Installation Manual

Tier 2/4i Engine Conversion

SB Units
TK 53757-2-IM (Rev. 0 02/08)
Copyright© 2008 Thermo King Corp., Minneapolis, MN, U.S.A.
Printed in U.S.A.
 Installation Manual
Release History
Released 02/08 Released manual
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 Introduction
This manual was written to assist with the installation of the Thermo King Due to its complexity, you should not attempt this installation unless
Compliance Solutions Tier 2/4i Engine Retrofit Kit onto older SB units you:
equipped with pre EPA, non-compliant diesel engines. After completing
• are an experienced mechanic.
the conversion, the unit will be Tier 4i compliant.
• can safely lift 75 lbs. (34 kilos).
It is important to note that since the controller and software configuration
may vary from unit to unit, the correct software upgrade kit must be • are EPA Section 609 certified and trained in the repair and maintenance
ordered specifically for each installation. of diesel powered refrigeration systems.
Additional information and specifications to complete this installation can • have a basic understanding of electricity and electrical wiring.
be found in the maintenance and diagnostic manuals specific to your unit.
• have the necessary tools and equipment to complete the installation.
This manual is published for informational purposes only. Thermo King makes no representations warranties express or implied, with respect to
the information recommendations and descriptions contained herein. Information provided should not be regarded as all-inclusive or covering
all contingencies. If further information is required, Thermo King Corporation Service Department should be consulted.
Thermo King’s warranty shall not apply to any equipment which has been “so installed, maintained, repaired or altered as, in the manufacturer’s
judgment, to affect its integrity.”
Manufacturer shall have no liability to any person or entity for any personal injury, property damage or any other direct, indirect,
special, or consequential damages whatsoever, arising out of the use of this manual or any information, recommendations or
descriptions contained herein.
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 Table of contents
Installation Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Radiator Rework . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Engine Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Compressor Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Engine Mounts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Air Cleaner Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Wire Harness Brackets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Heater Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Heat Deflector Shield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Fuel Solenoid Timer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Compressor Mounting Studs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Connecting the Harness Wires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Throttle Solenoid Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Harness Routing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Alternator Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Compressor High Pressure Cutout Switch . . . . . . . . . . . . . . . . . . . . . . . . . 20
Alternator Pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Manifold Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Coolant Hose Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Throttle Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Front Pulley and Spacer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Oil Level Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Coolant Temperature Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Oil Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Negative Battery Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Oil Drain Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Oil Level Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Water Temperature Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Oil Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Air Restriction Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Engine Ground Wires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
RPM Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Starter Solenoid. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Compressor Coupling and Mounting Plate Removal . . . . . . . . . . . . . . . . . . 14 RPM Flywheel Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Compressor Mounting Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Fuel Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Dowel Pins and Compressor Coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Completing the Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Engine Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
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BLANK PAGE
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 Installation Procedures
NOTE: SB Classic equipped with Thermoguard VI and Isuzu engine.
IMPORTANT: Before servicing the unit, record the uP setup
information using the procedure outlined in the Microprocessor
Operations and Diagnostic Manual specific to your unit.
IMPORTANT: Shut the unit controls to the OFF position and disconnect
the negative (-) battery cable from the battery first, followed by the
positive (+) battery cable.
Engine Removal
1. Remove the roadside and curbside doors from the front of the unit.
1. Remove the refrigerant from the unit. Refer to the refrigeration service
operations procedures in the Maintenance Manual specific to your
unit.
2. Drain and save the engine coolant.
3. Remove the engine coolant hoses.
4. Remove the air cleaner hose.
5. Disconnect the exhaust system at the engine’s manifold.
6. Disconnect the wire harness from the engine.
7. Disconnect the fuel lines from the engine.
8. Remove the battery and battery tray.
9. Disconnect the discharge and suction lines from the compressor and
cap them off.
10. Unbolt the engine mounting bolts and remove the engine and
compressor from the unit. Retain the mounting hardware for use later.
11. Remove the compressor from the engine.
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Installation Procedures
BLANK PAGE
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 Installation Procedures
INSTALLING COMPONENTS ONTO THE NEW ENGINE
Engine Mounts 7. Starter Mounted Wire Harness Bracket - push the tab in to capture
the bracket onto the starter.
NOTE: Install the steel engine mounts (items #1-4) onto the engine using
the new mounting hardware. Apply thread sealer (blue 203-400) and 8. Lower Front Wire Harness Bracket - install the battery cable/oil line
torque the mounting bolts to 73 ft-lbs. (99 N•m). bracket onto the engine with the two new M12 x 31 screws, M12
lockwashers and M12 flatwashers.
1. Service Side Mount - install the new mount with the new M12 screws,
M12 lockwashers and M12 flatwashers.
Heat Deflector Shield
2. Trailer Side Mount - install the new mount with the new M12 screws,
M12 lockwashers and M12 flatwashers. 9. Install the new heat deflector shield with the new M8 x 16 screws, M8
lockwashers, M8 flat washers and tighten securely.
3. Front Snubber Mount- install the new mount with the new M12
screws, M12 lockwashers and M12 flatwashers. Compressor Mounting Studs
4. Engine Mounted Snubber Plate -install the new plate onto the engine 10. Install the eight new threaded compressor mounting studs in the rear of
with the new M12 screws, M12 lockwashers and M12 flatwashers. the flywheel housing.
Wire Harness Brackets
5. Upper Wire Harness Bracket - attach the upper wire harness bracket
to the upper part of the flywheel housing with the new M12 x 25
screws, M12 lockwashers and M12 flatwashers and tighten securely.
6. Lower Wire Harness Bracket - attach the lower wire harness support
bracket to the engine block, above the oil pan near the oil level switch
with the new M10 x 1.5 screws, M10 lockwashers and M10 flatwashers
and tighten securely. NOTE: Rotate the bracket 5 degrees counter
clockwise to avoid interference between the bottom rivet on the
bracket and the engine.
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Installation Procedures
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 Installation Procedures
INSTALLING COMPONENTS ONTO THE NEW ENGINE (continued)
Throttle Solenoid Assembly Coolant Hose Assembly
11. Pre-assemble the solenoid to the bracket and install the assembly onto 14. Attach the short rubber coolant hose onto the coolant hose assembly
the engine with the new M8 x 20 x 35 mm screws, M8 lockwashers and with the hose clamp.
M8 flatwashers. Torque hardware to 16 ft-lbs. (21.7 N•m). Attach the
• Attach the coolant hose onto the engine’s water pump and then onto
solenoid rod to the lever.
the engine and tighten hardware and hose clamps securely.
IMPORTANT: Attach the diode assembly onto the back of the solenoid
with the red sleeving facing UP and apply sealer over the diode. Front Pulley and Spacer
15. Install the new front fan drive pulley onto the new engine with the new
Alternator Bracket front spacer, longer M10 x 1.5 bolts and M10 lockwashers. Torque
12. Install the new alternator brackets to the engine with the three M8 x 20 hardware to 31 ft-lbs.(42 N•m).
x 40 mm screws, lockwashers and flatwashers. Attach the small wire
harness bracket to the side of the alternator bracket with one screw,
lockwasher and flatwasher. Torque hardware to 31 ft-lbs. (42 N•m).
Alternator Pulley
13. Remove the old pulley from the alternator and install the new one with
the thick end facing outwards.
NOTE: The alternator will be installed onto the engine after the engine is
installed into the frame.
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Installation Procedures
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 Installation Procedures
INSTALLING COMPONENTS ONTO THE NEW ENGINE (continued)
NOTE: When installing items #16-20, apply removable sealer (203-385) Water Temperature Sensor
and tighten securely.
19. Remove the plug from the water pump and install the water
temperature sensor and tighten securely.
Oil Level Switch
16. Remove the plug from the oil pan and install the oil level switch and Air Restriction Indicator
tighten securely.
20. Install the air restriction indicator and fitting onto the new engine.
Oil Pressure Switch
RPM Sensor (not supplied)
17. Remove the plug from the engine and install the oil pressure switch and
21. Remove the RPM sensor from the old engine and reinstall onto new
tighten securely.
engine.
Oil Drain Valve
18. Remove the plug from the oil pan and install the oil drain valve and
tighten securely.
NOTE: The drain valve should be installed until only 2 or 3 threads
are exposed and with the nickel plated nut pointing to the left
position.
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Installation Procedures
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 Installation Procedures
Compressor Coupling and Mounting Plate Removal Compressor Mounting Plate
IMPORTANT: Two different compressor coupling kits are available for 2. Install the new compressor mounting plate onto the compressor and
either small shaft or large shaft compressors. Confirm the kit you have is torque the mounting bolts to 23 ft-lbs. (31 N•m).
correct for your application before proceeding.
NOTE: Refer to the Compressor Coupling Removal and Installation Dowel Pins and Compressor Coupling
procedures in the your units SB Maintenance Manual for additional 3. Install the eight new dowel pins into the flywheel.
service procedures.
4. Reinstall the coupling onto the compressor shaft with the key, washer
1. Remove the existing compressor coupling and mounting plate from the and bolt and torque to 90 ft.-lbs. (122 N•m).
compressor and retain the mounting bolts, washer and the shaft key for
reuse.
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Installation Procedures
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 Installation Procedures
INSTALLING THE ENGINE
Engine Installation 5. Install the supplied rubber grommet into the hole of the rear engine
lifting bracket, route the fuel supply and return lines through the
1. Lift the new engine into place and install the new rubber mounts using
grommet and down to the fuel supply and return lines to the fuel pump
the old mounting hardware:
fittings. Connect lines and tighten securely.
• One set of rubber mounts for each rear mount.
6. Install the oil line to the frame mounted sender and tighten fittings
• One set of rubber mounts for the front snubber mount. securely.
• One set of rubber mounts for the front of the engine. 7. Install the alternator with the new hardware and tighten securely.
• One set of rubber mounts for the rear frame mounted snubber 8. Install the new alternator belt and adjust the tension to 59-61 on the belt
bracket. tension gauge.
• Torque all engine mounting bolts tightly. 9. Install the fan drive belt and adjust the tension.
2. Install the exhaust pipe to the exhaust manifold with the new gasket 10. Install the exhaust pipe to the exhaust manifold with the new gasket
and tighten hardware securely. and tighten hardware securely.
3. Install the new engine outlet coolant hose (13-882) and hose clamps to
the radiator inlet tube and tighten the clamps securely. Compressor Installation
11. Install the compressor onto the threaded studs on the flywheel housing
4. Radiator hose (13-881) needs to be modified by cutting it as shown.
and secure with eight new nuts lockwashers and flatwashers. Torque
Install it along with new hose clamps to the radiator outlet tube and
hardware to 35 ft-lbs. (48 N•m).
tighten the clamps securely.
12. Reconnect the suction and discharge lines onto the compressor.
Radiator Rework
NOTE: When this kit is installed on a SB unit built before 1996, the Air Cleaner Installation
radiator outlet tube must be trimmed. 13. Discard the old air intake tube and hoses. Install the new air cleaner
• After the engine is mounted in the frame, install the radiator to hose from the intake manifold to the air cleaner and secure with the two
engine hose onto the water pump tube. new supplied clamps.
• Mark and trim the radiator tube.
• Solder the supplied nipple to the trimmed tube.
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 Installation Procedures
Modify hose by measuring and cutting as shown New hose shown connected to air filter
Oil and fuel lines shown routed through rubber
grommet installed in engine lifting bracket.
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 Installation Procedures
NEW ELECTRICAL COMPONENTS AND CONNECTIONS INSIDE THE CONTROL BOX
Heater Relay Connecting the Harness Wires - 8D
1. Position the 70A heater relay as shown inside the control box. 4. Locate connector J1 on the PC board.
• Mark and drill an appropriate size hole and attach the relay to the • Cut the 8D wire approximately 2.00 inches (50 mm) down from the
box with a #10 screw, flatwasher and locking nut. Tighten hardware connector.
securely. • Strip both the wire ends and insert both of them into the butt splice
• Attach the 4-pin connector (H, 2, H1 and CH) to the relay. connector located on the 8D wire of the new wire harness.
Fuel Solenoid Timer • Crimp the wires firmly and then use a heat gun to apply heat to the
splice connector.
2. Position the fuel solenoid timer as shown inside the control box.
• Mark and drill three appropriate size holes through the control box. Connecting the Harness Wires - 2A
5. Locate the 2A wire with the fork terminal on the new harness,
• Snap the spacers into the rear of the board and attach the board with
three #6 screws, flatwashers and locking nuts. Tighten hardware • Attach the 2A wire to the 2A terminal on the relay board
securely. (DETAIL A).
• Insert the 30A relay and attach the 4-pin connector Connecting the Harness Wires - 2
(8D, 8DP, 2A and CH) onto the timer board.
6. Locate the existing 2 wire on the relay board terminal.
Connecting the Harness Wires - H • Remove the 2 wire from the board and cut the forked terminal off.
3. Locate connector J7 on the relay board. • Strip the wire end and insert it into the butt splice connector located
• Cut the H wire approximately 2.00 inches (50 mm) down from the on the 2 wire of the new wire harness.
connector. • Crimp the wires firmly and then use a heat gun to apply heat to the
• Strip only the wire end coming out from the connector and insert it splice connector.
into the butt splice connector located on the H wire of the new wire • Attached the new 2 wire with a forked terminal onto the 2 terminal
harness. on the relay board.
• Crimp the wire firmly and then use a heat gun to apply heat to the Connecting the Harness Wire - CH
splice connector. NOTE: The new H wire should now be 7. Locate the CH wire and attach it to the ground stud inside the control
connected to the PC board with the existing 6-pin connector. box.
• Tape off the other end of the H wire as it is no longer used. Harness Routing
8. Route the new harness out of the control box following the main
harness towards the engine. Secure the new harness to the main harness
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with tie bands.
Installation Procedures
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 Installation Procedures
NEW ELECTRICAL COMPONENTS AND CONNECTIONS OUTSIDE THE CONTROL BOX
IMPORTANT: All wiring should be routed neatly and secured to the Coolant Temperature Switch
appropriate wire mounting brackets with tie bands as shown.
5. Connect the water temperature switch (WTN, WTP).
Compressor High Pressure Cutout Switch Negative Battery Cable
1. Route and connect the 8D and 8P connector to the high cutout switch 6. Attach the negative battery cable to the engine and tighten bolt
located on the compressor. securely.
Manifold Heater Oil Level Switch
2. Route the single wire (H1) to the manifold heater and attach securely. 7. Route and connect the oil level switch wires (OLS, 2AAL).
Throttle Solenoid Oil Pressure Switch
3. On the existing main wire harness, locate the 8D wires with the forked 8. Route and connect the oil pressure switch wire (20B).
terminal.
Engine Ground Wires
• Cut the forked trimmings off the 8D wires, strip the wire ends and
insert both of them into the butt splice connector located on the 8D 9. Route the CH wires to the engine ground bolt (M10 bolt, flatwasher
wire of the new wire harness. and star washer) and attach securely.
• Crimp the wires firmly and then use a heat gun to apply heat to the Starter Solenoid
splice connector.
10. Route and connect the starter solenoid wire (8S) and the positive (+)
• Connect wires to the throttle solenoid. battery cable to the starter solenoid and attach securely.
• Cap off the 8D wire not used on the main harness.
RPM Flywheel Sensor
Alternator 11. Reattach wires (FS1,FS2) to the flywheel sensor.
4. Attach the 2A and CHA wires and the connector (2, EXC) to the
alternator as shown. Fuel Solenoid
12. Connect the 3-pin connector (8D, 8DP and CH) to the fuel solenoid.
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Installation Procedures
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 Installation Procedures
Completing the Installation
1. Install the battery.
2. Route and connect the new negative (-) battery cable to the battery.
3. Route and install the new positive (+) battery cable to the battery.
4. Reinstall the doors.
5. Add oil to the engine.
6. Add coolant to the radiator.
7. Recharge the unit with refrigerant. Refer to the refrigeration service
operations procedures in the Maintenance Manual specific to your
unit.
8. Prime the fuel system and start the unit.
9. Check for coolant, oil, fuel, exhaust and refrigerant leaks.
10. Check and adjust the engine RPM’s.
11. Download unit information (if required).
12. Operate the new engine for eight hours under load.
13. Preform a pre-trip check and return unit to service.
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