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General| Cylinders | 4 |
|---|---|
| Fuel | Diesel |
| Cooling System | Liquid cooled |
| Starter | Electric |
| Battery | 12V |
| Displacement | 2.2 L |
| Engine Type | 4-cycle |
General safety guidelines for operating and servicing the unit, including eye protection and avoiding hazards.
Precautions for handling refrigerants, including first aid for exposure.
Guidelines for avoiding contact with refrigerant oil and first aid for eye contact.
Details on the TK 486 engine, including model, cylinders, firing order, fuel, and oil.
Specifications for alternator and fan belt tensions, measured using a specific gauge.
Details on the S391 compressor, refrigerant type, oil charge, and system settings.
Information on voltage, battery, fuses, alternator, and voltage regulator settings.
Current draw and resistance values for various electrical components like solenoids and heaters.
Features and settings for the microprocessor-based temperature controller, including defrost timers.
List of standard and optional features of the SB-400 unit, highlighting key components and systems.
Identification of where to find unit, engine, and compressor serial numbers for service and parts.
Visual identification of the SB-400 unit through front view images.
Pretrip test requirement for the microprocessor system.
Routine checks and services for the engine based on operating hours or time intervals.
Inspection points for the unit's electrical components, wiring, and connections.
Scheduled checks for refrigerant level, compressor oil, and system efficiency.
Inspection points for unit structure, coils, drains, and mounting hardware.
Overview of the SB-400 as a self-contained diesel refrigeration unit with hot gas defrost.
Details on the microprocessor control system, its functions, and features like CYCLE-SENTRY.
Explanation of the CYCLE-SENTRY system for fuel saving and optimized operation based on demand.
Functionality of data logging and the Data Acquisition System for recording unit events and temperatures.
Description of the Tracker system's interface with satellite communication for data transmission.
Role of the ETV in controlling refrigerant flow and managing suction pressure.
Characteristics of the S391 screw compressor, including its loading valves and lack of oil pump.
Key features of the S391 screw compressor refrigeration system, such as no accumulator and economizer system.
Step-by-step process when the unit is turned on, including self-check and ETV testing.
Explanation of various operating modes like High Speed Cool, Low Speed Cool, and Defrost.
Refrigeration system diagram illustrating high and low speed cooling cycles.
How the unit operates in modulated cool mode, adjusting capacity with loading valves.
Refrigeration system diagram illustrating modulated cool with LV1 open.
Description of the Running Null mode where the engine runs but refrigeration is off.
Refrigeration system diagram illustrating the Running Null operational state.
Explanation of the low speed heat cycle, including refrigerant flow and component status.
Refrigeration system diagram illustrating the low speed heat operational state.
Details on high speed heat operation and the defrost cycle initiation and termination.
Explanation of bucking heat and defrost modes used during unit start-up in cold conditions.
Procedure for unit startup when high box temperatures are detected, affecting compressor operation.
Details on the CTMP sensor, its function in monitoring compressor temperature, and associated alarm codes.
Microprocessor's use of auxiliary modes for protection, controlling discharge pressure, CTMP, compression ratio, and suction pressure.
Description of specific alarm codes for the SB-400 unit, including conditions and results.
Introduction to the control panel layout, identifying key components like the display, keypad, and switches.
Instructions for using the On/Off switch to power the unit and its implications for starting.
Functionality of the On/Off/Sleep switch for unit control and entering sleep mode.
Explanation of icons displayed on the unit and the function of each key on the keypad.
Information on connecting external devices like computers and printers for data logging and reporting.
Description of unit indicators like sight glasses and status lights, plus fuse link protection.
Essential checks to perform before starting the unit and loading cargo, covering fuel, oil, coolant, belts, and electrical connections.
Procedure for performing a complete unit checkout using the electronic full pretrip test before operation.
Guidance on selecting between CYCLE-SENTRY and Continuous Run modes based on commodity requirements.
Steps for restarting units that have been shut off for short or extended periods.
Quick checks to confirm unit operation after starting, including oil pressure, ammeter, and refrigerant charge.
Steps for loading cargo, including unit preparation and post-load defrost cycle initiation.
Routine checks to perform on the unit after a trip, focusing on cleanliness and physical condition.
Diagnostic procedures for the Australian Bosch alternator and charging system, including voltage regulator precautions.
Procedure for testing alternator field windings, brushes, and slip rings to diagnose output issues.
Maintenance checks for the unit's battery terminals and wiring harnesses to ensure proper electrical function.
Identification and function of fuses and the fuse link for protecting electrical circuits.
Description of the air heater's role in cold weather starting and its operational checks.
Reference to the diagnostic manual for detailed information on the microprocessor controller.
Overview of the EMI 3000 package, its components, and extended maintenance intervals.
Description of the TK 486 engine's pressure lubrication system.
Procedures for changing engine oil and filter, including oil type and capacity specifications.
Factors affecting low oil pressure and diagnostic approaches, referencing a flow chart.
Diagnostic flowchart to troubleshoot and identify causes of low engine oil pressure.
Explanation of the pressurized cooling system, its components, and how it maintains engine temperature.
Information on Extended Life Coolant, its approved types, and usage guidelines.
Procedures for checking and changing antifreeze, including mixing ratios and compatibility warnings.
Steps to remove trapped air from the engine block to ensure proper cooling system function.
Specification for the engine thermostat and its impact on operating modes.
Components and operation of the TK 486 engine's direct injection fuel system.
Maintenance tasks for the fuel system, including cleaning filters and ensuring fuel quality.
Diagram illustrating the components of the engine fuel system, including pumps and filters.
Procedure for removing air from the fuel system, crucial after fuel depletion or repairs.
Steps to drain accumulated water from the fuel tank to prevent system damage.
Procedure for replacing the fuel filter/water separator to maintain fuel cleanliness.
Procedures for adjusting high and low engine speeds to maintain correct operating RPM.
Detailed procedure for setting the injection pump timing, critical for engine performance.
Steps for removing and reinstalling the injection pump, including necessary tools and procedures.
Instructions on using specialized tools for the removal and reinstallation of the injection pump gear.
Procedures for testing the fuel solenoid's pull-in and hold-in coils and its role in engine start.
Steps for replacing the fuel solenoid, including proper installation and testing.
Procedure for checking and adjusting valve clearance on the TK 486 engine for optimal performance.
Description of the crankcase breather's function and maintenance checks to prevent condensation issues.
Guidelines for replacing the EMI 3000 air cleaner element and checking the air restriction indicator.
Procedures for inspecting belts for wear and adjusting their tension using a belt tension gauge.
Specific steps for adjusting the alternator belt tension to the correct specification.
Procedures for adjusting upper and lower fan belt tensions, noting they are adjusted simultaneously.
Detailed instructions for removing and installing lower and upper fan belts, emphasizing proper adjustment.
How to connect gauges and monitor suction pressures, including information on expansion valves and ETV.
Procedures for testing refrigerant charge in empty and loaded trailers and identifying overcharge symptoms.
How to interpret the sight glass color to determine refrigerant moisture content.
Methods for leak testing the refrigeration system, focusing on oil leakage as an indicator.
Procedure for checking the compressor shaft seal for refrigerant leaks, emphasizing the use of a leak detector.
How to check compressor oil level while the unit is running, noting acceptable oil loss.
Steps for adding compressor oil, including isolating the compressor and proper oil handling.
A chart showing expected oil levels in the compressor based on box and ambient temperatures.
Steps to pump down the compressor to isolate it for service, including precautions for vacuum operation.
Procedure for pumping down the low side of the refrigeration system to isolate components for service.
Test procedure for the HPCI switch, which backs up the discharge pressure transducer for compressor protection.
Test procedure for the HPCO switch, which shuts down the unit if discharge pressure becomes too high.
Explanation of the three-way valve's bypass check valve and its function in heat-to-cool shifting.
Procedure to check the operation of the condenser pressure bypass check valve.
Description of the ETV's function, testing, and the meaning of gauge readings like ETV.P.
Procedures for testing LV1 and LV2 loading valves to ensure proper capacity control.
Test procedure for the Liquid Line Solenoid (LLSV) to verify its operation in controlling refrigerant flow.
Test procedure for the Liquid Injection Valve (LIV) to check its function in controlling compressor temperature.
Procedure for testing the water valve (EWSV) to ensure proper coolant flow during heat and defrost cycles.
Procedures for repairing and replacing the heat check valve, which prevents refrigerant backflow.
Symptoms of compressor failure and a procedure to test the compressor's performance and capacity.
A flowchart to guide the diagnosis of compressor issues, starting from initial checks.
Steps for removing and installing the compressor, including oil level checks and system evacuation.
Instructions for removing and installing the compressor coupling, emphasizing the use of specific tools.
Further details on installing the compressor coupling, focusing on taper fit and key alignment.
Torque specifications and corrosion protection measures for compressor coupling installation.
General procedures for cleaning the refrigeration system after compressor failure, based on oil condition.
Steps for cleaning the system using internal oil filter replacement when compressor oil is fairly clear.
Procedure for using the clean-up kit for systems with contaminated oil, including component replacement.
Instructions for replacing the in-line condenser check valve, noting its non-repairable nature and soldering precautions.
Procedures for removing and installing the discharge vibrasorber, including heat sink precautions.
Steps for removing and installing the receiver tank, including handling the high pressure relief valve.
Procedures for removing and installing the filter drier, including purging and leak testing.
Steps for removing and installing the evaporator expansion valve, identifying it by part numbers and its role.
Procedure for checking and adjusting superheat for the evaporator expansion valve, crucial for cooling performance.
Steps for removing the evaporator coil assembly, including disconnecting sensors and panels.
Steps for installing the evaporator coil, ensuring proper alignment and soldering.
Detailed instructions for repairing the three-way valve, including disassembly and inspection of parts.
Procedures for checking end caps and bleed hole diameters of the three-way valve for proper function.
Checks for the piston bleed orifice and seat orifice in the three-way valve to ensure correct flow.
Steps for assembling and installing the three-way valve after cleaning and inspection.
Procedure for repairing the bypass check valve within the three-way valve assembly.
Steps for removing and installing the pilot solenoid, essential for controlling the three-way valve.
Procedures for removing and installing suction vibrasorbers to dampen pulsations.
Procedures for removing and installing high pressure cutout and cut-in switches for system protection.
Steps for removing and installing the high pressure relief valve to protect the system from overpressure.
Procedures for removing and installing the liquid line solenoid valve, crucial for refrigerant flow control.
Steps for removing and installing the subcooler/condenser/radiator assembly, including coolant and refrigerant line disconnections.
Procedures for removing and installing the discharge pressure transducer for system monitoring.
Procedures for removing and installing the suction pressure transducer for system monitoring.
Steps for removing the ETV assembly, including precautions for trapped refrigerant.
Procedures for installing a new ETV assembly or service kit, ensuring proper alignment and connections.
Steps for removing and installing the economizer heat exchanger, involving coolant and refrigerant lines.
Procedure for removing the economizer expansion valve, noting its identification and isolation steps.
Steps for installing the economizer expansion valve, ensuring proper connections and alignment.
Procedure for checking and adjusting superheat for the economizer expansion valve, crucial for system efficiency.
Disassembly and reassembly procedures for repairing the heat check valve.
Steps for removing and replacing the heat check valve, including soldering precautions.
Procedures for removing and installing the liquid injection valve, including checking the inlet screen.
Instructions for checking and tightening unit and engine mounting bolts to specified torque values.
Pre-trip and scheduled inspection points for physical damage, loose wires, or oil leaks.
Procedures for cleaning condenser, evaporator, and radiator coils to ensure proper airflow.
Importance of keeping defrost drain lines open during scheduled maintenance.
Notes on accessibility and types of nuts used for unit mounting to the trailer.
Procedure for adjusting the defrost damper to ensure proper airflow control.
Guidelines for mounting condenser and evaporator fans, ensuring proper alignment for airflow.
Steps for installing and aligning the condenser fan blower, including torque specifications.
Procedures for centering and installing the evaporator fan blower wheel and housing.
Description of the fan shaft assembly, its sealed oil reservoir, and maintenance requirements.
Steps for disassembling the fan shaft assembly, including draining oil and removing components.
Instructions for reassembling the fan shaft assembly, including bearing installation and end-play measurement.
Description of the idler assembly, its sealed oil reservoir, and inspection points.
Steps for disassembling the idler assembly, including oil draining and seal removal.
Procedures for reassembling the idler assembly, focusing on bearing installation and oil filling.
Troubleshooting common causes for engine not cranking, not starting after cranking, or stopping after starting.
Diagnosis for issues like low power, excessive speed, failure to stop, and engine knocking.
Troubleshooting for engine overheating, low oil pressure, and high oil consumption.
Identifying causes of excessive white, black, or blue smoke emitted by the engine.
A systematic approach to diagnosing refrigeration system problems, including checking alarms and pressures.
Charts correlating symptoms with possible causes for refrigeration system issues, used with diagnostic procedures.
A visual representation of the refrigerant flow during high and low speed cool operation.
A diagram illustrating the refrigerant flow in modulated cool mode with LV1 open.
A diagram showing the refrigerant flow during the Running Null operational mode.
A diagram illustrating the refrigerant flow during defrost and heat cycles.
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