Thermo King TK 5984 - Fuel Solenoid Diagnostic and Replacement

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Engine Maintenance

Fuel Solenoid Diagnostic and

Replacement

See the Interface Board diagnostic procedures in

the Microprocessor Controller Diagnosis Manual.

BELT TENSIONS

Correct belt tension is critical for proper unit

operation. Belts that are too loose will slip, squeal

or whip causing excessive vibration levels and

poor unit performance. Belts that are too tight will

cause excess vibration along with premature belt

and bearing failures.

NOTE: DO NOT attempt to remove or install

belts without adjustments. Belts that are installed

by prying will fail prematurely due to internal

cord damage.

1. Throttle Lever 6. Eye Bolt

2. Fuel Solenoid 7. Boot

3. Low Speed Adjustment Screw 8. Throttle Solenoid

4. Rod 9. Ball Joint

5. Clip

Figure 40: Integral Fuel Solenoid Components

Main Page

Table of Contents5
List of Figures9
Safety Precautions11
General Practices11
Auto Start/Stop11
Refrigerant11
First Aid11
Refrigeration Oil12
First Aid12
Electrical Hazards12
Microprocessor Service12
Welding of Units or Truck Bodies13
High Voltage13
Low Voltage14
Specifications15
Maintenance Inspection Schedule19
Unit Description21
General Description21
Unit Instruments22
Unit Protection Devices23
Unit Operation24
Pre-Trip Inspection (before Starting Unit)24
Starting Unit (Full Unit Self Check)24
Selection of Operating Modes on CYCLE-SENTRY Equipped Units25
Products Requiring Continuous Run Operation for Air Flow25
Products Acceptable for CYCLE-SENTRY Operation25
Continuous Run Operation25
Auto Start-Stop Operation25
Restarting the Unit26
After Start Inspection26
Loading Procedure27
Post Load Procedure27
Post Trip Checks27
Unit Photographs28
Figure 1: Front Curbside View-MD-20028
Figure 2: Front Roadside View-MD-20028
Figure 3: X214 Compressor29
Figure 4: X214 Compressor30
Figure 5: Access Panel Open (Curbside)-MD-20031
Figure 6: Rear View (Curbside)-MD-20031
Figure 7: Side View (Roadside)32
Figure 8: Top View33
Figure 9: Control Box34
Figure 10: Power Receptacle Box-MD-200 5035
Figure 11: THERMOGUARD Remote Control Panel36
Μp-T System Description37
General Description37
Μp-T Control System37
Microprocessor Power Switch37
Optional Electric Standby (Model 50 Units Only)37
Figure 12: Microprocessor Power Switch37
Standard Model 50 Features38
Optional Model 50 Features38
Figure 13: High Voltage Tray no Options38
Figure 14: High Voltage Tray with Phase Correction38
Figure 15: High Voltage Tray with Electric Heat39
Figure 16: High Voltage Tray with Phase Correction and Electric Heat39
Figure 17: High Voltage Tray with Single Phase Power and Electric Heater39
Remote Control Panel Features41
Keypad Keys41
Understanding the Display41
Display Icons42
Reading a Typical Display42
The Standard Display43
Changing the Setpoint43
Selecting CYCLE-SENTRY or Continuous Mode44
Starting the Engine44
Initiating a Manual Defrost Cycle45
Checking the Software Revision45
Viewing Prompt and Display Screens46
Viewing and Clearing Alarm Codes47
Remote Control Panel Features (Continued)47
To View Alarm Codes47
To Clear Alarm Codes47
Μp-T Alarms47
Μp-T Unit Self Check Test50
Electrical Maintenance51
Alternator (Prestolite) Charging System Diagnostic Procedures51
Figure 18: Prestolite Terminal Locations51
Excessive Voltage Output52
Battery52
Unit Wiring53
Electrical Contacts53
Charging System (12 VDC)53
Preheat Buzzer53
RPM Sensor53
Figure 19: Flywheel (RPM) Sensor53
Figure 20: RPM+ and RPM- Wires53
Glow Plugs54
Defrost Air Switch Checkout and Adjustment54
Figure 21: Glow Plug Test54
Figure 22: Testing Air Switch55
Figure 23: Air Switch55
High Capacity Thermax56
TM Heating System56
Cool Mode56
Heat/Condenser Evacuation Mode56
Defrost Mode56
Start up Mode56
Units Equipped with a Three-Phase Electric Motor and a Phase Converter that Operates on Single-Phase Power57
Conversion System57
Start System57
Figure 24: First and Second-Phase Connections58
Figure 25: Motor Start Contactor Control Coil Circuit59
Run System60
Figure 26: Third Phase Connection During a Start60
Figure 27: Third Phase Connection During a Start61
Troubleshooting the Phase Conversion System62
Troubleshooting Chart64
Engine Maintenance69
Emi 200069
Engine Lubrication System69
Engine Oil Pressure Switch69
Figure 28: Engine Oil Pressure Switch69
Engine Oil Change70
Oil Filter Change70
Crankcase Vent70
Engine Air Cleaner (EMI 2000)70
Figure 29: Oil Filter Parts70
Figure 30: Dry Type Air Cleaner70
Engine Cooling System71
General Description71
Figure 31: Engine Cooling Components71
ELC (Extended Life Coolant)72
Figure 32: ELC Nameplate-Located on Expansion Tank72
Antifreeze Maintenance Procedure73
Checking the Antifreeze73
Engine Thermostat74
Engine Fuel System74
Figure 33: Water Pump Assembly and Thermostat74
Bleeding the Fuel System75
Figure 34: Fuel and Oil System Components76
Figure 35: Fuel and Oil System Components for Figure 12277
Draining Water from Fuel Tank78
Fuel Filter Replacement78
Electric Fuel Pump78
Figure 36: Electric Fuel Pump78
Injection Pump79
Figure 37: Timing Marks80
Figure 38: Individual Cylinder Timing and Firing Order81
Adjust Engine Valve Clearance82
Fuel Limit Screw82
Integral Fuel Solenoid82
Figure 39: Emission Control Label82
Fuel Solenoid Diagnostic and Replacement83
Belt Tensions83
Figure 40: Integral Fuel Solenoid Components83
Auto Start/Stop84
Figure 41: MD-II SR Belt Arrangement84
Figure 42: Idler Assembly85
Figure 43: New Idler Assembly86
Figure 44: Belt Layout87
Figure 45: Alternator Mounting and Belt Tension Screws88
Engine Speed Adjustments89
Low Speed Adjustment89
High Speed Adjustment89
Refrigeration Maintenance91
Evacuation91
Figure 46: Evacuation Station92
Figure 47: Vacuum Gauge93
Set up and Test of Evacuation Equipment94
Figure 48: Leak94
Figure 49: Moisture94
Unit Evacuation95
Refrigerant Leaks95
Unit Charging95
Figure 50: Unit Charging97
Refrigerant Charge98
Testing the Refrigerant Charge with an Empty Box98
Testing the Refrigerant Charge with a Loaded Box98
Checking Compressor Oil98
High Pressure Cutout (HPCO)99
Figure 51: X214 Compressor99
Figure 52: High Pressure Cutout Manifold99
Compressor Pump down and Checkout100
Low Side Pump down100
Figure 53: Install Gauge Manifold100
Figure 54: Compound Gauge Indicating 20 In. Vacuum100
Three-Way Valve Condenser Pressure Bypass Check Valve101
Figure 55: Three-Way Valve Condenser Pressure Bypass Check Valve101
Refrigeration Service Operations103
Accumulator103
Removal103
Installation103
Compressor103
Condenser/Radiator Coil103
Installation104
Liquid Line Check Valve Replacement104
Removal104
Dehydrator (Filter-Drier)104
Evaporator Coil104
Expansion Valve Assembly105
Removal105
Installation105
Cleaning In-Line Screen105
Figure 56: Location of Expansion Valve Bulb105
Figure 57: Completely Wrap Bulb with Tape105
Heat Exchanger106
Removal106
Installation106
Figure 58: Expansion Valve106
High Pressure Cutout Switch107
Removal107
Installation107
High Pressure Relief Valve107
Pilot Solenoid107
Pressure Regulator Valve107
Receiver Tank108
Removal108
Installation108
Three-Way Valve Condenser Pressure Bypass Check Valve Repair108
Refrigeration Service Operations (Continued)108
Figure 59: Condenser Pressure Bypass Check Valve108
Three-Way Valve Repair109
Removal109
Installation110
Compressor Pulley Removal and Installation110
Figure 60: Three-Way Valve Assembly110
Oil Filter Maintenance111
Figure 61: Anti-Seize Lubricant Application111
Figure 62: Compressor Oil Filter112
Equipment Recommendations for Use with R-404A113
Hilliard Clutch Maintenance115
Large Truck Unit Centrifugal Clutch Change115
Figure 63: Front View and Cross Section115
Figure 64: Hilliard Centrifugal Clutch116
Clutch Maintenance117
Tools Required117
Grease117
Disassembly Procedure117
Figure 65: Housing Removal117
Figure 66: Bearing Removal117
Assembly Procedure (Using New Bearings and Seal)118
Figure 67: Bushing Removal118
Figure 68: Bushing Insertion118
Figure 69: Clutch119
Structural Maintenance121
Unit and Engine Mounting Bolts121
Lift Points121
Unit Inspection121
Evaporator Coil121
Condenser Coil121
Defrost Damper121
Figure 70: Check Bolts for Tightness121
Figure 71: Lift Points121
Jackshaft Assembly122
Figure 72: Defrost Damper Adjustment122
Fanshaft Assembly124
Fanshaft Assembly Overhaul124
Disassembly124
Figure 73: Jackshaft Assembly124
Figure 74: Removing Bearing Retainer Bolts124
Figure 75: Removing Shaft124
Figure 76: Removing Oil Seal124
Reassembly125
Figure 77: Removing Roll Pin125
Figure 78: Installing Bearings125
Figure 79: Installing Splash Guard125
Figure 80: Installing Oil Seal125
Figure 81: Shims and O-Ring125
Figure 82: Torquing Retainer Plate Bolts126
Figure 83: Checking End Play126
Figure 84: Fan Shaft Assembly126
Mechanical Diagnosis127
Electric Standby (Optional) Diagnosis131
Refrigeration Diagnosis133
Index135
Wiring and Schematic Diagrams Index137

Thermo King TK 5984 - Fuel Solenoid Diagnostic and Replacement

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