Trane Technologies Thermo King Advancer A360 Maintenance Manual
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Trane Technologies Thermo King Advancer A360 Maintenance Manual

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Maintenance Manual
Trailer Edition
A360
Single Temperature Units
Revision A
November 2020
T T K K 6 6 1 1 7 7 5 5 3 3 - - 2 2 - - M M M M - - E E N N

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Summary of Contents for Trane Technologies Thermo King Advancer A360

  • Page 1 Maintenance Manual Trailer Edition A360 Single Temperature Units Revision A November 2020 T T K K 6 6 1 1 7 7 5 5 3 3 - - 2 2 - - M M M M - - E E N N...
  • Page 2 At Thermo King®, we recognize the need to preserve the environment and limit the potential harm to the ozone layer that can result from allowing refrigerant to escape into the atmosphere. We strictly adhere to a policy that promotes the recovery and limits the loss of refrigerant into the atmosphere. ©2020 Trane Technologies TK 61753-2-MM-EN...
  • Page 3 I I n n t t r r o o d d u u c c t t i i o o n n When working on transport temperature control systems, a recovery process that prevents or minimizes refrigerant loss to the atmosphere is required by law. In addition, service personnel must be aware of the appropriate European Union, National, Federal, State, and/or Local regulations governing the use of refrigerants and certification of technicians.

  • Page 4: Table Of Contents

    Table of Contents S S a a f f e e t t y y P P r r e e c c a a u u t t i i o o n n s s ................................1 1 0 0 Danger, Warning, Caution, and Notice .
  • Page 5 T T a a b b l l e e o o f f C C o o n n t t e e n n t t s s Battery Load Test ................43 Battery Cables .
  • Page 6 T T a a b b l l e e o o f f C C o o n n t t e e n n t t s s Injection Pump Removal ..............79 Injection Pump Reinstallation .
  • Page 7 T T a a b b l l e e o o f f C C o o n n t t e e n n t t s s Removal................. . 110 Installation .
  • Page 8 T T a a b b l l e e o o f f C C o o n n t t e e n n t t s s Installation ................123 High Pressure Relief Valve .
  • Page 9 T T a a b b l l e e o o f f C C o o n n t t e e n n t t s s R R e e f f r r i i g g e e r r a a t t i i o o n n D D i i a a g g n n o o s s i i s s ............................. . 1 1 4 4 8 8 R R e e f f r r i i g g e e r r a a t t i i o o n n D D i i a a g g r r a a m m s s .

  • Page 10: Danger, Warning, Caution, And Notice

    Safety Precautions Danger, Warning, Caution, and Notice Thermo King® recommends that all service be performed by a Thermo King dealer and to be aware of several general safety practices. Safety advisories appear throughout this manual as required (refer to examples below). Your personal safety and the proper operation of this unit depend upon the strict observance of these precautions.

  • Page 11: Battery Installation And Cable Routing

    S S a a f f e e t t y y P P r r e e c c a a u u t t i i o o n n s s D D A A N N G G E E R R C C o o n n f f i i n n e e d d S S p p a a c c e e H H a a z z a a r r d d s s ! ! A A v v o o i i d d e e n n g g i i n n e e o o p p e e r r a a t t i i o o n n i i n n c c o o n n f f i i n n e e d d s s p p a a c c e e s s a a n n d d a a r r e e a a s s o o r r c c i i r r c c u u m m s s t t a a n n c c e e s s w w h h e e r r e e f f u u m m e e s s f f r r o o m m t t h h e e e e n n g g i i n n e e c c o o u u l l d d b b e e c c o o m m e e t t r r a a p p p p e e d d a a n n d d c c a a u u s s e e s s e e r r i i o o u u s s i i n n j j u u r r y y o o r r d d e e a a t t h h .

  • Page 12: Battery Removal

    S S a a f f e e t t y y P P r r e e c c a a u u t t i i o o n n s s W W A A R R N N I I N N G G H H a a z z a a r r d d o o f f E E x x p p l l o o s s i i o o n n ! ! I I m m p p r r o o p p e e r r l l y y i i n n s s t t a a l l l l e e d d b b a a t t t t e e r r y y c c a a b b l l e e s s c c o o u u l l d d r r e e s s u u l l t t i i n n a a f f i i r r e e , , e e x x p p l l o o s s i i o o n n , , o o r r i i n n j j u u r r y y .

  • Page 13: Refrigerant Hazards

    S S a a f f e e t t y y P P r r e e c c a a u u t t i i o o n n s s positive side and the frame simultaneously will cause sparks or arcing. If there are sufficient hydrogen gases emitted from the battery, an explosion might occur, causing equipment damage, serious injury, even death.

  • Page 14: Electrical Hazards

    S S a a f f e e t t y y P P r r e e c c a a u u t t i i o o n n s s N N O O T T I I C C E E S S y y s s t t e e m m C C o o n n t t a a m m i i n n a a t t i i o o n n ! ! D D o o n n o o t t e e x x p p o o s s e e t t h h e e r r e e f f r r i i g g e e r r a a n n t t o o i i l l t t o o t t h h e e a a i i r r a a n n y y l l o o n n g g e e r r t t h h a a n n n n e e c c e e s s s s a a r r y y .

  • Page 15: Low Voltage

    S S a a f f e e t t y y P P r r e e c c a a u u t t i i o o n n s s Low Voltage W W A A R R N N I I N N G G L L i i v v e e E E l l e e c c t t r r i i c c a a l l C C o o m m p p o o n n e e n n t t s s ! ! C C o o n n t t r r o o l l c c i i r r c c u u i i t t s s u u s s e e d d i i n n r r e e f f r r i i g g e e r r a a t t i i o o n n u u n n i i t t s s a a r r e e l l o o w w v v o o l l t t a a g g e e ( ( 1 1 2 2 t t o o 4 4 8 8 v v o o l l t t s s d d c c ) ) .

  • Page 16: First Aid

    S S a a f f e e t t y y P P r r e e c c a a u u t t i i o o n n s s First Aid R R E E F F R R I I G G E E R R A A N N T T •...

  • Page 17: Engine

    Specifications Engine Model Thermo King TK486VMGS5 (NRMM Stage V compliant) Fuel Type Diesel fuel must conform to EN590 Oil Capacity 12.3 liters/litres crankcase and oil filter Fill to full mark on dipstick Oil Type Petroleum Multi-grade Oil API Type CI-4, ACEA Class E3 Synthetic Multi-grade Oil API Type CI-4, ACEA Class E3 (after first 500 hours) Oil Viscosity (based on ambient...

  • Page 18: Belt Tension

    S S p p e e c c i i f f i i c c a a t t i i o o n n s s Belt Tension Notes: All Belt Tension Values indicated are at room temperature Belt Tension to be measured at longer span.

  • Page 19: Electrical Components

    S S p p e e c c i i f f i i c c a a t t i i o o n n s s Electrical Components Note: Disconnect components from the unit circuit to check resistance. Component Current Draw (Amperes) at Resistance (Ohms)
  • Page 20 Maintenance Inspection Schedule N N o o t t e e : : Please refer to your Advancer Operator Manual TK 61738-2-OP for Operator Weekly Checks The service technician is responsible for assessing the condition of all parts & components found during any service operation to be in a condition suitable for further operation up to the next scheduled service.

  • Page 21: M M A A I I N N T T E E N N A A N N C C E E I I N N S S P P E E C C T T I I O O N N S S C C H H E E D D U U L L E

    M M a a i i n n t t e e n n a a n n c c e e I I n n s s p p e e c c t t i i o o n n S S c c h h e e d d u u l l e e The service technician is responsible for assessing the condition of all parts &...
  • Page 22 M M a a i i n n t t e e n n a a n n c c e e I I n n s s p p e e c c t t i i o o n n S S c c h h e e d d u u l l e e The service technician is responsible for assessing the condition of all parts &...

  • Page 23: General Information

    Unit Description General Information This Thermo King A-Series unit is a one piece, self-contained, diesel/electric powered cooling/heating trailer unit. The unit mounts on the front of the trailer with the evaporator extending through an opening in the front wall. It features a fully programmable microprocessor controller designed exclusively for transport refrigeration applications, all-new DDE (Diesel Direct Electric) architecture, a quiet running Thermo King diesel engine, and a Thermo King X430 reciprocating compressor.

  • Page 24: Cycle-Sentry™ Start-Stop Controls

    U U n n i i t t D D e e s s c c r r i i p p t t i i o o n n Use the Gauges Menu to observe the ETV position during the ETV test. The expected ETV position observation is a decrease followed by an increase.

  • Page 25: Data Logging

    U U n n i i t t D D e e s s c c r r i i p p t t i i o o n n Data Logging There are two separate data loggers. The data is downloaded through one of the data ports using a flash drive or a PC and WinTrac software.

  • Page 26: Operating Modes

    U U n n i i t t D D e e s s c c r r i i p p t t i i o o n n • Display and Change Setpoint • Display and Initiate Defrost •...

  • Page 27: Defrost

    U U n n i i t t D D e e s s c c r r i i p p t t i i o o n n N N o o t t e e s s : : 1.

  • Page 28: Unit Protection Devices

    U U n n i i t t D D e e s s c c r r i i p p t t i i o o n n C C A A U U T T I I O O N N S S e e r r v v i i c c e e P P r r o o c c e e d d u u r r e e s s ! ! T T u u r r n n t t h h e e u u n n i i t t o o f f f f b b e e f f o o r r e e a a t t t t e e m m p p t t i i n n g g t t o o c c h h e e c c k k t t h h e e e e n n g g i i n n e e o o i i l l .

  • Page 29: Serial Number Locations

    U U n n i i t t D D e e s s c c r r i i p p t t i i o o n n Table 1. 12 Volt Fuses in Harness (continued) Charge Supply Starter Solenoid LPM (Low Power Module) HPM (High Power Module...

  • Page 30: Ac Generator

    Electrical Maintenance AC Generator W W A A R R N N I I N N G G H H a a z z a a r r d d o o u u s s V V o o l l t t a a g g e e ! ! T T h h e e s s e e u u n n i i t t s s u u s s e e A A C C v v o o l l t t a a g g e e f f r r o o m m t t h h e e A A C C g g e e n n e e r r a a t t o o r r f f o o r r t t h h e e A A c c t t i i v v e e r r e e c c t t i i f f i i e e r r .
  • Page 31 E E l l e e c c t t r r i i c c a a l l M M a a i i n n t t e e n n a a n n c c e e Figure 5.
  • Page 32 E E l l e e c c t t r r i i c c a a l l M M a a i i n n t t e e n n a a n n c c e e W W A A R R N N I I N N G G R R i i s s k k o o f f I I n n j j u u r r y y ! ! T T a a k k e e p p r r e e c c a a u u t t i i o o n n s s t t o o v v e e r r i i f f y y t t h h e e u u n n i i t t w w i i l l l l n n o o t t a a c c c c i i d d e e n n t t a a l l l l y y s s t t a a r r t t w w h h i i l l e e s s e e r r v v i i c c i i n n g g t t h h e e s s y y s s t t e e m m .
  • Page 33 E E l l e e c c t t r r i i c c a a l l M M a a i i n n t t e e n n a a n n c c e e 2.
  • Page 34 E E l l e e c c t t r r i i c c a a l l M M a a i i n n t t e e n n a a n n c c e e 4.
  • Page 35 E E l l e e c c t t r r i i c c a a l l M M a a i i n n t t e e n n a a n n c c e e 6.
  • Page 36 E E l l e e c c t t r r i i c c a a l l M M a a i i n n t t e e n n a a n n c c e e 7.
  • Page 37 E E l l e e c c t t r r i i c c a a l l M M a a i i n n t t e e n n a a n n c c e e 8.
  • Page 38 E E l l e e c c t t r r i i c c a a l l M M a a i i n n t t e e n n a a n n c c e e Secure front frame cross member with a podger bar.
  • Page 39 E E l l e e c c t t r r i i c c a a l l M M a a i i n n t t e e n n a a n n c c e e 10.
  • Page 40 E E l l e e c c t t r r i i c c a a l l M M a a i i n n t t e e n n a a n n c c e e 11.
  • Page 41 E E l l e e c c t t r r i i c c a a l l M M a a i i n n t t e e n n a a n n c c e e 12.
  • Page 42 E E l l e e c c t t r r i i c c a a l l M M a a i i n n t t e e n n a a n n c c e e 13.

  • Page 43: Battery

    E E l l e e c c t t r r i i c c a a l l M M a a i i n n t t e e n n a a n n c c e e 14.
  • Page 44 E E l l e e c c t t r r i i c c a a l l M M a a i i n n t t e e n n a a n n c c e e Figure 6.
  • Page 45 E E l l e e c c t t r r i i c c a a l l M M a a i i n n t t e e n n a a n n c c e e It is recommended that the battery with OCV below 12,65V is recharged before installation.

  • Page 46: Electronic Tester Setting

    E E l l e e c c t t r r i i c c a a l l M M a a i i n n t t e e n n a a n n c c e e Electronic Tester Setting 1.
  • Page 47 E E l l e e c c t t r r i i c c a a l l M M a a i i n n t t e e n n a a n n c c e e 5.

  • Page 48: Electrical Modules

    E E l l e e c c t t r r i i c c a a l l M M a a i i n n t t e e n n a a n n c c e e Electrical Modules All Advancer units contain the following modules: •...

  • Page 49: Power Distribution Module (Pdm)

    E E l l e e c c t t r r i i c c a a l l M M a a i i n n t t e e n n a a n n c c e e Power Distribution Module (PDM) The Power Distribution Module (PDM) is located under the High Power Module (HPM), and close to the HMI.
  • Page 50 E E l l e e c c t t r r i i c c a a l l M M a a i i n n t t e e n n a a n n c c e e Table 3.

  • Page 51: Power Modules

    E E l l e e c c t t r r i i c c a a l l M M a a i i n n t t e e n n a a n n c c e e Power Modules High Power Module (HPM) The High Power Module (HPM) is a part of the A-Series control system.

  • Page 52: Led Functions Power Modules

    E E l l e e c c t t r r i i c c a a l l M M a a i i n n t t e e n n a a n n c c e e Figure 8.
  • Page 53 E E l l e e c c t t r r i i c c a a l l M M a a i i n n t t e e n n a a n n c c e e Colour Function Green...

  • Page 54: A-Series Controller

    E E l l e e c c t t r r i i c c a a l l M M a a i i n n t t e e n n a a n n c c e e A-Series Controller Refer to the A-Series Trailer Single Temperature Diagnostic Manual TK 61755 for complete service information about the Controller and related components.

  • Page 55: Connecting To A Third Party Device

    E E l l e e c c t t r r i i c c a a l l M M a a i i n n t t e e n n a a n n c c e e Connecting to a Third Party Device All A–Series trailer units come equipped with dedicated device connection points for external devices.

  • Page 56: Emi 3000

    Engine Maintenance EMI 3000 EMI 3000 is an extended maintenance interval package. The EMI 3000 package consists of the following key components: • EMI 3000-Hour Cyclonic Air Cleaner Assembly and Air Cleaner Element • EMI 3000-Hour 5-Micron Fuel Filter • EMI 3000-Hour Dual Element Oil Filter (blue with white lettering) •...

  • Page 57: Engine Cooling System

    E E n n g g i i n n e e M M a a i i n n t t e e n n a a n n c c e e Figure 10. Low Oil Pressure Flow Chart Engine Cooling System The engine employs a closed, circulating type, pressurized cooling system.

  • Page 58: Extended Life Coolant (Elc)

    E E n n g g i i n n e e M M a a i i n n t t e e n n a a n n c c e e 3. Retards corrosion (acid) that can attack accumulator tanks, water tubes, radiators, and core plugs. 4.

  • Page 59: Checking The Antifreeze

    E E n n g g i i n n e e M M a a i i n n t t e e n n a a n n c c e e temperatures. This antifreeze mixture will provide the required corrosion protection and lubrication for the water pump. Checking the Antifreeze Check the solution concentration by using a temperature compensated antifreeze hydrometer or a refractometer (P/N 204-754) designed for testing antifreeze.

  • Page 60: Engine Thermostat

    E E n n g g i i n n e e M M a a i i n n t t e e n n a a n n c c e e Figure 12. Remove Plug from Water Pump Plug Verify that the amount of coolant that goes back into the system is approximately equal to the amount of coolant that came out of the system.

  • Page 61: Testing The Coolant Level Switch

    E E n n g g i i n n e e M M a a i i n n t t e e n n a a n n c c e e Figure 13. Plastic Expansion Tank Expansion Tank Coolant Level Switch Testing the Coolant Level Switch Testing the switch in the unit is accomplished by adjusting the coolant level or alternatively by removing the expansion...

  • Page 62: Operation

    E E n n g g i i n n e e M M a a i i n n t t e e n n a a n n c c e e • Fuel filter (or Primary and Secondary Fuel Filters) •...
  • Page 63 E E n n g g i i n n e e M M a a i i n n t t e e n n a a n n c c e e • Engine speed adjustments. • Injection pump timing. •...

  • Page 64: Fuel Return Line Replacement

    E E n n g g i i n n e e M M a a i i n n t t e e n n a a n n c c e e Water bleed shaft Hose (3/8 od x 35 ft lg) Fuel Fitting (Quick Connect 1/4) Fuel Filter/Water separator Banjo Joint...

  • Page 65: Draining Water From Fuel Tank

    E E n n g g i i n n e e M M a a i i n n t t e e n n a a n n c c e e 1. Loosen the bleed screw about one turn. Bleed Screw Priming Pump 2.

  • Page 66: Fuel Filter/Water Separator

    E E n n g g i i n n e e M M a a i i n n t t e e n n a a n n c c e e Install the drain plug. Fuel Filter/Water Separator The fuel filter/water separator filters the fuel, and removes water from the fuel and returns it to the fuel tank.
  • Page 67 E E n n g g i i n n e e M M a a i i n n t t e e n n a a n n c c e e N N o o t t e e : : Please refer to the A-Series Controller Diagnostic manual on how to access the Main Menu+ screen. Initial Steps before NRMM Speed Calibration 1.
  • Page 68 E E n n g g i i n n e e M M a a i i n n t t e e n n a a n n c c e e Figure 17. Component Layout - shown in high idle position (solenoid energized) Engine Throttle Throttle Linkage Adjust throttle linkage so throttle touches HS stop screw...
  • Page 69 E E n n g g i i n n e e M M a a i i n n t t e e n n a a n n c c e e 1450 RPM High Speed Calibration For unit models such as this one which have 1450 High Speed, the high speed calibration is performed manually. The technician will be required to manually adjust the 1450 (extra) high speed stop screw position in order to calibrate high speed setting.
  • Page 70 E E n n g g i i n n e e M M a a i i n n t t e e n n a a n n c c e e Table 4. High Speed Stop screw position adjustments 1.
  • Page 71 E E n n g g i i n n e e M M a a i i n n t t e e n n a a n n c c e e Figure 19. Shown in low idle position – solenoid de-energized Engine Throttle LS Stop Screw –...
  • Page 72 E E n n g g i i n n e e M M a a i i n n t t e e n n a a n n c c e e Table 5. Low Speed Stop Screw Position Adjustments 1.

  • Page 73: Injection Pump Timing

    E E n n g g i i n n e e M M a a i i n n t t e e n n a a n n c c e e Injection Pump Timing Use this timing procedure when installing a new injection pump. It is not necessary to use this timing procedure when removing and reinstalling the original injection pump.
  • Page 74 E E n n g g i i n n e e M M a a i i n n t t e e n n a a n n c c e e Index Mark on Injection Pump Existing Index Mark on Gear Case Make New Mark on Gear Case If Needed 2.
  • Page 75 E E n n g g i i n n e e M M a a i i n n t t e e n n a a n n c c e e Figure 25. Removing Injection Pump Gear Do Not Loosen or Remove These Four Bolts Remove Nut and Lock Washer 4.
  • Page 76 E E n n g g i i n n e e M M a a i i n n t t e e n n a a n n c c e e Figure 27. Injection Angle Mark Injection Angle Mark N N o o t t e e : : If you cannot read the injection angle mark, contact the Thermo King Service Department with the injection pump serial number or the engine serial number and they will provide the injection angle.
  • Page 77 E E n n g g i i n n e e M M a a i i n n t t e e n n a a n n c c e e Figure 29. Examples of Injection Pump Index Mark Alignment with Injection Angle Sticker Injection Pump Index Mark at –0.6 Degrees Injection Pump Index Mark at +1.8 Degrees 8.
  • Page 78 E E n n g g i i n n e e M M a a i i n n t t e e n n a a n n c c e e Figure 31. Align Flat Sides of Crankshaft Gear with Flat Sides of Inner Rotor in Timing Gear Cover Crankshaft Gear Oil Pump Cover Outer Rotor...

  • Page 79: Injection Pump Removal

    E E n n g g i i n n e e M M a a i i n n t t e e n n a a n n c c e e Injection Pump Removal The injection pump drive gear will not fit through the gear housing when removing the pump, the gear must be separated from the pump.

  • Page 80: Injection Pump Reinstallation

    E E n n g g i i n n e e M M a a i i n n t t e e n n a a n n c c e e 5. Align the threaded holes in the injection pump gear with the two holes in the tool plate by rotating the engine crankshaft.

  • Page 81: Fuel Solenoid

    E E n n g g i i n n e e M M a a i i n n t t e e n n a a n n c c e e Fuel Solenoid The fuel solenoid is located on the end of the injection pump. It contains two coils: the pull-in coil, and the hold-in coil. The pull-in coil draws approximately 35 to 45 amps at 12 volts.
  • Page 82 E E n n g g i i n n e e M M a a i i n n t t e e n n a a n n c c e e d. If the resistance is out of specifications, proceed to “Fuel Solenoid Replacement” (below). If the resistance is OK, continue to step 4.

  • Page 83: Fuel Solenoid Replacement

    E E n n g g i i n n e e M M a a i i n n t t e e n n a a n n c c e e -18 C 30.4 Amps 37.2 Amps 25 F -4 C 28.7 Amps...

  • Page 84: Engine Valve Clearance Adjustment

    E E n n g g i i n n e e M M a a i i n n t t e e n n a a n n c c e e Fuel Solenoid O-ring Groove in Fuel Injection Pump 8.

  • Page 85: Crankcase Breather

    E E n n g g i i n n e e M M a a i i n n t t e e n n a a n n c c e e Figure 39. Adjusting the Valve Clearance Hold the adjustment screw in place and tighten the locknut.

  • Page 86: Emi 3000 Air Cleaner

    E E n n g g i i n n e e M M a a i i n n t t e e n n a a n n c c e e Figure 40. Crankcase Breather Breather Hose Baffle Breather Insulation Baffle Plate...

  • Page 87: Belts

    E E n n g g i i n n e e M M a a i i n n t t e e n n a a n n c c e e Figure 41. EMI 3000 Air Cleaner Assembly Figure 42.

  • Page 88: Ac Generator Belt

    E E n n g g i i n n e e M M a a i i n n t t e e n n a a n n c c e e Figure 43. Drive Belt Arrangement Combined standby motor and generator Compressor Clutch Bracket Drive End Drive Belt...

  • Page 89: Installation Of Belt, Pulley And Tensioner

    E E n n g g i i n n e e M M a a i i n n t t e e n n a a n n c c e e Please refer to (“AC Generator Repair,” p. 30) for the procedure for removal and replacement of the AC Generator Belt.

  • Page 90: Pulley Alignment Check After Belt Replacement

    E E n n g g i i n n e e M M a a i i n n t t e e n n a a n n c c e e • Once the required frequency is set, tighten the M10x1.5 bolts (Qty:02) on the back of the sliding idler. Pulley Alignment Check after Belt Replacement Alignment needs to be checked using a Laser Alignment tool developed by Thermoking.

  • Page 91: Bearing/Idler Assembly Replacement

    E E n n g g i i n n e e M M a a i i n n t t e e n n a a n n c c e e Compressor Flange Clutch Pulley (Fixed Position) Emitter Block Laser Receiver Block...

  • Page 92: Tensioner Assembly Replacement

    E E n n g g i i n n e e M M a a i i n n t t e e n n a a n n c c e e Tensioner Assembly Replacement 1. Release the Tension on the belt by loosening the Lock Plate Fastener and Tensioning Bolt. Bolt need not be fully removed.
  • Page 93 E E n n g g i i n n e e M M a a i i n n t t e e n n a a n n c c e e W W A A R R N N I I N N G G R R i i s s k k o o f f I I n n j j u u r r y y ! ! T T h h e e u u n n i i t t c c a a n n s s t t a a r r t t a a t t a a n n y y t t i i m m e e w w i i t t h h o o u u t t w w a a r r n n i i n n g g .

  • Page 94: Refrigerant Charge

    Refrigeration Maintenance N N o o t t e e : : Some of the following service procedures are regulated by EU regulation known as "F-Gas" and /or local laws. All regulated refrigeration service procedures must be performed by a certified technician, using approved equipment and complying with all EU and local laws.

  • Page 95: Testing For An Overcharge

    R R e e f f r r i i g g e e r r a a t t i i o o n n M M a a i i n n t t e e n n a a n n c c e e Testing for an Overcharge Use the following procedure to identify a Thermo King unit with an excessive refrigerant charge: 1.

  • Page 96: Moisture Indicating Sight Glass

    R R e e f f r r i i g g e e r r a a t t i i o o n n M M a a i i n n t t e e n n a a n n c c e e Moisture Indicating Sight Glass The receiver tank is equipped with a moisture indicating sight glass.

  • Page 97: High Pressure Cutout Switch (Hpco)

    R R e e f f r r i i g g e e r r a a t t i i o o n n M M a a i i n n t t e e n n a a n n c c e e Sight Glass C C h h e e c c k k C C o o m m p p r r e e s s s s o o r r O O i i l l L L e e v v e e l l - - A A m m b b i i e e n n t t A A i i r r T T e e m m p p A A b b o o v v e e 1 1 0 0 C C ( ( 5 5 0 0 F F ) ) 1.

  • Page 98: Three-Way Valve Condenser Pressure Bypass Check Valve

    R R e e f f r r i i g g e e r r a a t t i i o o n n M M a a i i n n t t e e n n a a n n c c e e Figure 46.

  • Page 99: Electronic Throttling Valve (Etv)

    R R e e f f r r i i g g e e r r a a t t i i o o n n M M a a i i n n t t e e n n a a n n c c e e Figure 47.

  • Page 100: Pressure Transducers

    R R e e f f r r i i g g e e r r a a t t i i o o n n M M a a i i n n t t e e n n a a n n c c e e The ETV has two internal coils.

  • Page 101: Refrigeration System Components

    Refrigeration Service Operations N N o o t t e e : : Some of the following involve servicing the refrigeration system and are regulated by EU regulation known as "F- Gas" and /or local laws. All regulated refrigeration service procedures must be performed by a certified technician, using approved equipment and complying with all EU and local laws.
  • Page 102 R R e e f f r r i i g g e e r r a a t t i i o o n n S S e e r r v v i i c c e e O O p p e e r r a a t t i i o o n n s s Figure 49.
  • Page 103 R R e e f f r r i i g g e e r r a a t t i i o o n n S S e e r r v v i i c c e e O O p p e e r r a a t t i i o o n n s s Pilot Solenoid Heat Exchanger Condenser Coil...

  • Page 104: Compressor

    R R e e f f r r i i g g e e r r a a t t i i o o n n S S e e r r v v i i c c e e O O p p e e r r a a t t i i o o n n s s Gasket Plate Cover Sealing Washer...

  • Page 105: Compressors With Pressurized Seal Cavity

    R R e e f f r r i i g g e e r r a a t t i i o o n n S S e e r r v v i i c c e e O O p p e e r r a a t t i i o o n n s s Compressors with Pressurized Seal Cavity Starting in the first quarter of , the pressurized seal cavity was phased into use on large shaft four cylinder compressors.
  • Page 106 R R e e f f r r i i g g e e r r a a t t i i o o n n S S e e r r v v i i c c e e O O p p e e r r a a t t i i o o n n s s 2.
  • Page 107 R R e e f f r r i i g g e e r r a a t t i i o o n n S S e e r r v v i i c c e e O O p p e e r r a a t t i i o o n n s s Figure 54.
  • Page 108 R R e e f f r r i i g g e e r r a a t t i i o o n n S S e e r r v v i i c c e e O O p p e e r r a a t t i i o o n n s s Figure 56.

  • Page 109: Condenser Coil

    R R e e f f r r i i g g e e r r a a t t i i o o n n S S e e r r v v i i c c e e O O p p e e r r a a t t i i o o n n s s Figure 58.

  • Page 110: Installation

    R R e e f f r r i i g g e e r r a a t t i i o o n n S S e e r r v v i i c c e e O O p p e e r r a a t t i i o o n n s s Remove the condenser coil mounting bolts and remove the coil from the unit.

  • Page 111: In-Line Condenser Check Valve

    R R e e f f r r i i g g e e r r a a t t i i o o n n S S e e r r v v i i c c e e O O p p e e r r a a t t i i o o n n s s In-Line Condenser Check Valve This unit uses an in-line condenser check valve.

  • Page 112: Receiver Tank

    R R e e f f r r i i g g e e r r a a t t i i o o n n S S e e r r v v i i c c e e O O p p e e r r a a t t i i o o n n s s Solder the bypass check valve line to the bypass check valve.

  • Page 113: Installation

    R R e e f f r r i i g g e e r r a a t t i i o o n n S S e e r r v v i i c c e e O O p p e e r r a a t t i i o o n n s s Installation Install and bolt the expansion valve assembly in the unit.

  • Page 114: Installation

    R R e e f f r r i i g g e e r r a a t t i i o o n n S S e e r r v v i i c c e e O O p p e e r r a a t t i i o o n n s s Installation Clean the tubes for soldering.

  • Page 115: Accumulator

    R R e e f f r r i i g g e e r r a a t t i i o o n n S S e e r r v v i i c c e e O O p p e e r r a a t t i i o o n n s s Accumulator Removal Pump down the low side and equalize the pressure to slightly positive.

  • Page 116: Removal/Disassembly

    R R e e f f r r i i g g e e r r a a t t i i o o n n S S e e r r v v i i c c e e O O p p e e r r a a t t i i o o n n s s Figure 61.
  • Page 117 R R e e f f r r i i g g e e r r a a t t i i o o n n S S e e r r v v i i c c e e O O p p e e r r a a t t i i o o n n s s Figure 62.

  • Page 118: End Cap Checks

    R R e e f f r r i i g g e e r r a a t t i i o o n n S S e e r r v v i i c c e e O O p p e e r r a a t t i i o o n n s s Figure 63.
  • Page 119 R R e e f f r r i i g g e e r r a a t t i i o o n n S S e e r r v v i i c c e e O O p p e e r r a a t t i i o o n n s s Figure 64.

  • Page 120: Assembly/Installation

    R R e e f f r r i i g g e e r r a a t t i i o o n n S S e e r r v v i i c c e e O O p p e e r r a a t t i i o o n n s s •...

  • Page 121: Three-Way Valve Condenser Pressure Bypass Check Valve Repair

    R R e e f f r r i i g g e e r r a a t t i i o o n n S S e e r r v v i i c c e e O O p p e e r r a a t t i i o o n n s s Figure 67.

  • Page 122: Installation

    R R e e f f r r i i g g e e r r a a t t i i o o n n S S e e r r v v i i c c e e O O p p e e r r a a t t i i o o n n s s Figure 68.

  • Page 123: Installation

    R R e e f f r r i i g g e e r r a a t t i i o o n n S S e e r r v v i i c c e e O O p p e e r r a a t t i i o o n n s s Disconnect the wires and remove the coil from the valve.

  • Page 124: High Pressure Relief Valve

    R R e e f f r r i i g g e e r r a a t t i i o o n n S S e e r r v v i i c c e e O O p p e e r r a a t t i i o o n n s s wire terminals, or install a new connector and wire terminals.
  • Page 125 R R e e f f r r i i g g e e r r a a t t i i o o n n S S e e r r v v i i c c e e O O p p e e r r a a t t i i o o n n s s 2.

  • Page 126: Installation Of Service Kit

    R R e e f f r r i i g g e e r r a a t t i i o o n n S S e e r r v v i i c c e e O O p p e e r r a a t t i i o o n n s s Figure 70.
  • Page 127 R R e e f f r r i i g g e e r r a a t t i i o o n n S S e e r r v v i i c c e e O O p p e e r r a a t t i i o o n n s s 2.

  • Page 128: Installation Of Complete Etv Assembly

    R R e e f f r r i i g g e e r r a a t t i i o o n n S S e e r r v v i i c c e e O O p p e e r r a a t t i i o o n n s s Figure 74.

  • Page 129: Hot Gas Bypass Solenoid Valve

    R R e e f f r r i i g g e e r r a a t t i i o o n n S S e e r r v v i i c c e e O O p p e e r r a a t t i i o o n n s s Hot Gas Bypass Solenoid Valve Removal Recover the refrigerant charge.
  • Page 130 R R e e f f r r i i g g e e r r a a t t i i o o n n S S e e r r v v i i c c e e O O p p e e r r a a t t i i o o n n s s 1.

  • Page 131: Checking Compressor Oil Pressure

    R R e e f f r r i i g g e e r r a a t t i i o o n n S S e e r r v v i i c c e e O O p p e e r r a a t t i i o o n n s s Checking Compressor Oil Pressure The oil pressure at the oil pressure access port varies with the suction pressure in the compressor.

  • Page 132: Unit And Engine Mounting Bolts

    Structural Maintenance Unit and Engine Mounting Bolts Check and tighten all unit and engine mounting bolts during scheduled maintenance inspections.Torque the unit mounting bolts to 81 N•m (60 ft-lb). Torque the engine mounting bolts to 203 N•m (150 ft-lb). Please refer to your unit Installation Manual for further information. Unit Inspection Inspect the unit during pretrip inspection and scheduled maintenance inspections for loose or broken wires or hardware, compressor oil leaks, or other physical damage which might affect unit performance and require repair or...
  • Page 133 S S t t r r u u c c t t u u r r a a l l M M a a i i n n t t e e n n a a n n c c e e N N o o t t e e s s : : 1.

  • Page 134: Defrost Drains

    S S t t r r u u c c t t u u r r a a l l M M a a i i n n t t e e n n a a n n c c e e Figure 80.

  • Page 135: Condenser Fan Component Description And Locations

    S S t t r r u u c c t t u u r r a a l l M M a a i i n n t t e e n n a a n n c c e e Condenser Fan Component Description and Locations Fan (Blower) Housing (Left) Fan (Blower) (Counter Clockwise)

  • Page 136: Fan Controller Replacement

    S S t t r r u u c c t t u u r r a a l l M M a a i i n n t t e e n n a a n n c c e e Drain Hose Harness Clip Bracket...
  • Page 137 S S t t r r u u c c t t u u r r a a l l M M a a i i n n t t e e n n a a n n c c e e 4.

  • Page 138: Installation

    S S t t r r u u c c t t u u r r a a l l M M a a i i n n t t e e n n a a n n c c e e 6.
  • Page 139 S S t t r r u u c c t t u u r r a a l l M M a a i i n n t t e e n n a a n n c c e e 2.

  • Page 140: Fan Cover Replacement

    S S t t r r u u c c t t u u r r a a l l M M a a i i n n t t e e n n a a n n c c e e 4.

  • Page 141: Installation

    S S t t r r u u c c t t u u r r a a l l M M a a i i n n t t e e n n a a n n c c e e Installation 1.

  • Page 142: Condenser Fan Replacement

    S S t t r r u u c c t t u u r r a a l l M M a a i i n n t t e e n n a a n n c c e e 3.

  • Page 143: Installation

    S S t t r r u u c c t t u u r r a a l l M M a a i i n n t t e e n n a a n n c c e e Installation 1.

  • Page 144: Idler Assemblies

    S S t t r r u u c c t t u u r r a a l l M M a a i i n n t t e e n n a a n n c c e e Idler Assemblies The idler assemblies contains special sealed bearings.
  • Page 145 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 does Starter clutch defective Replace not crank...
  • Page 146 M M e e c c h h a a n n i i c c a a l l D D i i a a g g n n o o s s i i s s CONDITION POSSIBLE CAUSE REMEDY Engine does not develop full power Air intake system clogged...
  • Page 147 M M e e c c h h a a n n i i c c a a l l D D i i a a g g n n o o s s i i s s CONDITION POSSIBLE CAUSE REMEDY High oil consumption 10 hour engine break in running was not...
  • Page 148 Refrigeration Diagnosis POSSIBLE CAUSES Overcharge of refrigerant • • • • Shortage of refrigerant • • • • • • No refrigerant • • • • • Air through condenser too hot (ambient) • Air flow through condenser restricted • Air through condenser too cold (ambient) •...
  • Page 149 R R e e f f r r i i g g e e r r a a t t i i o o n n D D i i a a g g n n o o s s i i s s POSSIBLE CAUSES •...
  • Page 150 Refrigeration Diagrams Cool Cycle TK 61753-2-MM-EN...
  • Page 151 R R e e f f r r i i g g e e r r a a t t i i o o n n D D i i a a g g r r a a m m s s Compressor Feeler Bulb Discharge Service Valve...
  • Page 152 R R e e f f r r i i g g e e r r a a t t i i o o n n D D i i a a g g r r a a m m s s Heat/Defrost Cycle TK 61753-2-MM-EN...
  • Page 153 R R e e f f r r i i g g e e r r a a t t i i o o n n D D i i a a g g r r a a m m s s Compressor Feeler Bulb Discharge Service Valve...
  • Page 154 Diagram Index The following table lists the diagrams that are relevant to this unit. The diagrams are available on EMEA Info Central.. Drawing No. Drawing Title 3E84673 Schematic Diagram 3E59281 Wiring Diagram TK 61753-2-MM-EN...
  • Page 155 N N o o t t e e s s TK 61753-2-MM-EN...
  • Page 156 Thermo King – by Trane Technologies (NYSE: TT), a global climate innovator – is a worldwide leader in sustainable transport temperature control solutions. Thermo King has been providing transport temperature control solutions for a variety of applications, including trailers, truck bodies, buses, air, shipboard containers and railway cars since 1938.

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