A possible cause could be that the phase select module detects a phase loss or voltage drop below 160 volts AC. When this happens and the condition remains for 3 seconds, the module cuts the 12-volt DC output to the microprocessor, stopping electric power. If voltage returns above 165 volts AC and all three phases are present, the module restores the 12-volt DC output after 2 to 4 seconds. This cycle could cause intermittent power stopping and restarting.

This answer is automatically generated

Zach Human

January 20, 2025

What is the electric power requirements

1 comments:

Mr. Anderson

February 4, 2025

The electric power requirements for the Thermo King T-1000R Series are:

- Voltage/Phase/Frequency:
- 230/3/50
- 208-230/3/60
- 400/3/50
- 460/3/60

- Horsepower:
- 10.0 HP for 230/3/50 and 400/3/50
- 12.0 HP for 208-230/3/60 and 460/3/60

- Kilowatts:
- 7.5 kW for 230/3/50 and 400/3/50
- 8.9 kW for 208-230/3/60 and 460/3/60

- Full Load Amps:
- 22.5 amps for 230/3/50
- 28.8 amps for 208-230/3/60
- 17.0 amps for 400/3/50
- 14.4 amps for 460/3/60

- Overload Relay Setting:
- 25 amps for 230/3/50
- 32 amps for 208-230/3/60
- 16 amps for 400/3/50 and 460/3/60

- Standby Power Requirements:
- Supply Circuit Breaker:
- 200-230/3/50-60: 50 amps
- 380-460/3/50-60: 20 amps

- Extension Cord Size:
- Up to 50 ft: 10 gauge
- 75 ft: 8 gauge

This answer is automatically generated

Summary of Contents for Thermo King T-1000R Series

Page 1 Maintenance Manual SB-210+ SB-210+ SB-210+ T-600R, T-800R, T-1000R Series Additional text information Additional text information Additional text information to be placed here to be placed here to be placed here TK 54326-1-MM (Rev. 1, (10/14) TK 5XXXX-X-PL TK 5XXXX-X-PL TK 5XXXX-X-PL...
Page 3 If further information is required, Thermo King Corporation should be consulted. Sale of product shown in this manual is subject to Thermo King’s terms and conditions including, but not limited to, the Thermo King Limited Express Warranty. Such terms and conditions are available upon request.
Page 4 Ester compressor oil in tightly sealed containers. If Polyol Ester oil becomes contaminated with moisture or standard oils, dispose of properly–DO NOT USE. When servicing Thermo King R-404A unit, use only those service tools certified for and dedicated to R-404A refrigerant and Polyol Ester compressor oils.
Page 5 ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ Return to: NORTH AMERICA EUROPEAN SERVED AREA THERMO KING CORPORATION THERMO KING CORPORATION 314 West 90th Street Ingersoll Rand Climate Control Technologies Mail Stop 38 Monivea Road Minneapolis, MN 55420 Mervue, Galway, Ireland Attn: Service Department...
Page 6: Table Of Contents
Table of Contents Safety Precautions ..............10 General Practices .
Page 7 Table of Contents Operating Instructions for Standard HMI Control Panel ........32 SR-2 Truck HMI Controller Description .
Page 8 Table of Contents Adjust Brightness ............... . 69 Time .
Page 9 Table of Contents Refrigeration Service Procedures ............114 Evacuation, Dehydration, and Charging .
Page 10 Table of Contents Hot Gas Solenoid (HGS) Test ............. . 137 In-Line Check Valve Replacement .
Page 11: Safety Precautions
Safety Precautions Thermo King recommends that all service be DANGER: Avoid engine operation in performed by a Thermo King dealer. However, confined spaces and areas or you should be aware of several general safety circumstances where fumes from the practices: engine could become trapped and cause serious injury or death.
Page 12: Auto Start/Stop
CAUTION: Do not connect other manufacturer’s equipment or accessories DANGER: Do not use a Halide torch. to the Thermo King unit. This could result When a flame comes in contact with in severe damage to equipment and void refrigerant, toxic gases are produced.
Page 13: Refrigerant Oil Hazards
Safety Precautions DANGER: Do not use oxygen (O ) or CAUTION: Do not expose the refrigerant oil to the air any longer than necessary. compressed air for leak testing. Oxygen The oil will absorb moisture, which results mixed with refrigerant is combustible. in much longer evacuation times and possible system contamination.
Page 14: Low Voltage
Safety Precautions • If the microprocessor has a power switch, turn WARNING: Never work alone on high it OFF before connecting or disconnecting the voltage circuits in the refrigeration unit. battery. Another person should be nearby to shut off the unit and provide aid in the event of •...
Page 15: First Aid
Safety Precautions First Aid, Electrical Shock • Components that could be damaged by welding sparks should be removed from the Take IMMEDIATE action after a person has unit. received an electrical shock. Get quick medical • Use normal welding procedures, but keep the assistance, if possible.
Page 16: Specifications
Specifications Engine Model: T-600R and T-800R TK370 (Tier 4) T-1000R TK376 (Tier 4) Fuel Type No. 2 Diesel fuel under normal conditions No. 1 Diesel fuel is acceptable cold weather fuel Oil Capacity: T-600R and T-800R Crankcase & Oil Filter 9.0 quarts (8.5 liters) T-600R and T-800R w/Bypass Oil Filter 10.0 quarts (9.5 liters) Fill to full mark on dipstick...
Page 17: Belt Tension
66 ft-lb (89.5 N•m) minimum @ 1600 RPM Refrigeration System Compressor Model: T-600R and T-800R Thermo King X214 T-1000R Thermo King X426 LSC5 Refrigerant Charge: T-600R with Tube and Fin Condenser Coil (ending 6/12) 8.0 lb (3.6 kg) R-404A T-600R with Micro-Channel Condenser Coil (starting 6/12) 7.0 lb (3.2 kg) R-404A...
Page 18: Electrical Control System
7.5A HPCO/Run Circuit F4 Remove fuse F4 for Model 30 units with Australian Bosch or Thermo King Alternators. Install fuse F4 for Model 50 units with Prestolite Alternator. F10 When fuse F10 is installed in the upper position the On/Off keys on the HMI turn the unit on and off. When fuse F10 is installed in the lower position the unit will start and run without the HMI control panel.
Page 19: Electrical Standby (Model 50 Units Only)
Specifications Electrical Components (Continued) Component Current Draw (Amps) Resistance at 12.5 Vdc (Ohms) Damper Solenoid Condenser Inlet Solenoid (CIS) Hot Gas Solenoid (HGS) 11.3 Purge Valve (PV) 11.3 Starter Motor (No Load Bench Test) Electrical Standby (Model 50 Units Only) T-600R and T-800R Electric Motor and Overload Relay Voltage/Phase/Frequency Horsepower...
Page 20 Maintenance Inspection Schedule Pretrip 1,200 2,000 Annual/ Inspect/Service These Items Hours Hours 3,000 Hours Microprocessor • Run pretrip test (see “Pretrip Test” in Operating Instructions Chapter). Engine • Check fuel supply. • • Check engine oil level. • • Check condition of belts. •...
Page 21 Maintenance Inspection Schedule Pretrip 1,200 2,000 Annual/ Inspect/Service These Items Hours Hours 3,000 Hours Electrical • Check controller for alarms. • Run pretrip test • Check battery voltage. • Inspect battery terminals and electrolyte level. • Inspect wire harness for damaged wires or connections. •...
Page 22: Unit Description
Grade 2 Coat Paint Finish possible malfunctions. • X214 Compressor (T-600R and T-800R) The built-in CYCLE-SENTRY, an exclusive Thermo King feature, automatically starts and • X426 Compressor (T-1000R) stops the unit according to temperature demands. • Stainless Steel Condenser and Evaporator...
Page 23: Unit Options
Unit Description Unit Options ELC (Extended Life Coolant) The maintenance interval for ELC is five years or • 134a Refrigerant 12,000 hours. A nameplate on the coolant • Body Mount HMI Enclosure Systems expansion tank identifies units with ELC (see “Safety Decals and Locations”).
Page 24: Mechanics Hmi Control Panel
Unit Description CYCLE-SENTRY Start/Stop System The CYCLE-SENTRY Start/Stop fuel saving system provides optimum operating economy. WARNING: Turn the unit off by pressing key before opening doors or Figure 1: Standard HMI Control Panel inspecting any part of the unit. The unit can Mechanics HMI Control Panel start at any time without warning if it has been turned on by pressing the...
Page 25: Das - Data Acquisition System (Optional)
Unit Description DAS - Data Acquisition System • Auto Switching (Optional) Engine Compartment The DAS (Data Acquisition System) monitors and Components records the temperatures of (up to) six additional The coolant level and sensors. The sensors are independent from the Coolant Expansion Tank: temperature are monitored by the base controller.
Page 26 Unit Description This This sensor Electronic Throttling Valve (ETV): Coolant Temperature Sensor: component is an electromechanical control device provides an engine coolant temperature input to used to limit the suction pressure to the the microprocessor. If the engine coolant compressor. The valve is controlled by the temperature is too high, the controller stops the microprocessor controller.
Page 27 Unit Description AMA828 Figure 5: Main Components Engine Oil Dipstick (on side of engine) Alternator Engine Compressor Coolant Expansion Tank Dehydrator (Filter-Drier) Electric Motor On/Off Switch Main Components in Figure 5...
Page 28: Refrigeration System Components
Unit Description Refrigeration System Receiver Tank Pressure Check Valve Components This check valve allows hot gas to force the liquid refrigerant out of the receiver tank during the heat The refrigeration system in these units does not and defrost modes. It prevents refrigerant from have a three-way valve.
Page 29: Refrigeration System Diagrams
Unit Description Refrigeration System Diagrams NOTE: The drawings show the refrigeration system with a two-cylinder compressor. The The following pages show the refrigeration refrigeration system with the four-cylinder system and examples of the refrigerant flow in the compressor is basically the same except for the various modes.
Page 30: Cool Mode
Unit Description Cool Mode Solenoid and Check Valves The refrigerant flow in Cool Mode is a 1. Condenser Inlet Solenoid (CIS)-Open/ conventional refrigeration cycle. High pressure De-energized refrigerant vapor leaves the compressor and flows 2. Condenser Check Valve-Open through the open CIS to the condenser where the refrigerant releases heat and condenses into high 3.
Page 31: Purge Mode
Unit Description Purge Mode Solenoid and Check Valves Purge Mode is similar to Condenser Evacuation 1. Condenser Inlet Solenoid (CIS)-Open/ Mode in previous systems. It is used to move the De-energized refrigerant out of the condenser into the 2. Condenser Check Valve-Open accumulator when the unit shifts from Cool (or Null) to Heat.
Page 32: Heat/Defrost Mode
Unit Description Heat/Defrost Mode Solenoid and Check Valves The refrigerant flow in Heat/Defrost Mode is a 1. Condenser Inlet Solenoid (CIS)-Closed/ conventional hot gas heat cycle. The CIS is closed Energized and the HGS is open so high pressure refrigerant 2.
Page 33: Operating Instructions For Standard Hmi Control Panel
Alarm Code 91 Check Electric Ready Alarm Code(s). Input occurs. It will also glow if a 15 pin Thermo King data cable is connected to the The lower row of numbers can display the serial port on the back of the controller (DPD).
Page 34 Operating Instructions for Standard HMI Control Panel The meaning of the display icons are shown in the table below. When this icon is present the upper display is showing the actual box temperature inside the truck box. When this icon is present the lower display is showing the current setpoint.
Page 35: Keys And Led Indicators
This indicator will glow if Alarm Code 91 Check Electric Ready Input occurs. It will also light if a 15 pin Thermo King data cable is connected to the serial port on the back of the controller (DPD). Figure 12: Keys and LED Indicators The primary and secondary key uses are shown in the table below.
Page 36 Operating Instructions for Standard HMI Control Panel CYCLE-SENTRY/Continuous Key If the unit is turned on and is in Continuous Mode, pressing the CYCLE-SENTRY/CONTINUOUS Key will switch operation to CYCLE-SENTRY Mode and the amber LED indictor will glow. If the unit is running in CYCLE-SENTRY Mode, pressing this key will switch operation to Continuous Mode and the amber LED will turn off.
Page 37: Turning The Unit On And Off
Operating Instructions for Standard HMI Control Panel Turning the Unit On and Off shown in the lower display. The box temperature shown in Figure 15 is 35.8 F (2.1 C) with a 35 F IMPORTANT: Verify the Base Controller (1.6 C) setpoint. On/Off Switch is turned on before turning on the HMI Control Panel.
Page 38: Changing The Setpoint
Operating Instructions for Standard HMI Control Panel Changing the Setpoint From the Standard Display, press the UP ARROW Key and/or DOWN ARROW Key until the desired setpoint is shown. In Figure 18 the setpoint has been increased to 40 F (4.4 C) using the UP ARROW Key.
Page 39: Starting The Electric Motor
Operating Instructions for Standard HMI Control Panel Switching from Diesel to WARNING: Never use starting fluid. Electric When the engine is preparing to start, the SR-2 Standard Truck HMI Control Panel will continue IMPORTANT: Applies to units with the Electric to display the Standard Display as shown in Standby Option only.
Page 40: Selecting Cycle-Sentry Or Continuous Mode
Operating Instructions for Standard HMI Control Panel will glow, the Alarm Icon will glow and the box 4. Press the Standard Truck HMI Control Panel temperature and setpoint displays will disappear ON Key again to clear Alarm Code 91 Check as shown in Figure 23.
Page 41: Selecting The High Speed Lock-Out Feature
Operating Instructions for Standard HMI Control Panel IMPORTANT: HIGH SPEED LOCKOUT amber LED indictor will glow. If the unit is running in CYCLE-SENTRY Mode, pressing this TIMER: If High Speed Lockout Mode is key will switch operation to Continuous Mode selected, the High Speed Inhibit Timeout feature and the amber LED will turn off.
Page 42: Alarms
Operating Instructions for Standard HMI Control Panel IMPORTANT: During the defrost cycle, the box indicates that Alarm Code 127 Setpoint Not temperature will rise toward 50 F (10 C). This is Entered has been set. The lower display indicates normal and is caused by the defrost cycle that only one alarm code exists.
Page 43: Sending A Servicewatch Data Logger Start Of Trip
Operating Instructions for Standard HMI Control Panel Conditions where Pretrip Tests are • Some alarms cannot be cleared using the not allowed Standard Truck HMI Control Panel. These alarms must be cleared by maintenance • Pretrip Tests are not allowed if any shutdown personnel from the Maintenance or Guarded alarms are present.
Page 44: Pretrip Test Considerations
Operating Instructions for Standard HMI Control Panel • Heat Check - The ability of the unit to heat in low speed is checked. • Report Test Results - The test results are reported when the Pretrip Test is completed. If the Pretrip Test fails, alarm codes will exist to direct the technician to the source of the Figure 35: Pretrip Test...
Page 45: Pretrip Test Results
Operating Instructions for Standard HMI Control Panel Fail Pretrip Test with Shutdown Alarms • A flashing Pretrip LED indicates that the Pretrip Test is being initialized. When the • If the unit fails the Pretrip Test with a Pretrip Test starts, the Pretrip LED will glow Shutdown alarm, the Alarm Icon will appear steady amber to indicate the test is in progress.
Page 46: Checking Truck Hmi Control Panel Software Revision And Serial Number
Operating Instructions for Standard HMI Control Panel Checking Truck HMI Control Panel Software Revision and Serial Number The Standard Truck HMI Control Panel serial number and software revision can be displayed if necessary. To display the serial number and software revision press and hold the PRETRIP key for 5 seconds when the unit is turned off.
Page 47: Operating Instructions For Premium Hmi Control Panel
Operating Instructions for Premium HMI Control Panel SR-2 Truck Premium HMI • Changes Setpoint Controller Description • Indicates Alarm Condition Exists • Displays and Clears Alarms Premium HMI Control Panel • Selects and Indicates CYCLE-SENTRY or The Premium Truck HMI (Human/Machine Continuous Mode Operation Interface) Control Panel is available as an option on SR-2 Truck applications.
Page 48: Keys
Operating Instructions for Premium HMI Control Panel Figure 43: Soft Keys Figure 41: Display Soft Keys Keys Soft Key Description The four "soft" keys under the display are multi-purpose keys. Their function changes depending on the operation being performed. If a soft key is active the key function is shown in the display directly above the key.
Page 49: If More Than One Language Is Enabled
Operating Instructions for Premium HMI Control Panel IMPORTANT: The ON key must be held down until the Thermo King Logo appears as shown in Figure 44. If the ON key is not held down long enough (approximately ½ second), the display may flicker but the unit will not start up.
Page 50: The Standard Display
Operating Instructions for Premium HMI Control Panel Figure 51: Language Menu Figure 55: Standard Display When the unit is ready to run the Standard Display The CYCLE-SENTRY Icon in the upper right appears. corner of the display shows that the unit is operating in CYCLE-SENTRY Mode.
Page 51: Starting The Diesel Engine
Operating Instructions for Premium HMI Control Panel Figure 61: Standard Display, New Setpoint Figure 58: Increase Setpoint IMPORTANT: If the setpoint is changed using The YES and NO soft keys confirm the setpoint the "+" or "-" keys, the change must be change.
Page 52: Starting The Electric Motor
Operating Instructions for Premium HMI Control Panel WARNING: Never use starting fluid. After the motor is running the display returns to the Standard Display of temperature and setpoint. When the engine is preparing to start the HMI control panel will display the engine start screen, as shown in Figure 62.
Page 53: Switching From Electric To Diesel
Operating Instructions for Premium HMI Control Panel Switching from Electric to If unit operation is required the diesel engine will start as shown previously in STARTING THE Diesel DIESEL ENGINE. Units equipped with the Electric Standby option only. Initiating a Manual Defrost Cycle If the Electric to Diesel Autoswitch Enabled feature in Guarded Access is set YES then the unit...
Page 54: Terminating A Defrost Cycle
Continuous Mode the setting, press the High Speed Lockout key as shown below. With Thermo King Truck unit applications, CYCLE-SENTRY Mode or Continuous Mode operation is selected from the Main Menu - Mode Submenu. See the Main Menu - Mode Submenu material later in this section for complete details.
Page 55: Using The Sensors Key
Operating Instructions for Premium HMI Control Panel Discharge Pressure - Displays the unit discharge pressure. (ETV units only) Suction Pressure - Displays the unit suction pressure. (ETV units only) ETV Position - Displays the current position of the Electronic Throttling Valve (ETV). (ETV Figure 78: Gauges Key units only) The first gauge display will appear.
Page 56: Using The Main Menu
Operating Instructions for Premium HMI Control Panel Using The Main Menu The first sensor display will appear. Press the NEXT and BACK keys to scroll thru the sensors The Main Menu contains several additional as desired. The Discharge Air Temperature sensor submenus that allow the operator to view is shown in Figure 81.
Page 57: Languages
Operating Instructions for Premium HMI Control Panel TIME - Allows the operator to view the unit time DATA LOGGER - Allows the operator to set a Start of Trip marker to the ServiceWatch data and date. The time and date cannot be changed logger.
Page 58: Alarms
NEXT key. To return to the Standard Display When the unit is turned on the display will show press the EXIT key. the Thermo King Logo and then the "Configuring System" message. If log alarm(s) are present the IMPORTANT: If necessary, English and all...
Page 59 Operating Instructions for Premium HMI Control Panel become log alarms when switched to the alternate be on during this period. The Standard Display will appear and the remote indicator alarm light operating mode (diesel to electric or electric to will go to the white T symbol after 60 seconds. diesel).
Page 60 Alarm Code 91 Check Electric Ready Input - Alarm Code Notification Clears automatically when the unit starts running. The Alarm Icon used in previous Thermo King controllers has been incorporated. If a Check • Alarm Code 92 Sensor Grades Not Set -...
Page 61 Operating Instructions for Premium HMI Control Panel Displaying and Clearing Alarm Codes After the alarm situation is resolved press the CLEAR key to clear the alarm. For additional Alarms are displayed and cleared using the Alarm information regarding the alarm shown on the Menu.
Page 62: Datalogger
Operating Instructions for Premium HMI Control Panel Refer to the Truck SR-2 Single Temp Diagnostic Manual TK 54292 for more information about alarm codes and their diagnosis. Datalogger The unit can be equipped with an optional DAS Figure 101: Start of Trip Data Logger if desired.
Page 63: Mode
Operating Instructions for Premium HMI Control Panel User Programmable - The Engine Reminder 2: number of hours before an Engine Run Time Maintenance Reminder 2 occurs. User Programmable - The Electric Reminder 1: number of hours before an Electric Run Time Maintenance Reminder 1 occurs.
Page 64: Selecting Cycle-Sentry Or Continuous Mode
Operating Instructions for Premium HMI Control Panel The following features are available in Sleep Mode. This feature allows a Program Wakeup Time: wakeup time to be specified. When the selected time is reached the unit will start and resume normal operation. Figure 108: Select and Next Keys If a Wakeup Time is selected the following features are available:...
Page 65: Selecting Sleep Mode
Operating Instructions for Premium HMI Control Panel Pressing the Select key will change the mode in cold ambient conditions. Sleep mode does not from CYCLE-SENTRY to Continuous. consider setpoint or maintain cargo temperatures - it only keeps the engine warm and the unit battery charged.
Page 66 Operating Instructions for Premium HMI Control Panel Figure 118: Sleep Mode Menu Figure 122: Yes Key The screen shown in Figure 119 will appear.. The display will prompt the operator for the DAY the unit is to restart in normal operation. In Figure 123 Monday has been chosen.
Page 67: Pretrip
Operating Instructions for Premium HMI Control Panel Pretrip Test Conditions • Current unit settings are saved and restored at the end of the Pretrip Test or if the unit is turned off and back on. • Pretrip Test can be run in either Diesel or Electric Mode.
Page 68 Operating Instructions for Premium HMI Control Panel CHECK or FAIL alarm codes will exist to direct the technician to the source of the problem. Pretrip Test Considerations When performing a Pretrip Test, the following issues should be considered. Figure 128: Menu Key •...
Page 69: Diesel/Electric Menu
Operating Instructions for Premium HMI Control Panel If the Pretrip Test results are CHECK or FAIL the problem should be diagnosed and corrected before the unit is released for service. Diesel/Electric Menu The Diesel Mode/Electric Standby menu allows Figure 132: Pretrip Test Display the operator to manually select diesel or electric •...
Page 70: Adjust Brightness
Operating Instructions for Premium HMI Control Panel Electric Mode operation will briefly be confirmed. If unit operation is required the electric motor will start as shown previously in STARTING THE ELECTRIC MOTOR. Switching from Electric to Diesel - Units equipped with the Electric Standby option Figure 139: Display when YES is selected only If unit operation is required the diesel engine will...
Page 71: Time
Operating Instructions for Premium HMI Control Panel Figure 142: + and - Keys Figure 146: + and - Keys The display will briefly show ADJUSTING BRIGHTNESS - PLEASE WAIT. Figure 143: Adjusting Brightness The display brightness is changed to the new setting.
Page 72: Electrical Maintenance
F2 Terminal (Do Not Ground) B- Terminal (Negative Ground - CH Wire) Voltage Regulator and Brush Assembly S Terminal (Regulator Sense - 2 Wire) W Terminal (AC Output) L Terminal (Regulator Excite - 7K Wire) Figure 147: Thermo King Alternator Terminal and Component Locations...
Page 73: Interface Board Fuse F4
King alternators. The voltage regulator on the charging system are in good condition and are Thermo King alternators will be damaged if the adjusted properly before testing the alternator. unit is turned On with the F4 fuse in place on Be sure the pulleys are the correct size.
Page 74 CAUTION: Energizing the circuit with should fall to normal unit load plus charge the resistor bypass fuse installed will current to the unit battery (typically 5-10 damage Thermo King alternators. Be sure amps). the resistor bypass fuse is removed for Thermo King alternators.
Page 75: Field Current Test
Perform this test with the unit turned off. 1. Attach a clamp-on ammeter to the 2A wire near the B+ terminal on the alternator. 2. Energize the field on the Thermo King alternator by connecting a jumper wire between the F2 terminal and the B+ terminal.
Page 76: Fuses
7.5A HPCO/Run Circuit F4 Remove fuse F4 for Model 30 units with Australian Bosch or Thermo King Alternators. Install fuse F4 for Model 50 units with Prestolite Alternator. F10 When fuse F10 is installed in the upper position the On/Off keys on the HMI turn the unit on and off.
Page 77: Interface Board Leds
Electrical Maintenance Interface Board LEDs Smart FETs are not field repairable. Refer to the appropriate Microprocessor Diagnostic Manual The interface board has LEDs that indicate which for more information about the Smart FETs. outputs are energized. The LED is illuminated when the associated circuit output is energized.
Page 78: Glow Plugs
Electrical Maintenance If the engine will not start, an alternate less • Ohmmeter reliable test may be performed as follows: The flywheel sensor may be checked as follows: Disconnect the sensor from all wires, and measure 1. Position the flywheel so a ring gear tooth is in the resistance across the terminals and from each the center of the sensor mount hole.
Page 79: Unit Wiring
Electrical Maintenance Condenser Fan Rotation A shorted glow plug will show excessive current draw (more than 13 amps) during preheat, and The condenser fan is belt driven. On electric may cause fuse F5 (40 A) to blow. Check each standby operation, check for correct fan rotation glow plug individually.
Page 80 Electrical Maintenance Inputs L1, L2 and L3 respectively. Operating power from 12 to 24 volts is supplied to the module via the 8 Input Description wire and CH wire. This Brown wire supplies standby power L1 When the voltage sensed rises above 165 volts to the phase select module.
Page 81 Electrical Maintenance Connector Pinout Tape the Black wire back onto itself. It is not used on single-phase installations. Pin Wire Description 11. Connect the plug on the short harness from the Power to Module phase select module. CH/CHV Chassis ground 12.
Page 82: Overload Relay
Electrical Maintenance be on. If voltage is not present on either the 2. Use a small screwdriver to set the opening 7EB or 7EC output, replace the phase select amperage. See “Electric Motor and Overload module. Relay” in the “Specifications” chapter for the correct overload relay setting.
Page 83 Electrical Maintenance 4. Move the slide switch down until it clicks into place at the bottom of the slot (from which the tab marked “H” was removed). This sets the overload relay to reset automatically. Switch Clicks into Place at Bottom of Slot Figure 156: Move Switch Down The new overload relay is now set up correctly.
Page 84: Engine Maintenance
“Specifications” chapter) and check the dipstick package do require regular inspection in level. Run the unit, and then recheck the oil level. accordance with Thermo King's maintenance recommendations. CAUTION: The fill port on top of the engine should not be used to add engine NOTE: The new EMI 2000 oil filters and new oil.
Page 85: Oil Filter Change
Oil Filter Change Both oil filters should be changed along with the engine oil. Use genuine Thermo King extended maintenance oil filters. 1. Remove the filter. 2. Apply oil to rubber ring of new filter and install filter.
Page 86: Crankcase Breather System
Engine Maintenance Crankcase Breather System The vacuum will increase as the air cleaner gets dirty and becomes more restrictive. Remove the The crankcase breather system ducts crankcase breather cover and the baffle plate and check to gases formed in the crankcase directly to the air make sure nothing is plugged or damaged.
Page 87: Engine Cooling System
Engine Maintenance Engine Cooling System All water-cooled engines are shipped from the factory with a mixture of 50 percent permanent type antifreeze concentrate and 50 percent water General Description in the engine cooling system. The engine employs a closed, circulating type, This provides the following: pressurized cooling system.
Page 88 Engine Maintenance Engine Coolant Level Sensor Overflow Cap Coolant Temperature Sensor Expansion Tank Cap Radiator Expansion Tank Drain Cock Figure 162: Engine Cooling System Components for Units with Micro-Channel Radiator Coil (Starting 06/12)
Page 89: Elc (Extended Life Coolant)
The following are the Extended Life Coolants The factory recommends the use of a 50/50 currently approved by Thermo King for use in percent antifreeze mixture in all units even if they ELC units for five years or 12,000 hours: are not exposed to freezing temperatures.
Page 90: Bleeding Air From The Cooling System
Engine Maintenance Changing the Antifreeze Bleeding Air from the Cooling System 1. Run the engine until it is up to operating temperature. Stop the unit. Often when a self powered truck unit cooling system is refilled, air is trapped in the engine 2.
Page 91: Engine Thermostat
Engine Maintenance 3. Reinstall the bleeder set screw or reinstall the WARNING: Failure to follow this thermostat and housing. procedure can result in engine damage. Air trapped in the engine block and head 4. On units with TK376 engines and tube and fin radiator coils only: Continue slowly pour the can create localized hot spots that can cause permanent damage.
Page 92: Coolant Level Switch
Engine Maintenance Coolant Level Switch 2. Drain coolant from the expansion tank until the coolant level is well below the switch. The coolant expansion tank uses a magnetic float type coolant level switch. When the coolant level 3. Remove (unscrew) the coolant level switch is at or above the switch, the float is in the upper from the expansion tank.
Page 93: Maintenance
53163 for injection nozzle testing and repair procedures. Injector Line Bleeder Screw Thermo King recommends that any major Figure 169: Injection Pump injection pump or nozzle repairs be done by a quality diesel injection service specialty shop. The 2. Turn on the electric fuel pump. The electric...
Page 94 Engine Maintenance Figure 170: Fuel and Oil System Components...
Page 95 Engine Maintenance Elbow - hose fitting (3/8) 16. Plug - pipe Kit - sleeve & eyelet (3/8) 17. Plug - pipe Nut (3/8) 18. Filter - oil bypass (EMI 2000) Hose (3/8 od) 19. Stud - bypass filter Adapter - oil line 20.
Page 96: Draining Water From Fuel Tank
Engine Maintenance Draining Water from Fuel Tank Electric Fuel Pump Water run through the system may damage the Operation injection pump or nozzles. Damage to the fuel system will subsequently cause more expensive The electric fuel pump must be mounted next to damage to the engine.
Page 97: Injection Pump Timing
Engine Maintenance Assembly 1. Screw the fuel filter back into the pump housing (finger tight). 2. Place the fuel filter bowl gasket in place and hand tighten (or 100 in-lb [11.3 N•m]) the fuel filter bowl. If the pump does not operate, check for: •...
Page 98 Engine Maintenance TDC mark on the flywheel lines up with the timing mark on the starter mounting plate. Delivery Valve Holder Injection Timing Marks Figure 174: Injection Pump Top Dead Center Mark for Number 1 Cylinder 9. Slowly turn the engine in the normal direction Index Timing Mark on Starter Mounting Plate of rotation until you see the fuel rise in the end Figure 173: Timing Marks...
Page 99: Injection Pump Removal And Installation
Engine Maintenance a. Pull the top of the injection pump away from the engine to advance the timing. b. Push the top of the injection pump toward the engine to retard the timing. 12. Tighten the injection pump mounting nuts and recheck the timing.
Page 100 Engine Maintenance 2. Place the injection pump in the gear case. NOTE: The injection pump gear assembly is made of two pieces, the flange and the gear. Rotate the injection pump shaft to mate the Do not loosen or remove the four bolts that key in the shaft with the keyway in the fasten the gear to the flange because that injection pump gear.
Page 101: Fuel Limit Screw
Engine Maintenance Fuel Limit Screw The fuel limit screw is not adjustable. It is equipped with an anti-tamper cap to fulfill requirements for CARB (California Air Resources Board) emission regulations. Service technicians must be CARB certified to perform service on the fuel limit screw for equipment operating in California.
Page 102 Engine Maintenance pin C) in the fuel solenoid connector. The NOTE: The fuel solenoid may be removed from the injection pump to visually check its resistance of the pull-in coil should be 0.2 operation. The fuel solenoid must be to 0.3 ohms. If the resistance of the pull-in energized when it is re-installed in the coil is not in this range, replace the fuel solenoid.
Page 103: Engine Speed Adjustments
Engine Maintenance 4. Use the Mechanics/Premium HMI Control Make the engine speed adjustments with the Panel to enter the Interface Board Test Mode. engine fully warmed up. Refer to the appropriate Microprocessor Diagnostic Manual for specific information Low Speed Adjustment about the Relay Test Mode.
Page 104: Adjust Engine Valve Clearance
Engine Maintenance On the three cylinder engines the order for the 3. If the engine speed is not correct, loosen the jam nuts at both ends of the high speed flywheel timing marks is 1, 2, 3, but the firing adjuster in the throttle linkage.
Page 105 Engine Maintenance AGA148 Adjustment Screw Lock Nut Top Dead Center Timing Mark for Number 1 Cylinder Figure 186: Valve Clearance Index Timing Mark on Starter Mounting Plate 5. Hold the adjustment screw in place and Figure 185: Timing Marks tighten the lock nut. b.
Page 106 Engine Maintenance 8. Check and adjust both valves for the number 3 cylinder. 9. Place the engine at top dead center of the compression stroke for the number 2 cylinder. a. Rotate the engine in the normal direction of rotation (counterclockwise viewed from the flywheel end) until the top dead center timing mark for the number 2 cylinder on the flywheel lines up with the index timing...
Page 107: Engine Mounts
Engine Maintenance Engine Mounts The engine mounting system contains three vibration mounts and a chain restraining mount (snubber). Figure 188: Engine Mounting Components...
Page 108: Restraining Mount (Snubber) Adjustment
Engine Maintenance Bracket - engine (upper rear) Bracket - engine (compressor side) 10. Washer - belleville Bracket - engine (door side) Screw - chain Screw - plate & bracket (socket head) 12. Chain - 3 links Washer - belleville 13. Bolt - eye 1/2 in. Sealer - thread 14.
Page 109: Belts
Engine Maintenance Belts The unit uses only two belts to transfer power from the engine and the electric motor to the alternator, compressor, and evaporator fans. Engine 10. Compressor Pulley Clutch Compressor Engine/Electric Motor (Jackshaft) Belt 12. Evaporator Fan Pulley (Compressor Side) Evaporator Fan Pulley (Engine Side) 13.
Page 110: Engine/Electric Motor (Jackshaft) Belt
Engine Maintenance Engine/Electric Motor (Jackshaft) 7. Take a straight edge, place it against the side Belt of the muffler can and mark the frame as shown below. This is the unloaded engine The engine/electric motor (jackshaft) belt is a 3V position.
Page 111 Engine Maintenance NOTE: It is important to turn the belt as the NOTE: Make sure the two nuts under the bracket near the top of the adjusting bolt are nut is being tightened to prevent tension locked together to ensure the adjusting bolt from building up in the belt.
Page 112: Electric Motor (Jackshaft)/ Compressor Belt
Engine Maintenance Electric Motor (Jackshaft)/ Compressor Belt The electric motor (jackshaft)/compressor belt is a polyvee stretch belt that also drives the compressor side evaporator fan and the alternator. The alternator/motor (jackshaft) bracket has two sets of adjustment steps that are aligned with the alternator clevis bracket to set the belt tension.
Page 113 Engine Maintenance NOTE: The two inside sets of adjustment steps are for single temp units with reciprocating compressors and multi-temp units with scroll compressors. The two outside sets of adjustment steps are for single temp units with scroll compressors and multi-temp units with reciprocating compressors.
Page 114: Water Pump Belt
Engine Maintenance 6. Push the alternator and the alternator clevis bracket down to loosen the belt. 7. Remove the old belt and note how it fits on the pulleys. 8. Install the new belt. Make sure it fits on the pulleys correctly.
Page 115: Refrigeration Service Procedures
See the diagram of the Thermo King Evacuation Moisture in the system will produce acid and Station (Figure 201 on page 115) and note the other contaminants that lead to compressor location of the valves and other components.
Page 116 Refrigeration Service Procedures AGA654 Iso-Valve To 110 Vac Power Calibration Standard 10. Vacuum or Micron Gauge Thermistor Charging Port Two Stage Vacuum Pump Figure 201: Evacuation Station...
Page 117 Refrigeration Service Procedures 100 Microns 500 Microns 1000 Microns 2500 Microns 5000 Microns 20,000 Microns Atmospheric Pressure Calibration Adjustment Screw Example: Meter needle shown at calibration position when Calibration Standard specifies 0.15 mm Hg. Figure 202: Vacuum Gauge...
Page 118: Set Up And Test Of Evacuation Equipment
Refrigeration Service Procedures Set Up and Test of Evacuation NOTE: Dirty vacuum pump oil or a defective Equipment vacuum pump will prevent a low micron reading. Hoses and fittings can be isolated NOTE: See the previous two pages for the individually to identify leaks.
Page 119 Refrigeration Service Procedures 7. When the desired micron level has been NOTE: The presence of refrigerant in the compressor oil may prevent a low micron achieved (500 to 1000 microns), close valve reading from being achieved. The oil can V-1, stop the pump. continue to “outgas”...
Page 120: Unit Charging
Refrigeration Service Procedures Unit Charging Refrigerant Gauge Removal NOTE: Before charging, make sure that the 1. Operate the unit in cool mode. refrigerant lines from the gauge manifold to the 2. Backseat the discharge service valve. refrigerant supply bottle have been evacuated or purged.
Page 121: Testing The Refrigerant Charge With A Loaded Box (Quick Check)
Refrigeration Service Procedures 4. The discharge or head pressure gauge should read 290 to 310 psig (1999 to 2137 kPa). If the pressure is below this, it can be raised by covering a portion of the condenser coil with a piece of cardboard.
Page 122: Refrigeration System Checks
Refrigeration Service Procedures To check compressor oil level with an ambient air psig (1379 to 1724 kPa) or higher. The temperature below 50 F (10 C): compressor is probably faulty if the discharge pressure is below 200 psig (1379 kPa). Run the unit through a complete Defrost cycle.
Page 123: R404A
Compressor Oil The Thermo King Evacuation Station is recommended. This station is available from Thermo King Corporation has chosen to use a service parts (see Tool Catalog). See Truck and compressor oil called Polyol Ester (POE)—also Trailer Service Bulletin T&T 061 for additional called ester based oil.
Page 124: Refrigerant Recovery
Refrigeration System Gauge manifolds and manifold hoses used with Component Locations other Thermo King refrigerants maybe used but The following drawings show the locations of extreme care should be taken to prevent various refrigeration system components.
Page 125 Refrigeration Service Procedures Figure 208: Condenser Refrigeration Component Locations in Units with Tube and Fin Condenser Coils (Ending 06/12) (Two-Cylinder Compressor Shown, Similar with Four-Cylinder Compressor)
Page 126 Refrigeration Service Procedures Suction Access Port Receiver Tank Outlet Valve Suction Pressure Regulator (SPR) 12. Receiver Tank Sight Glass Suction Service Valve 13. Receiver Tank Discharge Service Valve 14. Condenser Check Valve Compressor 15. Condenser Inlet Solenoid (CIS) Discharge Strainer 16.
Page 127 Refrigeration Service Procedures Figure 209: Condenser Refrigeration Component Locations in Units with Micro-Channel Condenser Coils (Starting 06/12) (Two-Cylinder Compressor Shown, Similar with Four-Cylinder Compressor)
Page 128: Accumulator Replacement
Refrigeration Service Procedures Suction Access Port Receiver Tank Outlet Valve Suction Pressure Regulator (SPR) 12. Receiver Tank Sight Glass Suction Service Valve 13. Receiver Tank Discharge Strainer 14. Purge Valve (PV) Discharge Service Valve 15. Condenser Check Valve Compressor 16. Condenser Inlet Solenoid (CIS) Hot Gas Solenoid (HGS) 17.
Page 129: Installation
Refrigeration Service Procedures 8. Back seat the receiver tank outlet valve. Mid 3. Open both service manifold hand valves to bleed the pressure in the head, or heads and seat the discharge and suction service valves. discharge manifold, into the compressor 9.
Page 130 Refrigeration Service Procedures Oil Pressure Access Port Inlet Fitting Oil Pressure Access Port Outlet Fitting Inlet Fitting Figure 210: Compressor Oil Filter Outlet Fitting (Two-Cylinder Compressor) Figure 211: Compressor Oil Filter (Four-Cylinder Compressor) Use the following procedure to change the compressor oil filter.
Page 131: Checking Compressor Oil Pressure
Hold the oil filter with a Installations back-up wrench on the hex behind the ORS Thermo King remanufactured compressors have fitting. had a special break in process to assure that the oil 8. Evacuate the compressor and filter to remove pump is primed, functioning, and broken in.
Page 132: Condenser Check Valve And Purge Check Valve Test
Refrigeration Service Procedures through one (or more) of following 5. As soon as the compressor develops 10 psi (96 kPa) of net oil pressure, re-connected the components: hot gas solenoid, purge valve, or fuel solenoid wires. receiver tank pressure check valve. 6.
Page 133: Condenser Inlet Solenoid (Cis) Test
Refrigeration Service Procedures Condenser Inlet Solenoid (CIS) If the CIS is stuck closed, the unit will stop very quickly after is starts to run and will record Alarm Test Code 10 (High Discharge Pressure). Use the 1. Attach a gauge manifold to the suction service following procedure to check for a CIS that is valve and the discharge service valve.
Page 134: Installation
Refrigeration Service Procedures 4. Unsolder the hot gas inlet and liquid outlet IMPORTANT: Micro-channel refrigerant line connections. On units with condenser/radiator coils are used in these micro-channel coils make sure to use a heat units starting in June 2012. Micro-channel sink on the copper stub tubes.
Page 135: Discharge Strainer Test
Refrigeration Service Procedures 4. Pressurize the low side and check for leaks. 3. Unsolder the refrigeration lines from the discharge strainer and remove the discharge 5. If no leaks are found, evacuate the low side. strainer from the unit. 6. Open the refrigeration valves and place the Installation unit in operation.
Page 136: Expansion Valve Replacement
Refrigeration Service Procedures 9. Recharge the unit with refrigerant and check the compressor oil. Expansion Valve Replacement Removal 1. Pump down the low side and equalize the Suction Line pressure to slightly positive. Make sure to Capillary Bulb front seat the suction service valve to isolate End View the low side and use the suction access port to Figure 213: Location of Expansion Valve Bulb...
Page 137: Installation
Refrigeration Service Procedures High Pressure Cutout Switch 5. Unsolder the liquid line to the expansion valve. (HPCO) Test 6. Note the position of the feeler bulb on the side The HPCO is located on the compressor discharge of the suction line. Remove the expansion manifold.
Page 138: High Pressure Cutout Switch (Hpco) Replacement
Refrigeration Service Procedures Removal NOTE: The discharge pressure should never be allowed to exceed a pressure of 477 psig 1. Recover the refrigerant charge. (3289 kPa) on R-404A systems. 2. Unscrew and remove the high pressure relief 4. If the HPCO opens too soon or does not open valve from the receiver tank.
Page 139: In-Line Check Valve Replacement
Refrigeration Service Procedures Installation 8. Use the Mechanics/Premium HMI Control Panel to enter the Interface Board Test Mode. NOTE: A heat sink must be used on the in-line Refer to the appropriate Microprocessor check valve when it is being soldered in place to Diagnostic Manual for specific information prevent damage to the neoprene seal.
Page 140: Receiver Tank Pressure Check Valve Test
Refrigeration Service Procedures 8. Back seat the receiver tank outlet valve and 8. Use the Mechanics/Premium HMI Control Panel to enter the Interface Board Test Mode. the suction service valve, and remove the Refer to the appropriate Microprocessor gauges to return the unit to normal operation. Diagnostic Manual for specific information about the Interface Board Test Mode.
Page 141: Installation
Refrigeration Service Procedures Installation 2. Unsolder and remove the SPR. Note the position of the SPR so the new one will be 1. Clean the tubes for soldering. placed in the same position. 2. Remove the coil and place the valve in Installation position.
Page 142: Installation
Refrigeration Service Procedures 2. Disconnect the wires and remove the suction pressure transducer from the suction adapter. Installation 1. Apply a refrigerant Loctite to the threads of the suction pressure transducer. 2. Install and tighten the suction pressure transducer and reconnect the wires. 3.
Page 143: Clutch Maintenance
Clutch Maintenance Centrifugal Clutch The centrifugal clutch has three belt grooves and its engagement speed is 600 ± 100 RPM. AGA127 Figure 217: Front View and Cross Section...
Page 144 Clutch Maintenance aea558 (3 belt grooves) Screw Grease Seal Washer Roller Bearing Inner Race Snap-Ring Pulley Housing Ball Bearing Elastic Stop Nuts (6) Large & Small Spacers Connector Link (6) Rolling Bearing Spring (6) Lockwasher (12) Shoe Assembly (3) Bushing (6) Screws (6) Figure 218: Centrifugal Clutch...
Page 145: Clutch Maintenance
Clutch Maintenance Clutch Maintenance 3. Remove housing from hub by supporting hub (in a minimum of three places) in spoke area, Using an inspection mirror, inspect the clutch and pressing on the housing shaft. The inner every 1000 hours of operation or yearly, race of the roller bearing will remain on the whichever occurs first.
Page 146: Assembly Procedure (Using New Bearings And Seal)
Clutch Maintenance 7. Press bushings out of hub. Figure 221: Bushing Removal 8. Remove inner race of roller bearing from the housing shaft. Figure 222: Bushing Insertion NOTE: This race had Loctite applied and was pressed in place. A puller will be *DO NOT USE SOAP OR OIL TO required to remove it.
Page 147 Clutch Maintenance 6. Apply Mobil (see Tool Catalog) grease to roller bearing and fill cavity between large and small spacers. A small amount of grease should also be applied to the seal lip and space between the seal and roller bearing. 7.
Page 148: Structural Maintenance
Structural Maintenance Unit and Engine Mounting Bolts Cleaning Methods (listed in order of recommended method) Periodically check and tighten all unit and engine • Take a cloth or towel and wipe the air side of mounting bolts. Torque the unit mounting the coil going with the fins, across the tubes.
Page 149: Fan Location
Structural Maintenance Fan Location When mounting the fan and hub assembly on the fanshaft, position the assembly in the orifice as follows for proper fan performance: • For the ten-blade condenser fan, position the fan with 50 percent of the blade width to the air discharge side.
Page 150: Plastic Defrost Damper
Structural Maintenance Plastic Defrost Damper The blade pivots of the ends of the plastic damper blade are not adjustable. However, the position of These units use a plastic defrost damper blade the damper can be adjusted if necessary by instead of the aluminum defrost damper blade adjusting the position of the eye bolt in the previously used in self powered truck units.
Page 151: Fanshaft Assembly
Structural Maintenance Fanshaft Assembly The unit is equipped with one-piece fanshaft assemblies that contain tapered roller bearings in a sealed oil reservoir. A fanshaft assembly does not require any maintenance. There is a level plug and a fill plug, but they are not normally utilized except after removal and repair of the fanshaft assembly.
Page 152 Structural Maintenance 2. After draining the oil from the housing, 4. Using a punch, remove the oil seal from the remove the four retaining bolts from the evaporator end of the assembly. With the seal bearing retainer cap. removed, clean the housing in solvent. Figure 235: Removing Oil Seal 5.
Page 153: Reassembly
Structural Maintenance Reassembly 3. Install a new oil seal after replacing the bearing race and splash guard. 1. Install the new bearings on the shaft with a pipe in the same way they were removed. NOTE: Tape shaft holes or keyway to prevent seal damage.
Page 154: Jackshaft Assembly
Structural Maintenance Jackshaft Assembly 6. Torque the bolts in a criss-cross pattern in equal steps to 80 in.-lbs (9.04 N•m). The unit is equipped with a jackshaft that contains special sealed bearings. The jackshaft bearings should be checked when the belts are replaced. Spin the jackshaft with the belts removed and listen.
Page 155: Reassembly
Structural Maintenance Reassembly CAUTION: To prevent damage to the bearings, use bearing drivers (or other suitable tools) on the bearing races when installing the bearings. NOTE: Place a thin layer of grease (Mobil 28 or its equivalent) on the inner and outer bearing races before assembly.
Page 156: Mechanical Diagnosis
Mechanical Diagnosis Condition Possible Cause Remedy Engine will not crank Electrical problem Check and repair electrical system Defective starter solenoid Replace solenoid Defective starter Repair starter Water in cylinders Check for hydrostatic lock. Remove injectors and turn engine slowly Starter motor turns but engine Starter clutch defective Replace does not crank...
Page 157 Mechanical Diagnosis Condition Possible Cause Remedy Engine does not reach full power Air or dirt in fuel system Repair Fuel line leaks Tighten connections of fuel lines. If necessary, replace damaged lines Speed adjustment wrong Adjust speed Electric fuel pump does not run Check voltage.
Page 158 Mechanical Diagnosis Condition Possible Cause Remedy Engine runs hot Engine coolant is low Add coolant slowly while engine is in operation Dirty or plugged radiator Clean radiator Cooling system heavily scaled Clean cooling system Water pump leaks Repair or replace water pump Worn or loose belt Replace belt or adjust Cylinder head gasket leaks (bubbles...
Page 159 Mechanical Diagnosis Condition Possible Cause Remedy Battery is not recharging Loose alternator belt Tighten belt Loose connections in electrical Check all electrical connections and system charging system Worn brushes in alternator Repair Voltage regulator faulty Replace Battery defective Replace Alternator defective Repair or replace Dirty battery terminals Clean and retighten...
Page 160: Electric Standby (Optional) Diagnosis
Electric Standby (Optional) Diagnosis Condition Possible Cause Remedy Unit turned On—Microprocessor Battery discharged Charge or replace battery display does not come on Faulty battery cable connections Clean battery cables Fuse F21 blown Check for short circuits and replace fuse Fuse F2 blown Check for short circuits and replace fuse Open circuit...
Page 161 Electric Standby (Optional) Diagnosis Condition Possible Cause Remedy Contact chatter Low battery voltage Check voltage condition. Check momentary voltage dip during starting—low voltage prevents magnet sealing Defective or incorrect coil Replace coil Poor contact in control circuit Check auxiliary switch contacts and overload relay contacts.
Page 162: Refrigeration Diagnosis
Refrigeration Diagnosis Possible Causes • • • • Overcharge of refrigerant • • • • • • Shortage of refrigerant • • • • • • No refrigerant • Air through condenser too hot (ambient) • Air flow through condenser restricted •...
Page 163 Refrigeration Diagnosis Possible Causes • • • • Restricted line on the high side • • • • Restricted drier • Defrost damper stays open • • • Defrost damper stuck closed • Suction service valve back seated • • •...
Page 164: Index
Index Design Features 21, 22 diagnosis, mechanical 155 AC components 78 diagnosis, refrigeration 161 accumulator replacement 127 discharge strainer alternator 71 test 134 field current test 74 draining water from fuel tank 95 general diagnostic and warranty evaluation procedure 72 identification 71 load test 72 ELC (Extended Life Coolant) 22...
Page 165 Index refrigerant charge 119 refrigerant gauge removal 119 glow plugs 77 refrigerant leaks 119 refrigeration diagnosis 161 refrigeration system heat exchanger 135 checks 121 heat/defrost mode 31 component locations 123 High Pressure Cutout 24 components 27 high pressure cutout switch (HPCO) 136 diagrams 28 replacement 137 refrigeration system specifications 16...
Page 166: Wiring And Schematic Diagrams Index
Wiring and Schematic Diagrams Index Dwg No. Drawing Title Page 1E28186 Schematic Diagram 167-168 1E28187 Wiring Diagram 169-173...
Page 167 Wiring and Schematic Diagrams Index...
Page 168 Schematic Diagram - Page 1 of 2...
Page 169 Schematic Diagram - Page 2 of 2...
Page 170 DETAIL C CAD GENERATED DRAWING, THERMO KING PROPRIETARY DATA DO NOT MANUALLY UPDATE THIS DOCUMENT CONTAINS PROPRIETARY Thermo King INFORMATION OF THE THERMO KING CORPORATION. IT IS TRANSMITTED TO DRAWN DATE YOU IN CONFIDENCE AND TRUST, AND TITLE DIAGRAM WIRING IS TO BE RETURNED UPON REQUEST.
Page 171 FUEL PUMP GROUND J_FP1 J_FP 8DF-01 GND-03 BLACK FUEL PUMP J_FP2 J_FP_ HARNESS GND-01 MAIN HARNESS GND_ENGINE Thermo King GND-02 SIZE CODE IDENT NO DWG NO 1E28187 F TO SHEET 4 CHPR SCALE: NONE REF DWG: SHEET 2 OF 5...
Page 172 AC MOTOR AC MOTOR AC MOTOR ONLY GRN-YEL GRN-YEL GRN-YEL 400/50 230/60 230/50 460/60 MOTOR CONNECTIONS GRN-YEL Thermo King GND3_HV SIZE CODE IDENT NO DWG NO HV COVER 1E28187 F GROUND STUD SCALE: NONE REF DWG: SHEET 3 OF 5...
Page 173 J_FM J_FM2 REMOTE HARNESS COMMS HARNESS REMOTE TO SHEET 1 (OPTIONAL) CONNECTOR SHLD1 ASSY CH-GRN2 HARNESS CH-GRN (OPTIONAL) 2-BLU SP10 Thermo King 2-ORN 2A-BLU2 SIZE CODE IDENT NO DWG NO 1E28187 F SCALE: NONE REF DWG: SHEET 4 OF 5...
Page 174 RXD-1 TO COMMS HARNESS J_DAS_COM. 2D-1 8XP-1 RXD-1 TXD-1 CH-3 COM-1 RXD-3 TO DAS COMM HARNESS J_DAS_FM. TXD-3 COM-2 J_DAS. CHPR P_DAS_COM. Thermo King SIZE CODE IDENT NO DWG NO 1E28187 F SCALE: NONE REF DWG: SHEET 5 OF 5...
Page 175 Ingersoll Rand’s Climate Solutions sector delivers energy-efﬁ cient HVACR solutions for customers globally. Its world class brands include Thermo King, the leader in transport temperature control and Trane, a provider of energy efﬁ cient heating, ventilating and air conditioning systems, building and contracting services, parts support and advanced controls for commercial buildings and homes.

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