62-03709 Stardbird Plus

Starbird
TDB/TDS-215
and
Starbird Plus
TDB/TDS-219
62-03709-02 $6.00
OPERATION AND
SERVICE MANUAL
TRUCK REFRIGERATION UNIT
Starbird
TDB/TDS-215
and
Starbird Plus
TDB/TDS-219
Carrier Transicold Division, Carrier Corporation, P.O. Box 4805, Syracuse, N.Y. 13221
ã Carrier Corporation 1993 D Printed in U. S. A. 0993
TABLE OF CONTENTS
Section Page
1 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.2 Electrical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
1.3 Compressor Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
1.4 Refrigeration Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
1.5 Engine Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
1.6 Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
1.7 Safety Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13
1.8 Startronic --- Operating Controls and Instruments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14
1.8.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14
1.8.2 Startronic Control Panel and Related Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14
1.8.3 Startronic Power Panel and Related Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15
1.9 Ecotronic --- Operating Controls and Instruments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16
1.9.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16
1.9.2 Ecotronic Control Panel, Power Board and Related Components . . . . . . . . . . . . . . . . . . . . . . . . 1-16
1.9.3 Ecotronic Power Panel and Related Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-18
1.10 Standby Remote-Mounted Power Receptacle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19
1.11 Cab Command (Remote Control Box) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19
1.12 Compressor Pressure Regulating Valve (CPR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20
1.13 Hot Gas Valve (Three-Way) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20
1.14 Defrost Air Switch (DA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-21
1.15 Defrost Timer (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-21
1.16 Accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-21
1.17 Refrigerant System During Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-22
1.18 Refrigerant System During Heat and Defrost . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-23
2 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2.1 Startronic and Ecotronic Starting and Stopping Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2.1.1 Startronic --- Starting and Stopping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
2.1.2 Ecotronic --- Starting and Stopping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
2.2 Startronic Control Circuit Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
2.2.1 Startronic Engine Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
2.2.2 Startronic Cooling --- Engine Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
2.2.3 Startronic Heating --- Engine Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
2.2.4 Startronic Defrost --- Engine Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
2.2.5 Startronic Cooling --- Standby Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
2.2.6 Startronic Heating --- Standby Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
2.2.7 Startronic Defrost --- Standby Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
2.3 Ecotronic Control Circuit Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
2.3.1 Ecotronic Engine Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
2.3.2 Ecotronic Cooling --- Engine Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
2.3.3 Ecotronic Heating --- Engine Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
2.3.4 Ecotronic Defrost --- Engine Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
2.3.5 Ecotronic Cooling --- Standby Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17
2.3.6 Ecotronic Heating --- Standby Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18
2.3.7 Ecotronic Defrost --- Standby Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19
3 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3.1 Diesel Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3.1.1 Engine Will Not Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3.1.2 Engine Starts Then Stops . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
i
TABLE OF CONTENTS (CONTINUED)
Section Page
3 TROUBLESHOOTING (CONTINUED)
3.1.3 Starter Motor Malfunction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3.1.4 Malfunction in the Engine Starting Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
3.2 Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
3.3 Refrigeration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
3.3.1 Unit Will Not Cool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
3.3.2 Unit Runs But Has Insufficient Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
3.3.3 Unit Operates Long or Continuously in Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
3.3.4 Unit Will Not Heat or Has Insufficient Heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
3.3.5 Defrost Cycle Malfunction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
3.3.6 Abnormal Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
3.3.6.1 Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
3.3.6.2 Heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
3.3.7 Abnormal Noise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
3.3.8 No Evaporator Air Flow or Restricted Air Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
3.3.9 Hot Gas (Three-Way) Valve Malfunction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
3.3.10 Thermostatic Expansion Valve Malfunction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
3.4 Standby Motor Malfunction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
4 SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.1 Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.1.1 Daily Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.1.2 First 50 Hour Inspection and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.1.3 First 100 Hour Inspection and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.1.4 Every 100 Hour Inspection and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
4.1.5 Every 200 Hour Inspection and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
4.1.6 Every 750 Hour Inspection and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
4.2 Servicing Engine Related Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
4.2.1 Engine Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
4.2.2 Changing Lube Oil and Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
4.2.3 Optional Oil By-pass Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
4.2.4 Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
4.2.5 Replacing the Speed and Run Control Solenoids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
4.2.6 Servicing Glow Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
4.3 Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
4.3.1 Replacing the Fuel Pump Filter --- Old Style . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
4.3.2 Replacing the Fuel Pump Filter --- New Style . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
4.3.3 Priming the Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
4.4 V-Belts and Tensioners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
4.4.1 Changing Belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
4.4.2 Belt Tensioner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
4.5 Manifold Gauge Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
4.6 Pumping the Low Side Down or Removing the Refrigerant Charge Completely . . . . . . . . . . . . . . . . . . 4-7
4.6.1 Low Side Pump Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
4.6.2 Removing Refrigerant Charge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
4.7 Refrigerant Leak Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
4.8 Evacuation and Dehydration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
4.8.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
4.8.2 Preparation for Evacuation and Dehydration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
4.8.3 Procedure for Evacuation and Dehydration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
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TABLE OF CONTENTS (CONTINUED)
Section Page
4 SERVICE (CONTINUED)
4.9 Charging the Refrigeration System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
4.9.1 Installing a Complete Charge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
4.9.2 Adding a Partial Refrigerant Charge to the System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
4.9.3 Checking the Refrigerant Charge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
4.10 Purging Noncondensibles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
4.11 Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
4.11.1 Replacing the Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
4.11.2 Checking the Compressor Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
4.11.3 Adding Oil to the Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
4.12 Adjusting the Compressor Pressure Regulating Valve (CPR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
4.13 Quench Valve (Starbird Plus Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
4.14 Thermostatic Expansion Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
4.15 Hot Gas (Three-Way) Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
4.15.1 Replacing Solenoid Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
4.15.2 Replacing Hot Gas Valve Internal Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
4.16 Sight Glass --- Moisture Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
4.16.1 Moisture Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
4.17 Replacing the Filter-Drier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
4.18 High Pressure Cutout Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
4.18.1 Replacing High Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
4.18.2 Checking High Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
4.19 Adjusting the Low Pressure Cutout Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
4.20 Defrost Air Switch (DA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
4.20.1 Checking Calibration of the Defrost Air Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
4.21 Servicing the Alternator (12 vdc) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
4.21.1 Preliminary Checks and Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
4.21.2 Alternator Test Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
4.21.3 Diode Test Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
4.21.4 Brush Test Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
4.22 Checking and Replacing Fan Motor Brushes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
4.23 Setting the Cab Command . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
4.23.1 Setting the Critical Cargo Monitor Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
4.23.2 Calibrating the Cab Command . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
4.24 Adjusting Evaporator Fan Motor Potentiometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19
4.25 Temperature Controller Checkout Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19
4.25.1 Temperature Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19
4.25.2 Box Temperature Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19
4.25.3 Controller Set Point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19
4.26 Checking Diodes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20
4.27 Startronic Control System Test Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20
4.28 Ecotronic Control System Test Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21
4.28.1 Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21
4.28.2 Unit Running . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21
4.28.3 Operational Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21
4.28.4 Check Start/Stop Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21
4.28.5 Check Defrost . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21
4.28.6 Check Main Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22
4.28.7 Standby Operational Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22
5 ELECTRICAL WIRING AND TROUBLESHOOTING DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
5.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
iii
LIST OF ILLUSTRATIONS
Figure Page
1-1 Condensing Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1-2 Evaporator Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1-3 Roadside View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
1-4 Curbside View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
1-5 Startronic Control Panel --- Front View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
1-6 Startronic Control Panel --- Back View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
1-7 Startronic Logic Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
1-8 Ecotronic Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
1-9 Ecotronic Power Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
1-10 Ecotronic Evaporator Fan Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
1-11 Standby Power Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
1-12 Standby Remote Mounted Power Receptacle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19
1-13 Cab Command . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19
1-14 Hot Gas Valve --- Cooling Operation Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20
1-15 Hot Gas Valve --- Heat and Defrost Operation Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20
1-16 Refrigeration System --- Cooling Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-22
1-17 Refrigeration System --- Heat and Defrost Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-23
2-1 Automatic Starting Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

2-2 Temperature Controller Operating Sequence --- Engine Drive
Controller Set Point Above +10_F (---12_C) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
2-3 Temperature Controller Operating Sequence --- Engine Drive
Controller Set Point Below +10_F (---12_C) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
2-4 Temperature Controller Operating Sequence --- Standby Operation
Controller Set Point Above +10_F (---12_C) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
2-5 Temperature Controller Operating Sequence --- Standby Operation
Controller Set Point Below +10_F (---12_C) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
2-6 Startronic Starting --- Engine Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
2-7 Startronic High Speed Cooling --- Engine Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
2-8 Startronic Low Speed Heat --- Engine Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
2-9 Startronic Defrost --- Engine Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
2-10 Startronic Cooling --- Standby Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
2-11 Startronic Heating --- Standby Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
2-12 Startronic Defrost --- Standby Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
2-13 Ecotronic Starting --- Engine Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
2-14 Ecotronic High Speed Cooling --- Engine Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
2-15 Ecotronic Low Speed Heating --- Engine Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
2-16 Ecotronic Defrost --- Engine Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
2-17 Ecotronic Cooling --- Standby Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17
2-18 Ecotronic Heating --- Standby Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18
2-19 Ecotronic Defrost --- Standby Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19
4-1 Engine Oil Filter(s) System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

4-2 Speed and Run Control Solenoids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
4-3 Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
4-4 Electric Fuel Pump --- Old . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
4-5 Electric Fuel Pump --- New . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
4-6 V-Belts and Pulley Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
4-7 Standby Motor/Compressor Belt Tensioner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
4-8 Engine/Compressor Belt Tensioner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
iv
LIST OF ILLUSTRATIONS (CONTINUED)
Figure Page
4-9 Alternator Belt Tensioner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
4-10 Belt Tensioner Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
4-11 Manifold Gauge Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
4-12 Vacuum Pump Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
4-13 Sight Glass Refrigerant Charge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
4-14 05K Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
4-15 Compressor Oil Charge Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
4-16 Compressor Pressure Regulating Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
4-17 Thermostatic Expansion Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
4-18 Thermostatic Expansion Valve Bulb and Thermocouple . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
4-19 Hot Gas (Three-Way) Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
4-20 Checking High Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
4-21 Defrost Air Switch Test Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
4-22 Rotor Checkout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
4-23 Stator Checkout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
4-24 Regulator Checkout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
4-25 Diode Bridge Checkout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
4-26 Diode Bridge Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
4-27 Alternator Brush Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
4-23 Fan Motor Brushes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
4-29 Cab Command . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
4-30 Cab Command Side View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19
4-31 Evaporator Fan Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19
5-1 Startronic Control Panel and Logic Module Troubleshooting Diagram

Units prior to S/N BDL90069850 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2/5-3
5-2 Startronic Control Panel and Logic Module Troubleshooting Diagram
Units starting with S/N BDL90069850 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4/5-5
5-3 Ecotronic Control Panel and Logic Module Troubleshooting Diagram . . . . . . . . . . . . . . . . . . . . . 5-6/5-7
5-4 Ecotronic Power Board and Fan Module Troubleshooting Diagram
Units prior to S/N BDL90069848 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8/5-9
5-5 Ecotronic Power Board and Fan Module Troubleshooting Diagram
Units starting with S/N BDL90069848 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10/5-11
5-6 Startronic Wiring Diagram --- Three Phase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12/5-13
5-7 Ecotronic Wiring Diagram --- Three Phase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14/5-15
LIST OF TABLES
Table Page
1-1 Model Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1-2 Safety Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
4-1 R-500 Pressure --- Temperature Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21

4-2 R-12 Pressure --- Temperature Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22
4-3 R-22 Pressure --- Temperature Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23
v
SECTION 1
DESCRIPTION
1.1 INTRODUCTION and high speed heat. During standby drive, only cooling
and heating are provided. When in engine or standby op-
WARNING eration defrost may be initiated manually, automatically
Beware of unannounced starting of the fans and by the defrost air switch or by the optional solid state de-
V-belts caused by the thermostat and the frost timer.
start/stop cycling of the unit.
Unit operating controls are located on the Startronic
This manual contains Operating Data, Electrical or optional Ecotronic control panels, located on the
Data and Service Instructions for the truck refrigeration roadside of the unit. These panels contain a fully auto-
units listed in Table 1-1. Also Table 1-1 charts some sig- matic electronic control system which provides automatic
nificant differences between these models. preheat and starting. The panels have touch sensitive
keys for selecting unit operation, such as: Manual De-
The Starbird models are one piece units designed for frost, Fuel Mizer (fuel saver) On and Off, Standby and
truck applications. The TDS models are equipped with Road, and Manual Preheat and Starting. Also, the panels
an electric standby motor. The TDB model has a standby provide safety fault and indicating light emitting diodes
motor shell installed (without the motor winding) to al- (LED) to indicate unit operation.
low the same belt arrangement for both units. (Refer to
Table 1-1.) In addition, the optional Ecotronic system allows you
the choice between continuous run or stop/start opera-
The model/serial number plate is located inside the tion with minimum off time intervals of 22, 45 or 90 min-
unit on the rear frame as shown in Figure 1-4. utes after the signal to restart for more economical op-
An optional by-pass lube oil filter is available on this eration.
engine. With this lubricating system, oil is filtered a se- A remote receptacle is standard with all standby units.
cond time in the by-pass filter. This remote receptacle is equipped with a road/stop/
The temperature controller provides a range of standby switch to control the unit from ground level. The
---20_F to 70_F (---30_C to 20_C). The required operat- unit can also be controlled by the optional remote Cab
ing mode is automatically selected by the thermostat in Command within the cab. The remote standby receptacle
response to the evaporator return air temperature. When switch and Cab Command can not be used simultaneous-
in engine drive, the thermostat provides a four-step op- ly to control the unit.
eration: high speed cool, low speed cool, low speed heat
Table 1-1. Model Chart

Model Refrigerant Engine Compressor Standby Motor *
Starbird TDB-215N0-7 R-500 or R-12 CT3-37 (D600) V60 4 Cylinder ---
Starbird TDS-215N4-7 R-500 or R-12 CT3-37 (D600) V60 4 Cylinder 6.5 hp
Starbird Plus TDB-219E0-4 R-22 CT3-44 (D722) 05K 4 Cylinder ---
Starbird Plus TDS-219E4-4 R-22 CT3-44 (D722) 05K 4 Cylinder 6.5 hp
*208/230-volt,3-phase,60-hertz
1-1
STARBIRD
STARBIRD PLUS
1. Fuel Filter Assembly 8. Defrost Air Switch 15. Low Pressure Switch
2. Muffler 9. Temperature Controller 16. Compressor Pressure
3. Engine 10. Receiver Regulating Valve (CPR)
4. Compressor 11. Hot Gas (Three-Way) Valve 17. Water Temperature Switch
5. Electric Standby Motor 12. Sight Glass 18. Radiator Overflow Reservoir
6. Alternator (70 amp) 13. Filter-Drier 19. Air Cleaner
7. Accumulator 14. Condenser 20. Quench Valve (R-22 only)
Figure 1-1. Condensing Section
1-2
1. Thermostatic Expansion Valve
2. Evaporator Fan Motor
3. Evaporator Fan
4. Defrost Drip Pan Heater
5. Temperature Controller Sensor
Figure 1-2. Evaporator Section
1-3
1. Temperature Selector
2. Power Panel (Standby)
3. Control Panel
Figure 1-3. Roadside View
1. Fuel Filter Assembly 6. Fuel Supply Connection

2. Speed and Run Control Solenoids 7. Positive Battery Cable Connection
3. Negative Battery Cable Connection 8. Engine Oil Dipstick
4. Fuel Return Connection 9. Serial Plate (Located behind door)
5. Fuel Pump Electrical Connection
Figure 1-4. Curbside View
1-4
1
2
3
17
4
16 ON
5
15 OFF FUSE
S
AUTO 6
14 ON ALARM
R START
7
13 START
STARTRONIC ON OFF
MAN.
8
12
9
11 Prior to S/N BDL90069850 10
1
2
3
17
4
16
FUSE
5
15
ON AUTO ALARM
6
14 START
7
13 MAN.
STARTRONIC ON OFF
START
8
12
11 9
Starting with S/N BDL90069850 10
1. Control Panel --- Startronic 7. High/Low Pressure Fault LED 13. Road Operation Key/LED (R)
2. Engine Hourmeter 8. Water/Oil Safety Fault LED 14. Standby Operation Key/LED (S)
3. Heating LED 9. “OFF” Key 15. Fuel Mizer OFF Key/LED
4. Cooling LED 10. “ON” Key 16. Fuel Mizer ON Key/LED
5. Fuse Fault LED 11. Manual Preheat Key 17. Manual Defrost Key/LED
6. Battery Fault LED 12. Manual Engine Start Key
1-5
Figure 1-5. Startronic Control Panel --- Front View
1 2 3 4 5 6
16 LOGIC MODULE 7
(Z) I N (X)
AV
15 GPR SR D D FR1
SS
R9 D R3 D D R6/1
SSR D RR D D D D
FR2
R11 R26 D D D D R6/2
14
13 12 11 10 9 8
Prior to S/N BDL90069850
1 2 3 5 6
7
16
LOGIC MODULE
I N
AV
15 GPR D D FR1 FR2

SS
R9 DD D D R6/1 R6/2
I N
10 SSR DD RR D D D
FR3
R11 R26 D D D R6/3
14
SR
R3
13 12 4 11 17 9 8
Starting with S/N BDL90069850
1. Run Solenoid Control Shunt (Z) 7. Evaporator Fan Relays (1, 2 & 3) 13. Connector D
2. Remote Control Shunt (X) 8. Connector H 14. Starter Solenoid Relay
3. Electronic System Fuse 9. Evaporator Fan Fuses 15. Glow Plug Relay
(F14, 2 amp) (F2-1, 2, & 3, 20 amp) 16. Logic Module
4. Speed Relay 10. Main Fuse (F1, 15 amp) 17. Run Relay (R26) Control Shunt (W)
5. Fuel Pump Fuse (F18, 3 amp) 11. Run Relay
6. Voltage Regulator Fuse 12. Connector C (Optional Heat Plug)
(F19, 3 amp)
Figure 1-6. Startronic Control Panel --- Back View
1-6
1
HR 2
R5
N I MCR FPR 3
(C3) R4b R28
CR
R10 ULR VRR
R20 R29
4
8 7 6 5
1. Logic Module
2. Heat Relay
3. Fuel Pump Relay
4. Voltage Regulator Relay
5. Motor Contact or Relay
6. Unloader Relay (not used in this application)
7. Control Relay
8. Speed Relay Control Shunt (C3)
Figure 1-7. Startronic Logic Module
1-7
1 2 3
17
16
1
4
15 2
14 OFF AUTO
ON START 3 5
OFF
13
S 6
ON
12
R
7
11 ECOTRONIC
8
10
9
ECOTRONIC CONTROL PANEL --- FRONT VIEW
19
18
20
(X) AV
SS
RIBBON CABLE
21
D
D 22
23
ECOTRONIC CONTROL PANEL --- BACK VIEW

1. Control Panel --- Ecotronic 10. Manual Engine Start Key 19. Off Time Override Pins
2. Control Selector Switch 11. Road Operation Key/LED 20. Control Relay
3. Engine Hourmeter 12. Standby Operation Key/LED 21. Remote Control Shunt (X)
4. Evaporator Fan Fault LED 13. Fuel Mizer OFF Key/LED 22. Electronic System Fuse
5. Battery Fault LED 14. Fuel Mizer ON Key/LED (F14, 2 amp)
6. Fuse Fault LED 15. Manual Defrost Key/LED 23. Connector C (Optional
7. High/Low Pressure Fault LED 16. Cooling LED Heat Plug)
8. Water/Oil Safety Fault LED 17. Heating LED
9. Manual Preheat Key 18. Logic Module
Figure 1-8. Ecotronic Control Panel
1-8
1 2 3 4 5 6 7
FR1 FR2 FR3 BR SR RR SSR

R6/1 R6/2 R6/3 R25 R3 R26 R27 R11
I (Z)
fff N d 8
fff
fff FAN PROTECTION MODULE D
d(C3)
D
GPR
D D d d R9 9
D D RIBBON CABLE
10
14 13 16 12 11
Prior to S/N BDL90069848
1 2 4 5 6 17
FR1 FR2 FR3 SR RR I

(W) SSR
7
R6/1 R6/2 R6/3 R3 R26 N d R11
I (Z)
fff N d 8
fff
I
d (C3)
D
GPR
D D N d d R9 9
D D RIBBON CABLE
10
15 14 13 16 12 11
Starting with S/N BDL90069848
1. Power Board 7. Starter Solenoid Relay 13. Fuel Pump Fuse (F18, 3 amp)
2. Evaporator Fan Relays (1, 2 & 3) 8. Run Solenoid Control Shunt (Z) 14. Voltage Regulator Fuse
3. Battery Relay 9. Glow Plug Relay (F19, 3 amp)
4. Speed Relay 10. Connector D 15. Connector H
5. Run Relay 11. Main Fuse (F1, 15 amp) 16. Fan Module
6. Relay LEDs 12. Speed Relay Control Shunt (C3) 17. Run Relay Control Shunt (W)
Figure 1-9. Ecotronic Power Board
1-9
1 2 3 4 5
FPR MCR
R28 R4b
8 ULR VRR
R20 R29
HR
R5 6
7 (C2)
1. Fan Module
2. Fuel Pump Relay
3. Motor Contact or Relay
4. Voltage Regulator Relay
5. Fan Potentiometer
6. Evaporator Fan Shunt (C2)
7. Heat Relay
8. Unloader Relay
Figure 1-10. Ecotronic Evaporator Fan Module
1-10
1
DIESEL EN-
GINE
HOURMET-
ROAD OPERATION
ER
STANDBY
OPERA-
GLOW PLUG
TION
START
COOLING
HEATING
ALARM
Low DEFROST
Water/Oil Battery
HOURMETER STANDBY Safety
Protection Pres- POWER SAVER
Fuse sure
Fault
2 3 4 5
1. Power Panel --- Startronic and Ecotronic

2. Motor Overload Relay (MOL)
3. Motor Overload Timer (MOT)
4. Motor Overload Timer Fuse
5. Motor Contactor
(Startronic and Ecotronic TDS Models Only --- TDB Models have blank panels)
Figure 1-11. Standby Power Panel
1-11
1.2 ELECTRICAL DATA g. Thermostatic Expansion Valve Superheat
a. Evaporator Fan Motors Setting: 13 ¦ 1_F (7_C) (0_F box temp.)
Bearing Lubrication: Factory lubricated, h. Low Pressure Switch (LPS)
additional grease not required Cutout setting: 15 ¦ 1 in. Hg. Vacuum (22.9 cm)
Horsepower: 1/5 hp (.15 kw) Cut-in setting: 5 ¦ 1 psig (.35 kg/cm@)
Operating Amps: ± 12 amps
Speed: 2800 rpm i. Quench Valve (R-22 Models)
Voltage: 12 vdc Opens at: 270_F (132_C)
b. Standby Motors 1.5 ENGINE DATA
Bearing Lubrication: Factory lubricated
Starbird: Type: CT2-37
additional grease not required
Number of Cylinders: 3
Horsepower: 6.5 hp (4.8 kw)
Displacement: 36.6 cu. in. (600 cc)
Rotation Speed: 1740 rpm
Horsepower: 11 hp (8 kw)
208/230-vac, 3-ph, 60-hz or
Coolant Capacity: 3.7 U.S. quarts (3.5 liters)
optional 380/460-vac, 3-ph, 50/60-hz
Starbird Plus: Type: CT3-44TV
c. Alternator: 70 amps Number of Cylinders: 3
d. Motor Overload (3-ph) Displacement: 43.8 cu. in. (719 cc)
Setting: 12.5 amps (230 & 460 vac) Horsepower: 14 hp (10.4 kw)
Coolant Capacity: 3.7 U.S. quarts (3.5 liters)
1.3 COMPRESSOR DATA a. Water Safety Switch
Model Starbird Starbird Plus Closes at: 234_ ¦ 5_F (112 ¦ 3_C)
V60 Carrier b. Operating Speeds
Compressor
05KB024 High Speed: 2320 rpm
No. of Cylinders 4 4 Low Speed: 1800 rpm
Weight 70 lb. (31.75 kg) 108 lb. (49 kg) c. Injector Setting
20.7 cu. in. 24.4 cu. in. Minimum Working Pressure: 1990 psig (140 kg/cm@)
Displacement Setting Pressure: 2133 psig (150 kg/cm@)
(339 cc) (400 cc)
2 quarts 5.5 pints d. Lubrication System
Oil Charge
(1.9 liters) (2.6 liters) Capacity: 8 U.S. quarts (7.7 litres) (Includes filter)
Approved Oil ESSO 568 SUNISO 3GS Lube Oil Viscosity: (API Classification CD)
Oil Sight Glass: Oil level should be between 1/4 to
1/2 of sight glass with the compressor in operation. Outdoor Temperature
SAE
Fahrenheit Centigrade
1.4 REFRIGERATION DATA
Below 32_ 0_C 10W or 10W30
a. Defrost Air Switch Setting
Initiates at: 0.70 ¦ .07 inch wg (20.3 ¦ 1.7 mm) 32_ to 77_F 0_ to 25_C 20W
b. Defrost Thermostat Over 77_F Over +25_C 30W or 15W40

Opens at: 47_ ¦ 5_F (8_ ¦ 3_C)
e. Oil Pressure Safety Switch
Closes at: 37_ ¦ 5_F (3_ ¦ 3_C)
Closes at: 14 ¦ 3 psig (1¦ 0.2 kg/cm@)
c. Defrost Timer (Optional)
Setting: 1-1/2, 3 or 6 hours 1.6 TORQUE VALUES
d. High Pressure Cutout Switch (HP) 1. Power Tray to Frame: 51 ft-lb. (7 kg-m)
2. Standby Motor to Power Tray: 51 ft-lb. (7 kg-m)
R-500, R-12: Cutout at: 350 ¦ 10 psig (25 ¦ 0.7 kg/cm@)
3 Engine to Power Tray: 51 ft-lb. (7 kg-m)
Cut-in at: 285 ¦ 10 psig (20 ¦ 0.7 kg/cm@) 4. Compressor to Power Tray: 29 ft-lb. (4 kg-m)
R-22: Cutout at: 397 ¦ 10 psig (27 ¦ 0.7 kg/cm@) 5. Standby Motor Pulley: 18 ft-lb. (2.5 kg-m)
Cut-in at: 323 ¦ 10 psig (22 ¦ 0.7 kg/cm@) 6. Engine Pulley: 51 ft-lb. (7 kg-m)
e. Refrigerant Charge 7. Compressor Pulley: 26 ft-lb. (3.6 kg-m)
R-500 15.5 lb (7 kg) 8. Evaporator Fan Motor: 13 ft-lb. (1.8 kg-m)
R-12 15.5 lb (7 kg) 9. Evaporator Fan Grille: 13 ft-lb. (1.8 kg-m)
R-22 13.6 lb (6.2 kg) 10. Condenser Coil to Chassis: 7 ft-lb. (1 kg-m)
11. Tensioner to Power Tray: 29 ft-lb. (4 kg-m)
f. Compressor Pressure Regulating Valve (CPR) Setting 12. Speed/Run Solenoid: 7 ft-lb. (1 kg-m)
R-500,R-12 3-phase 18 ¦ 1 psig (1.05 kg/cm@) 13. Standby Motor Pulley: 27 ft-lb. (3.8 kg-m)
14. Condenser Fan Blade: 22 ft-lb. (3 kg-m)
R-22 3-phase 17 ¦ 1 psig (1.2 kg/cm@) 15. Engine Clutch: 40 ft-lb. (5.5 kg-m)
1-12
1.7 SAFETY DEVICES With the Startronic or Ecotronic system, if a safety de-
vice shuts down the unit, restarting can only be accom-
System components are protected from damage
plished by resetting the control system. To reset the sys-
caused by unsafe operating conditions by automatically
tem, it must be turned off and on again at the control pan-
shutting down the unit when such conditions occur. This
el, after the problem has been corrected.
is accomplished by the safety devices listed in Table 1-2.
Table 1-2. Safety Devices
Unsafe Conditions Safety Device Device Setting

1. Low engine lubricating oil Oil pressure safety switch (OP) Closes below 14 ¦ 3 psig (1 ¦ 0.2
pressure. Automatic reset kg/cm@)
2. High engine cooling water Water temperature Opens above 234_ ¦ 5_F (112 ¦
temperature. switch (WT). Automatic reset 3_C)
3. Excessive compressor High pressure cutout switch (HP). Opens at 350_¦ 10 psi
discharge pressure. Automatic reset. (25_ ¦ 0.7 kg/cm@) for R-500 & R-12
Opens at 395_¦ 10 psi
(28_ ¦ 0.7 kg/cm@) for R-22
4. Excessive motor Motor overload (MOL). Opens at 12.5 amps, cuts-in
current draw (3-ph). Automatic reset and delay timer. 10 minutes later (timer).
5. Excessive current draw by the Fuse (F1) Opens at 15 amps.
control circuit.
electronic system.
7. Excessive current draw by Fuse (F14) Opens at 2 amps.
the temperature controller.
fuel pump.
9. Excessive current draw by the Fuse F19 Opens at 3 amps.
voltage regulator.
10. Low compressor Low pressure switch Opens at 15 inches
suction pressure. (LP). Automatic Reset. (38 cm) hg vacuum.
*11. Excessive current draw Fuses F2/1, 2 or 3. Each opens at 20 amps
by the evaporator fan motors.
**12. Excessive current draw Current sensors will cause fan Each opens at 12 amps
by the evaporator fan motors. relays (FR1, 2 or 3) to open.
**13. Excessive motor Circuit breaker (CB) Opens at 30 amps.
current draw (3-ph). Manual reset.
*STARTRONIC ONLY **ECOTRONIC ONLY
1-13
1.8 STARTRONIC --- OPERATING CONTROLS lenoid to energize during unit operation by allowing the
AND INSTRUMENTS run relay R26 to always remain energized (See Figure 5-1
and Figure 5-2) The control solenoid will pull open the
1.8.1 Introduction fuel rack to allow the engine to run when energized.
Startronic is an electronic system for controlling and 3. Speed Relay Control Shunt (C3)
operating the refrigeration unit. The Startronic system The speed relay control shunt (C3) is located on the
provides automatic preheating and starting from the con- logic module. The shunt is positioned according to the re-
trol panel, Cab Command or the remote standby recep- quired operation of the speed control solenoid during
tacle switch. low and high speed modes. In this application, shunt C3 is
The Startronic system provides continuous unit op- placed in the “I ” position (to the right on the high speed
eration. During road operation, the unit will operate in control pin, see Figure 5-1 and Figure 5-2) This will allow
high or low speed. The required operating mode is auto- the speed relay (SR) to energize for high speed opera-
matically selected by the thermostat in response to evap- tion.
orator return air temperature (see Figure 2-2 and 4. Run Relay (R26) Control Shunt (W)
Figure 2-3).
The Run Relay (R26) control shunt (W) is located on
When in standby operation, the thermostat will cycle the back of the control panel. The position of shunt W is
the unit on or off in response to evaporator return air determined by a normally open (‘‘N”) or normally closed
temperature (see Figure 2-4 and Figure 2-5). (‘‘I”) R26 relay. In this application shunt W is placed in
the ‘‘N” position (normally open, see Figure 5-1 and
1.8.2 Startronic Control Panel and Related Compo- Figure 5-2)
nents (See Figure 1-5, Figure 1-6 and Figure 1-7.)
d. Hourmeter
a. Control Panel The digital engine hourmeter and optional standby
The front of the control panel consists of a touch-sen- hourmeter display the total hours of engine standby mo-
sitive key pad, fault and indicating light emitting diodes tor operation. This data can be used to record running
(LEDs) and a digital hourmeter. These features allow hours for periodic maintenance. The hourmeter is a re-
the user to observe and control the operation of the unit. placeable item.
On the back of the control panel are replaceable re- e. Manual Switches
lays, fuses, a logic module (plug in circuit board), and the
remote and speed relay control shunts. 1. Manual Defrost Key
b. Logic Module The defrost key will allow manual initiation of de-
NOTE frost. When the key is pushed, the unit will go into defrost
in the same manner as when initiated by the defrost air
If it is necessary to change the logic module, the
switch (DA). Defrost cannot be initiated unless the de-
battery connections must first be disconnected
frost termination switches (DTs) are closed. Defrost is
to prevent damage to the electronic system.
terminated by the opening of the DT switches. The de-
The logic module located on the back of the control frost LED will light to indicate initiation of defrost.
panel consists of non-replaceable relays and a speed relay 2. Fuel Mizer ON Key
control shunt (C3). The logic module accepts data from The fuel mizer ON key when pressed during engine
various control sensors and safety devices (thermostat, operation will reduce fuel consumption. Initiating the
klixon, defrost air switch, fuel mizer switch, oil pressure fuel mizer mode will place the unit in low speed opera-
and water temperature) and according to the input given tion. The speed relay is energized to reduce the engine
by the user, it monitors and controls the relays. speed from 2320 rpm to 1800 rpm. The LED will light to
c. Control Shunts indicate initiation of fuel mizer mode.
1. Remote Control Shunt (X) 3. Fuel Mizer OFF Key
The remote control shunt (X) is located on the back of The fuel mizer OFF key will allow the unit to resume
the control panel. The position of this shunt depends on normal operation controlled by the temperature control-
the application of the Cab Command or remote standby ler. An LED will light to indicate that the fuel mizer mode
receptacle box. (See Figure 5-1 and Figure 5-2) If either is off.
the Cab Command or the remote standby receptacle is 4. Standby Operation Key
used, shunt (X) is positioned in the “AV” position. When
only the control panel is used to control the unit, the Standby operation is selected by this key. Selection of
shunt is placed in the ‘‘SS’ position. standby operation is only necessary during the initial
start-up. When the unit is restarted, it will automatically
2. Run/Stop Solenoid Control Shunt (Z) default to standby unless previously changed to road (en-
The run solenoid control shunt (Z) is located on the gine) operation. The standby LED will light to indicate
back of the control panel. The shunt position controls standby operation.
whether the run relay R26 is always energized during unit
operation or only when high speed is required. In this ap-
plication shunt Z is in the “I” position to allow the run so-
1-14
5. Road Operation Key g. Indicator LEDs
Road operation is selected by this key. Selection of 1. Heating LED
road operation is only necessary during the initial start- A lighted LED indicates high or low speed heating.
up. When the unit is restarted, it will automatically de-
fault to road operation unless previously changed to 2. Cooling LED
standby operation. The road operation LED will light to A lighted LED indicates high or low speed cooling.
indicate road operation.
6. ‘‘ON” Key 3. Road Operation LED
The “ON” key will start the unit automatically in the A lighted LED indicates unit is running in engine op-
last mode of operation selected, road or standby. This key eration.
must also be pushed first to energize the control system
when using either the Cab Command or remote standby 4. Standby Operation LED
receptacle. The hourmeter colon will blink when the pow- A lighted LED indicates unit is running in standby op-
er is on. eration.
7. “OFF” Key 5. Fuel Mizer ON LED
The “OFF” key will stop the unit and shut down the A lighted LED indicates unit is locked-in (engine) low
control system. speed operation.
8. Manual Preheat Key 6. Fuel Mizer OFF LED
The manual preheat key will override automatic pre- A lighted LED indicates unit operation (high and low
heat and allow manual preheating of the engine from the speed) is controlled by the temperature controller.
control panel. This key may be used during pre-trip in- 7. Defrost LED
spection and servicing of the unit.
A lighted LED indicates unit is in defrost.
9. Manual Engine Start Key
h. Fault LEDs
The manual engine start key will override automatic
start-up and allow manual engine start-up from the con- 1. Fuse Fault LED
trol panel. This key may be used during pre-trip inspec- A lighted LED indicates one or more of the fan motor
tion and servicing the unit. fuses located on the back of the control panel has opened.
f. Safety Switches 2. Battery Fault LED
NOTE A lighted LED indicates excessive current draw on
If the unit shuts down because of a safety switch, the battery because of a lack of alternator output charge.
the control system must be reset by pushing the The unit will shut down.
control panel “OFF” key first, then the “ON” 3. High/Low Pressure Fault LED
key.
A lighted LED indicates either high or low pressure
1. High Pressure Cutout Switch (HP) within the system. Either condition will shut the unit
down.
If the compressor discharge pressure exceeds pressur-
es listed in section 1.4.d., this switch will open, de-ener- 4. Water/Oil Fault LED
gizing the control circuit to stop the unit. A lighted LED indicates either low engine oil pres-
2. Low Pressure Switch (LP) sure or high engine water temperature. Either condition
will shut the unit down.
The low pressure switch will open at 15 inches (38 cm)
hg vacuum if low pressure occurs in the refrigeration sys- 1.8.3 Startronic Power Panel and Related Components
tem. The LP switch will not re-close until system pressure (See Figure 1-11.)
is at least 5 psig.
All electric standby (TDS) units are equipped with
3. Oil Pressure Switch (OP) power panels. These units can run on either 230 vac or
The oil pressure switch will close at 14 ¦ 3 psig 460 vac. Depending on the available power supply, the
(1 ¦ 0.2 kg/cm@) upon loss of oil pressure to automatical- main plug (A), located on the back of the panel must be
ly stop the engine after 5 seconds to prevent engine dam- connected to the applicable connector plug labeled
age. “220v” for 230 vac power supply, or the connector plug la-
beled “380V” for 460 vac power supply. These plugs are
4. Water Temperature Switch (WT) also located on the back of the power panel. See
If engine water temperature rises to 234 ¦ 5_F (112 Figure 1-11 for reference.
¦ 3_C), the switch will close, as a result the engine will
stop 5 seconds later. WARNING
This change should only be done with the
main power disconnected.
1-15
a. Motor Overload (MOL) During engine continuous run operation the required
operating mode (high or low speed cooling and heating,)
The function of the motor overload is to protect the
is automatically selected by the thermostat in response to
standby motor against high amperage draw. The over-
the evaporator return air temperature. (See Figure 2-2
load provides an adjustable knob to set the maximum am-
and Figure 2-3.)
perage overload draw which should be set to 12.5 amps.
The overload adjustment remains the same for both 230 When in standby operation the thermostat will cycle
vac and 460 vac supply. the unit on and off in response to evaporator return air
temperature. (See Figure 2-4 and Figure 2-5.)
The motor overload is also equipped with a reset but-
ton. This button has three positions: automatic reset, The Ecotronic control system consists of a control
manual and test. In this application the button should re- panel, power board and an optional Cab Command or re-
main in the automatic reset position. mote standby receptacle.
b. Motor Overload Timer (MOT) 1.9.2 Ecotronic Control Panel, Power Board and
If the standby motor shuts down because of motor Related Components (See Figure 1-8, Figure 1-9 and
overload, the motor overload timer (MOT) will not allow Figure 1-10.)
the motor to restart for a minimum of 10 minutes. This a. Control Panel
delay allows the standby motor to cool; it has no effect on
the operation of the unit under normal operation. During The front of the control panel consists of a touch-sen-
the timing mode the LED will be blinking. sitive key pad, fault and indicating light emitting diodes
(LEDs) and a digital hourmeter (see Figure 1-8). These
components allow the user to observe and control the op-
1.9 ECOTRONIC --- OPERATING CONTROLS eration of the unit. A logic module is located on the back
AND INSTRUMENTS of the control panel.
b. Logic Module
1.9.1 Introduction NOTE
Ecotronic is an electronic system for controlling and If it is necessary to change the logic module, the
operating the refrigeration unit. The Ecotronic system battery connections must first be disconnected
allows a choice between automatic cycling (start/stop) of to prevent damage to the electronic system.
the diesel engine or continuous operation.
The logic module is located on the back of the control
In start/stop operation, if the box temperature reach- panel. This module, in conjunction with the power board,
es 1.4_F (0.75_C) above the set point and all safety pre- controls the relays by monitoring the operation of the
cautions outlined below are satisfied, the unit will shut unit and the input from the operator.
down. When the box temperature exceeds 2.7_F (1.5_C)
above or below set point, the minimum selected off time Also located on the logic module is a set of off-time
will begin (22, 45 or 90 minutes). After the selected time override pins (see Figure 1-8 and Figure 5-3). A Jumper
interval is completed, the unit will restart if the unit is still placed on these test points prior to starting, will override
2.7_F (1.5_C) from the set point. the preset off-times (22, 45 and 90 minutes) and restart
the unit within a few seconds. This may be done when
The start/stop system incorporates several safety fea- checking the operation or servicing the unit. Other test
tures to ensure reliable operation. The following condi- points are also provided on the module for troubleshoot-
tions must be satisfied before the unit will shut down: ing purposes.
1. The battery charge must be above 13.2 volts. This c. Power Board
will ensure a successful restart.
The power board (which is used in conjunction with
2. The engine Restart Override Thermostat (ROT) the control panel and logic module) is located inside the
must be open. control box. The power board is the interface between
3. The engine must run for a minimum of 10 minutes the relays and the control panel. The connection of the
in high speed after starting. This will maximize battery two is made with a ribbon cable.
charge while preventing short cycling of the unit. It will The power board consists of relays (with LEDs),
also ensure a sufficient air flow, time to sample load tem- fuses, speed relay control shunt (C3), run/stop solenoid
perature and prevent hot spots. control shunt, and a replaceable evaporator fan module.
Refer to section 1.9.2.e. for correct shunt positions.
NOTE
Battery maintenance is a must when operating in
the start/stop mode.
When in the off-time mode, if the box temperature

exceeds 11_F (6_C) above or below the set point the unit
will restart. If the engine block temperature drops to
41_F (5_C) the Restart Override Thermostat will close
and the controller will override the programmed off-time
and restart the unit.
1-16
d. Evaporator Fan Module f. Hourmeter
The evaporator fan module is plugged into the power The digital engine hourmeter and optional standby
board (see Figure 1-9, Figure 1-10, Figure 5-4 and hourmeter display the total hours of engine standby mo-
Figure 5-5). The module is an electrical device which con- tor operation. This data can be used to record running
trols and protects the evaporator fan motors. The protec- hours for periodic maintenance.
tion of the fan motors is accomplished by detecting the
current draw of fan motors. If the amperage draw on an g. Manual Switches
evaporator fan motor is below 3 amps or over the set 1. Control Selector Switch
point (on the potentiometer), the fan will stop and the
evaporator fan fault LED will light. A potentiometer is The selector switch is used to start the unit and allows
supplied to adjust the upper cut-out point. This poten- the operator the choice between continuous or start/stop
tiometer is factory set and should not require field adjust- operation of the diesel engine. The selector switch posi-
ment under normal conditions. (Refer to section 4.24.) tions are: Off, Auto/Start (automatic starting in continu-
An evaporator fan shunt (C2) is located on fan module; ous operation) and Start/Stop operating intervals of 22,
refer to the following section for correct shunt position. 45 or 90 minute delay times after restart signal.
If Start/Stop operation is desired, placing the switch
e. Control Shunts in one of the off-time positions will stop the unit when the
1. Remote Control Shunt (X) box temperature reaches 1.4_F (0.75_C) above the set
point. Refer to section 1.9.1 for description of start/stop
The remote control shunt (X) is located on the back of operation.
the control panel. The position of this shunt depends on
the application of the Cab Command or remote standby 2. Manual Defrost Key
receptacle box (see Figure 5-3). If either the Cab Com- The defrost key will allow manual initiation of de-
mand or the remote standby receptacle is used, shunt (X) frost. When the key is pushed, the unit will go into defrost
is positioned in the “AV” position to enable the unit to in the same manner as when initiated by the defrost air
function properly. switch (DA). Defrost cannot be initiated unless the ther-
2. Run/Stop Solenoid Control Shunt (Z) mostat klixons (DTs) are closed. Defrost is terminated by
the defrost DTs. An LED will light to indicate initiation
The run/stop solenoid control shunt (Z) is located on of defrost.
the Ecotronic power board. The shunt position is deter-
mined by the use of the run solenoid relay (R26). In this 3. Fuel Mizer ON Key
application the run relay (R26) is used and the shunt re- The fuel mizer ON key when pressed during engine
mains in the “I” position (see Figure 5-4 and Figure 5-5). operation will reduce fuel consumption. Initiating the
The control solenoid will pull open the fuel rack to allow fuel mizer mode will place the unit in low speed opera-
the engine to run when energized. tion. The speed relay is energized to reduce the engine
3. Speed Relay Control Shunt (C3) speed from 2320 rpm to 1800 rpm. The LED will light to
indicate initiation of fuel mizer mode.
The speed relay control shunt (C3) is located on the
Ecotronic power board. The shunt is positioned accord- 4. Fuel Mizer OFF Key
ing to the required operation of the speed control sole- The fuel mizer OFF key will allow the unit to resume
noid during low and high speed modes. In this applica- normal operation controlled by the temperature control-
tion, shunt C3 is placed in the ‘‘I’’ position (high speed ler. An LED will light to indicate that the fuel mizer mode
control pin, see Figure 5-4 and Figure 5-5). This will al- is off.
low the speed relay (SR) to energize for high speed op-
eration. When the relay energizes, a set of contacts 5. Standby Operation Key
closes, in turn energizing the speed control solenoid. Standby operation is selected by this key. Selection of
4. Run Relay (R26) Control Shunt (W) standby operation is only necessary during the initial
start-up. When the unit is restarted, it will automatically
The Run Relay (R26) control shunt (W) is located on default to standby unless previously changed to road (en-
the back of the control panel. The position of shunt W is gine) operation. An LED will light to indicate standby
determined by a normally open (‘‘N’’) or normally closed operation.
(‘‘I’’) R26 relay. In this application shunt W is placed in
the ‘‘N’’ position (normally open, see Figure 5-5). 6. Road Operation Key
5. Evaporator Fan Shunt (C2) Road operation is selected by this key. Selection of
road operation is only necessary during the initial start-
The evaporator fan shunt (C2) is located on the evap- up. When the unit is restarted, it will automatically de-
orator fan module. The shunt position is determined by fault to road operation unless previously changed to
the number of evaporator fans used with the unit. For a standby operation. An LED will light to indicate road op-
three fan application, such as this one, the switch should eration.
be positioned to the left on the 3 fan pin (see Figure 5-4
and Figure 5-5).
1-17
7. Manual Preheat Key 5. Standby Operation LED
The manual preheat key will override automatic pre- A lighted LED indicates the unit is in standby opera-
heat and allow manual preheating of the engine from the tion.
control panel. This key may be used during pre-trip in- 6. Fuel Mizer ON LED
spection and servicing of the unit.
A lighted LED indicates unit is locked-in (engine) low
8. Manual Engine Start Key speed operation.
The manual engine start key will override automatic 7. Fuel Mizer OFF LED
start-up and allow manual engine start-up from the con-
trol panel. This key may be used during pre-trip inspec- A lighted LED indicates unit operation (high and low
tion and servicing the unit. speed) is controlled by the temperature controller.
j. Fault LEDs
h. Safety Switches NOTE
NOTE
All fault LEDs will remain on for 20 minutes or
If the unit shuts down because of a safety device, until the problem is corrected.
the control system must be reset by placing the
control panel selector knob to the OFF position 1. Evaporator Fan LED
first, then back to the AUTO/START There is an LED for each of the three evaporator fan
(Automatic Starting) position. motors. A lighted LED indicates a fan motor has stopped
1. High Pressure Cutout Switch (HP) due to a minimum draw of 3 amps or a maximum amp
draw, regulated by the fan motor potentiometer.
If the compressor discharge pressure exceeds pres-
sure listed in section 1.4.d., this switch will open de-ener- 2. Battery Fault LED
gizing the control circuit to stop the unit. A lighted LED indicates excessive current draw on
2. Low Pressure Switch (LP) the battery because of a lack of alternator output charge.
The unit will shut down.
The low pressure switch will open at 15 inches (38 cm)
hg vacuum if low pressure occurs in the refrigeration sys- 3. Fuse Fault LED
tem. A lighted LED indicates the 15 amp main control fuse
3. Oil Pressure Switch (OP) located on the power board or the 2 amp electronic sys-
tem fuse located behind the control panel has opened. Ei-
The oil pressure switch will close at 14 ¦ 3 psig ther fuse, if opened, will shut the unit down.
(1 ¦ 0.2 kg/cm@) upon loss of oil pressure to automatical-
ly stop the engine after 5 seconds (to prevent engine dam- 4. High/Low Pressure Fault LED
age). A lighted LED indicates either high or low pressure
4. Water Temperature Switch (WT) within the system. Either condition will shut down the
unit.
If engine water temperature rises to 234 ¦ 5_F (112
¦ 3_C), the switch will close, and the engine will stop 5 5. Water/Oil Fault LED
seconds later. A lighted LED indicates low engine oil pressure or
5. Restart Override Thermostat (ROT) high engine water temperature. Either condition will
shut down the unit.
The Restart Override Thermostat which senses en-
gine block temperature will close at 41_F (5_C) to restart 1.9.3 Ecotronic Power Panel and Related Components
the engine during the off-time cycle of the start/stop op- (See Figure 1-11.)
eration. (This will prevent hard engine starting caused by All electric standby (TDS) units are equipped with
below normal temperature during the off-time cycle.) power panels. These units can run on either 230 vac or
460 vac. Depending on the available power supply, the
i. Indicator LEDs main plug (A), located on the back of the panel must be
1. Cooling LED connected to the applicable connector plug labeled
“220v” for 230 vac power supply, or the connector plug la-
A lighted LED indicates high or low speed cooling. beled “380V” for 460 vac power supply. These plugs are
2. Heating LED also located on the back of the power panel. See
A lighted LED indicates high or low speed heating. Figure 1-11 for reference.
3. Defrost LED WARNING
A lighted LED indicates unit is in defrost. This change should only be done with the
main power disconnected.
4. Road Operation LED
A lighted LED indicates the unit is in engine opera-
tion.
1-18
a. Motor Overload (MOL) When using the remote-mounted receptacle for unit
The function of the motor overload is to protect the operation, it is essential that the remote control shunt is
standby motor against high amperage draw. The over- positioned on the pin designated AV for proper opera-
load provides an adjustable knob to set the maximum am- tion (see Figure 5-1, Figure 5-2 and Figure 5-3). This
perage overload draw which should be set to 12.5 amps. shunt is located on the back of the control panel.
The overload adjustment remains the same for both 230
vac and 460 vac supply.
1.11 CAB COMMAND (Remote Control Box)
The motor overload is also equipped with a reset but-
ton. This button has three positions: automatic reset, NOTE
manual and test. In this application the button should re- The Cab Command can not be used
main in the automatic reset position. simultaneously with the remote receptacle switch.
b. Motor Overload Timer (MOT) 1 2 3
If the standby motor shuts down because of motor
overload, the motor overload timer (MOT) will not allow
the motor to restart for a minimum of 10 minutes. This
delay allows the standby motor to cool; it has no effect on
the operation of the unit under normal operation.
1.10 STANDBY REMOTE-MOUNTED POWER
RECEPTACLE OFF
ALARM
12 11 10 9 8 7 6 5 4
STOP
1. Heat Out-of-Range Indicator (LED)
2. Heat Out-of-Range Adjustment Screw
3. Digital Box Temperature Display
4. Safety Alarm LED
5. OFF Button
6. Manual Defrost Button/LED
7. Standby Operation Button/LED
8. City Speed Button LED
9. Road Operation Button/LED
10. Cool Out-of-Range Adjustment Screw
11. Acoustic Alarm Shut-off Button
12. Cool Out-of-Range Indicator (LED)
Figure 1-13. Cab Command
The Cab Command allows the operator to control and
Figure 1-12. Standby Remote-Mounted Power Receptacle observe the operation of the unit from inside the cab. The
operator can start (Engine or Standby), stop, manually
defrost the unit or place the engine in low speed (City
NOTE Speed button) with the Cab Command. The City Speed
The Standby/Stop/Road switch which is button performs the same function as the Fuel Mizer ON
mounted on the remote box can not be used key located on the control panel.
simultaneously with Cab Command. A switch located in the back of the Cab Command box
The standby power receptacle is 208/230 volt, allows the option between degrees Fahrenheit (_F) or de-
3-phase, 60-hertz (380/460-vac, 3-ph, 50/60-hz optional). grees Celsius (_C) for box temperature display.
The remote-mounted power receptacle is standard on When using the Cab Command for unit operation, it
TDS models. Mounted on the truck body below the con- is essential that the remote control shunt be positioned
densing unit, the receptacle enables the standby power on the pin designated “AV” for proper operation (See
plug to be connected from ground level. Figure 5-1, Figure 5-2 and Figure 5-3). This shunt is lo-
A feature of the remote-mounted receptacle is the cated on the back of the control panel (Startronic and
Standby/Stop/Road switch. This switch provides unit Ecotronic).
start-up in standby or engine operation from ground lev- The Cab Command is equipped with a Critical Cargo
el. The starting procedure will be the same as the Cab Monitor warning system. This system includes both visual
Command outlined in sections 2.1.1 and 2.1.2. and acoustic alarms.
1-19
The Critical Cargo Monitor alarm is factory set to
light the visual alarms (LEDs) when the box temperature SOLENOID
increases or decreases more than 9_F (5_C) from set DE-ENERGIZED
point. The factory setting of 9_F (5_C) can be adjusted or
changed as required; refer to section 4.23.
TO COMPRESSOR
The acoustic alarm is activated under the following CRANKCASE
conditions:
1. If the heat out-of-range LED remains activated for
more than one hour.
2. If the cool out-of-range LED remains activated for FROM
COMPRESSOR
more than 20 minutes.
The acoustic signal can be stopped by pressing the
shut-off button.
NOTE
The cool out-of-range indicator will not light TO CONDENSER
when the controller set point is below 10_F
Figure 1-14. Hot Gas Valve --- Cooling Operation Flow
(---12_C).
c. Heat and Defrost Operation (See Figure 1-15.)
1.12 COMPRESSOR PRESSURE REGULATING
VALVE (CPR) When the hot gas solenoid coil is energized, discharge
gas flows to the evaporator for heating or defrost. When
This adjustable regulating valve is installed on the suc- energized, the solenoid plunger is lifted, allowing dis-
tion line of the compressor to regulate the amount of suc- charge gas to fill the volume above the piston assembly.
tion pressure entering the compressor. The CPR valve is Discharge gas is also allowed to fill the volume below the
adjusted to maintain a maximum suction pressure as piston assembly through the compressor discharge con-
listed in section 1.4.f. nection. The pressure on both sides of the piston assem-
The suction pressure is controlled to avoid overload- bly is now equal and the piston spring exerts a force on top
ing the electric motor or engine during high box tempera- of the piston assembly and shifts it downward. The con-
ture operation. To adjust the CPR valve, refer to section denser port is now closed and the evaporator port is open.
4.12. In both the energized and de-energized positions, the by-
pass of discharge gas to the suction port is prevented.
1.13 HOT GAS VALVE (Three-Way)
SOLENOID
a. Description ENERGIZED
Operation of the hot gas (three-way) valve is gov-
erned by the position of the plunger in the hot gas sole-
TO COMPRESSOR
noid. The valve is pilot operated and therefore depends CRANKCASE
on the refrigerant gas to shift the piston assembly.
b. Cooling Operation (See Figure 1-14.)
TO EVAPORATOR
With the solenoid coil de-energized the valve is in the
cool operating mode and the refrigerant gas is diverted to FROM
the condenser. The volume directly above the piston as- COMPRESSOR
sembly is open to suction pressure through an internal pi-
lot connection and the volume underneath the piston as-
sembly is open to discharge pressure through the com-
pressor discharge connection. The old style valve may be Figure 1-15. Hot Gas Valve ---
equipped with an external pilot line. This difference in Heat and Defrost Operation Flow
pressure across the piston assembly results in the piston
assembly being shifted upward, shutting the evaporator
port, opening the condenser port, and allowing refriger-
ant to flow to the condenser.
1-20
1.14 DEFROST AIR SWITCH (DA) 1.16 ACCUMULATOR
Defrost is automatically initiated by the defrost air The accumulator is a refrigerant holding tank located
switch (DA). The defrost air switch is a pressure in the suction line between the evaporator and compres-
differential switch which measures the air pressure drop sor. The purpose of the accumulator is to prevent or mini-
through the evaporator coil. The air pressure differential mize entry of any liquid refrigerant (that may be en-
is sensed through a low side tube which ends at the outlet trained in the suction line) into the compressor, causing
side of the evaporator coil and a high side tube which internal damage.
ends in the leaving air side of the fan (located between the This is accomplished by the compressor drawing the
fan shroud and coil). refrigerant vapor through the outlet pipe of the accumu-
Defrost is initiated by closing the DA switch when the lator, which is equipped with an orifice. This orifice con-
air pressure differential increases to 0.80 inch (20.3 mm) trols the oil return to the compressor and prevents the ac-
water gauge (wg), indicating excessive frost build-up on cumulation of oil within the accumulator tank.
the evaporator coil surface.
The unit will remain in defrost until the evaporator
coil temperature reaches 47_F (8_C). At this point the
two defrost thermostats (DT) open to terminate the
defrost cycle.
NOTE
The evaporator coil temperature must be below
37_F (2.8_C) before defrost can be initiated.
1.15 DEFROST TIMER (Optional)

The solid state defrost timer is an optional method of
defrost initiation. The timer will automatically initiate
defrost mode at a preset time interval of 1-1/2, 3 or 6
hours. The defrost intervals are selected by placing the
jumper shunt in the appropriate interval position. The
interval time designations are labeled on the side of the
defrost timer.
A second jumper shunt located on the timer is used to
determine defrost termination. The two designations for
termination are the 1I and 20 minute positions. The 1I
position will allow termination by the defrost thermostats
(DT). The 20 minute position will automatically termi-
nate defrost after 20 minutes has elapsed. It is recom-
mended in applications where 7 day (approximately)
deep frozen conditions apply, the defrost termination
shunt should be placed in the 20 minute position. This
will prevent potential ice buildup over time.
NOTE
The evaporator coil temperature must be below
37_F (2.8_C) before defrost can be initiated.
Test points are provided on the defrost timer. Placing

a jumper across the test points (designated TEST on the
side of the timer) will accelerate the timer to initiate
defrost within seconds.
Also located on the defrost timer is an LED that will
blink on and off at approximately 3 second intervals
which indicates the timer is functioning, and a 1 amp fuse
for timer protection.
1-21
1.17 REFRIGERANT CIRCUIT DURING COOLING reduces the pressure of the liquid and meters the flow of
When cooling, the unit operates as a vapor liquid refrigerant to the evaporator to obtain maximum
compression refrigeration system (see Figure 1-16). The use of the evaporator heat transfer surface.
main components of the system are the reciprocating The evaporator tubes have aluminum fins to increase
compressor, air-cooled condenser, thermostatic expansion heat transfer; therefore heat is removed from the air
valve, direct expansion evaporator, and hot gas valve circulated through the evaporator. This cold air is
(three-way). circulated throughout the truck to maintain the cargo at
The compressor raises the pressure and temperature the desired temperature.
of the refrigerant and forces it into the condenser tubes. The transfer of heat from the air to the low
The condenser fan circulates surrounding air over the temperature liquid refrigerant causes the liquid to
outside of the condenser tubes. Heat transfer is thus vaporize. This low temperature, low pressure vapor
established from the refrigerant gas (inside the tubes) to passes into the accumulator tank. The compressor draws
the condenser air (flowing over the tubes). The this vapor out of the accumulator through a pick-up tube
condenser tubes have fins designed to improve the which is equipped with a metering orifice. This orifice
transfer of heat. This removal of heat causes the prevents the accumulation of oil in the accumulator tank.
refrigerant to liquefy; liquid refrigerant flows from the The metering orifice is calibrated to control the rate of oil
condenser through a check valve to the receiver. flowing back to the compressor.
The receiver stores the additional charge necessary for The vapor refrigerant then enters the compressor
low ambient operation and for heating and defrost modes. pressure regulating valve (CPR) which regulates
The refrigerant leaves the receiver and flows through a refrigerant pressure entering the compressor, where the
manual receiver shutoff valve(king valve), a filter-drier cycle starts over.
where an absorbent keeps the refrigerant clean and dry, For R-22 units the quench valve opens as required to
and a sight glass. maintain a 265 to 285_F (118 to 141_C) maximum
The liquid refrigerant then flows to an externally discharge temperature.
equalized thermostatic expansion valve (TXV) which
4 6 7 8
9
3 10
2
5
11
1
13 12
19
21
18
14
20
17
15
16
1. Drain Pan Heater 9. Receiver 17. High Pressure Switch (HP)

2. Expansion Valve Bulb 10. Receiver Inlet Check Valve 18. Compressor Pressure
3. Evaporator 11. Bypass Check Valve Regulating Valve (CPR)
4. External Equalizer Line 12. Condenser 19. Low Pressure Switch (LP)
5. Expansion Valve 13. Hot Gas Valve (Three-Way) 20. Accumulator
6. Sight Glass 14. Discharge Service Valves 21. Quench Valve (R-22 Only)
7. Filter-Drier 15 Suction Service Valve
8. Receiver (King) Valve 16. Compressor Oil Level Sight Glass
Figure 1-16. Refrigeration System --- Cooling Cycle
1-22
1.18 REFRIGERANT CIRCUIT DURING The main difference between heating and defrosting
HEAT AND DEFROST is that, when in heating all the evaporator fans continue
(Figure 1-17) to run, blowing the air over the heated coils to heat the
When refrigerant vapor is compressed to a high product. When defrosting, the evaporator fans stop,
pressure and temperature in a reciprocating compressor, allowing the heated vapor to defrost any ice build up
the mechanical energy necessary to operate the there may be.
compressor is transferred to the gas as it is being The function of the bypass line from the hot gas valve
compressed. This energy is referred to as the “heat of to the receiver is to allow discharge pressure into the
compression” and is used as the source of heat during the receiver. Under pressure the liquid refrigerant will flow
heating cycle. from the receiver through the expansion valve to the
When the controller calls for heating or defrost, the evaporator. This will force all the refrigerant out of the
hot gas valve (three-way) solenoid energizes, closing the receiver and into the evaporator to be used for heating.
port to the condenser and opening a port which allows On units with R-22 the quench valve opens as required
heated refrigerant vapor to flow directly to the to maintain a 265 to 285_F (118 to 141_C) maximum
evaporator coil. discharge temperature.
4 6 7 8
9
3 10
2
5
11
1
13 12
19
21
18
14
20
17
15
16
1. Drain Pan Heater 9. Receiver 17. High Pressure Switch (HP)

2. Expansion Valve Bulb 10. Receiver Inlet Check Valve 18. Compressor Pressure
3. Evaporator 11. Bypass Check Valve Regulating Valve (CPR)
4. External Equalizer Line 12. Condenser 19. Low Pressure Switch (LP)
5. Expansion Valve 13. Hot Gas Valve (Three-Way) 20. Accumulator
6. Sight Glass 14. Discharge Service Valves 21. Quench Valve (R-22 Only)
7. Filter-Drier 15 Suction Service Valve
8. Receiver (King) Valve 16. Compressor Oil Level Sight Glass
Figure 1-17. Refrigeration System --- Heat and Defrost Cycle
1-23
SECTION 2
OPERATION
2.1. STARTRONIC AND ECOTRONIC STARTING The variable cranking cycle is determined by the
AND STOPPING INSTRUCTIONS opening of the oil pressure switch or the initiation of
alternator output.
WARNING
The automatic starting sequence of the engine is
Beware of unannounced starting of the fans and shown below. If there are two unsuccessful attempts to
V-belts caused by the thermostat and the start the unit, a fault has occurred and the power supply to
start/stop cycling of the unit. the system will shut down. When the fault is corrected,
restarting can only be done by resetting the control
The Startronic and Ecotronic systems provide fully system. To reset the control system, first switch the unit
automatic diesel engine preheat and starting. These off at the control panel, then switch the unit back on.
functions can be initiated at the control panel or with an
optional Cab Command. The Startronic and Ecotronic automatic engine
preheat and starting sequence can be overridden by using
The automatic starting sequence of the engine is the engine and preheat keys located on the control panel.
shown below in Figure 2-1. The diesel engine will start These keys can be used when performing pre-trip
after an automatic variable length preheat and crank inspection or servicing the unit.
cycle. The variable preheat cycle depends on the ambient
temperature as follows: A remote control shunt (X) is located on the back of
the control panel. The position of this shunt (on its three
Ambient Temperature Glow Time pins) is determined by the application of the Cab
85_F to 125_F 30 seconds Command (remote control box) or the remote standby
(29.4_C to 52_C) receptacle. If the Cab Command or remote standby
receptacle is used, the shunt must be positioned on the
50_F to 70_F 40 seconds “AV” pin. For applications without the Cab Command or
(10_C to 21.1_C) remote standby receptacle, the shunt must be positioned
32_F (0_C) 60 seconds on the “SS” pin. It is essential that the shunt be
---5_F (---21_C) 90 seconds positioned correctly to allow the applicable control to
function properly. Refer to Section 5 for location and
position of the remote control shunt (X).
NOTE If the engine does not start after

the variable glow and cranking STARTRONIC & ECOTRONIC
The duration times cycle, the starting attempt se- STARTRONIC ONLY
shown in this automatic quence stops for 50 seconds be- ECOTRONIC ONLY
starting sequence chart fore repeating.
may vary according to GLOW CRANK
ambient temperatures or ENGINE RUNNING
voltage supply to the 30 --- 90 SEC 2 --- 20 SEC
(Variable) (Variable) 30 SEC 40 SEC 10 MIN CONTINUOUS
system.
Control Relay (CR)
Glow Plug Relay (GPR)
Fuel Pump Relay (FPR)
Heat Relay (HR)

Starter Solenoid Relay (SSR)
Voltage Regulator Relay (VRR)
Run Relay (RR)
Speed Relay (SR)
Fan Relays 1 , 2 & 3 (FR1, FR2 &

FR3)
Figure 2-1. Automatic Starting Sequence
2-1
2.1.1 STARTRONIC --- Starting and Stopping
a. Before start-up
1. Set the temperature selector switch to desired box temperature.
Engine Operation Standby Operation
b. Using the Control Panel
1. Press the ON key 1. Connect main power supply to receptacle.
2. To start, press the Road (R) key. 2. Press the ON key.
3. To stop the unit, press the OFF key. 3. To start, press the Standby (S) Key
4. To stop the unit, press the OFF key.
c. Using the Cab Command
1. Press the ON key located on 1. Connect main power supply to receptacle.

the control panel. (Initial start-up only.)
2. Press the ON key located on the control
2. To start, press the Road button on the Cab panel. (Initial start-up only.)
Command .
3. To start, press the Standby button on the Cab
3. To stop the unit, press the OFF button on Cab Command
the Cab Command.
4. To stop the unit, press the OFF
button on the Cab Command.
d. Using the Standby Remote Receptacle
1. Press the ON key located on the control 1. Connect main power supply to receptacle.
panel. (Initial start-up only.)
2. To start, place the remote receptacle switch to
2. To start, place the remote receptacle switch STANDBY position.
to ROAD position.
3. To stop the unit, place the switch in
3. To stop the unit, place the switch in the the STOP position.
STOP position.
2-2
2.1.2 ECOTRONIC --- Starting and Stopping
a. Before start-up
1. Set the temperature selector switch to desired box temperature.
Engine Operation Standby Operation
b. Using the Control Panel
1. Place the control selector switch to the 1. Connect main power supply to standby
desired mode: receptacle.
--- AUTO/START, continuous operation 2. Turn the control selector switch to one
--- START/STOP --- 22 minutes of the starting positions.
--- START/STOP --- 45 minutes
--- START/STOP --- 90 minutes 3. To start, press the Standby (S) key.
2. To start, press the Road (R) key 4. To stop the unit, place the control
selector switch in the OFF position.
3. To stop the unit, place the control
selector switch in the OFF position.
c. Using the Cab Command
1. Place the control selector switch located 1. Connect main power supply to standby
on the control panel to the desired mode. receptacle.
(Initial start-up only.)
2. Turn the control selector switch on the
--- AUTO/START, continuous operation control panel to desired mode. (Initial start-up
--- START/STOP --- 22 minutes only.)
--- START/STOP --- 90 minutes 3. To start, press the Standby button on the
remote Cab Command.
2. To start, push the Road button on the
Cab Command. 4. To stop the unit, push the OFF button
of the remote Cab Command.
3. To stop the unit, press the OFF button
on the Cab Command.
d. Using the Remote Standby Receptacle
1. Place the control selector switch 1. Connect main power supply to standby
located on the control panel to receptacle.
the desired mode. (Initial start-up only.)
2. Turn the control selector switch on the
--- AUTO/START, continuous operation control panel to desired mode. (Initial start-up
--- START/STOP --- 22 minutes only.)
--- START/STOP --- 90 minutes 3. To start, place the remote receptacle switch in
the STANDBY position.
2. To start, place the remote receptacle switch
in the ROAD position. 4. To stop the unit, place receptacle switch
in the STOP position.
3. To stop unit, place the switch in the
STOP position.
2-3
FALLING TEMPERATURE RISING TEMPERATURE
+2.7_F (+1.5_C)
+1.4_F (+0.75_C)
SET POINT
---1.4_F (---0.75_C)
---2.7_F (---1.5 C_)
Figure 2-2. Temperature Controller Operating Sequence --- Engine Drive

Controller Set Point Above +10_F (--- 12_C)
+2.7_F (+1.5_C)
+1.4_F (+0.75_C)
SET POINT
---1.4_F (---0.75_C)
---2.7_F (---1.5_C)
NOTE: The controller prevents heating when set below +10_F (---12_C).
Figure 2-3. Temperature Controller Operating Sequence --- Engine Drive
Controller Set Point Below +10_F (--- 12_C)
(Startronic and Ecotronic when unit is run in auto-start mode)
2-4
+2.7_F (+1.5_C)
+1.4_F (+0.75_C)
SET POINT
---1.4_F (---0.75_C)
---2.7_F (---1.5_C)
Figure 2-4. Temperature Controller Operating Sequence --- Standby Operation

Controller Set Point Above +10_F (--- 12_C)
+2.7_F (+1.5_C)
+1.4_F (+0.75_C)
SET POINT
---1.4_F (---0.75_C)
---2.7_F (---1.5_C)
NOTE: The controller prevents heating when set below +10_F (---12_C).
Figure 2-5. Temperature Controller Operating Sequence --- Startronic and Ecotronic* Standby Operation
Controller Set Point Below +10_F (--- 12_C)
*Ecotronic when operated in auto-start/stop (22, 45, 90) (The diesel engine will run in high speed only)
2-5
2.2. STARTRONIC CONTROL CIRCUIT Heat Relay (HR) --- The energized HR closes a set of
OPERATION HR contacts to energize the Hot Gas (HG) solenoid.
Energizing the HG solenoid at start-up allows the system
NOTES
pressures to equalize.
The Startronic control system is designed to
supply potential to the control relays at all times Voltage Regulator Relay (VRR) --- The energized
during unit operation. When the temperature VRR closes a set of VRR contacts to allow power to the
controller senses a change in box temperature, voltage regulator.
the logic module will automatically energize or Unloader Relay (ULR) --- There is an output of 12 ¦
de-energize the control relays by making or
breaking the ground of the relay coil (depending 2 vdc at A12 on units with or without a compressor
on required mode of operation). unloader.
2.2.1 Startronic Engine Start-Up (See Figure 2-6.)

Before start-up is initiated, the control system will
automatically preheat the engine. Refer to section 2.1.
for preheating cycle.
After start-up, the unit will run in high speed for a
minimum of 40 seconds. After the elapsed time, the unit
will resume the mode of operation required by the
temperature controller.
The following relays will be energized when starting:
(See Figure 2-6.)
Control Relay (CR) --- The energized CR closes a set
of CR contacts which supply power to the logic module
and all other relays that control unit operation. If a safety
malfunction occurs the unit will shut down. To restart the
unit, the Control Relay (CR) must be reset. (Refer to
section 1.7)
Starter Solenoid Relay (SSR) --- The energized SSR
closes a set of contacts to energize the Starter Solenoid
(SS). Energizing the SS will close a set of SSC contacts
which in turn will allow power to the Starter Motor (SM)
to start the engine.
Glow Plug Relay (GPR) --- The energized GPR closes
a set of contacts, allowing power to the Glow Plugs (GP)
to preheat the engine. The preheating duration depends
on the ambient temperature. (Refer to section 2.1.)
Run Relay (RR) --- The energized RR closes a set of
RR contacts to energize the Run Solenoid (RS).
Fuel Pump Relay (FPR) --- The energized FPR closes
a set of FPR contacts to energize the Fuel Pump (FP)
through fuse F18. The Running Time Meter (RTM) is
also energized.
Speed Relay (SR) --- The energized SR closes a set of
SR contacts to energize the Speed Control Solenoid Figure 2-6. Startronic Starting ---
(SCS). The energized SCS maintains an engine speed of Engine Drive
2320 rpm (high speed).
2-6
2.2.2 Startronic Cooling --- Engine Drive
(See Figure 2-7.)
If the return air is above 1.4_F (0.75_C) above set
point, the unit will be in high speed cooling. (See
Figure 2-7)
The following relays will be energized during high
speed cooling:
and all other relays that control unit operation. If a safety
malfunction occurs the unit will shut down. To restart the
unit, the Control Relay (CR) must be reset. (Refer to
section 1.7)
also energized.
SR contacts to energize the Speed Control Solenoid
(SCS). The energized SCS maintains an engine speed of
Voltage Regulator Relay (VRR) --- The energized
VRR closes a set of VRR contacts to allow power to the
voltage regulator.
Fan Relays (FR1, 2 & 3) --- The energized FRs close to
energize the three fan motors.
The unit will be in high speed cooling until the return
air decreases to 1.4_F (0.75_C) above set point. At this
time the speed relay (SR) de-energizes to open the
normally open SR contact to de-energize the speed
control solenoid (SCS). De-energizing the SCS will Figure 2-7. Startronic High Speed Cooling ---
reduce the engine speed from 2320 rpm to 1800 rpm, Engine Drive
placing the unit in low speed cooling.
2-7
2.2.3 Startronic Heating --- Engine Drive The following relays will be energized during high
(See Figure 2-8.) speed heating. (See Figure 2-8)
If the return air decreases to 1.4_F (0.75_C) below set Control Relay (CR) --- The energized CR closes a set
point, the unit will shift to low speed heat. of CR contacts which supply power to the logic module
and all other relays that control unit operation.
The unit will only heat when the controller is set above
+10_F (---12_C), as the heat relay is electronically locked Run Relay (RR) --- The energized RR closes a set of
out when the set point is below +10_F (---12_C). If the RR contacts to energize the Run Solenoid (RS).
return air decreases to 2.7_F (1.5_C) below the set point, Fuel Pump Relay (FPR) --- The energized FPR closes
the unit will shift to high speed heat. a set of FPR contacts to energize the Fuel Pump (FP)
During heating, operation is similar to cooling with through fuse F18. The Running Time Meter (RTM) is
the exception of energizing the Heat Relay (HR). also energized.
Energizing the Hot Gas (three-way) Valve (HG) will shift Speed Relay (SR) --- The energized SR closes a set of
the valve plunger to allow hot gas to flow directly to the SR contacts to energize the Speed Control Solenoid
evaporator coil. (SCS). The energized SCS maintains an engine speed of
Heat Relay (HR) --- The energized HR closes a set of
HR contacts to energize the Hot Gas (three-way) Valve
(HG). Energizing the HG solenoid will shift the valve
plunger to allow hot gas to flow directly to the evaporator
coil. There is a 3 second delay before the Heat Relay
(HR) will energize.
voltage regulator.
Fan Relays (FR1, 2 & 3) --- The energized FRs close
the FR contacts to energize the three fan motors.
The unit will remain in high speed heating until the
return air increases to 1.4_F (---0.75_C) below set point.
At this time the speed relay (SR) de-energizes to open SR
contacts to de-energize the speed control solenoid (SCS).
De-energizing the SCS will decrease the engine speed
from 2320 rpm to 1800 rpm, placing the unit in low speed
heating (see Figure 2-2).
Figure 2-8. Startronic High Speed Heat ---

Engine Drive
2-8
2.2.4 Startronic Defrost --- Engine Drive Voltage Regulator Relay (VRR) --- The energized
(See Figure 2-9.) VRR closes a set of VRR contacts to allow power to the
voltage regulator.
During defrost, the operation of the unit is similar to
high speed heating, with the exception of the evaporator
fan motors which are not energized during defrost.
NOTES
1. The evaporator coil temperature must be
below 37_F (2.8_C) before defrost can be
initiated.
2. The defrost cycle is activated independently of
the action of the temperature controller.
Defrost may be initiated by one of the following
methods:
a. Manually by the defrost button located on the
control panel or Cab Command.
b. Automatically by the defrost air switch (DA).
Refer to section 1.14.
c. Automatically by the (optional) defrost timer.
The following relays will be energized during defrost:
(See Figure 2-9.)
also energized.
Heat Relay (HR) --- The energized HR closes a set of Figure 2-9. Startronic Defrost ---
HR contacts to energize the Hot Gas (three-way) Valve Engine Drive
(HG). Energizing the HG Solenoid will shift the valve
(HR) will energize.
2-9
2.2.5 Startronic Cooling --- Standby Operation
(See Figure 2-10.)
Standby operation can be started by using the
procedures outlined in section 2.1.1.
The following relays will be energized during standby
cooling: (See Figure 2-10.)
Motor Contact Relay (MCR) --- The energized MCR
closes a set of MCR contacts to allow power to the Motor
Overload Timer (MOT) and Motor Overload (MOL)
switch. From the Motor Overload Timer (MOT), power
flows to the Motor Contact (MC) to start the Standby
Motor. The Standby Time Meter (STM) is also ener-
gized.
voltage regulator.
Fan Relays (FR1, 2 & 3) --- The energized FR’s close
The unit will remain in cooling until the return air
decreases to 1.4_F (+0.75_C) above set point, at which
time the Motor Contact Relay (MCR) will de-energize to
terminate power to the standby motor to stop unit
operation.
Figure 2-10. Startronic Cooling ---

Standby Operation
2-10
2.2.6 Startronic Heating --- Standby Operation The following relays will be energized during heating:
(See Figure 2-11.) (See Figure 2-11.)
The unit will only heat when the controller is set above Control Relay (CR) --- The energized CR closes a set
+10_F (---12_C); the heat relay is electronically locked of CR contacts which supply power to the logic module
out when the set point is set below +10_F (---12_C), refer and all other relays that control unit operation.
to Figure 2-5. Heat Relay (HR) --- The energized HR closes a set of
When the return air decreases to 2.7_F (1.5_C) below HR contacts to energize the Hot Gas (three-way) Valve
set point, the unit will shift to heating by energizing the (HG). Energizing the HG Solenoid will shift the valve
following relays: (See Figure 2-11.) plunger to allow hot gas to flow directly to the evaporator
(HR) will energize.
gized.
voltage regulator.
The unit will remain in heating until the return air
increases to set point, at which time the Motor Contact
Relay (MCR) will de-energize to terminate power to the
standby motor to stop unit operation.
Figure 2-11. Startronic Heating ---

Standby Operation
2-11
2.2.7 Startronic Defrost --- Standby Operation Voltage Regulator Relay (VRR) --- The energized
voltage regulator.
heating, with the exception of the evaporator fan motors
which are not energized during defrost.
NOTES
initiated.
2. The defrost cycle is activated independently
from the action of the temperature controller.
methods:
(See Figure 2-12.)
(HR) will energize.
Motor. The Standby Time Meter (STM) is also ener- Figure 2-12. Startronic Defrost ---
gized. Standby Operation
2-12
2.3. ECOTRONIC CONTROL CIRCUIT Heat Relay (HR) --- The energized HR closes a set of
OPERATION HR contacts to energize the Hot Gas (three-way) Valve
(HG). Energizing the HG valve at start-up allows the
NOTES
system pressures to equalize.
1. The Ecotronic control system is designed to
supply potential to the control relays at all times
during unit operation. When the temperature
voltage regulator.
controller senses a change in box temperature,
the logic module will automatically energize or
de-energize the control relays by making or
breaking the ground of the relay coil (depending
on required mode of operation).
2. If a safety malfunction occurs, the control
circuit must be reset (refer to section 1.7).
2.3.1 Ecotronic Engine Start-Up (See Figure 2-13.)
Before start-up is initiated, the control system will
automatically preheat the engine. Refer to section 2.1.
for preheating cycle.
After start-up, the unit will run in high speed for a
minimum of ten minutes. After the elapsed time, the unit
will resume the mode of operation required by the
temperature controller.
The unit can be started by using the procedures
outlined in section 2.1.2.
The following relays will be energized during starting:
(see Figure 2-13.)
Starter Solenoid Relay (SSR) --- The energized SSR
closes a set of contacts to energize the Starter Solenoid
Coil (SSC). Energizing the SSC will close a set of SSC
contacts which in turn will allow power to the Starter
Motor (SM) to start the engine.
Glow Plug Relay (GPR) --- The energized GPR closes
a set of contacts which allow power to the Glow Plugs
(GP) to preheat the engine. The preheating duration
depends on the ambient temperature. Refer to section
2.1. for cycle times.
also energized. Figure 2-13. Ecotronic Starting ---
Engine Drive
2-13
2.3.2 Ecotronic Cooling --- Engine Drive
(See Figure 2-14)
The unit will be in high speed cooling until the return
air decreases to 1.4_F (0.75_C) above set point. At this
time the speed relay (SR) de-energizes to open the SR
contacts to de-energize the speed control solenoid (SCS).
De-energizing the SCS will reduce the engine speed from
2320 rpm to 1800 rpm, placing the unit in low speed
cooling.
The following relays will be energized during high
speed cooling: (See Figure 2-14)
also energized.
voltage regulator.
Figure 2-14. Ecotronic High Speed Cooling ---

Engine Drive
2-14
2.3.3 Ecotronic Heating --- Engine Drive Fan Relays (FR1, 2 & 3) --- The energized FR’s close
(See Figure 2-15.) the FR contacts to energize the three fan motors.
During heating, the operation is similar to the cooling
operation with the exception of energizing the Heat
Relay (HR). Energizing the Hot Gas (three-way) Valve
(HG) will shift the valve plunger to allow hot gas to flow
directly to the evaporator coil.
+10_F (---12_C), as the heat relay is electronically locked
out when the set point is below +10_F (---12_C) (refer to
Figure 2-3).
When the return air decreases to 1.4_F (0.75_C)
below set point, the unit will shift to low speed heat.
If the return air decreases to 2.7_F (---1.5_C) below set
point, the speed relay (SR) energizes to close the
normally open SR contact to energize the speed control
solenoid (SCS). Energizing the SCS will increase the
engine speed from 1800 rpm to 2320 rpm, placing the unit
in high speed heating.
The following relays will be energized during low
speed heating: (See Figure 2-15.)
also energized.
(HR) will energize.
Figure 2-15. Ecotronic Low Speed Heating ---
Engine Drive
voltage regulator.
2-15
2.3.4 Ecotronic Defrost --- Engine Drive Voltage Regulator Relay (VRR) --- The energized
voltage regulator.
During defrost the operation of the unit is similar to
high speed heating with the exception of the evaporator
NOTES
initiated.
2. The defrost cycle is activated independently of
the action of the temperature controller.
methods:
(See Figure 2-16.)
also energized.
Heat Relay (HR) --- The energized HR closes a set of Figure 2-16. Ecotronic Defrost --- Engine Drive
(HR) will energize.
2-16
2.3.5 Ecotronic Cooling --- Standby Operation Control Relay (CR) --- The energized CR closes a set
(See Figure 2-17.) of CR contacts which supply power to the logic module
Standby operation can be started by using the
procedures outlined in section 2.1.2. Motor Contact Relay (MCR) --- The energized MCR
The following relays will be energized during standby
cooling: (See Figure 2-17.)
gized.
voltage regulator.
The unit will remain in cooling until the return air
decreases to 1.4_F (0.75_C) above set point, at which time
the Motor Contact Relay (MCR) will de-energize to
terminate power to the standby motor to stop unit
operation.
Figure 2-17. Ecotronic Cooling ---

Standby Operation
2-17
2.3.6 Ecotronic Heating --- Standby Operation
(See Figure 2-18.)
+10_F (---12_C); the heat relay is electronically locked
out when the set point is set below +10_F (---12_C).
When the return air decreases to 2.7_F (1.5_C) below
set point, the unit will shift to heat and the standby motor
will restart.
The following relays will be energized during heating:
(See Figure 2-18.)
(HR) will energize.
gized.
voltage regulator.
Figure 2-18. Ecotronic Heating ---

Standby Operation
2-18
2.3.7 Ecotronic Defrost --- Standby Operation Voltage Regulator Relay (VRR) --- The energized
(See Figure 2-19.) VRR closes a set of VRR contacts to supply power to the
voltage regulator.
high speed heating, with the exception of the evaporator
NOTES
initiated.
2. The defrost cycle is activated independently
from the action of the temperature controller.
methods:
(See Figure 2-19.)
(HR) will energize.
Motor. The Standby Time Meter (STM) is also ener- Figure 2-19. Ecotronic Defrost --- Standby Operation
gized.
2-19
SECTION 3
TROUBLESHOOTING
3.1 DIESEL ENGINE
INDICATION/ REFERENCE
TROUBLE POSSIBLE CAUSES SECTION
3.1.1 Engine Will Not Start
Starter motor will not low Battery insufficiently charged Check

crank or cranking speed Battery terminal post or battery defective Check
Bad electrical connections at starter Check
Starter motor malfunctions 3.1.3
Starter motor solenoid defective Engine Manual
Open starting circuit 3.1.4
Incorrect grade of lubricating oil 1.5.d.
Starter motor cranks but engine No fuel in tank Check

fails to start Air in fuel system 4.3.3
Water in fuel system Drain Sump
Plugged fuel filters Replace
Plugged fuel lines to injector (s) Check
Fuel control operation erratic 4.3
Glow plug (s) or relay GPR defective 4.2.6
Run solenoid (RS) or relay RR defective 4.2.5
Fuel pump (FP) malfunction or relay FPR defective 4.3
Starter cranks, engages but Engine lube oil too heavy 1.5.d.
quits after a few seconds Voltage drop in starter cable (s) Check
Low Battery Charge
3.1.2 Engine Starts Then Stops
Engine stops after several rotations Fuel supply restricted Check

No fuel in tank Check
Leak in fuel system Check
Faulty fuel control operation 4.3
Fuel filter restricted Replace
Injector nozzle (s) defective Engine Manual
Injection pump defective Engine Manual
Air cleaner or hose restricted 4.2.1
Safety device (closed) 1.7
Open wiring circuit to run solenoid (RS) Check
Fuel pump (FP) malfunction or relay FPR
defective 4.3
3.1.3 Starter Motor Malfunction
Starter motor will not crank Battery insufficiently charged Check

or turns slowly Battery cable connections loose or oxidized Check
Battery cables defective Replace
Starter brushes shorted out Engine Manual
Starter brushes hang up, defective or have no contact Engine Manual
3-1
3.1.3 Starter Motor Malfunction (Continued)
Starter solenoid (SS) damaged Replace

Engine lube oil too heavy 1.5.d.
Starter motor turns but pinion Pinion or ring gear obstructed or worn Clean both,
does not engage remove burrs,
or replace;
apply grease
Starter motor does not disengage Selector switch (SEL) defective Replace
after switch has been released Starter solenoid (SS) defective Engine Manual
Pinion does not disengage after Defective starter Engine Manual

engine is running
3.1.4 Malfunction In the Engine Starting Circuit
Run solenoid (RS) and starter Batteries defective Check

solenoid (SSC) do not energize Loose electrical connections Tighten
or do not remain energized Oil pressure safety switch (OP) defective 1.5.e.
Water temperature safety switch (WT) closed 1.5.a.
Run solenoid (RS) defective 4.2.5
Control relay (CR) defective Replace
Fuse F1 (15amps) open Replace
3.2 ALTERNATOR (AUTOMOTIVE TYPE)
Alternator fails to charge Voltage regulator relay defective (VRR) Replace

Limited charging system operating time Check
Battery condition Check
Alternator belt loose/broken 4.21.1
Loose, dirty, corroded terminals,
plugs or broken leads Check and Repair
Excessively worn, open or defective brushes
Isolator diode assembly (ISD) 4.21.3
Regulator faulty 4.21.2
Open diode trio 4.21.3
Open rotor (field coil) alternator Replace
Defective Diode Bridge 4.21.2
Low or unsteady charging rate Alternator belt loose 4.21.1
Loose, dirty, corroded terminals, plugs,
or broken leads Check and Repair
Excessively worn, sticky or intermittent brushes 4.21.4
Faulty regulator 4.21.2
Shorted or open rectifier diode 4.21.3
Grounded or shorted turns in rotor 4.21.2
Open, grounded or shorted turns in stator Replace alternator
3-2
3.2 Alternator (Automotive Type) --- (Continued)
Excessive charging rate Regulator leads loose, dirty, corroded Clean/Repair

(evident by battery terminals, plugs or wires broken or Replace
requiring too frequent Defective regulator 4.21.2
refilling)
Noisy alternator Defective or badly worn V-belt 4.21.1

Worn bearing (s) Replace
alternator
Misaligned belt or pulley Check
Loose pulley Tighten
3.3 REFRIGERATION
3.3.1 Unit Will Not Cool
Diesel engine Malfunction (s) 3.1
Compressor malfunction Compressor drive defective Replace

Compressor defective Replace
Refrigeration system Defrost cycle did not terminate 3.3.5

Abnormal pressure 3.3.6
Hot Gas (three-way) valve malfunction 3.3.9
3.3.2 Unit Runs But Has Insufficient Cooling
Compressor Compressor valves defective Replace
Refrigeration system Abnormal pressure 3.3.6

Expansion valve malfunction 3.3.10
No or restricted evaporator airflow 3.3.8
Engine does not develop Speed control solenoid (SCS) or linkage 4.2.5
full rpm Engine malfunction 3.1
3.3.3 Unit Operates Long or Continuously in Cooling
Container Hot Load Allow time to

pull down
Defective box insulation or air leak Correct
Refrigeration system Abnormal pressure 3.3.6

Temperature controller malfunction Replace
Temperature controller element defective Check
Compressor Defective Replace
3-3
3.3.4 Unit Will Not Heat or Has Insufficient Heating
Refrigeration Abnormal pressure 3.3.6

Temperature controller malfunction Replace
Hot Gas (three-way) valve malfunction 4.15
Compressor Compressor drive defective Replace

Compressor defective Replace
Engine does not develop Speed control linkage 4.2.5

full rpm Engine malfunction 3.1
3.3.5 Defrost Cycle Malfunction
Will not initiate defrost Defrost air switch (DA) out of calibration 4.20.1
automatically or defective
Solid State Defrost Timer fuse or defective timer 1.15
Defrost thermostats open or defective 1.4.b. & 4.20
Loose terminal connections Tighten
Air sensing tubes defective or disconnected Check
Will not initiate defrost manually Manual defrost switch defective 2.2.4 & 2.3.4
Loose terminal connections Tighten
Defrost thermostats (DT) open or defective 1.4.b. & 4.20
Initiates but does not defrost Hot Gas (three-way) valve malfunction 4.15
Defective Heat Relay (HR) Replace
Frequent defrost Defrost air switch (DA) out of adjustment 4.20

Wet load Normal
Does not terminate or cycles Defrost thermostats (DT) shorted closed 1.4.b.
on defrost Manual defrost switch shorted closed 2.2.4 & 2.3.4
Defrost air switch (DA) out of adjustment 4.20.1
Solid State Defrost Timer fuse or defective timer 1.15
3.3.6 Abnormal Pressure
3.3.6.1 Cooling
High discharge pressure Quench valve malfunction Replace

Condenser coil dirty Clean
Condenser fan defective Replace
V---belt broken or loose Check
Discharge check valve restricted Check/Replace
Noncondensibles or refrigerant overcharge 4.10
Low discharge pressure Compressor valves(s) worn or broken Check/Replace

Low refrigerant charge
High suction pressure Compressor valves(s) worn or broken Check

Compressor gasket(s) defective Check
Hot Gas (three-way) valve open 4.15
3-4
3.3.6.1 Cooling --- (Continued)
High suction pressure Compressor valve(s) worn or broken Check

Compressor gasket(s) defective Check
Hot Gas (three-way) valve open 4.15
Low suction pressure Suction service valve partially closed Open

Receiver outlet valve partially closed Open
Filter-drier partially plugged Replace
Low refrigerant charge 4.9
Expansion valve malfunction 4.14
No evaporator air flow or restricted air flow Check
Excessive frost on coil Check
Compressor Regulating Valve malfunction 4.12
Suction and discharge pressure tend Compressor valve(s) worn or broken Check
to equalize when unit is operating Hot Gas (three-way) valve malfunction 4.15
3.3.6.2 Heating
High discharge pressure Noncondensibles in system 4.10

Overcharged system 4.9.3
Low discharge pressure Compressor valve(s) worn or broken Check

Hot Gas (three-way) valve malfunction 4.15
Low suction pressure Low refrigerant charge 4.9

Compressor pressure regulator malfunction 4.12
Suction service valve partially closed Open
3.3.7 Abnormal Noise
Compressor Loose mounting bolts Tighten

Worn bearings Check
Worn or broken valves Check
Liquid slugging 3.3.10
Insufficient oil 1.3 & 4.11.3
Motor or evaporator fan Loose or striking shroud Check

Bearings defective Check
Bent shaft Check
V-belts Cracked or worn 4.4
3.3.8 No Evaporator Air Flow or Restricted Air Flow
Evaporator coil blocked Frost on coil Check

Dirty coil Check
Fan motor(s) defective Replace
No or partial evaporator Evaporator fan loose or defective Check/Replace

air flow Evaporator air flow blocked in trailer Check
Fan motor(s) defective Replace
Fuse FR1, FR2 or FR3 open Replace
3-5
3.3.9 Hot Gas (Three-Way) Valve Malfunction
Valve does not function properly No power to valve Check

Improper wiring or loose connections Check
Coil defective
Valve improperly assembled 4.15
Coil or coil sleeve improperly assembled
Temperature controller module malfunction Replace
Movement of plunger restricted due to:
a. Corroded or worn parts
b. Foreign material lodged in valve
c. Bent or dented enclosing tube 4.15
Valve shifts but refrigerant Foreign material lodged under seat

continues to flow Defective seat 4.15
3.3.10 Thermostatic Expansion Valve Malfunction
Low suction pressure with high Low refrigerant charge 4.9 & 4.14
superheat External equalizer line plugged Clean
Ice formation at valve seat 4.14
Wax, oil or dirt plugging valve or orifice 4.14
Broken capillary 4.14
Power assembly failure 4.14
Superheat setting too high 4.14.b
Low superheat and liquid slugging Superheat setting too high 4.14.b
in compressor External equalizer line plugged Clean
Ice formation at valve seat 4.14
Foreign material in valve 4.14
Fluctuating suction pressure Improper bulb location or installation 4.14

Low superheat setting 4.14.b
3.4 STANDBY MOTOR MALFUNCTION
Standby motor fails to start Motor contactor (MC) defective Replace

External Motor Overload (MOL) open Replace motor
Improper power supply 1.2.b.
Oil pressure switch (OP) open Check
Selector switch (SEL) defective Replace
Standby motor starts, then stops External Motor Overload (MOL) open 1.8.3.a.
High amperage draw Check
Motor Overload Timer defective (MOT) 1.8.3.b.
3-6
SECTION 4
SERVICE
WARNING
Beware of unannounced starting of the fans and
V-belts caused by automatic restarting of the unit.
4.1 MAINTENANCE SCHEDULE
Unit
Operation Reference
ON OFF Section
4.1.1 Daily Inspection
X Inspect engine air cleaner. Clean or replace as required 4.2.1

X Check engine lube oil level 1.5.d.
X Check radiator coolant level 1.5
X Check engine running time meter Run 10 minutes
4.1.2 First 50 Hour Inspection and Maintenance
X X Perform daily inspection 4.1.1

X Check battery fluid level. (Vehicle) None
X Check battery terminal connections None
X Check tension and condition of V-belts 4.4
X Check for lube oil leaks 4.2.2
X Check wire harness for chafing and loose terminals Replace/Tighten
X Check radiator for cleanliness 4.2.4
X Check unit mounting bolts for tightness 1.6
X Check cleanliness of evaporator coil None
X Check cleanliness of condenser coil 4.2.4
X Check standby motor bearings for end play None
Place Unit in Cooling, Engine Running at High Speed
X Check for clutch slippage None
X Check for belt slippage 4.4
X Check for abnormal noise or vibration 3.3.7
X Check evaporator fan motor for noise or vibration 3.3.7
X Check controller operation in cool, and heat Figure 2-2 &
Figure 2-3
X Check manual defrost mode 2.2.4
X Check refrigerant level 4.9.3
4.1.3 First 100 Hour Inspection and Maintenance
X X Perform 50 hour inspection and maintenance 4.1.2

X X Check compressor oil level 4.11.2
X X Change lube oil and filter 1.5.d. & 4.2.2
4-1
Unit
Operation Reference
ON OFF Section
4.1.4 Every 100 Hour Inspection and Maintenance
X X Perform 50 hour inspection 4.1.2

X Check compressor oil level 4.11.2
X Check or replace fuel pump filter 4.3.1
X X Check engine speeds 1.5.b.

X Tighten all electrical connections None
X Check air switch sensing tubes for leaks 4.20
X Check defrost air switch calibration 4.20.1
X Check that evaporator drain lines are clear None

X X Change lube oil and filter 4.2.2
X Replace fuel filter 4.3.1
X Remove and clean crankcase breather None
X Remove and inspect evaporator fan motor brushes
(Replace if brush length is less than 1/4-inch) 4.22
X Remove and clean battery terminals (vehicle).
Treat with anti-corrosion spray None
4-2
4.2 SERVICING ENGINE RELATED a. Remove oil cup. Check and clean center tube. DO
COMPONENTS NOT USE GASOLINE.
b. Pump solvent through the air outlet with sufficient
4.2.1 Engine Air Cleaner
force and volume to produce a hard, even stream out the
a. Inspection bottom of the body assembly. Reverse flush until all
foreign material is removed.
The oil type air cleaner, hose and connections should
be inspected constantly for leaks. A damaged air cleaner 4.2.2 Changing Lube Oil and Oil Filter(s)
or hose can seriously affect the performance and life of
the engine. If housing has been dented or damaged, WARNING
check all connections immediately.
Turn engine off before removing oil drain plug.
When inspecting air cleaner housing and hoses, check
the connections for mechanical tightness and look for To change the filter:
fractures in the inlet and outlet hoses. When leakage
occurs and adjustment does not correct the problem, a. After warming up the engine, remove plug from oil
replace necessary parts or gaskets. Swelled or distorted crankcase and drain engine lube oil.
gaskets must always be replaced. b. Remove the old oil filter and replace. Lightly oil
gasket on new filter before installing.
b. Service Intervals and Procedure
c. Add oil as specified in section 1.5.d. Warm up
The air cleaner is designed to effectively remove engine and check for leaks.
contaminants from the air stream entering the engine.
An excessive accumulation of these contaminants in the 4.2.3 Optional Oil By-Pass Filter
air cleaner will impair operation, therefore, a service An optional lube oil by-pass filter can be installed in
schedule must be set up and followed. the unit. The oil by-pass filter is installed in the oil line as
1. Oil Cups shown in Figure 4-1.
When to Service: Remove the oil cup at regular
intervals. Initially inspect daily or as often as conditions
require. Never allow more than 1/2 inch (12.7 mm) of dirt
deposit in either cup. More than 1/2 inch (12.7 mm)
accumulation could cause oil and dirt to enter the engine
causing accelerated engine wear. Heavily contaminated
oil will not allow the air cleaner to function properly.
CAUTION
Always cover the engine inlet tube while the air
cleaner is being serviced.
How to Service: Stop the engine and remove the oil 3
cup from the air cleaner. Dump the oil from the oil cups.
Remove the inner cup from the oil cup and clean.
Reassemble and fill both oil cups to the indicated level 1
with SAE #10 oil for temperatures below freezing or
SAE #30 for temperatures above freezing. It is generally 2
a recommended practice to use the same oil as required
in the engine crankcase.
CAUTION 1. Primary Oil Filter 3. By-Pass Oil
2. Oil Pump Filter
Do not under fill or over fill the cups. Over filling
of cups means loss of capacity and under filling Figure 4-1. Engine Oil Filter(s) System
means lack of efficiency.
2. Body Assembly 4.2.4 Cooling System
When to Service: The lower portion of the fixed The condenser and radiator assembly is designed with
element should be inspected each time the oil cup is the radiator located above the condenser coil. The
inspected or serviced. If there is any sign of contaminant condenser fan draws the air through the condenser and
build up or plugging, the body assembly should be radiator coil. To provide maximum air flow the condenser
removed and back flushed. At least once a year or at fan belt should be checked periodically and adjusted if
regular engine service periods remove the entire air necessary to prevent slippage.
cleaner and perform the following:
4-3
a. Servicing the Cooling System 4. Energize the solenoid with a jumper wire
connected to a battery. Slide the solenoid far enough
The condenser and radiator can be cleaned at the
back on the bracket to set the engine speed lever against
same time. The radiator must be cleaned internally as
the stop. Tighten solenoid mounting hardware.
well as externally to maintain adequate cooling.
5. With the engine stopped, place a mark on the
1. Remove all foreign material from the
crankshaft sheave (white paint for example). Check
radiator-condenser coil by reversing the normal air flow.
engine speed. Speed may be verified by a Strobette model
(Air is pulled in through the front and discharges over the
964 (strobe-tachometer) Carrier Transicold P/N
standby motor.) Compressed air or water may be used as
07-00206.
a cleaning agent. It may by necessary to use warm water
mixed with any good commercial dishwasher detergent. 6. Disconnect the jumper wire and start the engine.
Rinse coil with fresh water if a detergent is used. Engine speed should be 1800 rpm. Reconnect the jumper
wire to energize the solenoid. The engine should
2. Drain coolant completely by opening the
increase to high speed (2320 rpm). If engine speed is not
drain-cock and removing the radiator cap.
2320 rpm (engine lever against stop), stop engine and
3. The radiator should be cleaned with a commercial move the solenoid forward slightly. Repeat procedure if
cleaner, following the instructions on the container. adjustments need to be made.
4. Drain the cleaner from the system and fill with a 7. When operating correctly, tighten solenoid
pre-mixed 50/50 treated water/anti-freeze mixture. mounting hardware and reconnect the positive wire.
NEVER ADD COLD WATER TO A HOT ENGINE.
CAUTION 5 4
Use only low silicate Ethylene Glycol anti-freeze 1
2
(with inhibitor) in system. Glycol by itself will
damage the cooling system.
4.2.5 Replacing the Speed and Run Control Solenoids
a. Run Solenoid (See Figure 4-2.) 3

1. Remove spring (item 7) from the engine run lever.
2. Disconnect wiring to solenoid. Remove clip (item
5) from linkage rod (item 8). Remove mounting hardware
9 7
and solenoid.
3. Attach linkage to new solenoid and install the clip
to the linkage rod. Install the replacement solenoid and
mounting hardware loosely. Connect the ground wire 8
and spring. 6 5
4. Energize the solenoid with a jumper wire
connected to a battery. Slide the solenoid far enough 1. Speed Solenoid 5. Clip
forward on the bracket to set the engine run lever (item 2. Spring (Speed 6. Run Solenoid
9) against the stop. Tighten solenoid mounting hardware. Control) 7. Spring (Run Control)
5. De-energize the solenoid. If the engine does not 3. Engine Speed Lever 8. Linkage Rod (Run)
shut off, repeat step 4 and adjust the solenoid back 4. Linkage Rod (Speed) 9. Engine Run Lever
slightly. When operating correctly, tighten solenoid
mounting hardware and reconnect the positive wire. Figure 4-2. Speed and Run Control Solenoids
b. Speed Control Solenoid (See Figure 4-2.) 4.2.6 Servicing Glow Plugs
1. Remove spring (item 2) from the engine speed The glow plugs are connected in parallel and when
lever (item 3). energized, draw 7.5 to 10 amps each at 12 vdc. When
servicing, the glow plug is to be fitted carefully into the
2. Disconnect wiring to solenoid. Disconnect linkage cylinder head to prevent damage to the glow plug. Torque
rod (item 4) from solenoid. Remove mounting hardware value for the glow plug is 28.9 to 36.2 ft-lb (4.0 to 5.0 mkg).
and solenoid. Anti-seize lubricant may be used on threads to ensure
3. Attach linkage to new solenoid and install the clip easy servicing in the future.
(item 5) to the linkage rod. Install the replacement
solenoid and mounting hardware loosely. Connect the
ground wire and spring.
4-4
To check for a defective glow plug, proceed with one 13 12 11
of the following methods:
a. One method is to place an ammeter (or clip-on
ammeter) in series with each glow plug and energize the
plugs. Each plug (if good) should show an amperage draw
of 7.5 to 10 amps.
10 9 8 7 5 4 3 2 1
b. A second method is to disconnect the wire
connection to the plug and test the resistance from the
plug to a ground on the engine block. The reading should
be 0.7 to 1.2 ohms if the plug is good.
6
4.3 FUEL SYSTEM
1. Cover 7. Seat
The fuel is supplied to the unit from the fuel tank by 2. Gasket 8. Plunger
an electric (12 vdc) fuel pump controlled by the unit.This 3. Magnet 9. Plunger Spring
fuel pump supplies a constant pressure of 10 psi to the 4. Filter 10. Retainer
fuel lines of the unit. (See Figure 4-3) 5. Retainer Clip 11. O-Ring
6. Check Valve 12. Flat Washer
Assembly 13. Spring --- 10 psi
6 Figure 4-4. Electric Fuel Pump --- Old
4.3.2 Replacing the Fuel Pump Filter --- New Style

a. Remove 3 screws from cover (item 1, Figure 4-5).
4 b. Remove cover, gasket and filter.
3
c. Wash filter in cleaning solvent and blow out with air
2 pressure. Clean cover.
d. To Install reverse above steps.
7
1 5
1. Fuel Tank 4. Fuel Pump Outlet 3

2. Fuel Pump Inlet 5. Fuel Filter 2
3. Fuel Pump 6. Injection Fuel Pumps 1
7. Injectors
Figure 4-3. Fuel System
1. Cover
4.3.1 Replacing the Fuel Pump Filter --- Old Style
2. Gasket
a. Place box wrench on hex portion of cover, item 1, 3. Filter
Figure 4-4 and rotate cover counterclockwise (the
magnet and gasket, items 2 and 3, should stay with the
cover). Remove filter for inspection and replace if Figure 4-5. Electric Fuel Pump --- New
necessary.
4.3.3 Priming the Fuel System
b. To reassemble, reverse steps in paragraph a.
This unit is equipped with an automatic fuel system
NOTE bleed off. To prime the fuel system proceed with the
The pump must always be installed in vertical following outline.
position as close to the fuel tank as possible.
a. Turn the unit on and press the manual preheat key
(located on the control panel) for at least 60 seconds. This
will energize the fuel pump which will automatically
prime the fuel system.
b. If the unit does not start after cranking for 10
seconds, repeat step a.
4-5
4.4 V-BELTS AND TENSIONERS mm) long into hole as shown in Figure 4-8; turn
clockwise. This will draw the spring up and slacken the
The unit is equipped with an automatic belt tensioner
V-belt for easy removal.
on some models. The condition of the belts should be
checked when servicing the unit.It is recommended that 2. After replacing V-belt, remove the bolt to release
frayed, cracked or worn belts be replaced. It is also the drawn spring to return the idler to its correct tension.
important to keep sheaves and belt grooves clean and
free from any foreign mater which will cause belt A
slippage. (See Figure 4-6)
1 2 3 4
1. Standby Motor to Alternator V-belt

2. Standby Motor to Compressor V-belt
3. Engine to Compressor V-belt
4. Engine to Water Pump V-belt
Figure 4-6. V-Belts and Pulley Assembly Figure 4-8. Engine/Compressor Belt Tensioner
4.4.1 Changing Belts (Starbird Units) c. Alternator Belt Tensioner (See Figure 4-9.)
The following procedures must be taken to ensure the 1. Remove bolt C from nut D. Remove nut D.
proper as well as a safe removal and installation of the Reinstall nut D on threaded rod with the opposite end of
belts. the nut (end that bolt C was removed from). Turn
clockwise to compress the spring which will release the
a. Standby Motor to Compressor Belt Tensioner tension for easy removal of the belt.
(See Figure 4-7.)
2. After replacing the belt, release the tensioning
1. To compress the tensioner spring, place a M8 fully spring by turning nut D counter clockwise. Reinstall as
threaded bolt or rod (A), approximately 7-1/4 inches (200 originally configured. Tighten bolt C.
mm) long into hole as shown in Figure 4-7; turn
clockwise. This will compress the tension spring and
D A
slacken the V-belt for easy removal.
2. After replacing V-belt, remove the bolt to release
the compressed spring to return the idler to the correct C
tension.
A
B
Figure 4-9. Alternator Belt Tensioner
d. Water Pump Belt Tensioner

Figure 4-7. Standby Motor/Compressor Belt Tensioner Water pump belt is driven by the diesel engine
crankshaft pulley. The automatic belt tensioner ensures
b. Diesel Engine/Compressor Belt Tensioner the correct tension.
(See Figure 4-8.) To change the water pump belt, proceed as follows:
1. To compress the tensioner spring, place a M8 fully 1. Loosen the nut fitted on the wing nut.
threaded bolt or rod (A), approximately 7-1/4 inches (200
4-6
2. Compress the spring and slacken belt by turning Low Pressure High Pressure
the wing nut clockwise. Gauge Gauge
3. Replace the belt.
4. Turn the wing nut counterclockwise to release the
spring to the correct belt tension.
5. Tighten the nut to back of wing nut.
4.4.2 Belt Tensioner (Starbird Plus Units) Hand Valve A C B Hand Valve
For units without an automatic belt tensioner, a belt (Open) (Frontseated)
tensioner gauge is recommended whenever V-belts are A. Connection to C. Connection to Either:
adjusted or replaced (see Figure 4-10). All belts should Low Side of System Vacuum Pump
be tensioned to 30-50 lbs for a new belt or 20-40 lbs for a Refrigerant Cylinder
used belt. B. Connection to Oil Container
High Side of System Purge Line
Figure 4-11. Manifold Gauge Set
b. Connecting the Manifold Gauge Set

1. Remove both service valve stem and service port
caps. Backseat both service valves.
2. Connect the high side hose tightly to discharge
service valve port.
3. Connect the low side hose loosely to suction
service valve port.
4. Loosen charging (center) hose at dummy fitting of
manifold set.
5. Frontseat (clockwise) both manifold gauge hand
valves.
6. Crack open discharge service valve 1/4 to 1/2 turns.
Figure 4-10. Belt Tensioner Gauge 7. Slowly open (counter clockwise) manifold
discharge hand valve approximately one turn.
4.5 MANIFOLD GAUGE SET
8. Tighten charging hose on to dummy fitting.
a. Use
9. Slowly open the manifold suction hand valve to
The manifold gauge set can be used to determine purge line.
system operating pressure, add a refrigeration charge, 10. Tighten suction hose at the suction service valve
purge, equalize or evacuate the system. port.
The manifold gauge in Figure 4-11 shows hand valves, 11. Frontseat (close) both manifold hand valves.
gauges and refrigerant openings. When low pressure
hand valve is frontseated (turned all the way in), the low 12. Crack open suction service valve 1/4 to 1/2 turns.
(evaporator) pressure can be checked. When the high
pressure hand valve is frontseated, high (condensing) 4.6 PUMPING THE LOW SIDE DOWN OR
pressure can be checked. When both valves are open REMOVING THE REFRIGERANT
CHARGE COMPLETELY
(turning counter clockwise), high pressure vapor will flow
into the low side. When the low pressure valve is open, It is necessary to use a refrigerant recovery system
you can charge the system or evacuate it, put oil in the when removing refrigerant charge.
system or clean it.
4.6.1 Low Side Pump Down
To service or replace the filter-drier, sight glass,
expansion valve, evaporator coil, CPR valve, suction
accumulator or suction line; pump most of the refrigerant
into condenser coil and receiver as follows:
a. Install a manifold gauge set as outlined in section
4.5.
b. Frontseat (close) receiver outlet (king) valve by
turning clockwise. Start unit and run in high speed cool.
4-7
Stop the unit when the suction pressure reaches 1 psig 4.7 REFRIGERANT LEAK CHECK
(0.1 kg/cm@) to maintain a slight positive pressure. WARNING
c. Frontseat (close) suction service valve to trap the It has been determined that pressurized,
refrigerant between the compressor suction service valve air-rich mixtures of refrigerants and air can
and the receiver outlet (king) valve. undergo combustion when exposed to an
d. Remove center charging hose from the dummy ignition source.
fitting of the manifold gauge set. Open the suction hand a. The recommended procedure for finding leaks in a
valve on the manifold gauge set to reduce the low side system is with a halide torch or electronic leak detector.
system pressure to 0 psig. Testing joints with soapsuds is satisfactory only for
locating large leaks.
WARNING
b. If the system is without refrigerant, charge the system
Point the center charging hose and secure in a
with refrigerant to build up pressure between 2.1 to 3.5
safe direction away from operator.
kg/cm@ (30 to 50 psig). Remove refrigerant drum and leak
e. Service or replace the necessary component on the check all connections.
low side of the system. NOTE
It must be emphasized that only the correct
NOTE refrigerant drum be connected to pressurize the
When opening up the refrigerant system, certain system. Any other gas or vapor will contaminate
parts may frost. Allow the part to warm to the system which will require additional purging
ambient temperature before dismantling. This and evacuation of the high side (discharge) of
avoids internal condensation which puts the system.
moisture in the system. c. Remove refrigerant using a refrigerant recovery
system BEFORE repairing any leaks.
f. Leak check connections as outlined in section 4.7.
d. Evacuate and dehydrate the unit. (Refer to section
g. Evacuate and dehydrate the low side as outlined in 4.8.)
section 4.8.
e. Charge unit per section 4.9.1.
4.6.2 Removing the Refrigerant Charge
To service the condenser coil, receiver, hot gas
(three-way) valve, check valves and discharge
vibrasorber, connect a refrigerant recovery system to the
unit to remove the refrigerant charge. It is recommended
that the recovery machine be connected to the king valve
and the suction service valve. Mid-seat the king valve and
run the unit in high speed cool. The majority of the charge
will be in liquid form in the receiver. Using the recovery
machine, remove the charge at the king valve only. The
unit will shut off when the suction pressure reaches 15
inches (38 cm) hg vacuum. Any residual charge in the low
side of the system can be removed through the suction
service valve after the unit stops.
Operate the recovery machine per manufacturer’s
instructions and applicable local, state and federal
environmental regulations.
4-8
4.8 EVACUATION AND DEHYDRATION to approximately 2 psig by monitoring with a compound
gage.
4.8.1 General
g. Remove refrigerant using a refrigerant recovery
Moisture is the deadly enemy of refrigerant systems. system.
The presence of moisture in a refrigeration system can
have many undesirable effects. The most common are h. Repeat steps e through g one time.
copper plating, acid sludge formation, “freezing-up” of i. Evacuate unit to 500 microns. Close off vacuum
metering devices by free water, and formation of acids, pump valve and stop pump. Wait five minutes to see if
resulting in metal corrosion. vacuum holds. This checks for residual moisture and/or
leaks.
4.8.2 Preparation
j. With a vacuum still in the unit, the refrigerant charge
a. Evacuate and dehydrate only after pressure leak test. may be drawn into the system from a refrigerant
(Refer to section 4.7) container on weight scales. The correct amount of
b. Essential tools to properly evacuate and dehydrate refrigerant may be added by observing the scales. (Refer
any system include a good vacuum pump (5 cfm = 8m#H to section 4.9)
volume displacement, P/N 07-00176-01) and a good
7
vacuum indicator such as a thermocouple vacuum gauge
8
(vacuum indicator). (Available through Robinair
Manufacturing, Montpelier, Ohio, Part Number 14010.)
NOTE
It is not recommended using a compound gauge
as a vacuum gauge because of its inherent
inaccuracy. 9
c. Keep the ambient temperature above 60_F (15.6_C)
to speed evaporation of moisture. If ambient
temperature is lower than 60_F (15.6_C), ice might form
before moisture removal is complete. Heat lamps or
alternate sources of heat may be used to raise system
temperature. 11
4.8.3 Procedure for Evacuation and 10
Dehydrating System
a. Remove refrigerant using a refrigerant recovery
system.
4 4
b. The recommended method to evacuate and
dehydrate the system is to connect three evacuation
hoses (Do not use standard service hoses, as they are not 3
suited for evacuation purposes) as shown in Figure 4-12
to the vacuum pump and refrigeration unit. Also, as
shown, connect an evacuation manifold, with evacuation 1
hoses only, to the vacuum pump, electronic vacuum 4
6
gauge, and refrigerant recovery system.
c. With the unit service valves closed (back seated) and
the vacuum pump and electronic vacuum gauge valves
open, start the pump and draw a deep vacuum. Shut off 5
the pump and check to see if the vacuum holds. This 2
operation is to test the evacuation setup for leaks, repair 1. Refrigerant Recovery Unit
if necessary. 2. Refrigerant Cylinder
d. Midseat the refrigerant system service valves. 3. Evacuation Manifold
4. Valve
e. Then open the vacuum pump and electronic vacuum 5. Vacuum Pump
gauge valves, if they are not already open. Start the 6. Electronic Vacuum Gauge
vacuum pump. Evacuate unit until the electronic vacuum 7. Evaporator Coil
gauge indicates 2000 microns. Close the electronic 8. Receiver Outlet (King) Valve
vacuum gauge and vacuum pump valves. Shut off the 9. Condenser Coil
vacuum pump. Wait a few minutes to be sure the vacuum 10. Suction Service Valve
holds. 11. Discharge Service Valve
f. Break the vacuum with clean dry refrigerant. Use
refrigerant that the unit calls for. Raise system pressure Figure 4-12. Vacuum Pump Connection
4-9
4.9 CHARGING THE REFRIGERATION SYSTEM
4.9.1 Installing a Complete Charge (Unit must not be

running)
a. Dehydrate unit and leave in deep vacuum. (Refer
to section 4.8.)
b. Place refrigerant cylinder on scale and connect CORRECT CHARGE
charging line from the cylinder to receiver outlet (king)
valve. Purge charging line at outlet valve.
c. Note weight of refrigerant cylinder.
d. Open the liquid valve on the refrigerant cylinder.
Open the receiver outlet (king) valve half way and allow
the liquid refrigerant to flow into the unit. Monitor
weight of the refrigerant cylinder to determine how much
refrigerant is entering the system. The correct charge is INSUFFICIENT CHARGE
shown in section 1.4.e.
Figure 4-13. Sight Glass Refrigerant Charge
e. When refrigerant cylinder weight (scale) indicates
that the correct charge has been added, close liquid line
valve on drum and backseat the receiver outlet valve. 4.10 PURGING NONCONDENSIBLES
The recommended procedure for removing
4.9.2 Adding a Partial Refrigerant Charge to the System noncondensibles is to remove the entire refrigerant
NOTE charge using a refrigerant recovery machine. Purge
noncondensibles from the refrigerant cylinder before
The unit must not be running when charging recharging the unit.
liquid. It is possible that all liquid may not be
pulled into the receiver, as outlined in step d. In 4.11 COMPRESSOR
this case, vapor charge remaining refrigerant
through the suction service valve. 4.11.1 Replacing the Compressor
a. Install service manifold gauge set as outlined in WARNING
section 4.5.
Disable compressor drive before front-seating
b. Connect charging line to a refrigerant cylinder. discharge service valve.
c. Open vapor valve on the refrigerant cylinder to
purge charging line. a. Removing
d. Run the unit in cooling and midseat suction
service valve. 1. If compressor is inoperative and refrigerant
pressure still exists, frontseat the suction and discharge
4.9.3 Checking the Refrigerant Charge service valves to isolate the refrigerant in the system from
the compressor. Recover the refrigerant in the
a. To check for an under charged system, start the compressor using a refrigerant recovery machine.
unit and set the temperature controller to 35_F (2_C).
Allow the unit to stabilize in high speed cool for 10 If the compressor runs, pump down the compressor by
minutes and raise discharge pressure to 150 psig (if frontseating the suction service valve until the pressure
necessary, partially block condenser to raise the drops to 1 psig, then stop the unit.
discharge pressure). If the charge is correct, the sight 2. Slowly release compressor pressure.
glass will be clear. If the sight glass is not full or if foam is
present in the sight glass, refrigerant should be added to 3. Remove the suction and discharge service valves
bring the charge to the proper level (see Figure 4-13). from the compressor.
NOTE 4. Release automatic belt tensioner as outlined in

section 4.4 and remove belts.
A few occasional bubbles does not necessarily
mean that the unit is under charged. 5. Remove the four bolts holding the compressor to
the power tray. Remove the compressor from chassis.
b. To check for an over charged system, perform a 6. Remove the pulley from the compressor.
low side pump down while monitoring the discharge
pressure. The pressure should remain constant or start to b. Installing
drop. If the pressure starts to raise, this will indicate an
1. To install the compressor, reverse the procedure
over charged system.
outlined when removing the compressor. Refer to section
1.6 for torque values.
4-10
NOTE 4. Run compressor until suction pressure gauge
indicates 5 inches /hg. Shut down unit.
It is important to check the compressor oil level
of a new compressor and fill if necessary. 5. Crack open manifold valve and allow vacuum in
compressor to draw oil slowly into compressor. When
4.11.2 Checking the Compressor Oil Level level is just above one quarter glass, close (front seat)
manifold valve. Midseat the suction service valve.
To Check the Oil Level in the Compressor:
6. Start unit and check compressor oil level.
1. Operate the unit in high speed cooling for at least
20 minutes. 7. Backseat valve to remove hose from suction
service valve and replace service valve caps.
2. Check the oil sight glass on the compressor to
ensure that no foaming of the oil is present after 20
minutes of operation. If the oil is foaming excessively SUCTION MANIFOLD
after 20 minutes of operation, check the refrigerant SERVICE GAUGE
system for flood-back of liquid refrigerant. Correct this VALVE
situation before adding oil.
3. Check the level of the oil in the sight glass with the
compressor operating. The correct level should be
between 1/4 and 1/2 of the sight glass. If the level is above
1/2, oil must be removed from the compressor. If the level
is below 1/8, add oil to the compressor as outlined in the
following section. OIL
COMPRESSOR
CONTAINER
1 2
Figure 4-15. Compressor Oil Charge Connections
b. Oil Pump Method

1. Connect an oil pump to a one U.S. gallon (3.785
5 litres) refrigeration oil container. Using the Robinair
compressor oil pump (Carrier Transicold P/N 14388) is
recommended.
When the compressor is in operation, the pump check
4
3 valve prevents the loss of refrigerant, while allowing
servicemen to develop sufficient pressure to overcome
the operating suction pressure to add oil as necessary.
4 CYLINDER
2. Backseat suction service valve and connect oil
1. Suction Service Valve charging hose to port. Crack the service valve and purge
2. Discharge Service Valve the oil hose at oil pump. Add oil as necessary.
3. Oil Level Sight Glass
4. Oil Drain Plug 4.11.4 Removing Oil From the Compressor
5. Oil Fill Plug If the oil level in the compressor is found to be too
Figure 4-14. 05K Compressor high, oil must be removed to insure proper operation.
Pump down the compressor and relieve any internal
4.11.3 Adding Oil to the Compressor pressure. Remove the oil drain plug and allow the excess
oil to run out into container for proper environmental
Two methods for adding oil are the oil pump method
disposal. Recheck oil level per section 4.11.2.
and closed system method.
NOTE
a. Closed System Method
Anytime the compressor is opened to the
1. Connect two refrigerant hoses, manifold gauge set
atmosphere, evacuation of the compressor
and compressor oil container as shown in Figure 4-15
through the suction service valve is
2. Frontseat the suction service valve, start unit and recommended prior to putting the unit back in
pull crankcase pressure to 1 or 2 psig. Stop unit. service.
3. With the unit off and a positive pressure of about 1
or 2 psig showing on the gauge, open manifold valve to
purge air from lines.
4-11
4.12 ADJUSTING THE COMPRESSOR and (b) prevention of liquid refrigerant entering the
PRESSURE REGULATING VALVE (CPR) compressor. Unless the valve is defective, it seldom
requires any maintenance.
The CPR valve is factory pre-set and should not need
adjustment. If it is necessary to adjust the valve for any
1
reason, proceed with the following outline.
When adjusting the CPR valve, the unit must be 2 6
running in high speed heat. This will ensure a suction 14
7
pressure above the proper CPR setting specified in
section 1.4.f. 3
8
1 2 3
9
10
4 11
12
1. Cap 2. Jam Nut 3. Setting Screw 5 13
Figure 4-16. Compressor Pressure Regulating Valve 1. Power Head 7.Seat

Assembly 8.Pin
2. Valve Body 9.Pin, Carrier
To adjust the CPR valve, see Figure 4-16 and proceed 3. Strainer (Inlet) 10.Spring
as follows: 4. Bottom Cap 11.Spring Guide
a. Install a manifold gauge set as outlined in section Assembly 12.Adjusting Stem
4.5. 5. Seal Cap 13.Bulb
6. Pushrods 14.External Equalizer
b. Remove cap (item 1) from CPR valve. Port (opposite side)
c. With an 8 mm allen wrench, loosen the jam nut Figure 4-17. Thermostatic Expansion Valve
(Figure 4-16, item 2).
d. Using the 8 mm allen wrench, adjust the setting a. Replacing the Expansion Valve (See Figure 4-17)
screw. To raise the suction pressure turn the setting screw 1. Pump down the unit (refer to section 4.6.1).
(item 3) clockwise; to lower the suction pressure, turn the
setting screw counterclockwise. 2. Remove insulation and expansion valve bulb from
suction line.
e. When the setting has been adjusted, tighten the
jam nut securely against the setting screw (item 3). This 3. Loosen flare nut and disconnect equalizer line
will prevent any movement of the setting screw due to from expansion valve.
vibrations in the unit. Replace the cap. 4. Loosen valve body flare nuts and remove entire
valve. Check for foreign material in valve body.
4.13 QUENCH VALVE (STARBIRD PLUS ONLY)
For R-22 units the quench valve opens as required to 5. Install the thermal bulb on the suction line in the 3
maintain a 265 to 285_F (118 to 141_C) maximum o’clock position (see Figure 4-18). This area must be
discharge temperature. The quench valve operates at the clean to ensure positive bulb contact. Strap thermal bulb
temperature of the discharge line where the bulb is to suction line and insulate both.
clamped. This is not the same location as the Compressor 6. Install new expansion valve assembly and fasten
Discharge Sensor (CDT). The CDT will normally read the equalizer tube to the expansion valve.
about 20 to 25 degrees warmer than the location of the
quench valve bulb. When in question, place a thermometer 7. Check for leaks by opening the receiver service
next to the valve bulb to see what temperature the quench valve slightly to pressurize the valve. Close the receiver
valve is actually controlling to. service valve.
8. Evacuate by placing vacuum pump on suction
4.14 THERMOSTATIC EXPANSION VALVE service valve.
The thermostatic expansion valve (TXV) is an 9. Open receiver outlet valve and check refrigerant
automatic device which maintains constant superheat in level (refer to section 4.9.3).
the refrigerant gas leaving the evaporator regardless of
suction pressure. The valve functions are: (a) automatic 10. Check superheat as outlined in step b. (refer to
response of refrigerant flow to match the evaporator load section 1.4.g. for superheat setting).
4-12
b. Checking Superheat d. Adjusting Superheat
NOTE The thermostatic expansion valve used in this
Adjustment of the external adjustable valve is application is externally adjustable. The valve is preset at
not recommended and should only be done in the factory and should not be adjusted unnecessarily. If
emergency situations when there is no necessary to adjust the superheat, proceed as follows:
replacement expansion valve available. 1. Remove the seal cap to gain access to the
The valve comes from the factory with the proper superheat adjusting stem (see Figure 4-17).
superheat setting; if the setting has changed, a 2. Turn the adjusting stem clockwise to compress the
mechanical malfunction has occurred and adjusting valve spring which will decrease refrigerant flow through
superheat will not correct the malfunction. the valve, increasing superheat. Turn the adjusting stem
The valve may be adjusted if you do not have another counterclockwise to decompress the valve spring which
replacement valve on hand. Due to the time involved in will increase refrigerant flow through the valve,
adjusting the superheat, replace the valve rather than decreasing superheat.
adjusting it (step d.) 3. When the unit has stabilized operation for at least
c. Measuring Superheat 20 minutes, recheck superheat setting.
1. Remove insulation from expansion valve bulb and 4. If superheat setting is correct, replace stem cap,
suction line. remove gauge and thermocouple. Insulate bulb and
suction line.
2. Loosen one TXV bulb clamp and make sure area
under clamp (above TXV bulb) is clean. 4.15 HOT GAS (Three-Way) VALVE
3. Place the temperature thermocouple above
4.15.1 Replacing Solenoid Coil
(parallel) TXV bulb and tighten loosened clamp making
sure both bulbs are firmly secured to suction line as shown It is not necessary to pump the unit down to replace
in Figure 4-18. Re-insulate the suction line where the the coil (see Figure 4-19).
TXV bulb and the thermocouple are attached. a. Remove coil snap cap, voltage plate and coil
4. Connect the manifold suction gauge hose to the assembly. Disconnect leads and remove coil junction box
port on the suction service valve. if necessary.
5. Set controller selector to 0_F (---17.8_C) box b. Verify coil type, voltage and frequency. This
temperature. Run unit for at least 20 minutes in cool. information appears on the coil voltage plate and the coil
NOTE housing.
When conducting this test the suction pressure
c. Place new coil over enclosing tube and then install
must be below the compressor regulating valve’s voltage plate and snap cap.
setting specified in section 1.4.f. This will open
the valve completely allowing a true suction CAUTION
pressure reading at the suction service valve.
Do not damage or over tighten the enclosing tube
6. From the temperature/pressure chart (Table 4-1, assembly. Also make sure all parts are placed on
Table 4-2, or Table 4-3) determine the saturation the enclosing tube in proper sequence to avoid
temperature corresponding to the pressure taken at the premature coil burnout.
suction service valve.
7. Note the temperature of the suction gas at the 4.15.2 Replacing Hot Gas Valve Internal Parts
expansion valve bulb. If the hot gas valve is to be replaced or the internal
8. Subtract the saturation temperature determined parts serviced, the entire refrigerant charge must be
in Step 6 from the temperature measured in Step 7. The removed.
difference is the superheat of the suction gas. a. Remove the refrigerant charge using a refrigerant
9. Set superheat per specifications in section 1.4.g. recovery machine (refer to section 4.6.2).
b. Remove coil snap cap, voltage cover and coil
assembly. Remove the valve body head.
1 3 1. Suction Line
c. Check for foreign material in valve body.
(end view)
2. TXV Bulb Clamp d. Check for damaged plunger and O-ring. If O-ring
is to be replaced, always put refrigerant oil on O-rings
3. Thermocouple before installing.
2 4 4. TXV Bulb
e. Tighten enclosing tube assembly. If the valve has
not been removed from the unit, leak check the valve.
Figure 4-18. Thermostatic Expansion Valve Bulb and f. Install coil assembly, voltage cover and cap.
Thermocouple g. Evacuate and dehydrate the unit.
4-13
h. Install a complete refrigerant charge. e. Evacuate the low side by placing vacuum pump on
i. Start unit and check operation. suction service valve.
f. Open receiver outlet valve and check refrigerant
1 level (refer to section 4.9.3).
2
4.18 HIGH PRESSURE CUTOUT SWITCH
3
4.18.1 Replacing High Pressure Switch
1. Snap Cap
a. Pump down the compressor. Shut the unit off.
4 2. Voltage Plate
Front seat both suction and discharge service valves to
3. Coil Assembly isolate compressor. Then slowly release compressor
4. Enclosing Tube refrigerant charge.
5
5. Plunger Assembly b. Disconnect wiring from defective switch and
6 6. Body Head remove switch. The high pressure switch is located near
7. Gasket the top of the compressor.
7 8. Valve Body c. Install the cutout switch after verifying switch
Assembly settings.
d. Evacuate and dehydrate the compressor before
opening service valves.
8
4.18.2 Checking High Pressure Switch
(See Figure 4-20)
Figure 4-19. Hot Gas (Three-Way) Valve WARNING
4.16 SIGHT GLASS --- MOISTURE INDICATOR Do not use a nitrogen cylinder without a
pressure regulator. Cylinder pressure is
The sight glass/moisture indicator is located in the approximately 2350 psi (165 kg/cm@). Do not use
liquid line between the filter drier and thermostatic oxygen in or near a refrigeration system as an
expansion valve. The primary functions of the sight glass explosion may occur.
are:
a. Remove switch from compressor.
a. To check moisture in the refrigerant.
b. Connect ohmmeter across switch terminals. If the
b. To observe the refrigerant for restricted flow and
when charging the unit. switch is good the ohmmeter will indicate no resistance
indicating the contacts are closed.
4.16.1 Moisture Indicator c. Connect switch to a cylinder of dry nitrogen.
The moisture indicator in the center of the sight glass d. Back-off regulator adjustment completely.
will indicate the moisture content of the refrigerant.
e. Open cylinder valve. Slowly open the regulator
The moisture level is indicated by the changing color valve to increase the pressure until it exceeds opening
of the indicator as outlined below: pressure of the switch. Verify the open switch with a
a. A green color indicates the refrigerant contains no infinite reading on a ohmmeter (no continuity).
moisture. f. Close cylinder valve and release the pressure
b. A yellow color indicates an unacceptable level of through the bleed-off valve.
moisture in the refrigerant.
1
If a yellow color occurs, the filter-drier must be
replaced (refer to section 4.17). 4
5 1. Cylinder Valve
4.17 REPLACING THE FILTER-DRIER 2
and Gauge
a. Pump down the low side of the unit (refer to 2. Pressure Regulator
section 4.6.1). 3. Nitrogen Cylinder
4. Pressure Gauge
b. Loosen the filter-drier flare nuts first, then (0 to 400 psig =
remove one bolt and nut from the filter-drier clamp and 3 6
0 to 36 kg/cm@)
loosen the other bolt. Move the clamp and replace the old 5. Bleed-Off Valve
filter-drier with the new one. 6. 1/4 inch Connection
c. Tighten the flare nuts of the replacement
filter-drier before securing the clamp.
d. Leak test the low side of the system.
Figure 4-20. Checking High Pressure Switch
4-14
4.19 ADJUSTING THE LOW PRESSURE SWITCH
a. Cut-out Adjustment 2
1. Install manifold gauge set. 5
2. Front-seat the king valve.
3. Start the unit in cool mode.
4. Observe the suction pressure gauge. The unit
should shut down at 15 inches hg vacuum. If shut down 6 3
does not occur at 15 inches hg vacuum, adjust the low 4
pressure switch cut-out adjustment and restart. Repeat 1
until correct. It may be necessary to open the king valve to
raise suction pressure to restart the unit.
1. Ohmmeter
b. Cut-in Adjustment 2. Adjustment Screw (0.050 socket head size)
3. Low side connection
When cut-out pressure is correct, it is necessary to set 4. Pressure line and aspirator bulb
the cut-in pressure. With the unit shut off on low (P/N 07-00177-01)
pressure, slightly mid-seat both hand valves on the 5. Magnehelic gauge (P/N 07-00177)
manifold gauge set. This will allow suction pressure to 6. High side connection
rise. Listen to the low pressure switch. At 5 psig suction
pressure, the cut-in should ‘‘click’’ on. It may be necessary Figure 4-21. Defrost Air Switch Test Setup
to use an ohmeter if the switch action cannot be heard.
Repeat procedure until correct switch setting is a. With air switch in vertical position, remove both
accomplished. tubes from the air switch, connect high pressure side of
magnehelic gauge to high side connection of air switch.
4.20 DEFROST AIR SWITCH (DA)
See Figure 4-21.
To check the circuit, run unit in high speed cool until
b. Attach an ohmmeter to air switch electrical
the defrost thermostats (DT) close. Remove the two
contacts to monitor switch action.
leads connected to the defrost air switch and touch the
two wires together momentarily. This should start the c. With the magnehelic gauge reading at zero, apply
defrost cycle as it simulates the action of the defrost air air pressure very slowly to the air switch. The ohmmeter
switch. Bypassing the switch in this manner operates all will indicate continuity when the switch actuates. This
components involved in defrost. Reconnect the wires as procedure should be repeated several times to ensure the
soon as this step is satisfactorily completed. accuracy of the reading.
Unit should remain in defrost until evaporator coil NOTE
temperature reaches 47_F (8_C). At this point the two
defrost thermostats (DT) should open to terminate the Use a hand aspirator (P/N 07-00177-01) to apply
defrost cycle. Replace the defrost thermostats if unit fails air pressure, since blowing into tube by mouth
to terminate defrost. may cause an incorrect reading.
4.20.1 Checking Calibration of the Defrost Air Switch d. Switch should actuate at 0.8 ¦ 0.05 inches water
column. If switch fails to actuate at correct gauge reading,
If the above test indicates satisfactory operation, test
adjust switch by turning adjusting screw clockwise to
defrost air switch settings, using a Dwyer Magnehelic increase setting or counterclockwise to decrease setting.
gauge (P/N 07-00177) or similar instrument. (One inch of water column is equivalent to 0.036 psi.)
The air switch high pressure side tube ends between
e. Repeat checkout procedure until switch actuates
the evaporator fans and the evaporator coil. The low
at correct gauge reading.
pressure side tube ends on the supply air side of the
evaporator coil. f. After switch is adjusted, place a small amount of
sealing compound on the adjusting screw so that
NOTE vibration will not change switch setting.
The magnehelic gauge may be used in any
position, but must be re-zeroed if position of
gauge is changed from vertical to horizontal or
vice versa. USE ONLY IN POSITION FOR
WHICH IT IS CALIBRATED.
4-15
4.21 SERVICING THE ALTERNATOR (12 vdc)
4.21.1 Preliminary Checks and Test

NOTE
Before starting the actual electrical test
procedure, the charging system, battery and
wiring should be checked to eliminate possible
problem areas.
a. With Unit Off

1. Check the condition and adjustment of the
alternator V-belt.
2. If the alternator fan can be moved by pushing on a
fan blade with your finger, the belts tensioner should be
Figure 4-22. Rotor Checkout
checked.
3. Replace V-belt if worn or glazed. b. Stator Checkout (See Figure 4-23.)
4. Check to see that all terminals, connectors, and 1. Look at the winding of the stator to see if there is
plugs are clean and tight. damage caused by excessive heat.
5. Check for broken, loose or burned-out 2. Using an ohmmeter, check the insulation of the
connections and repair if necessary. Loose or corroded winding by placing one probe to ground and the other on
connections cause high resistance which could cause each of the diode terminals. The resistance reading
overcharging, undercharging, or damage to the charging should be infinite. No reading indicated on the
system. ohmmeter would indicate an open circuit.
6. Check battery and cable condition and charge or
replace if necessary. A low or discharged battery may
cause false or misleading readings. Badly corroded
battery cables could prevent the battery from reaching a
fully charged condition.
b. With Unit On
1. Using a voltmeter, check the voltage output at
terminal B+ of the alternator.
2. Check output at positive post of the battery. The
voltage reading should be the same at both points. If
conflicting readings are indicated, the connection
between the battery and alternator is bad.
4.21.2 Alternator Test Procedure

a. Rotor Checkout (See Figure 4-22.)
Figure 4-23. Stator Checkout
1. Clean brush contacting surface of the slip rings
with a fine crocus cloth, then wipe dust and residue away.
c. Regulator Checkout (See Figure 4-24)
2. Using an ohmmeter, place the probes on each of
the slip rings. The correct ohm reading should be between 1. Check the voltage at the rotor terminal of the
3.8 ohms and 5.2 ohms. regulator. The correct voltage is approximately 2 vdc.
3. Also check the insulation of the slip rings by 2. If the voltage is above 2 vdc, this will indicate a
putting one probe on a ring and the other probe to defective excitation circuit and the brushes should be
ground. The resistance reading should be infinite. checked.
4. If incorrect readings are indicated, replace entire 3. If the reading is 0 vdc, check the regulator
rotor assembly. connections.
4-16
4. Check the regulator circuit by disconnecting the 2. Negative Diodes (View B)
excitation wire and placing a voltmeter between the a. Place one probe of the ohmmeter on the negative
alternator excitation terminal and the regulator wire. coil of the diode bridge and the other on each diode
5. A reading between 8 and 12 vdc will indicate a terminal as shown in View B, Figure 4-26.
defective alternator and it should be replaced. b. A reading may or may not be indicated. If a
reading is indicated, when reversing the leads there
should be no reading. Inversely, if no reading is indicated
the first time, when reversing leads you should see a
reading. This will indicate a good diode. If both readings
are the same, diode is faulty.
3. Diode Trio (View C)
a. To check the diode trio, place one probe of the
ohmmeter on terminal D+ and the other on each diode
terminal as shown in View C, Figure 4-26.
b. A reading may or may not be indicated. If a
reading is indicated, when reversing the leads there
should be no reading. Inversely, if no reading is indicated
Figure 4-24. Regulator Checkout reading. This will indicate a good diode. If both readings
d. Diode Bridge Checkout (See Figure 4-25)
1. Check the voltage between one terminal of the
stator diode bridge and ground. Now place the ground
probe on the positive post B+
2. With correct polarity the voltage reading is 0 vdc.
A reading above 0 vdc will indicate a shorted diode bridge
and it should be replaced.
View A
View B
Figure 4-25. Diode Bridge Checkout
4.21.3 Diode Test Procedure

View C
a. Remove diode bridge from the alternator. It will
be necessary to unsolder the wire connection to remove. Figure 4-26. Diode Bridge Assembly
b. Check each diode with an ohmmeter.
4.21.4 Brush Test Procedure
1. Positive Diodes (View A) a. Remove brush assembly from alternator. It is
a. Place one probe of the ohmmeter on terminal B+ suggested to mark wires and their terminals for ease of
and the other probe on each diode terminal as shown in assembly. Care should be taken when removing not to
View A, Figure 4-26. damage brushes.
b. A reading may or may not be indicated. If a b. Check brush assembly for chipped or oil soaked
reading is indicated, when reversing the leads there brushes. Remaining brush length should be at least 3/16
should be no reading. Inversely, if no reading is indicated inch (4.76 mm) long.
reading. This will indicate a good diode. If both readings
4-17
c. Using a 12 vdc test lamp or ohmmeter, test brush For example purposes, assume the following:
assembly for continuity and insulation as shown in 1. The set point temperature is 27_F (15_C).
Figure 4-27. Replace brush assembly if necessary.
2. You require a temperature alarm differential of
12_F (6.7_C).
a. To Set the Heat Alarm LED (Upper LED)

1. Set the thermostat 12_F (6.7_C) below the box
temperature to 15_F (8.3_C). The LED should come on.
2. Turn the heat out-of-range adjusting screw with a
screwdriver until the LED goes off (if it is already on).
3. Turn the screw in the opposite direction until the
LED lights again.
b. To Set the Cool Alarm LED (Lower LED)

CONTINUITY CHECK 1. Set the thermostat 12_F (6.7_C) above the box
Continuity A to C OK temperature to 39_F (21.6_C). The LED should come
Continuity D to E OK on.
No Circuit C to E OK 2. Turn the heat out-of-range adjusting screw with a
screwdriver until the LED goes off (if it is already on).
Figure 4-27. Alternator Brush Assembly
3. Turn the screw in the opposite direction until the
4.22 CHECKING AND REPLACING FAN LED lights again.
MOTOR BRUSHES 1 2 3
The fan motor brushes should be checked periodically
for cleanliness and wear to maintain proper operation of
the the fan motors.
OFF
1. Brush Cap
2 2. Brush ALARM
1
12 11 10 9 8 7 6 5 4
1. Heat Out-of-Range Indicator (LED)
2. Heat Out-of-Range Adjustment Screw
Figure 4-28. Fan Motor Brushes 3. Digital Box Temperature Display
To check brushes proceed as follows. 4. Safety Alarm LED
5. OFF Button
a. With unit off and battery connections 6. Manual Defrost Button/LED
disconnected, remove brush cap (item 1; 2 per motor). 7. Standby Operation Button/LED
See Figure 4-28. 8. City Speed Button LED
b. Remove brushes (item 2; 2 per motor) and check 9. Road Operation Button/LED
the length of the brush. If the length is less than 3/8 inch. 10. Cool Out-of-Range Adjustment Screw
(10 mm) the brushes should be replaced. 11. Acoustic Alarm Shut-off Button
12. Cool Out-of-Range Indicator (LED)
c. Blow air into the motor to remove any dust caused
by the brushes. This dust could prevent a good contact Figure 4-29. Cab Command
between the brushes and rotor.
4.23.2 Calibrating the Cab Command
d. Change brushes if necessary and replace cap.
a. Check calibration of box temperature display on
4.23 SETTING THE CAB COMMAND controller as described in section 4.25.2. If controller is
out of calibration, it must be calibrated prior to
4.23.1 Setting the Critical Cargo Monitor Alarms adjustment of the cab command.
The set point of the alarm can be changed. The b. If the display on the cab command does not agree
procedure is outlined below: with the display on the controller, remove six screws from
the back of the cab command. Remove cab command
from its case. Newer style Cab Commands are equipped
4-18
with an access hole located on the right side of the Cab 4.25 TEMPERATURE CONTROLLER
Command for display calibration. CHECKOUT PROCEDURE
c. Connect harness and adjust the potentiometer A
4.25.1 Temperature Sensor
indicated below to make the display match the controller.
After adjusting, lock the potentiometer with a drop of The temperature sensor operates as a variable
lacquer and reassemble the cab command. resistor. To control the accuracy and the proper
A functioning of this sensor, use an accurate ohmmeter and
check its resistance value according to internal
temperature.
The reading must be taken across the two end
terminals. The reading is to be compared with the
following chart in accordance with the air return
temperature.
Ambient Resistance
Side view of Cab Command with case removed
Temperature Value
_F _C Ohms
Figure 4-30. Cab Command Side View
---67 ---55 495
4.24 ADJUSTING EVAPORATOR FAN MOTOR ---58 ---50 514
POTENTIOMETER (Ecotronic Only) ---40 ---40 568
The potentiometer is factory pre-set and normally ---22 ---30 625
should not need adjustment. If it is absolutely necessary ---4 ---20 686
to adjust the potentiometer, or the fan module has to be
replaced, the following procedure should be performed: 14 ---10 750
a. Set the potentiometer to 16 amps. 32 0 817
b. Start the unit in road operation. 50 10 887
c. After 20 to 25 seconds the evaporator fans will 68 20 961
start. 77 25 1000
d. Turn the potentiometer slowly counterclockwise 86 30 1039
(from 16 amps towards 5 amps) until one of the three 104 40 1120
evaporator fan LED’s on the control panel lights. This
will indicate that a fan has stopped. (See Figure 4-31) 4.25.2 Box Temperature Display
e. Then turn the potentiometer clockwise one a. Place the sensor in an ice-bath solution.
increment.
b. Start the unit. Run long enough to allow the unit
f. Wait 2 minutes. Proceed with the following
operation to stabilize.
applicable situation:
1. If the fan that has stopped restarts and c. If the digital readout does not indicate 32_F
continues to run, turn the potentiometer clockwise one (0_C), remove the controller from the unit. Remove the
increment (one amp) and stop the unit. two nuts on the rear of the case which hold the controller
in its case. Remove controller from the case and reattach
2. If the fan that has stopped restarts and stops to the unit harness.
again after 2 or 3 seconds, start at step e and repeat the
procedure. d. Locate the potentiometer marked “MO”. Turn
with a small screwdriver until display indicates 32_F
POTENTIOMETER (0_C). Lock potentiometer with a small drop of lacquer.
12 14 e. Reassemble controller.
FPR MCR I 10
R28 R4b 16 4.25.3 Controller Set Point
8
A
ULR VRR 6 a. Place the sensor in an ice-bath solution.
R20 R29
5 b. Start the unit. Run long enough to allow the unit
HR operation to stabilize.
R5
C2
c. Start with the digital readout indicating 32_F
(0_C). Position the set point knob fully clockwise. Slowly
turn the knob counter clockwise towards 32_F (0_C). The
unit will switch from high speed heat to low speed heat as
Figure 4-31. Evaporator Fan Module the pointer approaches 32_F (0_C). Note this switching
point. Continue turning the knob until the unit switches
to low speed cool. Note this switching point. 32_F (0_C)
should be exactly between the switching positions.
4-19
d. To adjust the pointer, remove the cap from the Check that the OP/WT alarm light illuminates.
knob, loosen the wedge nut and turn knob to desired Remove jumper.
position. Tighten the wedge nut.
e. Repeat step c. If controller is now properly STEP THREE
calibrated, replace the cap on the center of the knob; Turn unit off and then on (to clear alarm light).
otherwise, repeat step d. Manually pre-heat - GPR LED ON.
4.26 CHECKING DIODES Manually start (Overrides 20 seconds high speed).
The direction of the arrow on the diode case indicates By turning the thermostat check for:
current flow. High Speed Cool --- Cool Light ON
Test the diode with an ohmmeter. Connect the Low Speed Cool --- SR LED OFF
ohmmeter leads to each end of the diode. A reading may Low Speed Heat --- HR LED ON
or may not be indicated. If a reading is indicated, when
reversing the leads there should be no reading. Inversely, High Speed Heat --- Heat Light ON
if no reading is indicated the first time, when reversing Check Fuel Mizer operation.
leads you should see a reading. This will indicate a good Turn on, then off.
diode. If both readings are the same, diode is faulty.
Be sure lights illuminate.
4.27 STARTRONIC CONTROL SYSTEM TEST THEN:
PROCEDURE
Disconnect the high pressure switch.
STEP ONE Unit should shut down.
Disconnect Cab Command HP/LP alarm light ON.
“AV” “SS” Jumper to “SS” position Connect high pressure switch.
Switch the unit on in the engine mode.
Light should remain on.
Check the engine for preheat.
Check the glow plug relay (Minimum 30 seconds, STEP FOUR
Maximum 90 seconds). Switch off unit (Set thermostat for high speed
Check fuel pump “ON” --- FPR LED ON. operation).
THEN: Press Standby switch and ON switch.
Unplug (R-26) (Run Relay). Standby Light ON.

Motor contactor energized.
Check starter relay energized (Minimum 2 seconds,
Maximum 20 seconds) --- SSR LED ON, starter engages. Motor overload LED ON.
Start sequence should drop out (Minimum 20 Switch Unit off.
seconds, Maximum 60 seconds).
STEP FIVE
Plug Run Relay back into R-26 slot.
Restart unit manually in engine mode.
Unit should: Preheat during that time check the
following: Press defrost switch (If DTs open, jumper wire 196 to
ground).
GPR LED ON
FPR LED ON Check high speed defrost by setting the thermostat to
SSR LED ON Starter engages box temperature.
Check for the following:
STEP TWO
Defrost light ON.
Unit starts and runs
Evaporator fan motors OFF.
Set thermostat to box temperature (In-range, calling
for low speed) Hot gas solenoid energized.
Check: Allow unit to terminate defrost automatically (or remove
Hour meter operating jumper)
20 seconds after start up FR1 & FR2 LED ON (All 3
STEP SIX
Evaporator fans on)
Check for 20 seconds high speed operation after With the unit running in cool, remove one of the
start-up. three fan motor fuses (20 amp)
THEN: Check fuse light ON
Jumper the oil pressure safety switch to ground. Unit Put fuse light on.
should shut down within 5 seconds.
4-20
Remove fuse F-14 (2 amp) unit should shut down. c. Check for proper operation of the thermostat by
manually running through the operation modes.
4.28 ECOTRONIC CONTROL SYSTEM TEST
High speed cool
PROCEDURE
Low speed cool
4.28.1 Starting Low speed heat
High speed heat.
a. Place selector switch (SEL) to the AUTO-START
position. d. Place unit in City Speed mode from the Cab
Command or Fuel Mizer mode (on the control panel) if
b. Place Cab Command to ROAD operation. the Cab Command is not present.
1. Check that unit preheats (Glow Plug Relay) 1. Check that evaporator fans are running.
from 30 to 90 seconds.
e. Disconnect wire from High Pressure Safety (HP).
2. Fuel pump operates during this period.
1. Unit should shut down.
c. While unit is preheating, remove the Run Relay. 2. Pressure fault light on control panel should
1. When unit cranks, it will not start. Starter illuminate.
should engage for approximately 20 seconds. 3. Alarm light on Cab Command should
illuminate.
2. Unit will then go into null mode for
approximately 20 seconds. f. Reconnect wire on HP. Turn selector switch (SEL)
to STOP position.
d. During the null mode, replace relay (Run Relay,
RR) to Run Relay (R26) position. 4.28.4 Check START/STOP Operation
1. Glow plugs will energize from 30 to 90 seconds. a. Turn selector switch (SEL) to the 22 minute
2. Run Relay (RR) will energize, one second later position.
the starter will engage. b. Place Cab Command to ROAD operation.
3. When engine starts, starter will remain Start unit manually at control panel.
engaged for 2 to 3 seconds. c. After 30 second operation, place thermostat to the
same temperature that is indicated on the display.
4.28.2 Unit Running
1. Mode indicators should go off.
a. Hour meter should be running --- indicated by 2. Engine should go to high speed.
flashing colon. 3. Evaporator fan motors should shut off.
b. Evaporator fans should start after approximately 4. After 10 seconds the unit should shut off.
20 seconds. d. After 1 minute, set the thermostat to ---40_.
c. Relays FR1, FR2, and FR3 will energize fan 1. Unit should preheat and restart.
motors FM1, FM2 and FM3
e. Repeat the above operation with the selector
d. Ground the oil pressure safety switch. switch (SEL) positioned in the 45 minute and 90 minute
1. Unit should shut down (approximately 10 positions.
seconds).
2. Oil pressure light on control panel should 4.28.5 Check Defrost
illuminate. a. Start the unit manually. Run in high speed cool
3. Alarm light on Cab Command should until low temperature reaches 35_F (---2_C).
illuminate.
b. Depress the defrost button.
e. Turn selector switch (SEL) to OFF position.
1. Unit should operate in high speed.
4.28.3 Operational Control 2. Defrost light should be illuminated.
3. Hot gas solenoid valve should be energized.
a. Turn selector switch (SEL) to the AUTO-START 4. Fans should be off.
position.
b. Restart unit manually by pressing the start button
on the control panel. Hold the starter button until light
indicating operation mode (heat or cool) illuminates.
THIS CAUSES THE LOGIC TO BYPASS THE TEN
MINUTE HIGH SPEED RUN TIMER.
4-21
4.28.6 Check Main Fuses 4.28.7 Standby Operational Check
a. Remove fuse F14. a. Switch unit to standby mode without power cord
attached.
1. Unit should stop.
2. Fuse fault light on control panel should be 1. Contactor should energize.
illuminated. 2. Fan motors should not energize.
3. Alarm light on Cab Command should be b. Plug in the standby power cable.
illuminated. 1. Unit should operate normally.
b. Replace fuse F14. 2. Fans should be running.
c. Repeat above procedure with fuse F1. c. While unit is running, disconnect the standby power.
1. Fan motors should stop.
d. Reconnect the power cable and check operational
modes.
1. Cool
2. Off
3. Heat
4. Defrost
4-22
Table 4-1. R-500 Pressure --- Temperature Chart
BOLD FIGURES = Inches Mercury Vacuum (cm Hg Vac)
LIGHT FIGURES = psig (kg/cm)
TEMPERATURE PRESSURE TEMPERATURE PRESSURE
_F _C Psig Kg/cm@ Bar _F _C Psig Kg/cm@ Bar
---40 ---40 7.6 19.30 0.26 28 --- 2 34.5 2.43 2.38

---35 ---37 4.8 12.19 0.16 30 --- 1 36.2 2.55 2.50
---30 ---34 1.4 3.56 .05 32 0 37.9 2.66 2.61
---28 ---33 0.0 0.0 0.0 34 1 39.7 2.79 2.74
---26 ---32 1.0 .07 .07 36 2 41.5 2.92 2.86
---24 ---31 1.5 .11 .10 38 3 43.3 3.04 2.99
---22 ---30 2.4 .17 .17 40 4 45.2 3.18 3.12
---20 ---29 3.1 .22 .21 45 7 51.2 3.60 3.53
---18 ---28 3.9 .27 .27 50 10 57.5 4.04 3.96
---16 ---27 4.7 .33 .32 55 13 64.4 4.53 4.44
---14 ---26 5.5 .39 .38 60 16 71.7 5.04 4.94
---12 ---24 7.2 .51 .50 65 18 76.9 5.41 5.30
---10 ---23 8.1 .57 .56 70 21 85.1 5.98 5.87
--- 8 ---22 9.0 .63 .62 75 24 93.8 6.59 6.47
--- 6 ---21 10.0 .70 .69 80 27 103.0 7.24 7.10
--- 4 ---20 11.0 .77 .76 85 29 109.5 7.70 7.55
--- 2 ---19 12.0 .84 .83 90 32 119.7 8.42 8.25
0 ---18 13.0 .91 .90 95 35 130.6 9.18 9.00
2 ---17 14.1 .99 .97 100 38 142.0 9.98 9.79
4 ---16 15.2 1.07 1.05 105 41 154.1 10.83 10.62
6 ---14 17.6 1.24 1.21 110 43 162.6 11.43 11.21
8 ---13 18.8 1.32 1.30 115 46 175.8 12.36 12.12
10 ---12 20.0 1.41 1.38 120 49 189.8 13.34 13.09
12 ---11 21.3 1.50 1.47 125 52 204.5 14.38 14.10
14 ---10 22.6 1.59 1.56 130 54 214.7 15.09 14.80
16 --- 9 24.0 1.69 1.65 135 57 232.1 16.32 16.00
18 --- 8 25.3 1.78 1.74 140 60 247.5 17.40 17.06
20 --- 7 26.8 1.88 1.85 145 63 264.0 18.56 18.20
22 --- 6 28.2 1.98 1.94 150 66 283.6 19.94 19.55
24 --- 4 31.3 2.20 2.16 155 68 296.4 20.84 20.44
26 --- 3 32.9 2.31 2.27 160 71 318.7 22.41 21.97
4-23
BOLD FIGURES = Inches Mercury Vacuum (cm Hg Vac)
LIGHT FIGURES = psig (kg/cm)
---40 ---40 11.0 27.9 .37 28 --- 2 26.9 1.89 1.85

---35 ---37 8.4 21.3 .28 30 --- 1 28.5 2.00 1.97
---30 ---34 5.5 14.0 .19 32 0 30.1 2.12 2.08
---28 ---33 4.3 10.9 .15 34 1 31.7 2.23 2.19
---26 ---32 3.0 7.6 .10 36 2 33.4 2.35 2.30
---24 ---31 1.6 4.1 .05 38 3 35.2 2.47 2.43
---22 ---30 0.3 0.8 .01 40 4 37.0 2.60 2.55
---20 ---29 0.5 .04 .03 45 7 41.7 2.93 2.88
---18 ---28 1.3 .09 .09 50 10 46.7 3.28 3.22
---16 ---27 2.1 .15 .14 55 13 52.0 3.66 3.59
---14 ---26 2.8 .20 .19 60 16 57.7 4.06 3.98
---12 ---24 3.7 .26 .26 65 18 63.8 4.49 4.40
---10 ---23 4.5 . 32 .31 70 21 70.2 4.94 4.84
--- 8 ---22 5.4 .38 .37 75 24 77.0 5.41 5.31
--- 6 ---21 6.3 .44 .43 80 27 84.2 5.92 5.81
--- 4 ---20 7.2 .51 .50 85 29 91.8 6.45 6.33
--- 2 ---19 8.2 .58 .57 90 32 99.8 7.02 6.88
0 ---18 9.2 .65 .63 95 35 108.2 7.61 7.42
2 ---17 10.2 .72 .70 100 38 117.2 8.24 8.08
4 ---16 11.2 .79 .77 105 41 126.6 8.90 8.73
6 ---14 12.3 .86 .85 110 43 136.4 9.59 9.40
8 ---13 13.5 .95 .93 115 46 146.8 10.32 10.12
10 ---12 14.6 1.03 1.01 120 49 157.6 11.08 10.87
12 ---11 15.8 1.11 1.09 125 52 169.1 11.89 11.66
14 ---10 17.1 1.20 1.18 130 54 181.0 12.73 12.48
16 --- 9 18.4 1.29 1.27 135 57 193.5 13.60 13.34
18 --- 8 19.7 1.39 1.36 140 60 206.6 14.53 14.24
20 --- 7 21.0 1.48 1.45 145 63 220.3 15.49 15.19
22 --- 6 22.4 1.57 1.54 150 66 234.6 16.49 16.18
24 --- 4 23.9 1.68 1.65 155 68 249.5 17.54 17.20
26 --- 3 25.4 1.79 1.75 160 71 265.1 18.64 18.28
4-24

---40 ---40 .6 .04 .04 34 1 60.5 4.25 4.17

---36 ---38 2.3 .16 .16 36 2 63.3 4.45 4.36
---32 ---36 4.1 .29 .28 38 3 66.1 4.65 4.56
---28 ---33 6.0 .42 .41 40 4 69 4.85 4.76
---26 ---32 7.0 .49 .48 44 7 75.0 5.27 5.17
---24 ---31 8.1 .57 .56 48 9 81.4 5.72 5.61
---22 ---30 9.2 .65 .63 52 11 88.1 6.19 6.07
---20 ---29 10.3 .72 .71 54 12 91.5 6.43 6.31
---18 ---28 11.5 .81 .79 60 16 102.5 7.21 7.07
---16 ---27 12.7 .89 .88 64 18 110.2 7.75 7.6
---14 ---26 14.0 .98 .97 68 20 118.3 8.32 8.16
---12 ---24 15.2 1.07 1.05 72 22 126.8 8.91 8.74
---10 ---23 16.6 1.17 1.14 76 24 135.7 9.54 9.36
--- 8 ---22 18.0 1.27 1.24 80 27 145 10.19 10.0
--- 6 ---21 19.4 1.36 1.34 84 29 154.7 10.88 10.67
--- 4 ---20 21.0 1.48 1.45 88 31 164.9 11.59 11.37
--- 2 ---19 22.5 1.58 1.55 92 33 175.4 12.33 12.09
0 ---18 24.1 1.69 1.66 96 36 186.5 13.11 12.86
2 ---17 25.7 1.81 1.77 100 38 197.9 13.91 13.64
4 ---16 27.4 1.93 1.89 104 40 209.9 14.76 14.47
6 ---14 29.2 2.05 2.01 108 42 222.3 15.63 15.33
8 ---13 31.0 2.18 2.14 112 44 235.2 16.54 16.22
10 ---12 32.9 2.31 2.27 116 47 248.7 17.49 17.15
12 ---11 34.9 2.45 2.41 120 49 262.6 18.46 18.11
14 ---10 36.9 2.59 2.54 124 51 277.0 19.48 19.10
16 --- 9 39.0 2.74 2.69 128 53 291.8 20.52 20.12
18 --- 8 41.1 2.89 2.83 132 56 307.1 21.59 21.17
20 --- 7 43.3 3.04 2.99 136 58 323.6 22.75 22.31
22 --- 6 45.5 3.2 3.14 140 60 341.3 24.0 23.53
24 --- 4 47.9 3.37 3.3 144 62 359.4 25.27 24.78
26 --- 3 50.2 3.53 3.46 148 64 377.9 26.57 26.06
28 --- 2 52.7 3.71 3.63 152 67 396.6 27.88 27.34
30 --- 1 55.2 3.88 3.81 156 69 415.6 29.22 28.65
32 0 57.8 4.06 3.99 160 71 434.6 30.56 29.96
4-25
SECTION 5
ELECTRICAL WIRING AND TROUBLESHOOTING DIAGRAMS
5.1 INTRODUCTION
Section 5 contains Electrical Wiring and Trouble- NOTE

shooting Diagrams for the Starbird TDB/TDS-215 If the unit shuts down because of a safety
and Starbird Plus TDB/TDS-219 Startronic and device, units with a Startronic control
Ecotronic control systems. system must be reset by pushing the control
panel OFF key first, then the ON key; units
The following electrical system warning, caution with an Ecotronic control system must be
and notes must be observed when servicing the unit: reset by placing the control panel selector
knob to the OFF position first, then back to
WARNING the AUTO/START (Automatic Starting)
position.
Beware of unannounced starting of the fans
and V-belts caused by the thermostat and NOTE
the start/stop cycling of the unit. Battery maintenance is a must when
operating in the start/stop operation.
CAUTION
NOTE
When connecting the applicable power plug The cool out-of-range indicator will not
on the back of the power panel, the main light when the controller set point is below
power should be disconnected. 10_F (---12_C).
NOTE NOTE
If it is necessary to change the logic module Before starting the actual electrical test
the battery connections must first be procedure, the battery charging system and
disconnected to prevent damage to the wiring should be checked to eliminate
electronic system. possible problem areas.
5-1
STARTRONIC TEST POINTS
TEST POINTS DESCRIPTION
LOGIC BOARD
TP-1 Switched ground of control relay CR (R10). Shows approx. 0 vdc when unit is operating.
TP-2 12 ¦ 2 vdc input to logic module. Main power input to logic module.
TP-3 5 ¦ 2 vdc when control relay CR (R10) is energized. Power to logic circuits.
TP-4 Approx. 0 vdc indicates no potential to the starter motor.
If TP4 = 5 ¦ 2 vdc, check the following:
A) Oil pressure switch. B) 12 ¦ 2 vdc alternator
TP-5 Approx. 0 vdc immediately after start-up. 5 ¦ 2 vdc when the 40 second minimum
high speed run time is complete.
TP-6 When TP6 = 5 ¦ 2 vdc, unit will remain in high speed.
If TP6 = approx. 0 vdc, unit will switch to low speed.
TP-7 0 vdc will indicate that the fuel pump relay FPR (R28) is energized (ground).
TP-8 12 ¦ 2 vdc will indicate that the voltage regulator relay VRR (R29) is energized.
The VRR will de-energize 20 seconds after unit starts.
TP-9 Approx. 0 vdc (ground) will indicate that motor contact relay MCR (R4B) is energized.
TP-10 Approx. 0 vdc (ground) will indicate that the hot gas solenoid relay HR (R5) is energized.
TP-11 Approx. 0 vdc (ground) will indicate that the unloader relay ULR (R20) is energized.
TP-14 General ground approx. 0 vdc.
CONTROL PANEL
TP12 12 ¦ 2 vdc indicates main power to the control panel from the battery.
If TP12 = approx. 0 vdc, check the fuse or battery connection.
TP13 12 ¦ 2 vdc indicates potential from HP and LP switches.
If TP13 = approx. 0 vdc, check:
A) Fuse F1. B) HP or LP switch
Main power to common contact of relays RR (R26) and SR (R3).
CONNECTORS AND WIRE NUMBER DESIGNATIONS
Connector A Connector B Connector C Connector D Connector E *Connector H

Pin Wire No. Pin Wire No. Pin Wire No. Pin Wire No. Pin Wire No. Pin Wire No.
1 171 1 162 1 186 1 165 1 X 1 193
2 **192 2 14 2 195 2 162 2 Y 2 194
3 **193 3 177 3 187 3 163 3 6 3 192
4 176 4 198 4 166 4 8
5 -- 5 181 5 10
6 **194 6 12 6 --
7 172 7 7
8 195 8 186
9 164 9 13
10 173 10 2
11 -- 11 195
12 197 12 196
13 178
14 191
15 167
*Connector H used on newer power boards.
**Used if Connector H is not located on power board.
Figure 5-1 STARTRONIC Control Panel and Logic Module Troubleshooting Diagram (Sheet 1 of 2)
Units prior to S/N BDL90069850
5-2
STARTRONIC CONTROL PANEL REMOTE CONTROL
SHUNT (X)
RUN/STOP SOLENOID AV With Remote
CONTROL SHUNT (Z)
Refer to
I N Section 1.8.2.c.1
LOGIC MODULE
R26 energized R26 energized
AV
SS Without Remote
to run unit for high speed I N
Refer to Section 1.8.2.c.2
GPR SR FR1
SS
R9 R3 R6/1
H
SSR RR FR2 1 2
3
R11 R26 R6/2
3 2 1 R27
6 5 4
9 8 7 E
15 12 9 6 3
B
12 11 10 1 4
2 1 3
C2
TP-13 TP-12
D 14 11 8 5 2 2 5
4 3
1
A 13 10 7 4 1 3 6
STARTRONIC LOGIC MODULE

TP-14 TP-6 TP-11 TP-9 TP-7 TP-10
TP-4
TP-5
TP-3
HR
R5
SPEED RELAY CONTROL

N I MCR FPR
SHUNT (C3) R4b R28
CR
N I R10 ULR VRR
R20 R29
Low Speed High Speed
Control Control
TP-1 TP-2 TP-8
Figure 5-1. STARTRONIC Control Panel and Logic Module Troubleshooting Diagram (Sheet 2 of 2)
5-3
STARTRONIC TEST POINTS
LOGIC BOARD
TP-4 Approx. 0 vdc indicates no potential to the starter motor.
If TP4 = 5 ¦ 2 vdc, check the following:
A) Oil pressure switch. B) 12 ¦ 2 vdc alternator
TP-5 Approx. 0 vdc immediately after start-up. 5 ¦ 2 vdc when the 40 second minimum
high speed run time is complete.
TP-6 When TP6 = 5 ¦ 2 vdc, unit will remain in high speed.
If TP6 = approx. 0 vdc, unit will switch to low speed.
TP-7 0 vdc will indicate that the fuel pump relay FPR (R28) is energized (ground).
TP-8 12 ¦ 2 vdc will indicate that the voltage regulator relay VRR (R29) is energized.
The VRR will de-energize 20 seconds after unit starts.
TP-9 Approx. 0 vdc (ground) will indicate that motor contact relay MCR (R4B) is energized.
TP-10 Approx. 0 vdc (ground) will indicate that the hot gas solenoid relay HR (R5) is energized.
TP-11 Approx. 0 vdc (ground) will indicate that the unloader relay ULR (R20) is energized.
TP-14 General ground approx. 0 vdc.
CONTROL PANEL
TP12 12 ¦ 2 vdc indicates main power to the control panel from the battery.
If TP12 = approx. 0 vdc, check the fuse or battery connection.
TP13 12 ¦ 2 vdc indicates potential from HP and LP switches.
If TP13 = approx. 0 vdc, check:
A) Fuse F1. B) HP or LP switch
Main power to common contact of relays RR (R26) and SR (R3).

1 171 1 162 1 186 1 165 1 X 1 193
2 **192 2 14 2 195 2 162 2 Y 2 194
3 **193 3 177 3 187 3 163 3 6 3 192
4 176 4 198 4 166 4 8
5 -- 5 181 5 10
6 **194 6 12 6 --
7 172 7 7
8 195 8 186
9 164 9 13
10 173 10 2
11 -- 11 195
12 197 12 196
13 178
14 191
15 167
Figure 5-2 STARTRONIC Control Panel and Logic Module Troubleshooting Diagram (Sheet 1 of 2)
Units starting with S/N BDL90069850
5-4
STARTRONIC CONTROL PANEL
Units starting with S/N BDL90069850 REMOTE CONTROL RUN RELAY (R26)
SHUNT (X) CONTROL SHUNT (W)
RUN SOLENOID AV With Remote Normally I N Normally
closed R26 open R26
Refer to
CONTROL SHUNT (Z) Section
1.8.2.c.1
I N LOGIC MODULE
Refer to
Section
R26 energized R26 energized I N
AV
SS Without Remote 1.8.2.c.4
to run unit for high speed
Refer to Section 1.8.2.c.2 GPR FR1 FR2
SS
R9 R6/2
R6/1
I N
H
SSR RR FR3 1 2
R6/3 3
R11 R26
SR
3 2 1 R3
6 5 4
9 8 7 E
B
12 11 10 15 12 9 6 3
1 3 1 4
2
C2
TP-13 TP-12
D 14 11 8 5 2 2 5
4 3
1 A 13 10 7 4 1 3 6
STARTRONIC LOGIC MODULE

TP-14 TP-6 TP-11 TP-9 TP-7 TP-10
TP-4
TP-5
TP-3
HR
R5
SPEED RELAY CONTROL N I MCR FPR

SHUNT (C3) R4b R28
CR
N I R10 ULR VRR
R20 R29
Low Speed High Speed
Control Control
TP-1 TP-2 TP-8
Figure 5-2. STARTRONIC Control Panel and Logic Module Troubleshooting Diagram (Sheet 2 of 2)
5-5
ECOTRONIC TEST POINTS
LOGIC MODULE
TP-4 5 ¦ 2 vdc when selector switch (SEL) is in START position.
0vdc when SEL is in the STOP, 22’, 45’, or 90’ position.
TP-5 Approx. 0 vdc immediately after start-up.
5 ¦ 2 vdc when 10 minute minimum run time is complete.
TP-6 5 ¦ 2 vdc during start sequence. 0vdc at all other times.
TP-7 5 ¦ 2 vdc during starter cranking.
Approx. 0 vdc at TP-7 causes the starter to be de-energized.
If TP-7 = 5 ¦ 2 vdc and engine is running, check the oil pressure
safety and alternator for correct operation.
TP-8 5 ¦ 2 vdc indicates that fuel pump relay FPR (R28) is energized.
TP-9 5 ¦ 2 vdc indicates that run relay RR (R26) is energized.
CONTROL PANEL
TP-10 12 ¦ 2 vdc at all times. Main power input to control panel.
If TP-10 = approx. 0 vdc, check fuse F1 for continuity.
TP-11 5 ¦ 2 vdc when unit is in start sequence. Indicates correct operation of selector switch (SEL).
TP-12 5 ¦ 2 vdc when SEL is set to 22 minute position.
TP-13 5 ¦ 2 vdc when SEL is set to 45 minute position.
Connector A Connector B Connector C Connector D Connector E

Pin Wire No. Pin Wire No. Pin Wire No. Pin Wire No. Pin Wire No.
1 171 1 162 1 186 1 165 1 X
2 192 2 14 2 195 2 162 2 Y
3 193 3 177 3 187 3 163 3 6
4 176 4 198 4 166 4 8
5 -- 5 181 5 10
6 194 6 12 6 --
7 172 7 7
8 195 8 186
9 164 9 13
10 173 10 2
11 -- 11 195
12 197 12 196
13 178
14 191
15 167
Figure 5-3 ECOTRONIC Control Panel and Logic Module Troubleshooting Diagram (Sheet 1 of 2)
5-6
ECOTRONIC CONTROL PANEL REMOTE CONTROL
SHUNT (X)
With Remote
TP-10 TP-13
AV Refer to
Section
1.9.2.e.1
Without Remote
SS
LOGIC MODULE
AV
SS
RIBBON CABLE
D
F1
2A
D
3 2 1
6 5 4
9 8 7 1 TP-12 TP-11 3 2 1
B 12 11 10
3 2 C 6 5 4
E
ECOTRONIC LOGIC MODULE
TP-5 TP-6 TP-3
}Y
TP-8
TP-9
TP-7
CR
TP-2 R10
TP-4 TP-1
Figure 5-3. ECOTRONIC Control Panel and Logic Module Troubleshooting Diagram (Sheet 2 of 2)
5-7
POWER BOARD
TP-14 Power from battery. Common 12 ¦ 2 vdc to contacts R25, R9, R11 and R26.
TP-15 Power from pressure safety switches HP and LP. 12 ¦ 2 vdc indicates safety circuit is closed.
FAN PROTECTION MODULE

TP-16 Alternator output. 14vdc ¦ 1 vdc when unit is running.
TP-17 12 ¦ 2 vdc to fan protection module. Main power input to module.
TP-18 12 ¦ 2 vdc to contacts of relays ULR (R20), HR (R5), FPR (R28), VRR (R29), and MCR (R4b).
TP-19 Switched ground to unloader relay ULR (R20), 0 vdc when relay is energized.
TP-20 Switched ground to motor contact relay MCR (R4b), approximately 0 vdc when relay is energized.
TP-21 12 ¦ 2 vdc to contacts of heat relay HR (R5).
TP-22 Switched ground to fuel pump relay FPR (R28), approximately 0 vdc when relay is energized.
TP-23 Switched ground to voltage regulator relay VRR (R29), approximately 0 vdc when relay is energized.
TP-24 Approximately 0 vdc when conditions for operation of evaporator fans are met.

1 171 1 162 1 186 1 165 1 X 1 193
2 **192 2 14 2 195 2 162 2 Y 2 194
3 **193 3 177 3 187 3 163 3 6 3 192
4 176 4 198 4 166 4 8
5 -- 5 181 5 10
6 **194 6 12 6 --
7 172 7 7
8 195 8 186
9 164 9 13
10 173 10 2
11 -- 11 195
12 197 12 196
13 178
14 191
15 167
Figure 5-4. ECOTRONIC Power Board and Fan Module Troubleshooting Diagram (Sheet 1 of 2)
5-8
ECOTRONIC POWER BOARD RUN SOLENOID
CONTROL SHUNT (Z)
R26 energized
1 2 I
H
to run unit
3 TP-14 TP-15 R26 energized
for high speed N
Refer to Section 1.9.2.e.2
FR1 FR2 FR3 BR SR RR SSR

R6/1 R6/2 R6/3 R25 R3 R26 R27 R11
N d
fff
fff F1
I
d 15A GPR
D
F19
D
F18
D N d d R9
3 2 1 3A D D 3A RIBBON CABLE
6 5 4 High Speed Control
I
9 8 7 Refer to
Section 1.9.2.e.3
N 2 1
12 11 10 Low Speed Control
SPEED RELAY CONTROL D
4 3
A
15 14 13 SHUNT (C3)
ECOTRONIC EVAPORATOR FAN MODULE 12 14

10
16
8
A
FPR MCR 6 Refer to
R28 R4b 5 Section
1.9.2.d
FAN
ULR VRR POTENTIOMETER ( I )
R20 R29
HR TP-24
R5 TP-16
Refer to
TP-18 Section
1.9.2.e.5
TP-19 TP-21 TP-22 TP-23 TP-20 TP-17 3 fan position 2 fan position
EVAPORATOR FAN
SHUNT (C2)
5-9
POWER BOARD
TP-14 Power from battery. Common 12 vdc to contacts R25, R9, R11 and R26.
TP-15 Power from pressure safety switches HP and LP. 12vdc indicates safety circuit is closed.
FAN PROTECTION MODULE

TP-16 Alternator output. 14vdc ¦ 1 vdc when unit is running.
TP-17 12 vdc to fan protection module. Main power input to module.
TP-18 12 vdc to contacts of relays ULR (R20), HR (R5), FPR (R28), VRR (R29), and MCR (R4b).
TP-19 Switched ground to unloader relay ULR (R20), 0 vdc when relay is energized.
TP-20 Switched ground to motor contact relay MCR (R4b), 0 vdc when relay is energized.
TP-21 12 vdc to contacts of heat relay HR (R5).
TP-22 Switched ground to fuel pump relay FPR (R28), 0 vdc when relay is energized.
TP-23 Switched ground to voltage regulator relay VRR (R29), 0 vdc when relay is energized.
TP-24 0 vdc when conditions for operation of evaporator fans are met.

1 171 1 162 1 186 1 165 1 X 1 193
2 **192 2 14 2 195 2 162 2 Y 2 194
3 **193 3 177 3 187 3 163 3 6 3 192
4 176 4 198 4 166 4 8
5 -- 5 181 5 10
6 **194 6 12 6 --
7 172 7 7
8 195 8 186
9 164 9 13
10 173 10 2
11 -- 11 195
12 197 12 196
13 178
14 191
15 167
5-10
ECOTRONIC POWER BOARD
RUN SOLENOID RUN RELAY (R26)

CONTROL SHUNT (Z) CONTROL SHUNT (W)
Normally
R26 energized
1 2 I I
H
closed R26
to run unit
3 TP-15 R26 energized Normally
for high speed N open R26
N
Refer to Section 1.9.2.e.2 Refer to Section 1.9.2.e.4
FR1 FR2 FR3 SR RR I SSR

R6/1 R6/2 R6/3 R3 R26 N d R11
TP-14
I
fff N d
fff F1
I
d 15A GPR
3 2 1 D D N d d
D
F19 F18 R9
6 5 4 3A D D 3A RIBBON CABLE
High Speed Control
9 8 7 I
Refer to
2 1
D
Section 1.9.2.e.3
12 11 10 N Low Speed Control
SPEED RELAY CONTROL 4 3
A
15 14 13
SHUNT (C3)
ECOTRONIC EVAPORATOR FAN MODULE 12 14

10
16
8
A
FPR MCR 6 Refer to
R28 R4b 5
Section
1.9.2.d
FAN
ULR VRR POTENTIOMETER ( I )
R20 R29
HR TP-24
R5 TP-16
Refer to
Section
TP-18 1.9.2.e.5
TP-19 TP-21 TP-22 TP-23 TP-20 TP-17 3 fan position 2 fan position
EVAPORATOR FAN
SHUNT (C2)
5-11
5-12
Figure 5-6. STARTRONIC Wiring Diagram --- Three Phase
5-13
5-14
Figure 5-7. ECOTRONIC Wiring Diagram --- Three Phase
5-15

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Starbird

2-1 Automatic Starting Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

4-1 Engine Oil Filter(s) System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

5-1 Startronic Control Panel and Logic Module Troubleshooting Diagram

4-1 R-500 Pressure --- Temperature Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21

Table 1-1. Model Chart

Figure 1-1. Condensing Section

Figure 1-2. Evaporator Section

1. Fuel Filter Assembly 6. Fuel Supply Connection

15 GPR D D FR1 FR2

Starting with S/N BDL90069850

Figure 1-7. Startronic Logic Module

ECOTRONIC CONTROL PANEL --- FRONT VIEW

ECOTRONIC CONTROL PANEL --- BACK VIEW

FR1 FR2 FR3 BR SR RR SSR

FR1 FR2 FR3 SR RR I

Figure 1-10. Ecotronic Evaporator Fan Module

1. Power Panel --- Startronic and Ecotronic

b. Defrost Thermostat Over 77_F Over +25_C 30W or 15W40

Table 1-2. Safety Devices

Unsafe Conditions Safety Device Device Setting

*STARTRONIC ONLY **ECOTRONIC ONLY

When in the off-time mode, if the box temperature

1.15 DEFROST TIMER (Optional)

Test points are provided on the defrost timer. Placing

1. Drain Pan Heater 9. Receiver 17. High Pressure Switch (HP)

1. Drain Pan Heater 9. Receiver 17. High Pressure Switch (HP)

Figure 1-17. Refrigeration System --- Heat and Defrost Cycle

NOTE If the engine does not start after

Heat Relay (HR)

Speed Relay (SR)

Fan Relays 1 , 2 & 3 (FR1, FR2 &

Figure 2-1. Automatic Starting Sequence

Engine Operation Standby Operation

b. Using the Control Panel

1. Press the ON key 1. Connect main power supply to receptacle.

2. To start, press the Road (R) key. 2. Press the ON key.

4. To stop the unit, press the OFF key.

c. Using the Cab Command

1. Press the ON key located on 1. Connect main power supply to receptacle.

d. Using the Standby Remote Receptacle

Engine Operation Standby Operation

b. Using the Control Panel

c. Using the Cab Command

d. Using the Remote Standby Receptacle

---2.7_F (---1.5 C_)

Figure 2-2. Temperature Controller Operating Sequence --- Engine Drive

FALLING TEMPERATURE RISING TEMPERATURE

Figure 2-4. Temperature Controller Operating Sequence --- Standby Operation

FALLING TEMPERATURE RISING TEMPERATURE

2.2.1 Startronic Engine Start-Up (See Figure 2-6.)

Figure 2-8. Startronic High Speed Heat ---

Figure 2-10. Startronic Cooling ---

Figure 2-11. Startronic Heating ---

Figure 2-14. Ecotronic High Speed Cooling ---

Figure 2-17. Ecotronic Cooling ---

Figure 2-18. Ecotronic Heating ---

3.1 DIESEL ENGINE

3.1.1 Engine Will Not Start