFRIGERATION CIRCUIT DURING COOLING

Details the operation of the vapor compression refrigeration system during cooling.

2.13 REFRIGERANT CIRCUIT - HEATING AND DEFROSTING

Explains the refrigerant flow and operation during heating and defrost cycles.

SECTION 3 - OPERATION

3.1 DISPLAY

Describes the APX control system's LCD display interface, including its layout and key functions.

3.3 STARTING

Provides step-by-step instructions for starting the refrigeration unit, including safety warnings.

3.4 INTELLISET

Explains the IntelliSet feature for pre-selecting and managing unit settings for different products.

3.5 PRETRIP

Details the Pretrip function, a series of tests to verify unit operation before loading cargo.

3.6 CHANGING SETPOINT

Guides the user on how to adjust the temperature setpoint using the control panel keys.

3.7 START-STOP OPERATION

Explains how the Start-Stop feature reduces fuel consumption by cycling the engine based on conditions.

3.8 CONTINUOUS OPERATION

Describes the Continuous Operation mode, where the unit runs except for shutdown alarms.

3.9 DATA RECORDER

Covers the built-in DataLink data recorder, its capabilities, and data management.

3.9.3 Data Downloading

Details the process for downloading recorded data using TRU-Tech or a USB memory device.

3.10 MANUAL DEFROST

Explains how to manually initiate a defrost cycle when conditions are met.

3.12 ADVANCED USER

Describes how to access and use the Advanced User Mode for additional data and menu options.

3.13 UNIT DATA

Explains how to access and view various unit data points and system information.

3.14 VIEW ACTIVE ALARMS

Guides the user on how to view and interpret active alarms displayed on the system.

3.16 FUNCTIONAL PARAMETERS

Covers the various functional parameters that can be configured to customize unit operation.

3.18 STOPPING UNIT

Provides instructions on how to properly shut down the refrigeration unit.

SECTION 4 - ENGINE AND TEMPERATURE CONTROL

4.2 SEQUENCE OF OPERATION - ELECTRICAL

Details the electrical sequence of operations from battery connection to module communication.

4.3 ENGINE CONTROL

Explains how the engine is controlled, including start-up sequences and speed adjustments.

4.3.1 Engine Start-Up Sequence

Describes the automated process for starting the engine, including preheat and cranking.

4.4 MODES OF OPERATION

Outlines the various operating modes of the refrigeration system, such as cooling, heating, and defrost.

4.4.2 Cooling

Details the control system's operation during cooling mode, including component actions.

4.4.3 Heating

Details the control system's operation during heating mode, including component actions.

4.4.4 UltraFresh Temperature Control

Explains the UltraFresh temperature control for perishable and frozen ranges.

4.4.6 Defrost

Refers to Section 4.9 for a description of the defrost cycle operation.

4.5 TEMPERATURE CONTROL

Explains how the system determines and maintains compartment temperature.

4.5.1 Temperature Determination

Describes how temperature readings from specific sensors are used for control.

4.6 START-STOP OPERATION

Explains the Start-Stop feature for fuel efficiency and temperature control.

4.6.1 Start-Stop Configuration

Details how Start-Stop operation depends on Configuration and Functional Parameter settings.

4.6.2 Stop Parameters

Lists the five criteria that must be met for the unit to stop in Start-Stop Operation.

4.6.3 Re-Start Parameters

Outlines the conditions under which the unit will restart during an OFF cycle.

4.7 CONTINUOUS OPERATION

Describes Continuous Operation, typically used for fresh produce, where the unit runs except for shutdown alarms.

4.9 DEFROST

Explains the defrost cycle, its initiation, and operation.

4.9.1 Defrost Initiation And Start

Covers how defrost can be started manually or automatically based on conditions.

4.10 USER SELECTED OVERRIDE OPERATION

Details four optional software override programs for enhanced operation and product protection.

4.10.1 FreshProtectTM Supply Air Control

Explains the FreshProtect feature for flexible supply air temperature limits.

4.10.2 Temperature Range Lock 1 & 2

Describes how to lock the unit into Start-Stop or Continuous Operation based on setpoint ranges.

4.10.3 ProductShield

Details ProductShield configurations for improved operating efficiency and product protection.

4.11 PREPROGRAMMED SOFTWARE OVERRIDES

Lists and explains various software overrides that can alter unit operation.

4.11.1 Cargo Protect Mode

Explains Cargo Protect Mode activation when return and supply air sensors are simultaneously inactive.

4.11.2 Engine Speed Overrides

Explains engine speed override parameters based on various conditions.

4.11.3 Unloader Control Overrides

Lists factors that determine unloader operation in addition to temperature control.

4.11.4 CSMV Control Overrides

Details CSMV control overrides based on engine parameters and system pressures.

SECTION 5 - CONTROL SYSTEM INTERFACE

5.1 INTERFACE METHODS

Outlines the four methods for interacting with the APX control system.

5.2 TECHNICIAN MODE

Describes Technician Mode access for viewing alarms, hour meters, configurations, and performing tests.

5.2.1 Technician Hour Meters

Explains how to view additional hour meters available in Technician Mode.

5.2.2 Inactive Alarms

Details the two sections of the Alarm list (active and inactive) and how alarms are managed.

5.2.3 Configuration Settings

Explains how configuration settings match the system to the unit and define operational actions.

5.2.4 Component Test Mode

Describes Component Test Mode for energizing individual circuits for testing.

5.2.5 Service Mode

Explains when Service Mode must be used, such as for refrigerant removal or leak checking.

5.3 USB MEMORY DEVICES

Provides instructions for using USB memory devices for data transfer, software installation, and configuration.

5.3.1 Data Transfer USB Memory Device

Details the creation and use of a USB device for transferring data and software.

5.3.2 PC Mode

Explains PC Mode for accessing the system without the engine running for demonstrations and changes.

5.3.3 Downloading Data Files

Guides the user on downloading data from the DataLink recorder to a USB device.

5.3.4 Installing Software

Provides instructions for installing software from a USB memory device into the control system.

5.3.5 Transferring Configuration Files

Details how to install configuration files from a USB device into the control system.

5.4 TRU-TECH & TRU-VIEW

Covers the TRU-Tech & TRU-View software for accessing and downloading data.

5.4.1 TRU-Tech

Explains the functions of the TRU-Tech program for monitoring, recording, and editing system data.

5.4.2 TRU-View

Describes the TRU-View program's capabilities for reading and analyzing system data with customized reports.

5.4.3 Connecting Computer and Control System

Provides instructions for connecting a computer to the control system using a USB service cable.

5.5 MAIN MICROPROCESSOR REPLACEMENT

Covers the procedure for replacing the main microprocessor module, including necessary data and software.

5.5.1 Pre-Replacement Steps

Outlines essential unit-specific and time-sensitive data that must be known before microprocessor replacement.

5.5.2 Main Microprocessor Replacement

Details the physical process of replacing the main microprocessor module.

5.5.3 Main Microprocessor Setup

Explains the configuration steps required after installing a replacement microprocessor.

5.5.7 System Final Checkout

Details the final checks and Pretrip test after servicing to ensure proper unit operation.

SECTION 7 - ALARM TROUBLESHOOTING

7.1 INTRODUCTION

Provides guidance for troubleshooting alarms and reviewing active and inactive alarm lists.

7.3 ALARMS

Lists and describes various unit alarms, including activation conditions, unit control, and reset.

Engine Alarms

Lists and details troubleshooting steps for engine-related alarms.

Refrigeration;Temperature Control Alarms

Covers troubleshooting for refrigeration system and temperature control related alarms.

Electrical System Component Alarms

Details troubleshooting for alarms related to electrical components and communication.

Other Alarms

Covers alarms related to datalogger, door status, sensor inputs, and communication errors.

SECTION 8 - SERVICE

8.1 SECTION LAYOUT

Provides an overview of the Service section's presentation of procedures.

8.2 SCHEDULED MAINTENANCE

Outlines regular maintenance requirements for optimal unit operation and longevity.

8.3 PRE-TRIP INSPECTION

Details the pre-trip inspection procedures to be performed before each trip and at maintenance intervals.

8.4 EXTERNAL SURFACE SERVICE

Covers procedures for servicing external components like fresh air exchange, grille, and doors.

8.4.2 Grille Insert Removal

Details the process for removing the grille insert for access and service.

8.4.4 Door Latch Maintenance and Replacement

Explains how to maintain and replace door latch assemblies for smooth operation.

8.5 ENGINE AND ENGINE RELATED SYSTEMS SERVICE

Covers servicing procedures for the engine, fuel system, cooling system, and air cleaner.

8.5.1 Fuel System

Describes the components of the fuel system and its two configurations.

8.5.2 Priming the Fuel System

Provides step-by-step instructions for priming the fuel system, especially after running dry.

8.5.5 Spin-On Fuel Filter Replacement

Details the procedure for replacing the spin-on fuel filter element.

8.5.6 Suction Side Fuel Filter Replacement

Explains how to replace the suction side fuel filter.

8.5.9 Engine Oil And Oil Filter

Covers the procedures for checking and changing engine oil and the oil filter.

8.5.10 Air Cleaner

Details the inspection and maintenance of the air cleaner for engine performance.

8.5.14 Cooling System

Outlines procedures for cleaning and flushing the cooling system and refilling coolant.

8.5.15 Water Pump;Alternator Belt

Covers the inspection, replacement, and tensioning of the water pump/alternator belt.

8.6 POWER TRAIN SERVICE

Provides service instructions for the power train system, including belts, gearbox, and fanshaft.

8.6.1 Lower Belt

Details the procedure for removing and reinstalling the lower belt.

8.6.2 Upper Belt Replacement

Explains how to remove and reinstall the upper belt.

8.6.4 Clutch

Provides instructions for removing and reinstalling the clutch assembly.

8.6.5 Evaporator Fan

Details the procedure for removing and reinstalling the evaporator fan.

8.7 REFRIGERANT SYSTEM SERVICE

Covers procedures for servicing the refrigerant system, including charge, leak checking, and evacuation.

8.7.2 Servicing the Refrigerant Charge

Details methods for checking, removing, and adding refrigerant charge to the system.

8.7.3 Leak Checking

Explains procedures for leak checking the refrigerant system under various conditions.

8.7.4 Evacuation and Dehydration

Outlines the process for evacuating and dehydrating the refrigeration system to remove moisture.

8.8 COMPRESSOR AND UNLOADER SERVICE

Provides procedures for servicing the compressor and its unloaders.

8.8.1 Repair or Replacement Determination

Guides on checking conditions to determine if compressor repair or replacement is necessary.

8.8.2 Removal and Replacement of Compressor

Details the step-by-step process for removing and replacing the compressor.

8.8.3 Cylinder Head and Valve Plate Service

Covers the service procedures for the compressor's cylinder head and valve plate components.

8.8.4 Oil Pump and Bearing Head

Explains the service procedures for the compressor's oil pump and bearing head assembly.

8.8.5 Compressor Oil Level

Details how to check and add oil to the compressor while it is installed in the system.

8.8.6 Unloaders

Provides procedures for checking unloader operation and replacing unloader coils.

8.9 REFRIGERANT SYSTEM COMPONENT SERVICE

Covers service for individual refrigerant system parts.

8.9.1 Evaporator Coil

Explains how to clean the evaporator coil to maintain airflow and unit capacity.

8.9.2 Condenser Coil

Details cleaning procedures for the condenser coil and replacement of the assembly.

8.9.3 Filter-Drier

Covers checking the filter-drier for restriction and replacement procedures.

8.9.5 Condenser Pressure Control Solenoid Valve (SV1)

Provides checkout procedures for SV1 and steps for replacing its coil or internal components.

8.9.6 Liquid Line (SV2);Hot Gas (SV4) Solenoid Valves

Details procedures for replacing the coil or internal components of SV2 and SV4 solenoid valves.

8.9.8 Compressor Suction Modulation Valve (CSMV)

Explains the CSMV's purpose and provides diagnostic steps for malfunction.

8.9.9 Evaporator Expansion Valve (EVXV)

Details diagnostics and replacement procedures for the EVXV, noting it rarely requires maintenance.

8.9.11 High Pressure Switch

Covers replacement and checking procedures for the high pressure switch.

8.9.12 Pressure Transducers

Explains how to test transducer wiring and provides comparison notes for Unit Data readings.

8.9.13 Defrost Air Switch

Details testing procedures for the defrost air switch using a magnehelic gauge and ohmmeter.

8.10 ELECTRICAL SYSTEM COMPONENTS

Covers servicing procedures for key electrical system components.

8.10.1 Main Microprocessor Module (MM)

Refers to Section 5.5.2 for complete replacement instructions for the main microprocessor.

8.10.2 Power Control Module (PCM)

Provides instructions for disconnecting power leads and removing/replacing the Power Control Module.

8.10.4 Display Module (DM)

Covers the procedure for servicing the display module, including replacement and software compatibility.

8.10.5 Alternator

Provides a caution regarding battery polarity and instructions for inspection and brush replacement.

8.10.7 Sensor Checkout

Explains how to check sensor resistance values using an ohmmeter and test equipment.

SECTION 9 - UNIT TROUBLESHOOTING

9.1 ENGINE

Provides troubleshooting guidance for various engine indications and troubles.

9.1.1 Engine Will Not Start

Lists possible causes and actions for an engine that will not crank or start.

9.1.4 Starter Motor Malfunction

Covers troubleshooting for starter motor issues, including cranking problems and engagement failures.

9.3 REFRIGERATION; TEMPERATURE CONTROL

Addresses troubleshooting for various refrigeration and temperature control problems.

9.3.1 Unit Will Not Cool

Lists possible causes and actions when the unit fails to cool.

9.3.8 Defrost Cycle Malfunction

Covers issues related to the defrost cycle not initiating, manually initiating, or not terminating.

SECTION 10 - WIRING

10.1 HARNESS CONNECTOR WIRING

Illustrates and lists component-to-terminal assignments for PCM, 1MM, 2MM, and 3MM connectors.

10.2 SPLICE POINTS

Lists splice point numbers and their corresponding component connections for wiring analysis.

10.3 WIRING SCHEMATIC

Refers to the subsequent page for the complete wiring schematic of the unit's electrical system.

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