CHAPTER 1 GENERAL INFORMATION, EQUIPMENT DESCRIPTION, AND THEORY OF OPERATION FOR MULTI-TEMPERATURE REFRIGERATED CONTAINER SYSTEM (MTRCS)
MULTI-TEMPERATURE REFRIGERATED CONTAINER SYSTEM (MTRCS) GENERAL INFORMATION
Figure 1. MTRCS.
MAINTENANCE FORMS, RECORDS, AND REPORTS
NOMENCLATURE CROSS-REFERENCE LIST
NOMENCLATURE CROSS-REFERENCE LIST CONTINUED
NOMENCLATURE CROSS-REFERENCE LIST CONTINUED
NOMENCLATURE CROSS-REFERENCE LIST CONTINUED
NOMENCLATURE CROSS-REFERENCE LIST CONTINUED
NOMENCLATURE CROSS-REFERENCE LIST CONTINUED
LIST OF ACRONYMS/ABBREVIATIONS
LIST OF ACRONYMS/ABBREVIATIONS CONTINUED
LIST OF ACRONYMS/ABBREVIATIONS CONTINUED
LIST OF ACRONYMS/ABBREVIATIONS CONTINUED
QUALITY OF MATERIAL
Table 1. Location and Description of MTRCS Front View Components.
Table 1. Location and Description of MTRCS Front View Components Continued.
Figure 1. MTRCS Front View (Sheet 2 of 2).
Table 2. Location and Description of MTRCS Rear View Components.
Table 3. Location and Description of MTRCS Right Side View Components.
Table 4. Location and Description of MTRCS Left Side View Components.
Table 5. Location and Description of MTRCS Interior Left Wall Components.
Table 6. Location and Description of MTRCS Interior Right Wall Components.
Table 7. MTRCS System Specifications.
Table 7. MTRCS System Specifications Continued.
MULTI-TEMPERATURE REFRIGERATED CONTAINER SYSTEM (MTRCS) THEORY OF OPERATION
INSULATED CONTAINER
Emergency Escape Hatches
Table 1. Power Box Assembly Configuration for External Power.
Figure 3. Control Box.
Figure 4. Microprocessor Controller Display.
Figure 5. Evaporators.
Figure 6. CPR Valve.
Figure 7. Accumulator.
Figure 8. Compressor Unloader.
DIESEL ENGINE
Figure 10. Water Temperature Sensor.
Figure 11. Cooling System.
Figure 12. Engine Air Cleaner.
Figure 14. Fuel Filter.
ELECTRICAL DESIGN, CABLES, LIGHTING, ALARM, TEMPERATURE CONTROL, AND RECORDING
CHAPTER 2 TROUBLESHOOTING PROCEDURES FOR MULTI-TEMPERATURE REFRIGERATED CONTAINER SYSTEM (MTRCS)
Table 1. Crew Troubleshooting Malfunction/Symptom Index.
Figure 1. Relay Pin Out and Schematic.
Table 2. Maintainer Maintenance Troubleshooting Malfunction/Symptom Index.
Table 3. Sensor Voltage Chart for Suction Pressure Transducer.
Table 4. Sensor Resistance Chart for Air Temperature, Return Air, Supply Air, and Water Temperature Sensor - Continued
Initial Setup
Table 1. Microprocessor Control Box Component Identification for Model MTRCS01.
Table 1. Microprocessor Control Box Component Identification for Model MTRCS01 Continued.
Figure 1. Microprocessor Control Box Back Wall and Bottom (Model MTRCS01).
Figure 2. Microprocessor Control Box Door and Forward Wall (Model MTRCS01).
Figure 3. Microprocessor Control Box Aft Wall (Model MTRCS01).
Table 2. Microprocessor Control Box Component Identification for Model MTRCS02.
Figure 3.1. Microprocessor Control Box Back Wall and Bottom (Model MTRCS02).
Figure 3.2. Microprocessor Control Box Door (Model MTRCS02).
Figure 4. Engine Will Not Start.
Figure 5. Fault AL8 (STARTER) (Sheet 1 of 2).
Figure 5. Fault AL8 (STARTER) (Sheet 2 of 2).
Figure 6. Fault AL0 (ENG OIL) (Sheet 1 of 2).
Figure 6. Fault AL0 (ENG OIL) (Sheet 2 of 2).
Figure 7. Fault AL1 (ENG HOT) (Sheet 1 of 6).
Figure 7. Fault AL1 (ENG HOT) (Sheet 2 of 6).
Figure 7. Fault AL1 (ENG HOT) (Sheet 3 of 6).
Figure 7. Fault AL1 (ENG HOT) (Sheet 4 of 6).
Figure 7. Fault AL1 (ENG HOT) (Sheet 5 of 6).
Figure 7. Fault AL1 (ENG HOT) (Sheet 6 of 6).
Figure 8. Fault AL2 (HI PRESS) (Sheet 1 of 3).
Figure 8. Fault AL2 (HI PRESS) (Sheet 2 of 3).
Figure 8. Fault AL2 (HI PRESS) (Sheet 3 of 3).
Figure 9. Fault AL3 (STARTFAIL) (Sheet 1 of 6).
Figure 9. Fault AL3 (STARTFAIL) (Sheet 2 of 6).
Figure 9. Fault AL3 (STARTFAIL) (Sheet 3 of 6).
Figure 9. Fault AL3 (STARTFAIL) (Sheet 4 of 6).
Figure 9. Fault AL3 (STARTFAIL) (Sheet 5 of 6).
Figure 9. Fault AL3 (STARTFAIL) (Sheet 6 of 6).
SERVICE AND FIELD MAINTENANCE REFRIGERATION UNIT TROUBLESHOOTING PROCEDURES (FAULT CODES AL4 AL7, AL9 AL15)
Figure 1. Fault AL4 (LOW BATT).
Figure 2. Fault AL5 (HIGH BATT).
Figure 3. Fault AL6 (DEFRFAIL).
Figure 4. Fault AL7 (ALT AUX).
Figure 5. Fault AL9 (1RA SENSOR).
Figure 6. Fault AL10 (2RA SENSOR).
Figure 7. Fault AL11 (WT SENSOR).
Figure 8. Fault AL12 (HIGH CDT) (Sheet 1 of 4).
Figure 8. Fault AL12 (HIGH CDT) (Sheet 2 of 4).
Figure 8. Fault AL12 (HIGH CDT) (Sheet 3 of 4).
Figure 8. Fault AL12 (HIGH CDT) (Sheet 4 of 4).
Figure 9. Fault AL13 (CD SENSOR).
Figure 10. Fault AL14 (SBY MOTOR) (Sheet 1 of 2).
Figure 10. Fault AL14 (SBY MOTOR) (Sheet 2 of 2).
Figure 11. Fault AL15 (FUSE BAD).
Figure 12. Fault AL15 (FUSE BAD) F4 (Sheet 1 of 2).
Figure 12. Fault AL15 (FUSE BAD) F4 (Sheet 2 of 2).
Figure 13. Fault AL15 (FUSE BAD) F5.
Figure 14. Fault AL15 (FUSE BAD) F7 (Sheet 1 of 4).
Figure 14. Fault AL15 (FUSE BAD) F7 (Sheet 2 of 4).
Figure 14. Fault AL15 (FUSE BAD) F7 (Sheet 3 of 4).
Figure 14. Fault AL15 (FUSE BAD) F7 (Sheet 4 of 4).
Figure 15. Fault AL15 (FUSE BAD) F8 (Sheet 1 of 4).
Figure 15. Fault AL15 (FUSE BAD) F8 (Sheet 2 of 4).
Figure 15. Fault AL15 (FUSE BAD) F8 (Sheet 3 of 4).
Figure 15. Fault AL15 (FUSE BAD) F8 (Sheet 4 of 4).
SERVICE AND FIELD MAINTENANCE REFRIGERATION UNIT TROUBLESHOOTING PROCEDURES (FAULT CODES AL17 AL23)
Figure 1. Fault AL17 (DISPLAY).
Figure 2. Fault AL20 (1RA OUT) (Sheet 1 of 6).
Figure 2. Fault AL20 (1RA OUT) (Sheet 2 of 6).
Figure 2. Fault AL20 (1RA OUT) (Sheet 3 of 6).
Figure 2. Fault AL20 (1RA OUT) (Sheet 4 of 6).
Figure 2. Fault AL20 (1RA OUT) (Sheet 5 of 6).
Figure 2. Fault AL20 (1RA OUT) (Sheet 6 of 6).
Figure 3. Fault AL21 (2RA OUT) (Sheet 1 of 6).
Figure 3. Fault AL21 (2RA OUT) (Sheet 2 of 6).
Figure 3. Fault AL21 (2RA OUT) (Sheet 3 of 6).
Figure 3. Fault AL21 (2RA OUT) (Sheet 4 of 6).
Figure 3. Fault AL21 (2RA OUT) (Sheet 5 of 6).
Figure 3. Fault AL21 (2RA OUT) (Sheet 6 of 6).
Figure 4. Fault AL23 (NO POWER).
Figure 5. Refrigeration Unit Runs But Will Not Heat (Sheet 1 of 11).
Figure 5. Refrigeration Unit Runs But Will Not Heat (Sheet 2 of 11).
Figure 5. Refrigeration Unit Runs But Will Not Heat (Sheet 3 of 11).
Figure 5. Refrigeration Unit Runs But Will Not Heat (Sheet 4 of 11).
Figure 5. Refrigeration Unit Runs But Will Not Heat (Sheet 5 of 11).
Figure 5. Refrigeration Unit Runs But Will Not Heat (Sheet 6 of 11).
Figure 5. Refrigeration Unit Runs But Will Not Heat (Sheet 7 of 11).
Figure 5. Refrigeration Unit Runs But Will Not Heat (Sheet 8 of 11).
Figure 5. Refrigeration Unit Runs But Will Not Heat (Sheet 9 of 11).
Figure 5. Refrigeration Unit Runs But Will Not Heat (Sheet 10 of 11).
Figure 5. Refrigeration Unit Runs But Will Not Heat (Sheet 11 of 11).
Figure 6. No Microprocessor Display (Sheet 1 of 7).
Figure 6. No Microprocessor Display (Sheet 2 of 7).
Figure 6. No Microprocessor Display (Sheet 3 of 7).
Figure 6. No Microprocessor Display (Sheet 4 of 7).
Figure 6. No Microprocessor Display (Sheet 5 of 7).
Figure 6. No Microprocessor Display (Sheet 6 of 7).
Figure 6. No Microprocessor Display (Sheet 7 of 7).
MULTI-TEMPERATURE REFRIGERATED CONTAINER SYSTEM (MTRCS) INITIAL SETUP
Figure 1. Compartment 1 Evaporator Has No, or Limited, Airflow (Sheet 1 of 9).
Figure 1. Compartment 1 Evaporator Has No, or Limited, Airflow (Sheet 2 of 9).
Figure 1. Compartment 1 Evaporator Has No, or Limited, Airflow (Sheet 3 of 9).
Figure 1. Compartment 1 Evaporator Has No, or Limited, Airflow (Sheet 4 of 9).
Figure 1. Compartment 1 Evaporator Has No, or Limited, Airflow (Sheet 5 of 9).
Figure 1. Compartment 1 Evaporator Has No, or Limited, Airflow (Sheet 6 of 9).
Figure 1. Compartment 1 Evaporator Has No, or Limited, Airflow (Sheet 7 of 9).
Figure 1. Compartment 1 Evaporator Has No, or Limited, Airflow (Sheet 8 of 9).
Figure 1. Compartment 1 Evaporator Has No, or Limited, Airflow (Sheet 9 of 9).
Figure 2. Compartment 2 Evaporator Has No, or Limited, Airflow (Sheet 1 of 9).
Figure 2. Compartment 2 Evaporator Has No, or Limited, Airflow (Sheet 2 of 9).
Figure 2. Compartment 2 Evaporator Has No, or Limited, Airflow (Sheet 3 of 9).
Figure 2. Compartment 2 Evaporator Has No, or Limited, Airflow (Sheet 4 of 9).
Figure 2. Compartment 2 Evaporator Has No, or Limited, Airflow (Sheet 5 of 9).
Figure 2. Compartment 2 Evaporator Has No, or Limited, Airflow (Sheet 6 of 9).
Figure 2. Compartment 2 Evaporator Has No, or Limited, Airflow (Sheet 7 of 9).
Figure 2. Compartment 2 Evaporator Has No, or Limited, Airflow (Sheet 8 of 9).
Figure 2. Compartment 2 Evaporator Has No, or Limited, Airflow (Sheet 9 of 9).
Figure 3. Both Compartment Evaporators Have No Airflow (Sheet 1 of 3).
Figure 3. Both Compartment Evaporators Have No Airflow (Sheet 2 of 3).
Figure 3. Both Compartment Evaporators Have No Airflow (Sheet 3 of 3).
Figure 4. Standby Motor Will Not Come ON (NO ALARM) (Sheet 1 of 6).
Figure 4. Standby Motor Will Not Come ON (NO ALARM) (Sheet 2 of 6).
Figure 4. Standby Motor Will Not Come ON (NO ALARM) (Sheet 3 of 6).
Figure 4. Standby Motor Will Not Come ON (NO ALARM) (Sheet 4 of 6).
Figure 4. Standby Motor Will Not Come ON (NO ALARM) (Sheet 5 of 6).
Figure 4. Standby Motor Will Not Come ON (NO ALARM) (Sheet 6 of 6).
CHAPTER 3 MAINTAINER MAINTENANCE INSTRUCTIONS FOR MULTI-TEMPERATURE REFRIGERATED CONTAINER SYSTEM (MTRCS)
MULTI-TEMPERATURE REFRIGERATED CONTAINER SYSTEM (MTRCS) SERVICE UPON RECEIPT
PRELIMINARY SERVICE OF EQUIPMENT
MULTI-TEMPERATURE REFRIGERATED CONTAINER SYSTEM (MTRCS) PMCS INTRODUCTION
CORROSION PREVENTION AND CONTROL (CPC)
CLEANING AND LUBRICATION
MULTI-TEMPERATURE REFRIGERATED CONTAINER SYSTEM (MTRCS) PREVENTATIVE MAINTENANCE CHECKS AND SERVICES (PMCS)
Table 1. Maintainer Maintenance Preventative Maintenance Checks and Services (PMCS) Continued.
Table 1. Maintainer Maintenance Preventative Maintenance Checks and Services (PMCS) Continued.
Table 1. Maintainer Maintenance Preventative Maintenance Checks and Services (PMCS) Continued.
Table 1. Maintainer Maintenance Preventative Maintenance Checks and Services (PMCS) Continued.
Table 1. Maintainer Maintenance Preventative Maintenance Checks and Services (PMCS) Continued.
Table 1. Maintainer Maintenance Preventative Maintenance Checks and Services (PMCS) Continued.
Table 1. Maintainer Maintenance Preventative Maintenance Checks and Services (PMCS) Continued.
Table 1. Maintainer Maintenance Preventative Maintenance Checks and Services (PMCS) Continued.
Table 1. Maintainer Maintenance Preventative Maintenance Checks and Services (PMCS) Continued.
Table 1. Maintainer Maintenance Preventative Maintenance Checks and Services (PMCS) Continued.
Table 1. Maintainer Maintenance Preventative Maintenance Checks and Services (PMCS) Continued.
Table 1. Maintainer Maintenance Preventative Maintenance Checks and Services (PMCS) Continued.
Table 1. Maintainer Maintenance Preventative Maintenance Checks and Services (PMCS) Continued.
Table 1. Maintainer Maintenance Preventative Maintenance Checks and Services (PMCS) Continued.
Table 1. Maintainer Maintenance Preventative Maintenance Checks and Services (PMCS) Continued.
Table 1. Maintainer Maintenance Preventative Maintenance Checks and Services (PMCS) Continued.
Table 1. Maintainer Maintenance Preventative Maintenance Checks and Services (PMCS) Continued.
MAINTAINER MAINTENANCE FUEL TANK SERVICE
Figure 1. Fuel Drain Cock.
SERVICE CONTINUED
MULTI-TEMPERATURE REFRIGERATED CONTAINER SYSTEM (MTRCS) ACCESS PANELS REPLACE
Figure 1. Top Panels Looking Down.
Figure 2. Front Panel Assembly.
Remove Right-Side Panel
Figure 4. Left-Side Panel.
Install Right-Side Panel
Install Front Panel Cover Assembly
MAINTAINER MAINTENANCE REFRIGERATION UNIT SERVICE
Pump Refrigeration Unit Down
SERVICE CONTINUED
Figure 2. Receiver Outlet Valve.
Figure 3. Control Panel.
Release Refrigerant into System
SERVICE CONTINUED
SERVICE CONTINUED
Refrigerant Leak Check
SERVICE - CONTINUED
SERVICE - CONTINUED
Evacuation and Dehydration
SERVICE - CONTINUED
Charge System with Refrigerant
SERVICE CONTINUED
SERVICE CONTINUED
EMERGENCY STOP SWITCH REPLACE
Figure 2. Emergency Stop Switch.
REPLACE CONTINUED
MAINTAINER MAINTENANCE COMPRESSOR SERVICE
Check Compressor Oil Level
Figure 1. Compressor Oil Level Sight Glass (Typical).
Adding Oil to Compressor in System
Figure 2. Compressor Suction and Discharge Service Valves.
Adding Compressor Oil Using Oil Pump
Adding Oil to Replacement Compressor
SERVICE CONTINUED
MAINTAINER MAINTENANCE COMPRESSOR UNLOADER VALVE COIL TEST, REPLACE
Figure 1. Compressor Unloader Valve Test.
TEST CONTINUED
The compressor unloader valve solenoid coil can be replaced
Figure 2. Compressor Unloader Valve Replace.
MAINTAINER MAINTENANCE FILTER-DRIER TEST, REPLACE
Figure 1. Filter-Drier Test.
Replace a defective filter-drier as follows:
Figure 2. Filter-Drier.
REPLACE CONTINUED
HIGH PRESSURE CUTOUT SWITCH/PRESSURE CONTROL SWITCH TEST, REPLACE
Figure 1. High Pressure Cutout Switch Test Setup.
Replace either high pressure cutout switch, HP1 and HP2, as follows:
Figure 2. HP1 and HP2.
REPLACE CONTINUED
MAINTAINER MAINTENANCE COMPRESSOR SENSORS REPLACE, TEST
Figure 1. Compressor Discharge Temperature Sensor.
Figure 2. Suction Pressure Transducer.
Figure 3. Starter Solenoid Wire.
Figure 4. Microprocessor Controller Display.
Compressor Discharge Temperature Sensor
Suction Pressure Transducer
CONDENSER COIL INSPECT, SERVICE
Figure 1. Condenser Coil Location.
Service
SERVICE CONTINUED
MAINTAINER MAINTENANCE COMPRESSOR PRESSURE REGULATING VALVE ADJUST
Figure 1. Compressor Pressure Regulating Valve Adjustment.
ADJUST CONTINUED
SERVICE CONTINUED
Figure 1. Engine Oil Dipstick, Radiator Overflow, and Cap.
'Unknown' by Unknown - Page 309 of 1084
MAINTAINER MAINTENANCE OIL FILTER REPLACE
Figure 1. Engine Oil Drain Hose Unclamped.
REPLACE CONTINUED
Replace Oil Filter
Figure 3. Engine Oil Filter.
Add Engine Oil
REPLACE CONTINUED
REPLACE CONTINUED
MAINTAINER MAINTENANCE FUEL FILTER REPLACE
Figure 1. Replace Fuel Filter.
REPLACE CONTINUED
REPLACE CONTINUED
MAINTAINER MAINTENANCE COOLING SYSTEM SERVICE, REPAIR
Figure 1. Drain Cooling System.
SERVICE CONTINUED
Figure 2. Clean Cooling System.
Flush Cooling System
Figure 3. Flush Cooling System.
SERVICE CONTINUED
Figure 4. Refill Cooling System.
Replace Water Pump
Figure 5. Water Pump Assembly Flange.
Figure 6. Water Pump.
REPAIR CONTINUED
Replace Water Pump Return Hoses
Figure 7. Water Pump Return Hose.
Replace Water Pump Supply Hose
Figure 8. Water Pump Supply Hose.
MAINTAINER MAINTENANCE THERMAL WATER TEMPERATURE RESISTOR REPLACE
Figure 2. Emergency Stop Switch.
Figure 3. Thermal Water Temperature Resistor.
Figure 4. POWER ON/DOWN Switch.
MAINTAINER MAINTENANCE THERMOSTAT REPLACE
Figure 2. Emergency Stop Switch.
Figure 3. Thermostat.
REPLACE CONTINUED
REPLACE CONTINUED
MAINTAINER MAINTENANCE STARTER REPLACE
Figure 2. Emergency Stop Switch.
Figure 3. Starter.
REPLACE - CONTINUED
MAINTAINER MAINTENANCE ALTERNATOR (MTRC 501 ONLY) TEST, REPLACE
Figure 1. Battery Box.
Figure 2. POWER ON/DOWN Switch.
Figure 3. Emergency Stop Switch.
REPLACE CONTINUED
REPLACE CONTINUED
REPLACE CONTINUED
REPLACE CONTINUED
MAINTAINER MAINTENANCE ALTERNATOR (MTRC 502 ONLY) TEST, REPLACE
Figure 1. Battery Box.
Figure 2. POWER ON/DOWN Switch.
Figure 3. Emergency Stop Switch.
Figure 4. Alternator Removal.
REPLACE CONTINUED
REPLACE CONTINUED
REPLACE CONTINUED
MAINTAINER MAINTENANCE DIESEL ENGINE FUEL FEED PUMP SERVICE, REPLACE
SERVICE CONTINUED
Figure 2. Fuel Pump Service.
SERVICE CONTINUED
Figure 3. POWER ON/DOWN Switch.
Figure 4. Fuel Pump Removal.
REPLACE CONTINUED
Figure 5. Fuel Pump Installation.
REPLACE CONTINUED
MAINTAINER MAINTENANCE DIESEL ENGINE GLOW PLUGS TEST, REPLACE
Figure 2. Emergency Stop Switch.
Figure 3. Glow Plug Lead Assembly Test.
TEST CONTINUED
Figure 4. Glow Plug Lead Assembly Replacement.
REPLACE CONTINUED
MAINTAINER MAINTENANCE CONDENSER FAN REPLACE
Figure 1. Emergency Stop Switch.
Figure 2. Condenser Fan Removal (Sheet 1 of 2).
Figure 2. Condenser Fan Removal (Sheet 2 of 2).
REPLACE CONTINUED
Figure 3. Alternator Mounting Removal.
Figure 4. Standby Motor Alignment Clearances.
REPLACE CONTINUED
Figure 5. Condenser Fan Installation (Sheet 1 of 2).
Figure 5. Condenser Fan Installation (Sheet 2 of 2).
REPLACE CONTINUED
Figure 6. Alternator Mounting Installation.
REPLACE CONTINUED
STANDBY MOTOR TO SINGLE-PHASE ALTERNATOR V-BELT REPLACE, ADJUST
Figure 1. POWER ON/DOWN Switch.
Figure 3. Alternator V-Belt.
REPLACE CONTINUED
ADUJST V-Belt Tension Check
Figure 4. V-Belt Tension Check.
Figure 5. V-Belt Tension Gauge.
Figure 6. POWER ON/DOWN Switch.
Figure 7. Emergency Stop Switch.
Figure 8. Alternator V-Belt.
MAINTAINER MAINTENANCE STANDBY MOTOR TO COMPRESSOR V-BELT REPLACE, ADJUST
Figure 2. Emergency Stop Switch.
Figure 3. Standby Motor to Compressor V-Belt.
REPLACE CONTINUED
Figure 4. Standby Motor to Compressor V-Belt Tension.
V-Belt Tension Check
Figure 5. V-Belt Tension Check.
Figure 6. V-Belt Tension Gauge.
ADJUST CONTINUED
V-Belt Adjustment
Figure 7. Standby Motor to Compressor V-Belt Tension.
ADJUST CONTINUED
MAINTAINER MAINTENANCE ENGINE TO COMPRESSOR V-BELT REPLACE, ADJUST
Figure 1. POWER ON/DOWN Switch.
Figure 3. Engine to Compressor V-Belt Idler.
REPLACE CONTINUED
V-Belt Tension Check
ADJUST CONTINUED
Figure 5. V-Belt Tension Gauge.
V-Belt Adjustment
Figure 7. Emergency Stop Switch.
ADJUST CONTINUED
MAINTAINER MAINTENANCE WATER PUMP V-BELT REPLACE
Figure 3. Front Panel Cover.
REPLACE CONTINUED
Figure 4. Water Pump V-Belt.
REPLACE CONTINUED
Figure 5. V-Belt Tension Check.
Figure 6. V-Belt Tension Gauge.
REPLACE CONTINUED
MAINTAINER MAINTENANCE MUFFLER REPAIR, REPLACE
Figure 1. POWER ON/DOWN Switch.
Note the orientation of the rain cap before removing it
Figure 3. Exhaust Manifold.
REPAIR CONTINUED
REPLACE CONTINUED
Figure 4. Exhaust Manifold.
REPLACE CONTINUED
Figure 1. POWER ON/DOWN Switch.
Figure 2. Emergency Stop Switch.
Figure 3. Oil Pressure Switch.
Figure 4. Emergency Stop Switch.
MAINTAINER MAINTENANCE RUN SOLENOID REPLACE, TEST
Figure 2. Emergency Stop Switch.
Figure 3. Run Solenoid Removal.
Install Run Solenoid
Figure 4. Run Solenoid Installation.
Figure 5. Run Solenoid Test.
MAINTAINER MAINTENANCE SPEED SOLENOID REPLACE, TEST
Figure 2. Emergency Stop Switch.
Figure 3. Speed Control Solenoid Removal.
REPLACE CONTINUED
MAINTAINER MAINTENANCE EVAPORATOR BLOWER MOTOR REPLACE
Figure 1. Control Panel Assembly.
Figure 2. Evaporator Cover Removal.
Figure 3. Evaporator Blower Motor Removal.
Figure 4. Evaporator Blower Motor Installation.
Figure 5. Evaporator Cover Installation.
Figure 6. Control Panel Assembly.
MAINTAINER MAINTENANCE EVAPORATOR BLOWER MOTOR CAPACITOR REPLACE
Figure 1. Control Panel Assembly.
REPLACE - CONTINUED
Figure 2. Evaporator Capacitor.
MAINTAINER MAINTENANCE EVAPORATOR THERMOSTATIC EXPANSION VALVE INSPECT
Figure 1. Control Box.
Figure 2. Evaporator Thermostatic Expansion Valve.
INSPECT CONTINUED
MAINTAINER MAINTENANCE HEATER REPLACE
REPLACE CONTINUED
Figure 2. Heater Access.
Figure 3. Heater.
REPLACE CONTINUED
Figure 4. Heater Access.
Figure 5. Control Box.
MAINTAINER MAINTENANCE LIQUID SOLENOID VALVE COIL REPLACE
Figure 1. Liquid Solenoid Valve Coil Replacement.
REPLACE - CONTINUED
MAINTAINER MAINTENANCE HOT GAS VALVE COIL REPLACE
Figure 1. Hot Gas Valve Coil Replacement.
REPLACE CONTINUED
MAINTAINER MAINTENANCE EVAPORATOR SENSORS INSPECT, REPLACE
Figure 1. Evaporator Sensors.
Return Air Sensor
Figure 2. Return Air and Temperature Chart Recorder Sensors.
Figure 3. Cable Routing.
Figure 4. Wiring Disconnect.
Figure 5. Ferrite Noise Suppressor.
Figure 6. Cable Routing.
Figure 7. Evaporator Sensors.
21. On inside of container, carefully pull sensor (Figure 7, Item 5) and cable
Figure 8. Chart Recorder Rear Cover.
Defrost Thermistor Sensor (DTS)
Figure 10. DTS Mounting Bolt.
Figure 11. DTS Wire Splice.
MAINTAINER MAINTENANCE DRAIN HOSES REPLACE
Figure 1. Drain Hoses.
Breather Elements
Figure 2. Breather.
MAINTAINER MAINTENANCE LIGHTING REPLACE
Figure 1. Light Strip Replace.
Install Wall Mounted Light Strip Lamp Assemblies
Remove Multi-Light Assembly White LED Light Strip LT3.
Figure 2. Removal of White LT3 Light Strip.
Install Multi-Light Assembly White LED Light Strip LT3.
Figure 3. Installation of White LT3 Light Strip.
Figure 4. Removal of Red BLT3 Light Strip.
Install Multi-Light Assembly Red LED Light Strip BLT3.
Figure 5. Installation of Red BLT3 Light Strip.
Figure 6. Removal of White LT4 Light Strip.
Install Multi-Light Assembly White LED Light Strip LT4.
Figure 7. Installation of White LT4 Light Strip.
MAINTAINER MAINTENANCE POWER CABLE ASSEMBLIES TEST, REPLACE
Test Cable Assembly P1A
Figure 2. Switch S1 and S2 Contact Arrangement and Circuit Diagram.
Figure 4. Cable Assembly P1A and Contact Arrangement.
Test Cable Assembly P2A
Figure 5. Cable Assembly P2A and Contact Arrangement.
Test Cable Assembly P1B
Table 3. Cable Assembly P1B.
Figure 7. Cable Assembly P2B and Contact Arrangement.
Replace Cable Assembly P1A
Figure 9. Power Cable Assembly P1A Replacement.
There are three ground wires attached to the power box GND
1. Slide cord mesh (Figure 9, Item 12) over wires and onto replacement cable assembly
Replace Cable Assembly P2A
Figure 10. Power Cable Assembly P2A Removal.
REPLACE CONTINUED - Loosen Terminal
REPLACE CONTINUED - Install
Figure 11. Power Cable Assembly P2A Installation.
REPLACE CONTINUED
MAINTAINER MAINTENANCE BATTERY SERVICE, REPLACE
Figure 1. Service of Battery.
Reconnect Battery and Voltage Check
SERVICE CONTINUED
Figure 2. Voltage Check of Battery.
5. Clean battery positive (+) (Figure 3, Item 5) and negative (-)
Figure 3. Cleaning of Battery.
1. Loosen and remove two lock nuts (Figure 4, Item 7) and two flat washers
Figure 4. Removal/Installation of Battery.
1. Install replacement battery (Figure 4, Item 1) in battery box (Figure 4, Item 2).
MAINTAINER MAINTENANCE BATTERY JUMP START
1. Loosen and remove two lock nuts (Figure 1, Item 2)
If the MTRCS is being jumped from equipment with a 12VDC system
Figure 1. Battery.
Figure 2. MTRCS Jump-Start Procedure.
13. Allow good battery to charge in equipment
MAINTAINER MAINTENANCE TEMPERATURE CHART RECORDER TEST, REPLACE
Figure 1. Temperature Chart Recorder.
REPLACE CONTINUED
Figure 3. Evaporator Sensors.
Figure 4. Temperature Chart Recorder Replacement.
REPLACE CONTINUED
Figure 5. Evaporator Sensors.
Figure 6. Cartridge Pen Arm Removal.
Figure 7. Changing Cartridge Pen Arm.
MAINTAINER MAINTENANCE DOCUMENT HOLDER REPLACE, REPAIR
Figure 1. Document Holder.
Replace Lid Gaskets
REPAIR CONTINUED
MAINTAINER MAINTENANCE MULTI-TEMPERATURE REFRIGERATED CONTAINER SYSTEM (MTRCS) REPAIR
REPAIR CONTINUED
Figure 1. MTRCS Skin Patch Repair.
REPAIR CONTINUED
Replace PLS Roller Lanyards
Replace Swing Out Panels Lanyard, Clips
Figure 3. Swing Out Panel Lanyard and Clips.
Topcoat Application Without Primer.
Topcoat Application With Primer.
REPAIR CONTINUED
MAINTAINER MAINTENANCE FUEL TANK REPLACE, REPAIR
Figure 1. Fuel Tank.
REPLACE CONTINUED
Install Fuel Tank
Replace Liquid Level Gauge Assembly
Figure 2. Liquid Level Gauge.
REPAIR CONTINUED
Replace Fuel Level Sending Unit
Figure 3. Fuel Sending Unit.
REPAIR CONTINUED
Replace Fuel Tank Cap
Figure 4. Fuel Cap/Filler Neck/Strainer.
Replace Filler Neck Flange/Strainer
REPAIR - CONTINUED Replace Elbow
Figure 5. Fuel Tank Components.
6. Apply sealant to threads of replacement elbow
Replace Fuel Outlet Assembly
Figure 6. Fuel Tank Components.
Replace Fuel Tank Drain Hoses
Figure 7. Fuel Tank Drain Hoses.
MAINTAINER MAINTENANCE REFRIGERATION UNIT (MTRC 501 ONLY) REPLACE
Figure 1. Electrical and Fuel Line Disconnects.
6. Slightly above control panel assembly, tag and disconnect 50/60 Hz switch
The disconnect point of the braided line connector
Figure 4. Capacitor Box (P14/J14) and Power (P13/J13) Connectors.
13. Tag and disconnect evaporator control connector (P8/J8)
The ground wires for connectors 1CP and 2CP
Figure 7. Refrigeration Lines.
25. Loosen diesel engine muffler pipe U-bolt (Figure 8, Item 1)
Figure 9. Radiator Cap.
Figure 10. Electrical Cable Feeds.
Figure 11. Support Angle Bolt Layout.
30. Remove two bolts (Figure 12, Item 1), lock washers (Figure 12, Item 2), and washer
Figure 13. Forklift Slots.
Falling from the roof of the MTRCS can cause serious personal injury
Figure 14. Radiator Cap.
Figure 15. Forklift Slots.
7. While guiding cables in, slowly move forklift forward towards MTRCS
Figure 17. Refrigeration Unit Mounting Bolts.
Figure 18. Support Angle Bolt Layout.
REPLACE CONTINUED
Figure 20. Refrigeration Lines.
Figure 21. 1CP and 2CP Electrical Connectors.
25. Reconnect evaporator control connector (P8/J8)
Figure 23. Capacitor Box (P14/J14) and Power (P13/J13) Connectors.
29. Connect braided line connector (P12/J12)
32. Reconnect 50/60 Hz switch connector (P11/J11)
Figure 26. Electrical and Fuel Line Connections.
MAINTAINER MAINTENANCE REFRIGERATION UNIT (MTRC 502 ONLY) REPLACE
Figure 1. Electrical and Fuel Line Disconnects.
Figure 2. 50/60 Hz, P3/J3, and P9/J9 Electrical Connectors.
Figure 3. Braided Line (P12/J12) and P6/J6 Connectors.
Figure 4. Power (P13/J13) Connector.
Figure 5. Evaporator Control Connector.
Figure 6. 1CP and 2CP Electrical Connectors.
Figure 7. Refrigeration Lines.
Figure 8. Muffler Pipe U-Bolt.
Figure 9. Radiator Cap.
Figure 10. Electrical Cable Feeds.
27. Unbolt support angle at front end near bale bar by removing three bolts
Figure 12. Refrigeration Unit Mounting Bolts.
Figure 13. Forklift Slots.
32. Access top of MTRCS using roof access provided.
Figure 14. Radiator Cap.
Figure 15. Forklift Slots.
Figure 16. Electrical Cable Feeds.
Figure 17. Refrigeration Unit Mounting Bolts.
Figure 18. Support Angle Bolt Layout.
Figure 19. Muffler Pipe U-bolt.
Figure 20. Refrigeration Lines.
Figure 21. 1CP and
Figure 22. Evaporator Control Connector.
Figure 23. Power (P13/J13) Connector.
Figure 24. Braided Line P12/J12 and P6/J6 Connectors.
Figure 25. 50/60 Hz, P3/J3, and P9/J9 Electrical Connectors.
Figure 26. Electrical and Fuel Line Connections.
38. Reconnect battery (WP 0053, Reconnect). Tie wrap cables together.
MAINTAINER MAINTENANCE COMPRESSOR REPLACE
Figure 1. Refrigeration Support Bracket Removal.
6. Partially remove alternator (WP 0030, Remove).
Figure 2. Compressor Removal.
Figure 3. Compressor Mounting Aft End.
Figure 4. Compressor Hoist Install.
31. Drain compressor oil into suitable container (WP 0016
The two forward mount bolts will pass through the spacers
Figure 5. Compressor Installation.
23. Reconnect compressor discharge temperature sensor electrical connector
Figure 6. Refrigeration Support Bracket Installation.
33. Perform evacuation and dehydration to 500 (± 25) microns
MAINTAINER MAINTENANCE COMPRESSOR PRESSURE REGULATING VALVE REPLACE
Figure 1. CPR Valve.
The accumulator will need to be loosened from its mounting position
19. Reinstall refrigeration unit onto MTRCS
Main Heat Solenoid Valve
Figure 1. Main Heat Valve Coil.
A very small coil alignment pin is located at top of the valve outer body.
Main Heat Valve and 7/8-Inch Check Valve Assembly
Figure 2. Main Heat Valve Removal.
Because of tight clearance, it may be necessary to cut half of pipe
Figure 3. Heat Valve and Coil Installation.
16. On replacement main heat valve (Figure 2, Item 20)
32. Reconnect electrical connector to valve coil
MAINTAINER MAINTENANCE RECEIVER PRESSURE SOLENOID VALVE REPAIR, REPLACE
Figure 1. Receiver Pressure Solenoid Coil.
Perform the replacement task only if repair is ineffective.
Figure 2. Receiver Pressure Solenoid Valve.
7. Desolder each end of 1/4-inch receiver pressure solenoid
MAINTAINER MAINTENANCE DISCHARGE SERVIEC VALVE REPLACE
Figure 1. Discharge Service Valve Removal.
Many of the chemicals used while soldering are toxic
Figure 2. Discharge Service Valve Installation.
Many of the chemicals used while soldering are toxic.
22. Install top-left panel (WP 0013, Install).
MAINTAINER MAINTENANCE SUCTION SERVICE VALVE REPLACE
Figure 1. Suction Service Valve Assembly Removal.
Rear side of saddle clamp will stay in place until both saddle clamps have been removed
Figure 2. Support Arm.
Figure 3. Accumulator Mounting Removal.
Figure 4. Suction Service Valve Assembly (Standalone).
23. Install fitting (Figure 4, Item 4) in new valve (Figure 4, Item 1).
Figure 5. Suction Service Valve Assembly Installation.
36. Install support arm (Figure 3, Item 1) and support arm bracket
MAINTAINER MAINTENANCE RECEIVER AND CHECK VALVES REPLACE
Figure 1. Receiver.
11. Remove cap screw securing back of receiver.
Figure 2. Condenser to Receiver 3/8-Inch Check Valve
Figure 2. Condenser to Receiver 3/8-Inch Check Valve Replacement.
8. Carefully align piping (Figure 3, Item 2) with 1/4-inch check valve
MAINTAINER MAINTENANCE CONDENSER REPLACE
Figure 1. Lower Radiator Hose Disconnect.
Figure 2. Upper Radiator Hose Disconnect.
Figure 3. Overflow Tank.
Figure 4. Channel Bars.
Figure 5. Receiver Lines Disconnect.
18. Remove one screw (Figure 6, Item 1), nut (Figure 6, Item 2), lock washer
Figure 6. Clamp Removal at Filter-Drier.
24. Remove screw (Figure 7, Item 4) securing hot gas valve coil
Figure 8. Desolder Refrigerant Pipe.
Figure 9. Discharge Service Valve and Line.
There are four hex head bolts securing the base of the condenser assembly
The condenser assembly weighs approximately 40 pounds and is a bulky item
11. Install two clamps (Figure 6, Item 5) to two refrigerant pipes
The MTRCS contains high voltage sources and exposed rotating parts.
MAINTAINER MAINTENANCE ACCUMULATOR/HEAT EXCHANGER REPLACE
Figure 1. Support Arm.
Due to the fragile nature of the accumulator neck flanges and the tight workspace
Figure 2. Accumulator/Heat Exchanger Removal.
18. Desolder 1-1/8-inch refrigerant pipe (Figure 2, Item 24) between accumulator
Figure 3. Accumulator Buildup.
29. Carefully remove accumulator without disturbing pipe alignment
42. Install 3/8-inch refrigerant pipe fitting (Figure 4, Item 21)
Figure 4. Accumulator/Heat Exchanger Installation.
MAINTAINER MAINTENANCE SIGHT GLASS REPLACE
REPLACE CONTINUED
MAINTAINER MAINTENANCE REFRIGERATION UNIT DIESEL ENGINE REPLACE
Refrigeration unit diesel engine
Figure 2. Air Intake Manifold.
Figure 3. Air Intake Cleaner.
Figure 4. Water Pump Supply Hose Disconnect.
Figure 5. Radiator Hose.
Table 1. Engine Harness Disconnects.
Figure 7. Engine Inlet and Outlet Fuel Lines.
Figure 8. Oil Lines.
Figure 9. Engine Ground Strap.
Mounting bracket parts diagram
Figure 11. Hoist Attachment Points.
The engine fits tightly in the refrigeration unit chassis
Install the refrigeration unit diesel engine as follows:
Mounting bracket parts breakdown
11. Torque five bolts (Figure 12, Item 1) to 50 foot-pounds
Figure 13. Engine Ground Strap.
Figure 14. Oil Lines.
Figure 15. Engine Inlet and Outlet Fuel Lines.
Table 2. Engine Harness Connects.
Figure 17. Radiator Hose.
27. Secure wire harness (Figure 17, Item 2) to radiator return hose
30. Perform Alignment per this WP.
Alignment of the three major refrigeration unit components
Figure 22. Outboard Engine Mount Bracket Bolts.
9. Loosen five bolts (Figure 23, Item 1) on inboard engine mount bracket
Figure 24. Alignment Clearances.
15. Install top-right panel (WP 0013, Install).
MAINTAINER MAINTENANCE IDLER PULLEY REPLACE
Figure 1. Emergency Stop Switch.
Belt Installation Diagram
Engine to Compressor V-Belt Idler
Figure 3. Engine to Compressor V-Belt Idler.
12. Install tensioner adjustment bolt (Figure 3, Item 1) and washer (Figure 3, Item 3)
MAINTAINER MAINTENANCE ENGINE MOUNTED CENTRIFUGAL CLUTCH REPLACE
8. Partially remove engine to compressor V-belt (Figure 1, Item 8)
9. Immobilize flywheel (Figure 2, Item 3) by holding crankcase pulley
14. Install idler assembly (Figure 1, Item 3) onto bracket (Figure 1, Item 4).
MAINTAINER MAINTENANCE MICROPROCESSOR CONTROLLER ASSEMBLY REPLACE, SERVICE
Figure 1. Controller.
MAINTAINER MAINTENANCE ELECTRICAL BOX REPAIR
Figure 1. Electrical Box Repair.
Repair Replace Contactor
Figure 2. Contactor Repair.
MAINTAINER REPLACE STANDBY MOTOR/SINGLE-PHASE ALTERNATOR (MTRC 501 ONLY) REPLACE
Figure 1. Standby Motor Electrical Connection.
4. Remove standby motor to compressor V-belt (WP 0036, Remove).
Alternator Installation Diagram
Before removing fan, mark a fan blade to note the orientation
Parts Breakdown of Motor with Fan Blade
24. Lift standby motor/single-phase alternator assembly
Figure 4. Standby Motor/Single-Phase Alternator Assembly.
Install - The radiator coils damage easily.
REPLACE CONTINUED
12. Install condenser fan (Figure 5, Item 3) onto standby motor shaft
REPLACE CONTINUED
23. Reconnect electrical wiring (Figure 6, Item 10) to standby motor
Figure 7. Standby Motor Mount Bracket Bolts.
Figure 8. Alignment Clearances.
4. Tighten three bolts (Figure 7, Item 1) on inboard standby motor
MAINTAINER MAINTENANCE STANDBY MOTOR (MTRC S02 ONLY) REPLACE
Figure 1. Standby Motor Electrical Connection.
5. Loosen two alternator mounting bolts (Figure 2, Items 1 and 2) and self-locking nut
Figure 2. Alternator Removal.
17. Remove two screws (Figure 1, Item 6) and washers
23. Remove condenser fan (Figure 4, Item 3) from standby motor shaft
Figure 4. Standby Motor Attaching Hardware Removal.
Guide pulley around vibration absorber while lifting standby motor assembly.
Figure 5. Standby Motor Assembly.
The radiator coils damage easily. In order to install the standby motor
Figure 6. Standby Motor Attaching Hardware Installation.
Fan blades are sharp and can cut. Use gloves when handling fan blades
Mounting Bracket Diagram
13. Install new idler assembly shaft (Figure 8, Item 18) through idler pulley
Figure 8. Alternator Installation.
23. Install strain relief (Figure 9, Item 11) and nut (Figure 9, Item 10)
Figure 9. Standby Motor Electrical Connection.
MAINTAINER MAINTENANCE MICROPROCESSOR CONTROL BOX (MTRC S01 ONLY) REPAIR
REPAIR CONTINUED
Figure 2. MPC Box Relay Test.
Figure 3. MPC Box Relays, Capacitors, and Fuses.
5. Operate unit in accordance with normal operating procedures to verify proper operation
REPAIR CONTINUED
Figure 5. MPC Box Fuses.
Replace Time Delay
Figure 6. MPC Box Resistor, Ribbon Cable, Time Delay, and Diode.
Test Diode Block
Pin layout and circuit diagram
Figure 8. MPC Box Resistor, Ribbon Cable, Time Delay, and Diode.
Replace MPC Circuit Board
Figure 9. MPC Board.
13. Connect two electrical connectors (Figure 9, Item 17) to MPC circuit board
Figure 10. Microprocessor Control Display Panel
Table 1. Microprocessor Configuration Settings
Microprocessor Control Box Component Identification
Table 1. Microprocessor Control Box Component Identification Continued.
Figure 11. Microprocessor Control Box Back Wall and Bottom.
Figure 12. Microprocessor Control Box Door and Forward Wall.
Figure 13. Microprocessor Control Box Aft Wall.
Hybrid Standby Panel Relay Replace (Overload Protector OL)
REPAIR CONTINUED
7. Remove two nuts and washers from the 1EHR or 2EHR relay and remove the relay.
Shielded Ribbon Cable J12 Replace
REPAIR CONTINUED
Figure 17. J12
MAINTAINER MAINTENANCE MICROPROCESSOR CONTROL BOX (MTRC S02 ONLY) REPAIR
Table 1. Microprocessor Control Box Component Identification Continued.
Figure 1. Microprocessor Control Box Back Wall and Bottom.
Figure 2. Microprocessor Control Box Door.
Figure 3. Microprocessor Control Box.
1. Wait five minutes to allow stored energy to dissipate from capacitors
Figure 4. Capacitors.
1. Pull fuse holder (Figure 5, Item 1) up out of socket
Figure 5. Resistor and Fuses.
Replace Fuse F1
Evaporator Heater Relay Replace
Flashing Relay and Electric Motor Relay Replace
Panel Assembly Replace (Overload Protector (OL) and Motor Contactor (MC))
Figure 8. Panel Assembly (OL and MC).
7. Tag and remove four wires (Figure 9, Item 1) from top of MC
Figure 9. Overload Protector and Motor Contactor.
Replace Relay Board Fuse
Replace Relay
Figure 12. Relay Test.
Replace Relay Board
Replace Microprocessor (MPC) Board
Figure 14. Bolt Tightening Pattern.
The logic board will be destroyed if either terminal A1 or A3 is grounded.
Figure 16. Microprocessor Control Display Panel.
Table 2. Microprocessor Configuration Settings.
19. After all the proper settings are entered, move the main power (RS)
Figure 17. MPC Board.
MAINTAINER MAINTENANCE EVAPORATOR REPLACE
Figure 1. Control Box.
10. Tag and disconnect evaporator electrical connector (Figure 2, Item 1)
Figure 2. Evaporator Cover and Drain Line Disconnect.
Figure 3. 7/8-Inch Refrigerant Pipe Saddle Clamp.
Figure 4. 1/2-Inch and 3/8-Inch Refrigerant Pipes.
Steps 34 and 35 are for compartment 2 (aft) evaporator only.
Figure 5. Evaporator Mounting Removal.
Installation of compartment 1 (forward) and compartment 2 (aft)
Figure 6. Refrigerant Piping Stubout
Lifting or moving heavy equipment incorrectly can cause serious injury.
Figure 8. Evaporator Installation.
Use wet rags on either side of soldering points in order to dissipate heat
Figure 9. Evaporator Cover and Drain Line Installation.
24. Install drain tubes (Figure 9, Item 12) onto elbows
Figure 10. Control Box Assembly.
MAINTAINER MAINTENANCE EVAPORATOR THERMOSTATIC EXPANSION VALVE REPLACE
Figure 1. Control Panel.
Figure 2. TXV Replacement.
When removing the TXV bulb, it is important to note the position of the bulb
26. Solder equalizer line (Figure 2, Item 13) into TXV
Table 1. R-404A Pressure Temperature Chart to Determine S .
MAINTAINER MAINTENANCE CONTROL PANEL ASSEMBLY REPAIR
Figure 1. Control Panel Toggle Switches.
Replace Indicator Light Incandescent Lamps
Figure 2. Control Panel Indicator Light Incandescent Lamps.
Replace Indicator Lights
Figure 3. Control Panel Indicator Lights.
Replace Alarm Horns
Figure 4. Control Panel Alarm Horns.
Replace Terminal Board
Figure 5. Control Panel Terminal Board.
Replace Compartment ON/OFF Switches
Figure 6. Control Panel ON/OFF Switches.
Replace POWER ON/DOWN Switch
Figure 7. Control Panel POWER ON/DOWN Switch.
Replace Resistive Heating Element
Figure 8. Resistive Heating Element.
MAINTAINER MAINTENANCE POWER BOX (MTRC S01 ONLY) REPAIR
Figure 1. Power Control Box Door.
Replace Selector Switches S1, S2
Replace Circuit Breakers CB1, CB2
7. Carefully pull circuit breaker bracket (Figure 3, Item 11), with circuit breaker
Figure 3. Power Control Box Circuit Breaker.
Replace Toggle Switch
Figure 5. Control Panel Wire Bundle.
Figure 6. Power Box and Control Panel Assembly Door.
Figure 8. Power Box Attaching Hardware.
Figure 9. Control Panel Assembly Bolts.
Figure 10. Positioning Forklift Entering Power Box.
Figure 12. Top Power Box Mount Bolts.
Figure 14. Electrical Box Cover.
Figure 16. Power Box Door.
Figure 18. Lifting Strap.
Figure 20. Lifting Transformer from Power Box.
Figure 22. Transformer U-Nuts.
12. Install electrical box cover (Figure 14, Item 2) to electrical box
15. Move power box into position on MTRCS.
MAINTAINER MAINTENANCE POWER BOX (MTRC S02 ONLY) REPAIR
Figure 1. Power Control Box Door.
Replace Selector Switches S1, S2
Replace Circuit Breakers CB1, CB2
6. Remove four screws (Figure 3, Item 7), lock washers (Figure 3, Item 8)
REPAIR CONTINUED
Figure 4. Replace Relay.
2. Unplug and remove relay (Figure 4, Item 2) from relay socket
Replace Transformer TR1
Figure 6. Power Box and Control Panel Assembly Door.
Figure 8. Power Box Attaching Hardware.
Figure 9. Control Panel Assembly Bolts.
Figure 10. Positioning Forklift Entering Power Box.
Figure 11. Bottom Power Box Mount Bolts.
Figure 12. Top Power Box Mount Bolts.
Figure 13. Power Box Removal.
Figure 15. Removing TR1-X0 Wires
Figure 16. Lifting Strap.
Figure 17. Transformer Mounting Bolts.
24. Slowly lift transformer out of power box by guiding it around wires
Figure 19. Removing Wires on Transformer Terminal Block.
Figure 20. Transformer U-Nuts.
7. Secure transformer (Figure 16, Item 2) to power box (Figure 17, Item 4)
Figure 21. Lifting Power Box with Forklift.
Figure 22. Top Power Box Mount Bolts.
Figure 24. Control Panel Assembly Bolts.
19. Close control panel assembly door (Figure 6, Item 2).
MAINTAINER MAINTENANCEPOWER CABLE ASSEMBLIES REPAIR
Figure 1. Connector Repair.
11. Using contact crimp tool, locator, and die, crimp replacement contact (Figure 1, Item 9)
23. Reconnect battery (WP 0053, Reconnect).
MAINTAINER MAINTEANCE BATTERY BOX (MTRCS01 ONLY) REPLACE, REPAIR
Exercise caution when using tools on or around the battery.
Figure 3. Battery Cables.
12. Install negative (-) battery cable (Figure 3, Item 1) and secure negative
MAINTAINER MAINTENANCE BATTERY BOX (MTRC S02 ONLY) REPLACE, REPAIR
Replace Battery Cables
REPAIR CONTINUED
12. Install replacement positive (+) battery cable (Figure 3, Item 2)
MAINTAINER MAINTENANCE CAPACITOR BOX REPAIR
Figure 1. Capacitor Box.
Replace Capacitor Box Cover Seal
Figure 2. Capacitor Box Cover Seal.
MAINTAINER MAINTENANCE DOORS REPAIR
Figure 2. Prying Tool.
Replace Emergency Escape Hatch Gaskets
While removing the gasket you can damage the emergency escape hatch
Figure 5. Emergency Escape Hatch Inner Seal.
9. Apply lubricant to back of new outer gasket (Figure 3, Item 4).
MAINTAINER MAINTENANCE REFRIGERATION PIPING REPAIR
4. If desoldering a joint on a valve, disassemble valve as much as possible
1. Protect wiring harnesses and other components with appropriate heat shields.
2. Remove access panels as needed to gain access to piping or fittings.
MAINTAINER MAINTENANCE TORQUE LIMITS
Table 3. Bolt Torque Values for U.S. Threads in Foot-Pounds.
Table 4. Bolt Torque Values for Metric Threads in Foot Pounds.
MULTI-TEMPERATURE REFRIGERATED CONTAINER SYSTEM (MTRCS) GENERAL WIRING REPAIR
INTRODUCTION CONTINUED
WIRING DIAGRAMS, ELECTRICAL SCHEMATICS, AND REFRIGERATION SCHEMATICS
MULTI-TEMPERATURE REFRIGERATED CONTAINER SYSTEM (MTRCS) PREPARATION FOR STORAGE OR SHIPMENT
PREPARATION FOR STORAGE CONTINUED
CHAPTER 4 - SUPPORTING INFORMATION FOR MULTI-TEMPERATURE REFRIGERATED CONTAINER SYSTEM (MTRCS)
MULTI-TEMPERATURE REFRIGERATED CONTAINER SYSTEM (MTRCS) REFERENCES
INTRODUCTION FOR STANDARD MAINTENANCE ALLOCATION CHART (MAC)
Maintenance functions are limited to and defined as follows:
EXPLANATION OF COLUMNS IN THE MAC
EXPLANATION OF COLUMNS IN THE MAC CONTINUED
MULTI-TEMPERATURE REFRIGERATED CONTAINER SYSTEM (MTRCS) MAINTENANCE ALLOCATION CHART (MAC)
Table 1. MTRCS Maintenance Allocation Chart Continued.
Table 1. MTRCS Maintenance Allocation Chart Continued.
Table 1. MTRCS Maintenance Allocation Chart Continued.
Table 1. MTRCS Maintenance Allocation Chart Continued.
Table 1. MTRCS Maintenance Allocation Chart Continued.
Table 1. MTRCS Maintenance Allocation Chart Continued.
Table 1. MTRCS Maintenance Allocation Chart Continued.
Table 2. Tools and Test Equipment for MTRCS.
MULTI-TEMPERATURE REFRIGERATED CONTAINER SYSTEM (MTRCS) EXPENDABLE AND DURABLE ITEMS LIST
Table 1. Expendable and Durable Items List for MTRCS Continued.
Table 1. Expendable and Durable Items List for MTRCS Continued.
Table 1. Expendable and Durable Items List for MTRCS Continued.
MULTI-TEMPERATURE REFRIGERATED CONTAINER SYSTEM (MTRCS) MANDATORY REPLACEMENT PARTS LIST
Table 1. Mandatory Replacement Parts List for MTRCS Continued.
MULTI-TEMPERATURE REFRIGERATED CONTAINER SYSTEM (MTRCS) ADDITIONAL AUTHORIZATION LIST (AAL)
Table 1. Additional Authorization List (AAL) for MTRCS
MULTI-TEMPERATURE REFRIGERATED CONTAINER SYSTEM (MTRCS) GENERAL INFORMATION
Figure 1. MTRCS.
MAINTENANCE FORMS, RECORDS, AND REPORTS
NOMENCLATURE CROSS-REFERENCE LIST
NOMENCLATURE CROSS-REFERENCE LIST CONTINUED
NOMENCLATURE CROSS-REFERENCE LIST CONTINUED
NOMENCLATURE CROSS-REFERENCE LIST CONTINUED
NOMENCLATURE CROSS-REFERENCE LIST CONTINUED
NOMENCLATURE CROSS-REFERENCE LIST CONTINUED
LIST OF ACRONYMS/ABBREVIATIONS
LIST OF ACRONYMS/ABBREVIATIONS CONTINUED
LIST OF ACRONYMS/ABBREVIATIONS CONTINUED
LIST OF ACRONYMS/ABBREVIATIONS CONTINUED
QUALITY OF MATERIAL
Table 1. Location and Description of MTRCS Front View Components.
Table 1. Location and Description of MTRCS Front View Components Continued.
Figure 1. MTRCS Front View (Sheet 2 of 2).
Table 2. Location and Description of MTRCS Rear View Components.
Table 3. Location and Description of MTRCS Right Side View Components.
Table 4. Location and Description of MTRCS Left Side View Components.
Table 5. Location and Description of MTRCS Interior Left Wall Components.
Table 6. Location and Description of MTRCS Interior Right Wall Components.
Table 7. MTRCS System Specifications.
Table 7. MTRCS System Specifications Continued.
MULTI-TEMPERATURE REFRIGERATED CONTAINER SYSTEM (MTRCS) THEORY OF OPERATION
INSULATED CONTAINER
Emergency Escape Hatches
Table 1. Power Box Assembly Configuration for External Power.
Figure 3. Control Box.
Figure 4. Microprocessor Controller Display.
Figure 5. Evaporators.
Figure 6. CPR Valve.
Figure 7. Accumulator.
Figure 8. Compressor Unloader.
DIESEL ENGINE
Figure 10. Water Temperature Sensor.
Figure 11. Cooling System.
Figure 12. Engine Air Cleaner.
Figure 14. Fuel Filter.
ELECTRICAL DESIGN, CABLES, LIGHTING, ALARM, TEMPERATURE CONTROL, AND RECORDING
CHAPTER 2 TROUBLESHOOTING PROCEDURES FOR MULTI-TEMPERATURE REFRIGERATED CONTAINER SYSTEM (MTRCS)
Table 1. Crew Troubleshooting Malfunction/Symptom Index.
Figure 1. Relay Pin Out and Schematic.
Table 2. Maintainer Maintenance Troubleshooting Malfunction/Symptom Index.
Table 3. Sensor Voltage Chart for Suction Pressure Transducer.
Table 4. Sensor Resistance Chart for Air Temperature, Return Air, Supply Air, and Water Temperature Sensor - Continued
Initial Setup
Table 1. Microprocessor Control Box Component Identification for Model MTRCS01.
Table 1. Microprocessor Control Box Component Identification for Model MTRCS01 Continued.
Figure 1. Microprocessor Control Box Back Wall and Bottom (Model MTRCS01).
Figure 2. Microprocessor Control Box Door and Forward Wall (Model MTRCS01).
Figure 3. Microprocessor Control Box Aft Wall (Model MTRCS01).
Table 2. Microprocessor Control Box Component Identification for Model MTRCS02.
Figure 3.1. Microprocessor Control Box Back Wall and Bottom (Model MTRCS02).
Figure 3.2. Microprocessor Control Box Door (Model MTRCS02).
Figure 4. Engine Will Not Start.
Figure 5. Fault AL8 (STARTER) (Sheet 1 of 2).
Figure 5. Fault AL8 (STARTER) (Sheet 2 of 2).
Figure 6. Fault AL0 (ENG OIL) (Sheet 1 of 2).
Figure 6. Fault AL0 (ENG OIL) (Sheet 2 of 2).
Figure 7. Fault AL1 (ENG HOT) (Sheet 1 of 6).
Figure 7. Fault AL1 (ENG HOT) (Sheet 2 of 6).
Figure 7. Fault AL1 (ENG HOT) (Sheet 3 of 6).
Figure 7. Fault AL1 (ENG HOT) (Sheet 4 of 6).
Figure 7. Fault AL1 (ENG HOT) (Sheet 5 of 6).
Figure 7. Fault AL1 (ENG HOT) (Sheet 6 of 6).
Figure 8. Fault AL2 (HI PRESS) (Sheet 1 of 3).
Figure 8. Fault AL2 (HI PRESS) (Sheet 2 of 3).
Figure 8. Fault AL2 (HI PRESS) (Sheet 3 of 3).
Figure 9. Fault AL3 (STARTFAIL) (Sheet 1 of 6).
Figure 9. Fault AL3 (STARTFAIL) (Sheet 2 of 6).
Figure 9. Fault AL3 (STARTFAIL) (Sheet 3 of 6).
Figure 9. Fault AL3 (STARTFAIL) (Sheet 4 of 6).
Figure 9. Fault AL3 (STARTFAIL) (Sheet 5 of 6).
Figure 9. Fault AL3 (STARTFAIL) (Sheet 6 of 6).
SERVICE AND FIELD MAINTENANCE REFRIGERATION UNIT TROUBLESHOOTING PROCEDURES (FAULT CODES AL4 AL7, AL9 AL15)
Figure 1. Fault AL4 (LOW BATT).
Figure 2. Fault AL5 (HIGH BATT).
Figure 3. Fault AL6 (DEFRFAIL).
Figure 4. Fault AL7 (ALT AUX).
Figure 5. Fault AL9 (1RA SENSOR).
Figure 6. Fault AL10 (2RA SENSOR).
Figure 7. Fault AL11 (WT SENSOR).
Figure 8. Fault AL12 (HIGH CDT) (Sheet 1 of 4).
Figure 8. Fault AL12 (HIGH CDT) (Sheet 2 of 4).
Figure 8. Fault AL12 (HIGH CDT) (Sheet 3 of 4).
Figure 8. Fault AL12 (HIGH CDT) (Sheet 4 of 4).
Figure 9. Fault AL13 (CD SENSOR).
Figure 10. Fault AL14 (SBY MOTOR) (Sheet 1 of 2).
Figure 10. Fault AL14 (SBY MOTOR) (Sheet 2 of 2).
Figure 11. Fault AL15 (FUSE BAD).
Figure 12. Fault AL15 (FUSE BAD) F4 (Sheet 1 of 2).
Figure 12. Fault AL15 (FUSE BAD) F4 (Sheet 2 of 2).
Figure 13. Fault AL15 (FUSE BAD) F5.
Figure 14. Fault AL15 (FUSE BAD) F7 (Sheet 1 of 4).
Figure 14. Fault AL15 (FUSE BAD) F7 (Sheet 2 of 4).
Figure 14. Fault AL15 (FUSE BAD) F7 (Sheet 3 of 4).
Figure 14. Fault AL15 (FUSE BAD) F7 (Sheet 4 of 4).
Figure 15. Fault AL15 (FUSE BAD) F8 (Sheet 1 of 4).
Figure 15. Fault AL15 (FUSE BAD) F8 (Sheet 2 of 4).
Figure 15. Fault AL15 (FUSE BAD) F8 (Sheet 3 of 4).
Figure 15. Fault AL15 (FUSE BAD) F8 (Sheet 4 of 4).
SERVICE AND FIELD MAINTENANCE REFRIGERATION UNIT TROUBLESHOOTING PROCEDURES (FAULT CODES AL17 AL23)
Figure 1. Fault AL17 (DISPLAY).
Figure 2. Fault AL20 (1RA OUT) (Sheet 1 of 6).
Figure 2. Fault AL20 (1RA OUT) (Sheet 2 of 6).
Figure 2. Fault AL20 (1RA OUT) (Sheet 3 of 6).
Figure 2. Fault AL20 (1RA OUT) (Sheet 4 of 6).
Figure 2. Fault AL20 (1RA OUT) (Sheet 5 of 6).
Figure 2. Fault AL20 (1RA OUT) (Sheet 6 of 6).
Figure 3. Fault AL21 (2RA OUT) (Sheet 1 of 6).
Figure 3. Fault AL21 (2RA OUT) (Sheet 2 of 6).
Figure 3. Fault AL21 (2RA OUT) (Sheet 3 of 6).
Figure 3. Fault AL21 (2RA OUT) (Sheet 4 of 6).
Figure 3. Fault AL21 (2RA OUT) (Sheet 5 of 6).
Figure 3. Fault AL21 (2RA OUT) (Sheet 6 of 6).
Figure 4. Fault AL23 (NO POWER).
Figure 5. Refrigeration Unit Runs But Will Not Heat (Sheet 1 of 11).
Figure 5. Refrigeration Unit Runs But Will Not Heat (Sheet 2 of 11).
Figure 5. Refrigeration Unit Runs But Will Not Heat (Sheet 3 of 11).
Figure 5. Refrigeration Unit Runs But Will Not Heat (Sheet 4 of 11).
Figure 5. Refrigeration Unit Runs But Will Not Heat (Sheet 5 of 11).
Figure 5. Refrigeration Unit Runs But Will Not Heat (Sheet 6 of 11).
Figure 5. Refrigeration Unit Runs But Will Not Heat (Sheet 7 of 11).
Figure 5. Refrigeration Unit Runs But Will Not Heat (Sheet 8 of 11).
Figure 5. Refrigeration Unit Runs But Will Not Heat (Sheet 9 of 11).
Figure 5. Refrigeration Unit Runs But Will Not Heat (Sheet 10 of 11).
Figure 5. Refrigeration Unit Runs But Will Not Heat (Sheet 11 of 11).
Figure 6. No Microprocessor Display (Sheet 1 of 7).
Figure 6. No Microprocessor Display (Sheet 2 of 7).
Figure 6. No Microprocessor Display (Sheet 3 of 7).
Figure 6. No Microprocessor Display (Sheet 4 of 7).
Figure 6. No Microprocessor Display (Sheet 5 of 7).
Figure 6. No Microprocessor Display (Sheet 6 of 7).
Figure 6. No Microprocessor Display (Sheet 7 of 7).
MULTI-TEMPERATURE REFRIGERATED CONTAINER SYSTEM (MTRCS) INITIAL SETUP
Figure 1. Compartment 1 Evaporator Has No, or Limited, Airflow (Sheet 1 of 9).
Figure 1. Compartment 1 Evaporator Has No, or Limited, Airflow (Sheet 2 of 9).
Figure 1. Compartment 1 Evaporator Has No, or Limited, Airflow (Sheet 3 of 9).
Figure 1. Compartment 1 Evaporator Has No, or Limited, Airflow (Sheet 4 of 9).
Figure 1. Compartment 1 Evaporator Has No, or Limited, Airflow (Sheet 5 of 9).
Figure 1. Compartment 1 Evaporator Has No, or Limited, Airflow (Sheet 6 of 9).
Figure 1. Compartment 1 Evaporator Has No, or Limited, Airflow (Sheet 7 of 9).
Figure 1. Compartment 1 Evaporator Has No, or Limited, Airflow (Sheet 8 of 9).
Figure 1. Compartment 1 Evaporator Has No, or Limited, Airflow (Sheet 9 of 9).
Figure 2. Compartment 2 Evaporator Has No, or Limited, Airflow (Sheet 1 of 9).
Figure 2. Compartment 2 Evaporator Has No, or Limited, Airflow (Sheet 2 of 9).
Figure 2. Compartment 2 Evaporator Has No, or Limited, Airflow (Sheet 3 of 9).
Figure 2. Compartment 2 Evaporator Has No, or Limited, Airflow (Sheet 4 of 9).
Figure 2. Compartment 2 Evaporator Has No, or Limited, Airflow (Sheet 5 of 9).
Figure 2. Compartment 2 Evaporator Has No, or Limited, Airflow (Sheet 6 of 9).
Figure 2. Compartment 2 Evaporator Has No, or Limited, Airflow (Sheet 7 of 9).
Figure 2. Compartment 2 Evaporator Has No, or Limited, Airflow (Sheet 8 of 9).
Figure 2. Compartment 2 Evaporator Has No, or Limited, Airflow (Sheet 9 of 9).
Figure 3. Both Compartment Evaporators Have No Airflow (Sheet 1 of 3).
Figure 3. Both Compartment Evaporators Have No Airflow (Sheet 2 of 3).
Figure 3. Both Compartment Evaporators Have No Airflow (Sheet 3 of 3).
Figure 4. Standby Motor Will Not Come ON (NO ALARM) (Sheet 1 of 6).
Figure 4. Standby Motor Will Not Come ON (NO ALARM) (Sheet 2 of 6).
Figure 4. Standby Motor Will Not Come ON (NO ALARM) (Sheet 3 of 6).
Figure 4. Standby Motor Will Not Come ON (NO ALARM) (Sheet 4 of 6).
Figure 4. Standby Motor Will Not Come ON (NO ALARM) (Sheet 5 of 6).
Figure 4. Standby Motor Will Not Come ON (NO ALARM) (Sheet 6 of 6).
CHAPTER 3 MAINTAINER MAINTENANCE INSTRUCTIONS FOR MULTI-TEMPERATURE REFRIGERATED CONTAINER SYSTEM (MTRCS)
MULTI-TEMPERATURE REFRIGERATED CONTAINER SYSTEM (MTRCS) SERVICE UPON RECEIPT
PRELIMINARY SERVICE OF EQUIPMENT
MULTI-TEMPERATURE REFRIGERATED CONTAINER SYSTEM (MTRCS) PMCS INTRODUCTION
CORROSION PREVENTION AND CONTROL (CPC)
CLEANING AND LUBRICATION
MULTI-TEMPERATURE REFRIGERATED CONTAINER SYSTEM (MTRCS) PREVENTATIVE MAINTENANCE CHECKS AND SERVICES (PMCS)
Table 1. Maintainer Maintenance Preventative Maintenance Checks and Services (PMCS) Continued.
Table 1. Maintainer Maintenance Preventative Maintenance Checks and Services (PMCS) Continued.
Table 1. Maintainer Maintenance Preventative Maintenance Checks and Services (PMCS) Continued.
Table 1. Maintainer Maintenance Preventative Maintenance Checks and Services (PMCS) Continued.
Table 1. Maintainer Maintenance Preventative Maintenance Checks and Services (PMCS) Continued.
Table 1. Maintainer Maintenance Preventative Maintenance Checks and Services (PMCS) Continued.
Table 1. Maintainer Maintenance Preventative Maintenance Checks and Services (PMCS) Continued.
Table 1. Maintainer Maintenance Preventative Maintenance Checks and Services (PMCS) Continued.
Table 1. Maintainer Maintenance Preventative Maintenance Checks and Services (PMCS) Continued.
Table 1. Maintainer Maintenance Preventative Maintenance Checks and Services (PMCS) Continued.
Table 1. Maintainer Maintenance Preventative Maintenance Checks and Services (PMCS) Continued.
Table 1. Maintainer Maintenance Preventative Maintenance Checks and Services (PMCS) Continued.
Table 1. Maintainer Maintenance Preventative Maintenance Checks and Services (PMCS) Continued.
Table 1. Maintainer Maintenance Preventative Maintenance Checks and Services (PMCS) Continued.
Table 1. Maintainer Maintenance Preventative Maintenance Checks and Services (PMCS) Continued.
Table 1. Maintainer Maintenance Preventative Maintenance Checks and Services (PMCS) Continued.
Table 1. Maintainer Maintenance Preventative Maintenance Checks and Services (PMCS) Continued.
MAINTAINER MAINTENANCE FUEL TANK SERVICE
Figure 1. Fuel Drain Cock.
SERVICE CONTINUED
MULTI-TEMPERATURE REFRIGERATED CONTAINER SYSTEM (MTRCS) ACCESS PANELS REPLACE
Figure 1. Top Panels Looking Down.
Figure 2. Front Panel Assembly.
Remove Right-Side Panel
Figure 4. Left-Side Panel.
Install Right-Side Panel
Install Front Panel Cover Assembly
MAINTAINER MAINTENANCE REFRIGERATION UNIT SERVICE
Pump Refrigeration Unit Down
SERVICE CONTINUED
Figure 2. Receiver Outlet Valve.
Figure 3. Control Panel.
Release Refrigerant into System
SERVICE CONTINUED
SERVICE CONTINUED
Refrigerant Leak Check
SERVICE - CONTINUED
SERVICE - CONTINUED
Evacuation and Dehydration
SERVICE - CONTINUED
Charge System with Refrigerant
SERVICE CONTINUED
SERVICE CONTINUED
EMERGENCY STOP SWITCH REPLACE
Figure 2. Emergency Stop Switch.
REPLACE CONTINUED
MAINTAINER MAINTENANCE COMPRESSOR SERVICE
Check Compressor Oil Level
Figure 1. Compressor Oil Level Sight Glass (Typical).
Adding Oil to Compressor in System
Figure 2. Compressor Suction and Discharge Service Valves.
Adding Compressor Oil Using Oil Pump
Adding Oil to Replacement Compressor
SERVICE CONTINUED
MAINTAINER MAINTENANCE COMPRESSOR UNLOADER VALVE COIL TEST, REPLACE
Figure 1. Compressor Unloader Valve Test.
TEST CONTINUED
The compressor unloader valve solenoid coil can be replaced
Figure 2. Compressor Unloader Valve Replace.
MAINTAINER MAINTENANCE FILTER-DRIER TEST, REPLACE
Figure 1. Filter-Drier Test.
Replace a defective filter-drier as follows:
Figure 2. Filter-Drier.
REPLACE CONTINUED
HIGH PRESSURE CUTOUT SWITCH/PRESSURE CONTROL SWITCH TEST, REPLACE
Figure 1. High Pressure Cutout Switch Test Setup.
Replace either high pressure cutout switch, HP1 and HP2, as follows:
Figure 2. HP1 and HP2.
REPLACE CONTINUED
MAINTAINER MAINTENANCE COMPRESSOR SENSORS REPLACE, TEST
Figure 1. Compressor Discharge Temperature Sensor.
Figure 2. Suction Pressure Transducer.
Figure 3. Starter Solenoid Wire.
Figure 4. Microprocessor Controller Display.
Compressor Discharge Temperature Sensor
Suction Pressure Transducer
CONDENSER COIL INSPECT, SERVICE
Figure 1. Condenser Coil Location.
Service
SERVICE CONTINUED
MAINTAINER MAINTENANCE COMPRESSOR PRESSURE REGULATING VALVE ADJUST
Figure 1. Compressor Pressure Regulating Valve Adjustment.
ADJUST CONTINUED
SERVICE CONTINUED
Figure 1. Engine Oil Dipstick, Radiator Overflow, and Cap.
'Unknown' by Unknown - Page 309 of 1084
MAINTAINER MAINTENANCE OIL FILTER REPLACE
Figure 1. Engine Oil Drain Hose Unclamped.
REPLACE CONTINUED
Replace Oil Filter
Figure 3. Engine Oil Filter.
Add Engine Oil
REPLACE CONTINUED
REPLACE CONTINUED
MAINTAINER MAINTENANCE FUEL FILTER REPLACE
Figure 1. Replace Fuel Filter.
REPLACE CONTINUED
REPLACE CONTINUED
MAINTAINER MAINTENANCE COOLING SYSTEM SERVICE, REPAIR
Figure 1. Drain Cooling System.
SERVICE CONTINUED
Figure 2. Clean Cooling System.
Flush Cooling System
Figure 3. Flush Cooling System.
SERVICE CONTINUED
Figure 4. Refill Cooling System.
Replace Water Pump
Figure 5. Water Pump Assembly Flange.
Figure 6. Water Pump.
REPAIR CONTINUED
Replace Water Pump Return Hoses
Figure 7. Water Pump Return Hose.
Replace Water Pump Supply Hose
Figure 8. Water Pump Supply Hose.
MAINTAINER MAINTENANCE THERMAL WATER TEMPERATURE RESISTOR REPLACE
Figure 2. Emergency Stop Switch.
Figure 3. Thermal Water Temperature Resistor.
Figure 4. POWER ON/DOWN Switch.
MAINTAINER MAINTENANCE THERMOSTAT REPLACE
Figure 2. Emergency Stop Switch.
Figure 3. Thermostat.
REPLACE CONTINUED
REPLACE CONTINUED
MAINTAINER MAINTENANCE STARTER REPLACE
Figure 2. Emergency Stop Switch.
Figure 3. Starter.
REPLACE - CONTINUED
MAINTAINER MAINTENANCE ALTERNATOR (MTRC 501 ONLY) TEST, REPLACE
Figure 1. Battery Box.
Figure 2. POWER ON/DOWN Switch.
Figure 3. Emergency Stop Switch.
REPLACE CONTINUED
REPLACE CONTINUED
REPLACE CONTINUED
REPLACE CONTINUED
MAINTAINER MAINTENANCE ALTERNATOR (MTRC 502 ONLY) TEST, REPLACE
Figure 1. Battery Box.
Figure 2. POWER ON/DOWN Switch.
Figure 3. Emergency Stop Switch.
Figure 4. Alternator Removal.
REPLACE CONTINUED
REPLACE CONTINUED
REPLACE CONTINUED
MAINTAINER MAINTENANCE DIESEL ENGINE FUEL FEED PUMP SERVICE, REPLACE
SERVICE CONTINUED
Figure 2. Fuel Pump Service.
SERVICE CONTINUED
Figure 3. POWER ON/DOWN Switch.
Figure 4. Fuel Pump Removal.
REPLACE CONTINUED
Figure 5. Fuel Pump Installation.
REPLACE CONTINUED
MAINTAINER MAINTENANCE DIESEL ENGINE GLOW PLUGS TEST, REPLACE
Figure 2. Emergency Stop Switch.
Figure 3. Glow Plug Lead Assembly Test.
TEST CONTINUED
Figure 4. Glow Plug Lead Assembly Replacement.
REPLACE CONTINUED
MAINTAINER MAINTENANCE CONDENSER FAN REPLACE
Figure 1. Emergency Stop Switch.
Figure 2. Condenser Fan Removal (Sheet 1 of 2).
Figure 2. Condenser Fan Removal (Sheet 2 of 2).
REPLACE CONTINUED
Figure 3. Alternator Mounting Removal.
Figure 4. Standby Motor Alignment Clearances.
REPLACE CONTINUED
Figure 5. Condenser Fan Installation (Sheet 1 of 2).
Figure 5. Condenser Fan Installation (Sheet 2 of 2).
REPLACE CONTINUED
Figure 6. Alternator Mounting Installation.
REPLACE CONTINUED
STANDBY MOTOR TO SINGLE-PHASE ALTERNATOR V-BELT REPLACE, ADJUST
Figure 1. POWER ON/DOWN Switch.
Figure 3. Alternator V-Belt.
REPLACE CONTINUED
ADUJST V-Belt Tension Check
Figure 4. V-Belt Tension Check.
Figure 5. V-Belt Tension Gauge.
Figure 6. POWER ON/DOWN Switch.
Figure 7. Emergency Stop Switch.
Figure 8. Alternator V-Belt.
MAINTAINER MAINTENANCE STANDBY MOTOR TO COMPRESSOR V-BELT REPLACE, ADJUST
Figure 2. Emergency Stop Switch.
Figure 3. Standby Motor to Compressor V-Belt.
REPLACE CONTINUED
Figure 4. Standby Motor to Compressor V-Belt Tension.
V-Belt Tension Check
Figure 5. V-Belt Tension Check.
Figure 6. V-Belt Tension Gauge.
ADJUST CONTINUED
V-Belt Adjustment
Figure 7. Standby Motor to Compressor V-Belt Tension.
ADJUST CONTINUED
MAINTAINER MAINTENANCE ENGINE TO COMPRESSOR V-BELT REPLACE, ADJUST
Figure 1. POWER ON/DOWN Switch.
Figure 3. Engine to Compressor V-Belt Idler.
REPLACE CONTINUED
V-Belt Tension Check
ADJUST CONTINUED
Figure 5. V-Belt Tension Gauge.
V-Belt Adjustment
Figure 7. Emergency Stop Switch.
ADJUST CONTINUED
MAINTAINER MAINTENANCE WATER PUMP V-BELT REPLACE
Figure 3. Front Panel Cover.
REPLACE CONTINUED
Figure 4. Water Pump V-Belt.
REPLACE CONTINUED
Figure 5. V-Belt Tension Check.
Figure 6. V-Belt Tension Gauge.
REPLACE CONTINUED
MAINTAINER MAINTENANCE MUFFLER REPAIR, REPLACE
Figure 1. POWER ON/DOWN Switch.
Note the orientation of the rain cap before removing it
Figure 3. Exhaust Manifold.
REPAIR CONTINUED
REPLACE CONTINUED
Figure 4. Exhaust Manifold.
REPLACE CONTINUED
Figure 1. POWER ON/DOWN Switch.
Figure 2. Emergency Stop Switch.
Figure 3. Oil Pressure Switch.
Figure 4. Emergency Stop Switch.
MAINTAINER MAINTENANCE RUN SOLENOID REPLACE, TEST
Figure 2. Emergency Stop Switch.
Figure 3. Run Solenoid Removal.
Install Run Solenoid
Figure 4. Run Solenoid Installation.
Figure 5. Run Solenoid Test.
MAINTAINER MAINTENANCE SPEED SOLENOID REPLACE, TEST
Figure 2. Emergency Stop Switch.
Figure 3. Speed Control Solenoid Removal.
REPLACE CONTINUED
MAINTAINER MAINTENANCE EVAPORATOR BLOWER MOTOR REPLACE
Figure 1. Control Panel Assembly.
Figure 2. Evaporator Cover Removal.
Figure 3. Evaporator Blower Motor Removal.
Figure 4. Evaporator Blower Motor Installation.
Figure 5. Evaporator Cover Installation.
Figure 6. Control Panel Assembly.
MAINTAINER MAINTENANCE EVAPORATOR BLOWER MOTOR CAPACITOR REPLACE
Figure 1. Control Panel Assembly.
REPLACE - CONTINUED
Figure 2. Evaporator Capacitor.
MAINTAINER MAINTENANCE EVAPORATOR THERMOSTATIC EXPANSION VALVE INSPECT
Figure 1. Control Box.
Figure 2. Evaporator Thermostatic Expansion Valve.
INSPECT CONTINUED
MAINTAINER MAINTENANCE HEATER REPLACE
REPLACE CONTINUED
Figure 2. Heater Access.
Figure 3. Heater.
REPLACE CONTINUED
Figure 4. Heater Access.
Figure 5. Control Box.
MAINTAINER MAINTENANCE LIQUID SOLENOID VALVE COIL REPLACE
Figure 1. Liquid Solenoid Valve Coil Replacement.
REPLACE - CONTINUED
MAINTAINER MAINTENANCE HOT GAS VALVE COIL REPLACE
Figure 1. Hot Gas Valve Coil Replacement.
REPLACE CONTINUED
MAINTAINER MAINTENANCE EVAPORATOR SENSORS INSPECT, REPLACE
Figure 1. Evaporator Sensors.
Return Air Sensor
Figure 2. Return Air and Temperature Chart Recorder Sensors.
Figure 3. Cable Routing.
Figure 4. Wiring Disconnect.
Figure 5. Ferrite Noise Suppressor.
Figure 6. Cable Routing.
Figure 7. Evaporator Sensors.
21. On inside of container, carefully pull sensor (Figure 7, Item 5) and cable
Figure 8. Chart Recorder Rear Cover.
Defrost Thermistor Sensor (DTS)
Figure 10. DTS Mounting Bolt.
Figure 11. DTS Wire Splice.
MAINTAINER MAINTENANCE DRAIN HOSES REPLACE
Figure 1. Drain Hoses.
Breather Elements
Figure 2. Breather.
MAINTAINER MAINTENANCE LIGHTING REPLACE
Figure 1. Light Strip Replace.
Install Wall Mounted Light Strip Lamp Assemblies
Remove Multi-Light Assembly White LED Light Strip LT3.
Figure 2. Removal of White LT3 Light Strip.
Install Multi-Light Assembly White LED Light Strip LT3.
Figure 3. Installation of White LT3 Light Strip.
Figure 4. Removal of Red BLT3 Light Strip.
Install Multi-Light Assembly Red LED Light Strip BLT3.
Figure 5. Installation of Red BLT3 Light Strip.
Figure 6. Removal of White LT4 Light Strip.
Install Multi-Light Assembly White LED Light Strip LT4.
Figure 7. Installation of White LT4 Light Strip.
MAINTAINER MAINTENANCE POWER CABLE ASSEMBLIES TEST, REPLACE
Test Cable Assembly P1A
Figure 2. Switch S1 and S2 Contact Arrangement and Circuit Diagram.
Figure 4. Cable Assembly P1A and Contact Arrangement.
Test Cable Assembly P2A
Figure 5. Cable Assembly P2A and Contact Arrangement.
Test Cable Assembly P1B
Table 3. Cable Assembly P1B.
Figure 7. Cable Assembly P2B and Contact Arrangement.
Replace Cable Assembly P1A
Figure 9. Power Cable Assembly P1A Replacement.
There are three ground wires attached to the power box GND
1. Slide cord mesh (Figure 9, Item 12) over wires and onto replacement cable assembly
Replace Cable Assembly P2A
Figure 10. Power Cable Assembly P2A Removal.
REPLACE CONTINUED - Loosen Terminal
REPLACE CONTINUED - Install
Figure 11. Power Cable Assembly P2A Installation.
REPLACE CONTINUED
MAINTAINER MAINTENANCE BATTERY SERVICE, REPLACE
Figure 1. Service of Battery.
Reconnect Battery and Voltage Check
SERVICE CONTINUED
Figure 2. Voltage Check of Battery.
5. Clean battery positive (+) (Figure 3, Item 5) and negative (-)
Figure 3. Cleaning of Battery.
1. Loosen and remove two lock nuts (Figure 4, Item 7) and two flat washers
Figure 4. Removal/Installation of Battery.
1. Install replacement battery (Figure 4, Item 1) in battery box (Figure 4, Item 2).
MAINTAINER MAINTENANCE BATTERY JUMP START
1. Loosen and remove two lock nuts (Figure 1, Item 2)
If the MTRCS is being jumped from equipment with a 12VDC system
Figure 1. Battery.
Figure 2. MTRCS Jump-Start Procedure.
13. Allow good battery to charge in equipment
MAINTAINER MAINTENANCE TEMPERATURE CHART RECORDER TEST, REPLACE
Figure 1. Temperature Chart Recorder.
REPLACE CONTINUED
Figure 3. Evaporator Sensors.
Figure 4. Temperature Chart Recorder Replacement.
REPLACE CONTINUED
Figure 5. Evaporator Sensors.
Figure 6. Cartridge Pen Arm Removal.
Figure 7. Changing Cartridge Pen Arm.
MAINTAINER MAINTENANCE DOCUMENT HOLDER REPLACE, REPAIR
Figure 1. Document Holder.
Replace Lid Gaskets
REPAIR CONTINUED
MAINTAINER MAINTENANCE MULTI-TEMPERATURE REFRIGERATED CONTAINER SYSTEM (MTRCS) REPAIR
REPAIR CONTINUED
Figure 1. MTRCS Skin Patch Repair.
REPAIR CONTINUED
Replace PLS Roller Lanyards
Replace Swing Out Panels Lanyard, Clips
Figure 3. Swing Out Panel Lanyard and Clips.
Topcoat Application Without Primer.
Topcoat Application With Primer.
REPAIR CONTINUED
MAINTAINER MAINTENANCE FUEL TANK REPLACE, REPAIR
Figure 1. Fuel Tank.
REPLACE CONTINUED
Install Fuel Tank
Replace Liquid Level Gauge Assembly
Figure 2. Liquid Level Gauge.
REPAIR CONTINUED
Replace Fuel Level Sending Unit
Figure 3. Fuel Sending Unit.
REPAIR CONTINUED
Replace Fuel Tank Cap
Figure 4. Fuel Cap/Filler Neck/Strainer.
Replace Filler Neck Flange/Strainer
REPAIR - CONTINUED Replace Elbow
Figure 5. Fuel Tank Components.
6. Apply sealant to threads of replacement elbow
Replace Fuel Outlet Assembly
Figure 6. Fuel Tank Components.
Replace Fuel Tank Drain Hoses
Figure 7. Fuel Tank Drain Hoses.
MAINTAINER MAINTENANCE REFRIGERATION UNIT (MTRC 501 ONLY) REPLACE
Figure 1. Electrical and Fuel Line Disconnects.
6. Slightly above control panel assembly, tag and disconnect 50/60 Hz switch
The disconnect point of the braided line connector
Figure 4. Capacitor Box (P14/J14) and Power (P13/J13) Connectors.
13. Tag and disconnect evaporator control connector (P8/J8)
The ground wires for connectors 1CP and 2CP
Figure 7. Refrigeration Lines.
25. Loosen diesel engine muffler pipe U-bolt (Figure 8, Item 1)
Figure 9. Radiator Cap.
Figure 10. Electrical Cable Feeds.
Figure 11. Support Angle Bolt Layout.
30. Remove two bolts (Figure 12, Item 1), lock washers (Figure 12, Item 2), and washer
Figure 13. Forklift Slots.
Falling from the roof of the MTRCS can cause serious personal injury
Figure 14. Radiator Cap.
Figure 15. Forklift Slots.
7. While guiding cables in, slowly move forklift forward towards MTRCS
Figure 17. Refrigeration Unit Mounting Bolts.
Figure 18. Support Angle Bolt Layout.
REPLACE CONTINUED
Figure 20. Refrigeration Lines.
Figure 21. 1CP and 2CP Electrical Connectors.
25. Reconnect evaporator control connector (P8/J8)
Figure 23. Capacitor Box (P14/J14) and Power (P13/J13) Connectors.
29. Connect braided line connector (P12/J12)
32. Reconnect 50/60 Hz switch connector (P11/J11)
Figure 26. Electrical and Fuel Line Connections.
MAINTAINER MAINTENANCE REFRIGERATION UNIT (MTRC 502 ONLY) REPLACE
Figure 1. Electrical and Fuel Line Disconnects.
Figure 2. 50/60 Hz, P3/J3, and P9/J9 Electrical Connectors.
Figure 3. Braided Line (P12/J12) and P6/J6 Connectors.
Figure 4. Power (P13/J13) Connector.
Figure 5. Evaporator Control Connector.
Figure 6. 1CP and 2CP Electrical Connectors.
Figure 7. Refrigeration Lines.
Figure 8. Muffler Pipe U-Bolt.
Figure 9. Radiator Cap.
Figure 10. Electrical Cable Feeds.
27. Unbolt support angle at front end near bale bar by removing three bolts
Figure 12. Refrigeration Unit Mounting Bolts.
Figure 13. Forklift Slots.
32. Access top of MTRCS using roof access provided.
Figure 14. Radiator Cap.
Figure 15. Forklift Slots.
Figure 16. Electrical Cable Feeds.
Figure 17. Refrigeration Unit Mounting Bolts.
Figure 18. Support Angle Bolt Layout.
Figure 19. Muffler Pipe U-bolt.
Figure 20. Refrigeration Lines.
Figure 21. 1CP and
Figure 22. Evaporator Control Connector.
Figure 23. Power (P13/J13) Connector.
Figure 24. Braided Line P12/J12 and P6/J6 Connectors.
Figure 25. 50/60 Hz, P3/J3, and P9/J9 Electrical Connectors.
Figure 26. Electrical and Fuel Line Connections.
38. Reconnect battery (WP 0053, Reconnect). Tie wrap cables together.
MAINTAINER MAINTENANCE COMPRESSOR REPLACE
Figure 1. Refrigeration Support Bracket Removal.
6. Partially remove alternator (WP 0030, Remove).
Figure 2. Compressor Removal.
Figure 3. Compressor Mounting Aft End.
Figure 4. Compressor Hoist Install.
31. Drain compressor oil into suitable container (WP 0016
The two forward mount bolts will pass through the spacers
Figure 5. Compressor Installation.
23. Reconnect compressor discharge temperature sensor electrical connector
Figure 6. Refrigeration Support Bracket Installation.
33. Perform evacuation and dehydration to 500 (± 25) microns
MAINTAINER MAINTENANCE COMPRESSOR PRESSURE REGULATING VALVE REPLACE
Figure 1. CPR Valve.
The accumulator will need to be loosened from its mounting position
19. Reinstall refrigeration unit onto MTRCS
Main Heat Solenoid Valve
Figure 1. Main Heat Valve Coil.
A very small coil alignment pin is located at top of the valve outer body.
Main Heat Valve and 7/8-Inch Check Valve Assembly
Figure 2. Main Heat Valve Removal.
Because of tight clearance, it may be necessary to cut half of pipe
Figure 3. Heat Valve and Coil Installation.
16. On replacement main heat valve (Figure 2, Item 20)
32. Reconnect electrical connector to valve coil
MAINTAINER MAINTENANCE RECEIVER PRESSURE SOLENOID VALVE REPAIR, REPLACE
Figure 1. Receiver Pressure Solenoid Coil.
Perform the replacement task only if repair is ineffective.
Figure 2. Receiver Pressure Solenoid Valve.
7. Desolder each end of 1/4-inch receiver pressure solenoid
MAINTAINER MAINTENANCE DISCHARGE SERVIEC VALVE REPLACE
Figure 1. Discharge Service Valve Removal.
Many of the chemicals used while soldering are toxic
Figure 2. Discharge Service Valve Installation.
Many of the chemicals used while soldering are toxic.
22. Install top-left panel (WP 0013, Install).
MAINTAINER MAINTENANCE SUCTION SERVICE VALVE REPLACE
Figure 1. Suction Service Valve Assembly Removal.
Rear side of saddle clamp will stay in place until both saddle clamps have been removed
Figure 2. Support Arm.
Figure 3. Accumulator Mounting Removal.
Figure 4. Suction Service Valve Assembly (Standalone).
23. Install fitting (Figure 4, Item 4) in new valve (Figure 4, Item 1).
Figure 5. Suction Service Valve Assembly Installation.
36. Install support arm (Figure 3, Item 1) and support arm bracket
MAINTAINER MAINTENANCE RECEIVER AND CHECK VALVES REPLACE
Figure 1. Receiver.
11. Remove cap screw securing back of receiver.
Figure 2. Condenser to Receiver 3/8-Inch Check Valve
Figure 2. Condenser to Receiver 3/8-Inch Check Valve Replacement.
8. Carefully align piping (Figure 3, Item 2) with 1/4-inch check valve
MAINTAINER MAINTENANCE CONDENSER REPLACE
Figure 1. Lower Radiator Hose Disconnect.
Figure 2. Upper Radiator Hose Disconnect.
Figure 3. Overflow Tank.
Figure 4. Channel Bars.
Figure 5. Receiver Lines Disconnect.
18. Remove one screw (Figure 6, Item 1), nut (Figure 6, Item 2), lock washer
Figure 6. Clamp Removal at Filter-Drier.
24. Remove screw (Figure 7, Item 4) securing hot gas valve coil
Figure 8. Desolder Refrigerant Pipe.
Figure 9. Discharge Service Valve and Line.
There are four hex head bolts securing the base of the condenser assembly
The condenser assembly weighs approximately 40 pounds and is a bulky item
11. Install two clamps (Figure 6, Item 5) to two refrigerant pipes
The MTRCS contains high voltage sources and exposed rotating parts.
MAINTAINER MAINTENANCE ACCUMULATOR/HEAT EXCHANGER REPLACE
Figure 1. Support Arm.
Due to the fragile nature of the accumulator neck flanges and the tight workspace
Figure 2. Accumulator/Heat Exchanger Removal.
18. Desolder 1-1/8-inch refrigerant pipe (Figure 2, Item 24) between accumulator
Figure 3. Accumulator Buildup.
29. Carefully remove accumulator without disturbing pipe alignment
42. Install 3/8-inch refrigerant pipe fitting (Figure 4, Item 21)
Figure 4. Accumulator/Heat Exchanger Installation.
MAINTAINER MAINTENANCE SIGHT GLASS REPLACE
REPLACE CONTINUED
MAINTAINER MAINTENANCE REFRIGERATION UNIT DIESEL ENGINE REPLACE
Refrigeration unit diesel engine
Figure 2. Air Intake Manifold.
Figure 3. Air Intake Cleaner.
Figure 4. Water Pump Supply Hose Disconnect.
Figure 5. Radiator Hose.
Table 1. Engine Harness Disconnects.
Figure 7. Engine Inlet and Outlet Fuel Lines.
Figure 8. Oil Lines.
Figure 9. Engine Ground Strap.
Mounting bracket parts diagram
Figure 11. Hoist Attachment Points.
The engine fits tightly in the refrigeration unit chassis
Install the refrigeration unit diesel engine as follows:
Mounting bracket parts breakdown
11. Torque five bolts (Figure 12, Item 1) to 50 foot-pounds
Figure 13. Engine Ground Strap.
Figure 14. Oil Lines.
Figure 15. Engine Inlet and Outlet Fuel Lines.
Table 2. Engine Harness Connects.
Figure 17. Radiator Hose.
27. Secure wire harness (Figure 17, Item 2) to radiator return hose
30. Perform Alignment per this WP.
Alignment of the three major refrigeration unit components
Figure 22. Outboard Engine Mount Bracket Bolts.
9. Loosen five bolts (Figure 23, Item 1) on inboard engine mount bracket
Figure 24. Alignment Clearances.
15. Install top-right panel (WP 0013, Install).
MAINTAINER MAINTENANCE IDLER PULLEY REPLACE
Figure 1. Emergency Stop Switch.
Belt Installation Diagram
Engine to Compressor V-Belt Idler
Figure 3. Engine to Compressor V-Belt Idler.
12. Install tensioner adjustment bolt (Figure 3, Item 1) and washer (Figure 3, Item 3)
MAINTAINER MAINTENANCE ENGINE MOUNTED CENTRIFUGAL CLUTCH REPLACE
8. Partially remove engine to compressor V-belt (Figure 1, Item 8)
9. Immobilize flywheel (Figure 2, Item 3) by holding crankcase pulley
14. Install idler assembly (Figure 1, Item 3) onto bracket (Figure 1, Item 4).
MAINTAINER MAINTENANCE MICROPROCESSOR CONTROLLER ASSEMBLY REPLACE, SERVICE
Figure 1. Controller.
MAINTAINER MAINTENANCE ELECTRICAL BOX REPAIR
Figure 1. Electrical Box Repair.
Repair Replace Contactor
Figure 2. Contactor Repair.
MAINTAINER REPLACE STANDBY MOTOR/SINGLE-PHASE ALTERNATOR (MTRC 501 ONLY) REPLACE
Figure 1. Standby Motor Electrical Connection.
4. Remove standby motor to compressor V-belt (WP 0036, Remove).
Alternator Installation Diagram
Before removing fan, mark a fan blade to note the orientation
Parts Breakdown of Motor with Fan Blade
24. Lift standby motor/single-phase alternator assembly
Figure 4. Standby Motor/Single-Phase Alternator Assembly.
Install - The radiator coils damage easily.
REPLACE CONTINUED
12. Install condenser fan (Figure 5, Item 3) onto standby motor shaft
REPLACE CONTINUED
23. Reconnect electrical wiring (Figure 6, Item 10) to standby motor
Figure 7. Standby Motor Mount Bracket Bolts.
Figure 8. Alignment Clearances.
4. Tighten three bolts (Figure 7, Item 1) on inboard standby motor
MAINTAINER MAINTENANCE STANDBY MOTOR (MTRC S02 ONLY) REPLACE
Figure 1. Standby Motor Electrical Connection.
5. Loosen two alternator mounting bolts (Figure 2, Items 1 and 2) and self-locking nut
Figure 2. Alternator Removal.
17. Remove two screws (Figure 1, Item 6) and washers
23. Remove condenser fan (Figure 4, Item 3) from standby motor shaft
Figure 4. Standby Motor Attaching Hardware Removal.
Guide pulley around vibration absorber while lifting standby motor assembly.
Figure 5. Standby Motor Assembly.
The radiator coils damage easily. In order to install the standby motor
Figure 6. Standby Motor Attaching Hardware Installation.
Fan blades are sharp and can cut. Use gloves when handling fan blades
Mounting Bracket Diagram
13. Install new idler assembly shaft (Figure 8, Item 18) through idler pulley
Figure 8. Alternator Installation.
23. Install strain relief (Figure 9, Item 11) and nut (Figure 9, Item 10)
Figure 9. Standby Motor Electrical Connection.
MAINTAINER MAINTENANCE MICROPROCESSOR CONTROL BOX (MTRC S01 ONLY) REPAIR
REPAIR CONTINUED
Figure 2. MPC Box Relay Test.
Figure 3. MPC Box Relays, Capacitors, and Fuses.
5. Operate unit in accordance with normal operating procedures to verify proper operation
REPAIR CONTINUED
Figure 5. MPC Box Fuses.
Replace Time Delay
Figure 6. MPC Box Resistor, Ribbon Cable, Time Delay, and Diode.
Test Diode Block
Pin layout and circuit diagram
Figure 8. MPC Box Resistor, Ribbon Cable, Time Delay, and Diode.
Replace MPC Circuit Board
Figure 9. MPC Board.
13. Connect two electrical connectors (Figure 9, Item 17) to MPC circuit board
Figure 10. Microprocessor Control Display Panel
Table 1. Microprocessor Configuration Settings
Microprocessor Control Box Component Identification
Table 1. Microprocessor Control Box Component Identification Continued.
Figure 11. Microprocessor Control Box Back Wall and Bottom.
Figure 12. Microprocessor Control Box Door and Forward Wall.
Figure 13. Microprocessor Control Box Aft Wall.
Hybrid Standby Panel Relay Replace (Overload Protector OL)
REPAIR CONTINUED
7. Remove two nuts and washers from the 1EHR or 2EHR relay and remove the relay.
Shielded Ribbon Cable J12 Replace
REPAIR CONTINUED
Figure 17. J12
MAINTAINER MAINTENANCE MICROPROCESSOR CONTROL BOX (MTRC S02 ONLY) REPAIR
Table 1. Microprocessor Control Box Component Identification Continued.
Figure 1. Microprocessor Control Box Back Wall and Bottom.
Figure 2. Microprocessor Control Box Door.
Figure 3. Microprocessor Control Box.
1. Wait five minutes to allow stored energy to dissipate from capacitors
Figure 4. Capacitors.
1. Pull fuse holder (Figure 5, Item 1) up out of socket
Figure 5. Resistor and Fuses.
Replace Fuse F1
Evaporator Heater Relay Replace
Flashing Relay and Electric Motor Relay Replace
Panel Assembly Replace (Overload Protector (OL) and Motor Contactor (MC))
Figure 8. Panel Assembly (OL and MC).
7. Tag and remove four wires (Figure 9, Item 1) from top of MC
Figure 9. Overload Protector and Motor Contactor.
Replace Relay Board Fuse
Replace Relay
Figure 12. Relay Test.
Replace Relay Board
Replace Microprocessor (MPC) Board
Figure 14. Bolt Tightening Pattern.
The logic board will be destroyed if either terminal A1 or A3 is grounded.
Figure 16. Microprocessor Control Display Panel.
Table 2. Microprocessor Configuration Settings.
19. After all the proper settings are entered, move the main power (RS)
Figure 17. MPC Board.
MAINTAINER MAINTENANCE EVAPORATOR REPLACE
Figure 1. Control Box.
10. Tag and disconnect evaporator electrical connector (Figure 2, Item 1)
Figure 2. Evaporator Cover and Drain Line Disconnect.
Figure 3. 7/8-Inch Refrigerant Pipe Saddle Clamp.
Figure 4. 1/2-Inch and 3/8-Inch Refrigerant Pipes.
Steps 34 and 35 are for compartment 2 (aft) evaporator only.
Figure 5. Evaporator Mounting Removal.
Installation of compartment 1 (forward) and compartment 2 (aft)
Figure 6. Refrigerant Piping Stubout
Lifting or moving heavy equipment incorrectly can cause serious injury.
Figure 8. Evaporator Installation.
Use wet rags on either side of soldering points in order to dissipate heat
Figure 9. Evaporator Cover and Drain Line Installation.
24. Install drain tubes (Figure 9, Item 12) onto elbows
Figure 10. Control Box Assembly.
MAINTAINER MAINTENANCE EVAPORATOR THERMOSTATIC EXPANSION VALVE REPLACE
Figure 1. Control Panel.
Figure 2. TXV Replacement.
When removing the TXV bulb, it is important to note the position of the bulb
26. Solder equalizer line (Figure 2, Item 13) into TXV
Table 1. R-404A Pressure Temperature Chart to Determine S .
MAINTAINER MAINTENANCE CONTROL PANEL ASSEMBLY REPAIR
Figure 1. Control Panel Toggle Switches.
Replace Indicator Light Incandescent Lamps
Figure 2. Control Panel Indicator Light Incandescent Lamps.
Replace Indicator Lights
Figure 3. Control Panel Indicator Lights.
Replace Alarm Horns
Figure 4. Control Panel Alarm Horns.
Replace Terminal Board
Figure 5. Control Panel Terminal Board.
Replace Compartment ON/OFF Switches
Figure 6. Control Panel ON/OFF Switches.
Replace POWER ON/DOWN Switch
Figure 7. Control Panel POWER ON/DOWN Switch.
Replace Resistive Heating Element
Figure 8. Resistive Heating Element.
MAINTAINER MAINTENANCE POWER BOX (MTRC S01 ONLY) REPAIR
Figure 1. Power Control Box Door.
Replace Selector Switches S1, S2
Replace Circuit Breakers CB1, CB2
7. Carefully pull circuit breaker bracket (Figure 3, Item 11), with circuit breaker
Figure 3. Power Control Box Circuit Breaker.
Replace Toggle Switch
Figure 5. Control Panel Wire Bundle.
Figure 6. Power Box and Control Panel Assembly Door.
Figure 8. Power Box Attaching Hardware.
Figure 9. Control Panel Assembly Bolts.
Figure 10. Positioning Forklift Entering Power Box.
Figure 12. Top Power Box Mount Bolts.
Figure 14. Electrical Box Cover.
Figure 16. Power Box Door.
Figure 18. Lifting Strap.
Figure 20. Lifting Transformer from Power Box.
Figure 22. Transformer U-Nuts.
12. Install electrical box cover (Figure 14, Item 2) to electrical box
15. Move power box into position on MTRCS.
MAINTAINER MAINTENANCE POWER BOX (MTRC S02 ONLY) REPAIR
Figure 1. Power Control Box Door.
Replace Selector Switches S1, S2
Replace Circuit Breakers CB1, CB2
6. Remove four screws (Figure 3, Item 7), lock washers (Figure 3, Item 8)
REPAIR CONTINUED
Figure 4. Replace Relay.
2. Unplug and remove relay (Figure 4, Item 2) from relay socket
Replace Transformer TR1
Figure 6. Power Box and Control Panel Assembly Door.
Figure 8. Power Box Attaching Hardware.
Figure 9. Control Panel Assembly Bolts.
Figure 10. Positioning Forklift Entering Power Box.
Figure 11. Bottom Power Box Mount Bolts.
Figure 12. Top Power Box Mount Bolts.
Figure 13. Power Box Removal.
Figure 15. Removing TR1-X0 Wires
Figure 16. Lifting Strap.
Figure 17. Transformer Mounting Bolts.
24. Slowly lift transformer out of power box by guiding it around wires
Figure 19. Removing Wires on Transformer Terminal Block.
Figure 20. Transformer U-Nuts.
7. Secure transformer (Figure 16, Item 2) to power box (Figure 17, Item 4)
Figure 21. Lifting Power Box with Forklift.
Figure 22. Top Power Box Mount Bolts.
Figure 24. Control Panel Assembly Bolts.
19. Close control panel assembly door (Figure 6, Item 2).
MAINTAINER MAINTENANCEPOWER CABLE ASSEMBLIES REPAIR
Figure 1. Connector Repair.
11. Using contact crimp tool, locator, and die, crimp replacement contact (Figure 1, Item 9)
23. Reconnect battery (WP 0053, Reconnect).
MAINTAINER MAINTEANCE BATTERY BOX (MTRCS01 ONLY) REPLACE, REPAIR
Exercise caution when using tools on or around the battery.
Figure 3. Battery Cables.
12. Install negative (-) battery cable (Figure 3, Item 1) and secure negative
MAINTAINER MAINTENANCE BATTERY BOX (MTRC S02 ONLY) REPLACE, REPAIR
Replace Battery Cables
REPAIR CONTINUED
12. Install replacement positive (+) battery cable (Figure 3, Item 2)
MAINTAINER MAINTENANCE CAPACITOR BOX REPAIR
Figure 1. Capacitor Box.
Replace Capacitor Box Cover Seal
Figure 2. Capacitor Box Cover Seal.
MAINTAINER MAINTENANCE DOORS REPAIR
Figure 2. Prying Tool.
Replace Emergency Escape Hatch Gaskets
While removing the gasket you can damage the emergency escape hatch
Figure 5. Emergency Escape Hatch Inner Seal.
9. Apply lubricant to back of new outer gasket (Figure 3, Item 4).
MAINTAINER MAINTENANCE REFRIGERATION PIPING REPAIR
4. If desoldering a joint on a valve, disassemble valve as much as possible
1. Protect wiring harnesses and other components with appropriate heat shields.
2. Remove access panels as needed to gain access to piping or fittings.
MAINTAINER MAINTENANCE TORQUE LIMITS
Table 3. Bolt Torque Values for U.S. Threads in Foot-Pounds.
Table 4. Bolt Torque Values for Metric Threads in Foot Pounds.
MULTI-TEMPERATURE REFRIGERATED CONTAINER SYSTEM (MTRCS) GENERAL WIRING REPAIR
INTRODUCTION CONTINUED
WIRING DIAGRAMS, ELECTRICAL SCHEMATICS, AND REFRIGERATION SCHEMATICS
MULTI-TEMPERATURE REFRIGERATED CONTAINER SYSTEM (MTRCS) PREPARATION FOR STORAGE OR SHIPMENT
PREPARATION FOR STORAGE CONTINUED
CHAPTER 4 - SUPPORTING INFORMATION FOR MULTI-TEMPERATURE REFRIGERATED CONTAINER SYSTEM (MTRCS)
MULTI-TEMPERATURE REFRIGERATED CONTAINER SYSTEM (MTRCS) REFERENCES
INTRODUCTION FOR STANDARD MAINTENANCE ALLOCATION CHART (MAC)
Maintenance functions are limited to and defined as follows:
EXPLANATION OF COLUMNS IN THE MAC
EXPLANATION OF COLUMNS IN THE MAC CONTINUED
MULTI-TEMPERATURE REFRIGERATED CONTAINER SYSTEM (MTRCS) MAINTENANCE ALLOCATION CHART (MAC)
Table 1. MTRCS Maintenance Allocation Chart Continued.
Table 1. MTRCS Maintenance Allocation Chart Continued.
Table 1. MTRCS Maintenance Allocation Chart Continued.
Table 1. MTRCS Maintenance Allocation Chart Continued.
Table 1. MTRCS Maintenance Allocation Chart Continued.
Table 1. MTRCS Maintenance Allocation Chart Continued.
Table 1. MTRCS Maintenance Allocation Chart Continued.
Table 2. Tools and Test Equipment for MTRCS.
MULTI-TEMPERATURE REFRIGERATED CONTAINER SYSTEM (MTRCS) EXPENDABLE AND DURABLE ITEMS LIST
Table 1. Expendable and Durable Items List for MTRCS Continued.
Table 1. Expendable and Durable Items List for MTRCS Continued.
Table 1. Expendable and Durable Items List for MTRCS Continued.
MULTI-TEMPERATURE REFRIGERATED CONTAINER SYSTEM (MTRCS) MANDATORY REPLACEMENT PARTS LIST
Table 1. Mandatory Replacement Parts List for MTRCS Continued.
MULTI-TEMPERATURE REFRIGERATED CONTAINER SYSTEM (MTRCS) ADDITIONAL AUTHORIZATION LIST (AAL)
Table 1. Additional Authorization List (AAL) for MTRCS
