Thermo King UT-800 Manual
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Thermo King UT-800 Manual

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UT-800 and UT-1200
TK 55385-1-MM (Rev. 0, 05/12)
Copyright
2012 Thermo King Corp., Minneapolis, MN, U.S.A. Printed in
©
U.S.A.

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Summary of Contents for Thermo King UT-800

  • Page 1 UT-800 and UT-1200 TK 55385-1-MM (Rev. 0, 05/12) Copyright 2012 Thermo King Corp., Minneapolis, MN, U.S.A. Printed in © U.S.A.
  • Page 2 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 3 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 4 ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ 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 5: Table Of Contents

    Table of Contents List of Figures ................11 Safety Precautions .
  • Page 6 Table of Contents Starting the Diesel Engine ..............42 Starting the Electric Motor .
  • Page 7 Table of Contents Alternator Load Test ..............78 General Diagnostic and Warranty Evaluation Procedure .
  • Page 8 Table of Contents Testing the Refrigerant Charge with a Loaded Box (Quick Check) ......122 Checking Compressor Oil .
  • Page 9 Table of Contents Hot Gas Solenoid (HGS) Test ............. . 138 In-Line Check Valve Replacement .
  • Page 10 Table of Contents...

  • Page 11: List Of Figures

    Figure 4: UT-800/UT-1200 Components, Front and Side Views (Panels Removed) ....30 Figure 5: UT-800/UT-1200 Components, Rear View (Panels Removed) ......30 Figure 6: Refrigeration System Components .
  • Page 12 List of Figures Figure 59: Soft Keys ..............55 Figure 60: New Setpoint .
  • Page 13 Figure 146: + and - Keys ..............75 Figure 147: Thermo King Alternator Terminal and Component Locations ......77 Figure 148: Base Controller .
  • Page 14 List of Figures Figure 179: Fuel Solenoid Components ............107 Figure 180: Low Speed Adjustment Screw Location .

  • Page 15: 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 16: 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 17: 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 18: 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 19: 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 20 Safety Precautions...

  • Page 21: Specifications

    -13 to 104 F (-25 to 40 C): SAE 10W-40 -13 to 86 F (-25 to 30 C): SAE 10W-30 -22 to 32 F (-30 to 0 C): SAE 5W-40 Engine rpm: UT-800 Low Speed Operation 1450 ± 25 rpm UT-800 High Speed Operation 2200 ± 25 rpm UT-1200 Low Speed Operation 1625 ±...

  • Page 22: Engine Clutch

    12 volt, 65 amp, brush type, Thermo King alternator UT-1200 12 volt, 120 amp, brush type, Thermo King alternator Voltage Regulator Setting 13.8 to 14.4 volts @ 77 F (25 C) NOTE: Fuse F4 (Bypass resistor for Prestolite Alternator) must be removed for the Thermo King Alternator.

  • Page 23: Fuses

    HPCO Switch Circuit Power to CAN Connector J98 F4 Remove fuse F4 for units with Australian Bosch or Thermo King Alternators. Install fuse F4 for units with Prestolite Alternator. F10 When fuse F10 is installed in the right position the On/Off keys on the HMI turn the unit on and off. When fuse F10 is installed in the left position the unit will start and run without the HMI control panel.

  • Page 24: Evaporator Fan Motors

    Specifications Evaporator Fan Motors UTSE Evaporator: Number Used Power Rating 0.17 hp (0.12 kW) each 2860 Full Load Current Each 9.2 amps each Spectrum Evaporator (2 evaps used): Number Used 6 (3 per evaporator unit) Power Rating 0.13 hp (0.09 kW) each 2450 Full Load Current Each 7.0 amps/motor...

  • Page 25: Maintenance Inspection Schedule

    Maintenance Inspection Schedule Pretrip Annual Inspect/Service These Items Hours 2,000 Hours Microprocessor • Run pretrip test (see “Pretrip Test” in Operating Instructions Chapter). TK 376U Engine • Check fuel supply. • Check engine oil level. • • • Check engine coolant level. (CAUTION: Do not remove radiator cap while coolant is hot.) •...
  • Page 26 Maintenance Inspection Schedule Pretrip Annual Inspect/Service These Items Hours 2,000 Hours Electrical • Check controller for alarms. • Run pretrip test • Check battery voltage. • • Inspect/clean battery terminals and check electrolyte level. • • Inspect wire harness for damaged wires or connections. •...

  • Page 27: Unit Description

    • Unit Self Check-pretripping • Air Cleaner, Dry Type • Alternator, 65 amp for UT-800, 120 Amp for UT-1200 • Automatic Phase Correction (Model 50) • Bypass Oil Filter Figure 1: Standard HMI Control Panel •...

  • Page 28: Mechanics Hmi Control Panel

    Unit Description Mechanics HMI Control Panel The system monitors and maintains the compartment temperature, the engine block The Mechanics HMI Control Panel is available as temperature, and battery charge levels at a point a hand held diagnostic tool. It is used on units where quick, easy starts are possible.

  • Page 29: Unit Component Identification

    The relay resets when the alarm code is cleared. Unit Component Identification Figure 3: Front View (UT-1200 Shown, UT-800 Similar)

  • Page 30: Figure 4: Ut-800/Ut-1200 Components, Front And Side Views (Panels Removed)

    Receiver Tank Control Box Filter/Drier Electric Standby Power Receptacle Fuel Filter/Water Separator Microprocessor Power Switch Figure 4: UT-800/UT-1200 Components, Front and Side Views (Panels Removed) AMA756 Compressor Pulley Engine Clutch Electric Motor Pulley Figure 5: UT-800/UT-1200 Components, Rear View (Panels Removed)

  • Page 31: Refrigeration System Components

    Unit Description Refrigeration System Throttling Valve Components This component is a mechanical control device used to limit the suction pressure to the The refrigeration system in these units does compressor. not have a three-way valve. Instead, it uses a condenser inlet solenoid (CIS) and a hot gas Condenser Check Valve solenoid similar to multi-temp units.
  • Page 32 Unit Description Suction Pressure Transducer This transducer supplies the suction pressure at the compressor to the microprocessor. This information is used by the microprocessor and software to determine the unit operating conditions.

  • Page 33: Refrigeration System Diagrams

    Unit Description Refrigeration System Diagrams These diagrams show a nosemount unit. The undermount unit is basically the same except the The following pages show the refrigeration condenser and evaporators are separate system and examples of the refrigerant flow in the assemblies connected by refrigeration lines.

  • Page 34: 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. Liquid Injection Solenoid (LIS)-Closed/ through the open CIS to the condenser where the De-energized but the microprocessor will refrigerant releases heat and condenses into high open it if necessary to control compressor...

  • Page 35: 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. Liquid Injection Solenoid (LIS)-Closed/ accumulator when the unit shifts from Cool (or De-energized but the microprocessor will Null) to Heat or Defrost.

  • Page 36: 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 37: 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 38 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 39: 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 40 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 41: 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 42: 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 43: 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-3 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 44: 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 45: Selecting The High Speed Lock-Out Feature

    Operating Instructions for Standard HMI Control Panel amber LED indictor will glow. If the unit is IMPORTANT: HIGH SPEED LOCKOUT 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 46: 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 47: 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 48: 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 49: 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 50: 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 51: Operating Instructions For Premium Hmi Control Panel

    Operating Instructions for Premium HMI Control Panel SR-3 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-3 Truck applications.

  • Page 52: 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 53: 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 54: 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 55: 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 56: 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 57: Switching From Electric To Diesel

    Operating Instructions for Premium HMI Control Panel Switching from Electric to Diesel Units equipped with the Electric Standby option only. If the Electric to Diesel Autoswitch Enabled Figure 70: Display is YES is selected feature in Guarded Access is set YES then the unit will automatically switch to Diesel Mode If unit operation is required the diesel engine will operation when standby power is turned off or is...

  • Page 58: Terminating A Defrost Cycle

    Operating Instructions for Premium HMI Control Panel Figure 73: Defrost Display Figure 74: High Speed Lockout Key The display will briefly show [PROGRAMMING Terminating a Defrost Cycle HIGH SPEED LOCKOUT - PLEASE WAIT]. The defrost cycle terminates automatically when the coil temperature is greater than or equal to 52 F (11 C) or the defrost timer expires.

  • Page 59: Selecting Cycle-Sentry Or Continuous Mode

    OK or LOW. Continuous Mode Oil Pressure - Displays the engine oil pressure as With Thermo King Truck unit applications, OK or LOW. CYCLE-SENTRY Mode or Continuous Mode operation is selected from the Main Menu - Mode Oil Level - Displays the engine oil level as OK or Submenu.

  • Page 60: Using The Sensors Key

    Operating Instructions for Premium HMI Control Panel • Purge Valve Data Logger Sensor 1 Temperature - Display the temperature of Data Logger Sensor 1. Using the Sensors Key Data Logger Sensor 2 Temperature - Display the temperature of Data Logger Sensor 2. The SENSORS key allows the operator to view the temperatures read by the unit temperature Data Logger Sensor 3 Temperature - Display the...

  • Page 61: Main Menu Choices

    Operating Instructions for Premium HMI Control Panel Main Menu Choices the operator to manually select electric mode operation. This feature does not appear if the unit LANGUAGE - If more than one language is does not feature optional Electric Standby or if the enabled, this will be the first menu item to appear.

  • Page 62: Figure 84: Menu Key

    Operating Instructions for Premium HMI Control Panel • Languages currently supported by software The new language is confirmed, and then the revision 67xx are English, Japanese and Standard Display will appear in the new language Chinese. Other than the languages supported, as shown in Figure 88.

  • Page 63: Alarms

    When the unit is turned on the display will show • The remote indicator alarm light (if installed) the Thermo King Logo and then the “Configuring will display only a row of LEDs at the bottom. System” message. If log alarm(s) are present the...

  • Page 64: Figure 92: Alarm Icon

    • If the alarm does not reoccur during the timed running interval with reduced performance, The Alarm Icon used in previous Thermo King the unit will return to full performance to controllers has been incorporated. If a Check determine if continued operation is possible.

  • Page 65: Figure 93: Menu Key

    Operating Instructions for Premium HMI Control Panel • Alarm Code 92 Sensor Grades Not Set - If alarms are present, the quantity of alarms (if Clears when the sensor grade is changed from more than one) and the most recent alarm code number will be shown.

  • Page 66: Datalogger

    Operating Instructions for Premium HMI Control Panel To select a different Main Menu item press the NEXT key. To return to the Standard Display press the EXIT key. Important Alarm Notes • If an alarm will not clear, it may still exist. If the alarm is not corrected, it will not clear or Figure 100: Select Key may be immediately set again.

  • Page 67: Mode

    Operating Instructions for Premium HMI Control Panel User Programmable - The Total Run Reminder 2: number of hours before a Total Unit Run Time Maintenance Reminder 2 occurs. Total hours the controller Controller Power On: and HMI control panel have been turned on. User Programmable - number Pretrip Reminder : Figure 103: Menu Key...

  • Page 68: Selecting Cycle-Sentry Or Continuous Mode

    Operating Instructions for Premium HMI Control Panel Start Sleep Mode If enabled in Guarded Access, Sleep Mode is used to keep the engine warm and the battery charged when the unit is not in use. When the unit is in Sleep Mode the display will show “SLEEP”...

  • Page 69: Selecting Sleep Mode

    Operating Instructions for Premium HMI Control Panel The Turn Off/Turn On CYCLE-SENTRY screen will appear. In the display shown below, the unit is operating in CYCLE-SENTRY mode. Turning CYCLE-SENTRY mode off will result in the unit running in Continuous mode. Figure 115: Mode Menu IMPORTANT: If the unit is in CYCLE-SENTRY null and the mode is switched to Continuous...

  • Page 70: Figure 117: Select Key

    Operating Instructions for Premium HMI Control Panel The Language Menu or Alarm Menu will appear. Press the NEXT key as required to show the Mode Menu. When the Mode Menu is shown press the SELECT key. Figure 121: Sleep Mode Display To enter a Wake-up Time, verify the unit clock is set properly.

  • Page 71: Pretrip

    Operating Instructions for Premium HMI Control Panel the unit shut down a Full Pretrip Test with device amp checks will be performed. If the Pretrip Test is entered with the unit running in either diesel or electric mode a Running Pretrip Test is performed, but the device amps checks are not performed.

  • Page 72: Figure 128: Menu Key

    Operating Instructions for Premium HMI Control Panel • RPM Check - The engine RPM in high and • To stop a Pretrip Test at any time, turn the unit low speed is checked during the Cool Check. off. Alarm Code 28 Pretrip Abort will be set. Other alarms may also be set, depending upon •...

  • Page 73: 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 74: 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 75: 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 76 Operating Instructions for Premium HMI Control Panel...

  • Page 77: 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 78: 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 79 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 80: 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 81: Fuses

    Light/Optional Power) Main Fuse (2 Circuit) Alternator Sense 7.5A HPCO/Run Circuit Power to CAN Connector J98 F4 Remove fuse F4 for units with Australian Bosch or Thermo King Alternators. Install fuse F4 for units with Prestolite Alternator. Figure 148: Base Controller...

  • Page 82: Base Controller Leds

    Electrical Maintenance Base Controller LEDs condition occurs, the Smart FET will turn off until the over-current condition no longer exists. It will The base controller has LEDs that indicate which then resume normal operation. A fuse is not outputs are energized. The LED is illuminated required.

  • Page 83: Glow Plugs

    Electrical Maintenance Testing the Flywheel (RPM) Sensor: 5. Reconnect the FS1 and FS2 wires to the sensor. The following equipment is required: If the flywheel sensor passes the above test, the • AC voltmeter capable of reading up to 10 sensor may be considered good.

  • Page 84: Unit Wiring

    Electrical Maintenance NOTE: The cylinder head cover must be cloth or paper away from the grille. To correct removed to access the glow plugs. incorrect rotation, check the motor and motor contactor wiring per the unit wiring diagram. A shorted glow plug will show excessive current draw (more than 13 amps) during preheat, and Phase Select Module for Truck Unit may cause fuse F5 (40 A) to blow.
  • Page 85 Electrical Maintenance If phase orientation is L1, L2, L3 the 7EB wire Outputs will output voltage to energize the appropriate Output Description phase rotation contactor MCA. If phase orientation is L1, L3, L2 the 7EC wire will output If phase orientation is L1, L2, L3 then this wire will provide 12 volts DC to energize voltage to energize the appropriate phase rotation the appropriate phase rotation contactor...

  • Page 86: Overload Relay

    Electrical Maintenance 5. Disconnect the three wires from the phase 3. Check the 8 circuit to the phase select module select module at the motor contactor. for 12 Vdc. If voltage is not present, check the phase select module connector and the 6.

  • Page 87: Figure 154: Open Cover

    Electrical Maintenance Overload Relay Replacement When the overload relay is replaced, the new overload relay must be set up to open at the correct amperage and reset automatically. See the following procedure to set up a new overload relay. 1. Open the clear plastic cover. Set Opening Amperage Remove Tab Between “H”...
  • Page 88 Electrical Maintenance...

  • Page 89: Engine Maintenance

    NOTE: Units equipped with the EMI 2000 the crankcase. package do require regular inspection in accordance with Thermo King's maintenance Add oil as necessary to reach the full mark. See the “Specifications” chapter of this manual for recommendations.

  • Page 90: Oil Filter Change

    Remove the The oil filters should be changed along with the breather cover and the baffle plate and check to engine oil. Use genuine Thermo King extended make sure nothing is plugged or damaged. maintenance oil filters.

  • Page 91: Engine Air Cleaner (Emi 2000)

    Engine Maintenance Engine Air Cleaner (EMI 2000) The EMI 2000 air cleaner used with this unit is a dry element air cleaner. The air cleaner filters all of the air entering the engine. Excessive restriction of the air intake system affects horsepower, fuel consumption and engine life.

  • Page 92: 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 93: Elc (Extended Life Coolant)

    (Extended Life Coolant)” for more information about ELC. The following are the Extended Life Coolants currently approved by Thermo King for use in The factory recommends the use of a 50/50 ELC units for five years or 12,000 hours: percent antifreeze mixture in all units even if they are not exposed to freezing temperatures.

  • Page 94: Bleeding Air From The Cooling System

    Engine Maintenance Bleeding Air from the Cooling Changing the Antifreeze 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 95: Engine Thermostat

    Engine Maintenance 4. Fill the coolant expansion tank to the full WARNING: Failure to follow this mark. Then fill the overflow portion of the procedure can result in engine damage. tank to the full cold level. Air trapped in the engine block and head can create localized hot spots that can 5.

  • Page 96: Engine Fuel System

    TK376 Overhaul Manual TK 53163 for injection • Electric Fuel pump nozzle testing and repair procedures. • Fuel filter Thermo King recommends that any major • Injection pump injection pump or nozzle repairs be done by a quality diesel injection service specialty shop. The •...

  • Page 97: Figure 166: Injection Pump

    Engine Maintenance Injector Line Bleeder Screw Figure 166: Injection Pump 2. Turn on the electric fuel pump. The electric fuel pump is energized when the key is pushed. Tighten the bleeder screw on the injection pump when clear flow of fuel appears.

  • Page 98: Figure 167: Fuel Components

    Engine Maintenance Figure 167: Fuel Components...

  • Page 99: Draining Water From Fuel Tank

    Engine Maintenance HEAD - filter 13. HOSE - fuel (3/8 x 35 ft) SPUD - filter 14. JOINT - fuel SHAFT - water bleed 15. JOINT - fuel FILTER - fuel 16. PUMP - fuel injection HOSE - fuel (1/4 od x 35 ft lg) 17.

  • Page 100: Electric Fuel Pump

    Engine Maintenance Electric Fuel Pump Operation The electric fuel pump must be mounted next to the fuel tank. This pump is designed to push rather than pull fuel. Make sure the harness plug black wire pin completes a good ground with the battery. Check the voltage at the red wire pin of the harness plug.

  • Page 101: Injection Pump Timing

    Engine Maintenance Injection Pump Timing 2. Remove the delivery valve spring for the number 1 cylinder by removing the delivery This is the only timing procedure for this engine. valve holder and the delivery valve spring, It is not necessary to check the individual cylinder and then reinstalling the delivery valve holder timing.

  • Page 102: Figure 171: Injection Pump

    Engine Maintenance 6. Energize the fuel solenoid and the fuel pump by turning the unit On (or using the Service Test Mode, see the appropriate Microprocessor Diagnostic Manual). 7. Rotate the engine backwards (counterclockwise viewed from the water pump end) until the injection timing mark is positioned about 1.0 in.

  • Page 103: Injection Pump Removal And Installation

    Engine Maintenance Injection Pump Removal and 2. Remove the throttle linkage, fuel lines, wire Installation harness, and mounting hardware from the injection pump. Injection Pump Removal 3. Remove the injection pump timing cover from 1. Note the alignment of the index marks on the the gear case.

  • Page 104: Figure 175: Injection Pump Removal And Installation

    Engine Maintenance 4. Secure the injection pump gear to the injection 5. Install the injection pump timing cover on the pump shaft with the lock washer and gear case cover, and reinstall all components mounting nut. Use a shop rag, as before, to removed previously to facilitate the injection prevent the lock washer or nut from falling pump removal.

  • Page 105: 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 106: Figure 178: Fuel Solenoid Connector Pin Identification

    Engine Maintenance 5. If the fuel solenoid is not operating properly, 9. Test the hold-in coil. check the run relay (K1), the fuel solenoid pull a. Energize the hold-in coil by placing a in relay (K6), their fuses, and the associated jumper between the red wire (8D—pin A) circuits.

  • Page 107: Engine Speed Adjustments

    2. Check the operation of the electric fuel pump. and check the engine speed. The engine speed 3. Bleed the air out of the fuel system. Recheck should be 2200 ± 25 rpm for the UT-800, or the speed. 2425 ± 25 rpm for the UT-1200.

  • Page 108: Figure 181: High Speed Solenoid Components

    Engine Maintenance BRACKET - solenoid/engine mount LOCKWASHER SOLENOID 10. ADJUSTER - speed control PLUNGER - solenoid NUT (1/4-28 LH thread) BOOT - solenoid 12. BALL JOINT NUT - solenoid 13. LINK - throttle DIODE 14. LOCKWASHER ROD - throttle 15. NUT Figure 181: High Speed Solenoid Components...

  • Page 109: Adjust Engine Valve Clearance

    Engine Maintenance Adjust Engine Valve Clearance The valve clearance should be checked after every 2000 operating hours, maximum. It is important that valves be adjusted to the correct specifications for satisfactory engine operation. Insufficient valve clearance will result in compression loss and misfiring of cylinders resulting in burned valves and seats.

  • Page 110: Figure 184: Valve Clearance

    Engine Maintenance c. If the rocker arms are loose, the engine is 6. Recheck the valve clearance. at top dead center of the compression 7. Place the engine at top dead center of the stroke for the number 1 cylinder. compression stroke for the number 3 cylinder.

  • Page 111: Restraining Mount Adjustment

    Engine Maintenance Restraining Mount Adjustment Gauge (P/N 204-427). Set belt tension to a reading of 75 ± 5. Recheck restraining mount Install belts and remove slack. After belt tension alignment using a straight edge. has been set (no slack). Check seating in pulleys. Then proceed to tighten locknut (#2) to compress the mount until the top of mount is in the same plane as the gauge brackets (#20).

  • Page 112: Figure 187: Chain/Restraining Mount Bracket

    Engine Maintenance Screw (5/16-18 SS); Flatwasher (5/16); Screw (3/8-16 SS); Flatwasher (3/8); Nylock Nut (5/16-18 SS) Nylock Nut (3/8-16 SS) Vibration Mount 3-Link Chain Mount Frame Bracket This End Through Existing Hole In Engine Flange Figure 187: Chain/Restraining Mount Bracket...

  • Page 113: Belts

    Engine Maintenance Belts Compressor/Electric Motor Belt 1. Loosen the idler mounting nut. Belts should be regularly inspected during unit pre-trip inspections for wear, scuffing or cracking, 2. Turn the idler adjuster to obtain a tension of and belt tension. Belts that are too loose will 75 ±...

  • Page 114: Electric Motor/Alternator Belt

    Engine Maintenance Electric Motor/Alternator Belt Water Pump/Engine Belt 1. Remove the lower condenser panel to access The water pump pulley is a split type. Adjust the the alternator. tension by adding or removing shims between the pulley sheaves to obtain a reading of 40 on the TK 2.

  • Page 115: Refrigeration Service Procedures

    See the diagram of the Thermo King Evacuation Moisture in the system will produce acid and Station (Figure 191 on page 116) and note the other contaminants that lead to compressor location of the valves and other components.

  • Page 116: Figure 191: Evacuation Station

    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 191: Evacuation Station...

  • Page 117: Figure 192: Vacuum Gauge

    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 192: 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: Unit Evacuation

    Refrigeration Service Procedures 3. The Maintenance Menu Hourmeters will 4. Mid-seat the receiver tank outlet valve and appear. Press the NEXT key as required to suction service valve, and install the valve show Evacuation Test. When the Evacuation stem caps. Test is shown press the SELECT key.

  • Page 120: Unit Charging

    Refrigeration Service Procedures Moisture Leak Isolate the pump from the system by closing the Should the needle show a pressure rise but proper valve. Watch the movement of the vacuum finally level off to practically a constant mark, gauge needle. If the needle continues to rise, this is an indication that the system is vacuum this is an indication that a leak exists in the unit tight but is still too wet, requiring additional...

  • Page 121: Refrigerant Gauge Removal

    Refrigeration Service Procedures Final System Charge 6. Run the unit until a 3 to 5 psig (21 to 35 kPa) reading is obtained on the suction gauge, then 1. Install a gauge manifold set on the suction back seat the suction service valve. service valve and the discharge port of the scroll compressor.

  • Page 122: Testing The Refrigerant Charge With A Loaded Box (Quick Check)

    Refrigeration Service Procedures 5. The suction pressure gauge should be CAUTION: Oil is under pressure. See indicating 12 to 20 psig (83 to 138 kPa) gauge instructions for adding oil. pressure. 6. Under these conditions, the ball in the receiver tank sight glass should be floating.

  • Page 123: Low Side Pump Down

    Refrigeration Service Procedures accumulator inlet. Low loss fittings must be • If the low side pressure rises to 0 psig used on the hoses connected to the discharge (0 kPa) and stops, there is probably a leak service port and the suction access port. to the atmosphere.

  • Page 124: R404A

    5. Prepare to perform service on the low side by raising the low side pressure through the Thermo King Corporation has chosen to use a gauge manifold to 1 to 2 psig (7 to 14 kPa). compressor oil called Polyol Ester (POE)—also called ester based oil.

  • Page 125: Refrigerant Recovery

    Pumps used with other Thermo King refrigerants may be used but extreme care should be taken to 2. Unsolder the inlet and outlet refrigerant prevent contamination of R404A systems with suction lines from the accumulator tank.

  • Page 126: Compressor Replacement

    Refrigeration Service Procedures compressor is probably faulty if it cannot raise 9. Operate the unit at least 30 minutes and then the head pressure by 100 psig (689 kPa) or to inspect the oil level in the compressor. Add or 375 psig (2586 kPa).

  • Page 127: Figure 200: Compressor Components

    Refrigeration Service Procedures AMA420 Throttling Valve Shaft Seal Assembly Suction Service Valve Pulley Oil Filter (under Oil Filter Cover Plate) Oil Filter Cover Plate High Temperature Cutout Switch 10. Schraeder Valve Low Pressure Cut Out Oil Drain Cap 12. Pilot Solenoid ORS Fitting Figure 200: Compressor Components...

  • Page 128: Compressor Shaft Seal Change Procedure

    Thermo King recommends changing the compressor shaft seal when there is a major system interruption, such as component replacement or total loss of refrigerant charge. When the shaft seal is changed, Thermo King also recommends changing the compressor oil and oil filter. AGA576...

  • Page 129: Figure 203: Bellows Installation With Tool

    Refrigeration Service Procedures 13. Use seal installation tool (P/N 204-995) to NOTE: The following illustration shows the seal install the bellows squarely on the shaft. Clean installation tool being used on a reciprocating the seal installation tool and place it on the compressor seal cover.

  • Page 130: Compressor Oil Filter Replacement

    Measure amount of interruption, such as component replacement or oil drained from compressor. total loss of refrigerant charge. When the oil filter is changed, Thermo King also recommends 4. Remove two screws and oil drain cap from changing the oil. compressor.

  • Page 131: Compressor Temperature Sensor Testing

    Replacement the purge check valve. NOTE: Thermo King recommends changing the 1. Attach a gauge manifold to the suction service compressor temperature sensor whenever the valve and the discharge service port. Attach...

  • Page 132: Condenser Inlet Solenoid (Cis) Test

    Refrigeration Service Procedures 7. Use the Mechanics/Premium HMI Control accumulator inlet. Low loss fittings must be Panel to enter the Interface Board Test Mode. used on the hoses connected to the discharge Refer to the appropriate Microprocessor service port and the suction access port. Diagnostic Manual for specific information 2.

  • Page 133: Condenser/Radiator Coil Replacement

    Refrigeration Service Procedures 1. Connect a high pressure gauge to the 6. Connect the coolant hoses to the radiator and discharge service port to monitor the refill the engine cooling system with the 50/50 discharge pressure. antifreeze/water solution. 2. Start the unit while watching the discharge 7.

  • Page 134: Discharge Pressure Regulator (Dpr) Replacement

    Refrigeration Service Procedures 3. Check the discharge pressure on the gauge The discharge pressure transducer supplies attached to the discharge service port. It pressure information to the SR-3 Microprocessor should be within the range shown for the DPR Control System. Alarm Code 86 (Check setting in the “Specifications”...

  • Page 135: Discharge Strainer Replacement

    Refrigeration Service Procedures Evaporator Coil Replacement 2. Start the unit while watching the discharge pressure. (URDE Only) • If the unit stops before the discharge Removal pressure rises at all, it is more likely to be a plugged discharge strainer. 1.

  • Page 136: Installation

    Refrigeration Service Procedures 2. Remove the feeler bulb from the suction line 6. If no leaks are found, replace the liquid line clamp. Note the position of the feeler bulb on drier then evacuate the low side. the suction line. 7.

  • Page 137: High Pressure Cutout Switch (Hpco) Test

    Refrigeration Service Procedures High Pressure Cutout Switch NOTE: The discharge pressure should never be allowed to exceed a pressure of 477 psig (HPCO) Test (3289 kPa) on R-404A systems. The HPCO is located on the discharge line. If the 4. If the HPCO opens too soon or does not open discharge pressure rises above 470 ±...

  • Page 138: Hot Gas Solenoid (Hgs) Test

    Refrigeration Service Procedures 4. If no leaks are found, replace the liquid line slightly. If the low side pressure does not rise, drier then evacuate the system. the HGS is not opening. Check the continuity of the wiring and the solenoid coil before 5.

  • Page 139: Liquid Injection Solenoid (Lis) Test

    Refrigeration Service Procedures 4. Solder the inlet and outlet connections. the LIS is not opening. Check the continuity of the wiring and the solenoid coil before 5. Pressurize the refrigeration system and test for assuming the solenoid is faulty. leaks. 10.

  • Page 140: Receiver Tank Pressure Check Valve Test

    Refrigeration Service Procedures 3. Front seat the receiver tank outlet valve and CAUTION: Do not run scroll compressor allow the low side to pump down to 0 to 5 in. in a vacuum for more than 1 minute. Hg vacuum (0 to -17 kPa). 4.

  • Page 141: Solenoid Valve Replacement

    Refrigeration Service Procedures 4. Tighten the receiver tank mounting hardware 2. Operate the unit in high speed heat until the securely. system pressures stabilize. 5. Pressurize the system and test for leaks. 3. Check the suction pressure on the gauge attached to the suction service port.
  • Page 142 Refrigeration Service Procedures...

  • 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 209: Front View and Cross Section...

  • Page 144: Figure 210: Centrifugal Clutch

    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 210: 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 213: Bushing Removal 8. Remove inner race of roller bearing from the housing shaft. Figure 214: 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: Figure 215: Clutch

    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 Clutch Maintenance...

  • Page 149: Structural Maintenance

    Structural Maintenance Unit Inspection Condenser, Evaporator and Radiator Coils Inspect the unit daily for loose or broken wires or hardware, engine or compressor oil leaks, loose or Clean the coils during scheduled maintenance damaged belts, or other physical damage which inspections.
  • Page 150 Structural Maintenance...

  • Page 151: 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 152 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 153 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 154 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 155: Electric Standby Diagnosis

    Electric Standby 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 156 Electric Standby 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 157: 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 158 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 159: Index

    Index discharge pressure regulator (DPR) replacement 134 AC components 84 test 133 accumulator replacement 125 discharge pressure transducer alternator 77 replacement 134 field current test 80 testing 134 general diagnostic and warranty evaluation discharge strainer procedure 78 test 134, 135 identification 77 draining water from fuel tank 99 load test 78...
  • Page 160 Index refrigeration system checks 122 heat exchanger 136 components 31 heat/defrost mode 36 diagrams 33 high pressure cutout 28 refrigeration system specifications 22 high pressure cutout switch (HPCO) 137 restraining mount adjustment 111 replacement 137 high pressure relief valve replacement 137 hot gas solenoid (HGS) safety precautions 15 test 138...

  • Page 161: Wiring And Schematic Diagrams Index

    Wiring and Schematic Diagrams Index Dwg No. Drawing Title Page 1E59997 Schematic Diagram 163-164 1E59998 Wiring Diagram 165-169...
  • Page 162 Wiring and Schematic Diagrams Index...
  • Page 163 Schematic Diagram - Page 1 of 2...
  • Page 164 Schematic Diagram - Page 2 of 2...
  • Page 165 Wiring Diagram - Page 1 of 5...
  • Page 166 Wiring Diagram - Page 2 of 5...
  • Page 167 Wiring Diagram - Page 3 of 5...
  • Page 168 Wiring Diagram - Page 4 of 5...
  • Page 169 Wiring Diagram - Page 5 of 5...

This manual is also suitable for:

Ut-1200

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