Related Manuals for Thermo King UT-1000R
Summary of Contents for Thermo King UT-1000R
- Page 1 Maintenance Manual Self Powered Truck Edition UT-1000R, UT-1400R & UT-R EXTREME Single Temperature Units Revision A T T K K 6 6 2 2 0 0 5 5 5 5 – – 1 1 – – M M M M - - E E N N...
- Page 2 Regulations must be observed when working on refrigeration systems. 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.
- Page 3 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. For additional information on regulations and technician programs, contact your local THERMO KING dealer.
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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 Refrigeration System Components ............. . 29 Solenoids and Valves.
- 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 Glow Plugs ..................43 Unit Wiring.
- 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 High Speed Adjustment..............68 Speed Setting of the Engine via Wintrac .
- 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 Condenser Inlet Solenoid (CIS) Test ............. 94 Condenser/Radiator Coil Replacement .
- 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 Installation ................108 Solenoid Valve Replacement.
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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. Your personal safety and the proper operation of this unit depend upon the strict observance of these precautions. - Page 11 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 R R e e f f r r i i g g e e r r a a n n t t V V a a p p o o r r H H a a z z a a r r d d ! ! D D o o n n o o t t i i n n h h a a l l e e r r e e f f r r i i g g e e r r a a n n t t .
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Page 12: 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 C C A A U U T T I I O O N N S S h h a a r r p p E E d d g g e e s s ! ! E E x x p p o o s s e e d d c c o o i i l l f f i i n n s s c c a a n n c c a a u u s s e e l l a a c c e e r r a a t t i i o o n n s s . -
Page 13: 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 N N O O T T I I C C E E E E q q u u i i p p m m e e n n t t D D a a m m a a g g e e ! ! D D o o n n o o t t c c o o n n n n e e c c t t o o t t h h e e r r m m a a n n u u f f a a c c t t u u r r e e r r ’... -
Page 14: Refrigerant Oil 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 Refrigerant Oil Hazards W W A A R R N N I I N N G G P P e e r r s s o o n n a a l l P P r r o o t t e e c c t t i i v v e e E E q q u u i i p p m m e e n n t t ( ( P P P P E E ) ) R R e e q q u u i i r r e e d d ! ! P P r r o o t t e e c c t t y y o o u u r r e e y y e e s s f f r r o o m m c c o o n n t t a a c c t t w w i i t t h h 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 . -
Page 15: 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 Electrical Hazards High Voltage D D A A N N G G E E R R 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 ! ! W W h h e e n n s s e e r r v v i i c c i i n n g g o o r r r r e e p p a a i i r r i i n n g g a a t t e e m m p p e e r r a a t t u u r r e e c c o o n n t t r r o o l l u u n n i i t t , , t t h h e e p p o o s s s s i i b b i i l l i i t t y y o o f f s s e e r r i i o o u u s s o o r r e e v v e e n n f f a a t t a a l l i i n n j j u u r r y y f f r r o o m m e e l l e e c c t t r r i i c c a a l l s s h h o o c c k k e e x x i i s s t t s s . -
Page 16: 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 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 w w / / C C a a p p a a c c i i t t o o r r s s ! ! B B e e c c a a r r e e f f u u l l w w h h e e n n w w o o r r k k i i n n g g w w i i t t h h e e l l e e c c t t r r i i c c a a l l c c i i r r c c u u i i t t s s t t h h a a t t c c o o n n t t a a i i n n c c a a p p a a c c i i t t o o r r s s . - Page 17 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 • Disconnect power to the unit. •...
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Page 18: 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 19: Engine
-13 to 86 F (-25 to 30 C): SAE 10W-30 -22 to 122 F (-30 to 50 C): SAE 5W-40 (Synthetic) Below -22 F (-30 C): SAE 0W-30 (Synthetic) Engine RPM UT-1000R Low Speed Operation 1500 ± 50 RPM UT-1000R High Speed Operation 2050 ± 50 RPM UT-1400R/UT-R EXTREME Low Speed 1500 ±... -
Page 20: Engine Clutch
12 volt, AHr Rating - 75 AHrs, 640 Cold Cranking Amps at 0 F (-18 C) (ENCCA) Battery Charging System UT-1000R 12 volt, 65 amp, brush type, Thermo King Alternator UT-1400R/UT-R EXTREME 12 volt, 120 amp, brush type, Thermo King Alternator TK 62055–1–MM-EN... -
Page 21: Fuses
7.5A 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 controller. -
Page 22: Evaporator Fan Motor
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 Table 5. (continued) Component Current Draw (Amps) at Resistance (Ohms) 12.5 Vdc Fan Relay 13.5 Starter Motor (No Load Bench Test) - Page 23 Maintenance Inspection Schedule N N o o t t e e : : Please refer to the latest EDAC labour Standards Guide on EMEA infocentral for Service Inspection Schedules for your unit. N N o o t t e e : : Please refer to your UT– R Series Operator Manual TK 60483-1-OP for Operator Weekly Checks N N o o t t e e : : Please refer to the latest service bulletins for additional information.
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Page 24: General Description
Unit Description General Description The UT-R Series units are microprocessor based transport temperature control systems, which utilizes the SR-3 Truck HMI microcontroller to manage system functions. The unit is a two-piece under-mount refrigeration unit designed for truck applications. The condenser unit mounts underneath the truck and the evaporator mounts inside the truck body. -
Page 25: Basic Hmi Controller
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 • Telematics Basic HMI Controller The Basic HMI Controller (Human/Machine Interface) is used to operate the unit and display unit information. The Control Panel is typically located in the vehicle driver's compartment and communicates with the base controller using a connection on the interface board. -
Page 26: 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 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 27: Unit Component Identification
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 Unit Component Identification Figure 3. UT-R Series Components (Panels Removed) Filter/Drier Alternator Receiver Tank... - Page 28 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 Figure 4. UT-R Series Components (Panels Removed) Compressor Engine Clutch Electric Motor Electric Motor Pulley Fuel Filter/Water Separator...
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Page 29: Refrigeration System Components
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 Refrigeration System Components The refrigeration system in these units does not have a three-way valve. Instead, it uses a condenser inlet solenoid (CIS) and a hot gas solenoid similar to multi-temp units. -
Page 30: Refrigeration System Diagrams
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 Refrigeration System Diagrams The following pages show the refrigeration system and examples of the refrigerant flow in the various modes. Figure 5. -
Page 31: Cool Mode
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 Cool Mode The refrigerant flow in Cool Mode is a conventional refrigeration cycle. High pressure refrigerant vapor leaves the compressor and flows through the open CIS to the condenser where the refrigerant releases heat and condenses into high pressure liquid. -
Page 32: Purge Mode
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 Purge Mode Purge Mode is similar to Condenser Evacuation Mode in previous systems. It is used to move the refrigerant out of the condenser into the accumulator when the unit shifts from Cool (or Null) to Heat or Defrost. -
Page 33: Heat/Defrost Mode
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 Heat/Defrost Mode The refrigerant flow in Heat/Defrost Mode is a conventional hot gas heat cycle. The CIS is closed and the HGS is open so high pressure refrigerant vapor leaves the compressor and flows through the DPR (which maintains a minimum discharge pressure) to the hot has line. - Page 34 Operating Instructions Please refer to the EMEA Users Manuals Website - www.emea-user-manuals.thermoking.com to download all User documentation pertaining to your unit. TK 62055–1–MM-EN...
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Page 35: Alternator Diagnostic Procedures
The unit control circuits or installed accessories may be drawing excessive current. • An overcharged battery is usually caused by a defective voltage regulator. Alternator Identification These units use Thermo King Alternators, which are painted black. Figure 6. Thermo King Alternator Terminal and Component Locations RAJ524... -
Page 36: Base Controller Fuse F4
See the specific unit wiring diagram for exact details. N N o o t t e e : : The F4 fuse must be removed from the base controller on units equipped with Thermo King alternators. The voltage regulator on the Thermo King alternators will be damaged if the unit is turned On with the F4 fuse in place on the base controller. - 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 check the 2 and 2A circuits, and fuse F21. Disconnect the alternator harness from the voltage regulator. On Thermo King alternators, carefully push on the spring clip to release the plug lock.
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Page 38: Field Current Test
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. Do not connect the F2 terminal to ground or the alternator will be damaged. -
Page 39: Base 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 Base Controller Figure 7. -
Page 40: Base Controller Fuse Size & Function
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 Base Controller Fuse Size &... -
Page 41: Smart Fet Outputs
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 LED # LED # Function... -
Page 42: Fan Relay
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 43: Testing The Flywheel (Rpm) Sensor
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 If the flywheel sensor fails, the starter may not disengage or engage properly and a fault code will be generated. -
Page 44: Unit Wiring
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 shorted glow plug will show excessive current draw (more than 18 amps) during preheat, and may cause fuse F5 (40 A) to blow. -
Page 45: Removal And Replacement
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 Outputs Output Description... -
Page 46: Overload Relay
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 Overload Relay The overload relay protects the standby electric motor. - 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 Figure 11.
- Page 48 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 13.
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Page 49: Emi 2000
The EMI package allows standard maintenance intervals to be extended to 2,000 hours, or 1 year, whichever occurs first. N N o o t t e e : : Units equipped with the EMI 2000 package do require regular inspection in accordance with Thermo King's maintenance recommendations. -
Page 50: Oil Filter Change
5. Add oil as necessary to reach the full mark. 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 51 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 16. Crankcase Breather Components Breather Cover O-ring Baffle Baffle Plate...
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Page 52: Engine Air Cleaner (Emi 2000)
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 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. -
Page 53: 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 Engine Cooling System The engine employs a closed, circulating type, pressurized cooling system. Correct engine temperatures are controlled and maintained by a radiator, fan and thermostat. -
Page 54: 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 Figure 18. Engine Cooling System Components Radiator Coolant Refill Cap Drain Cock... -
Page 55: Antifreeze Maintenance Procedures
N N o o t t e e : : The new engine coolant, Chevron Extended Life Coolant, is RED in color instead of the current GREEN or BLUE- GREEN colored coolants. Figure 19. ELC Nameplate The following are the Extended Life Coolants currently approved by Thermo King for use in ELC units for five years or 12,000 hours: •... -
Page 56: 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 C C A A U U T T I I O O N N R R i i s s k k o o f f I I n n j j u u r r y y ! ! A A v v o o i i d d d d i i r r e e c c t t c c o o n n t t a a c c t t w w i i t t h h h h o o t t c c o o o o l l a a n n t t . -
Page 57: Engine Fuel 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 20. Water Pump Assembly and Thermostat Thermostat Housing Gasket Thermostat... -
Page 58: Maintenance
TTK270, TK370, TK374F, TK376, and TK380F Engine Overhaul Manual TK 53163 for injection nozzle testing and repair procedures. Thermo King recommends that any major injection pump or nozzle repairs be done by a quality diesel injection service specialty shop. The investment in equipment and facilities to service these components is quite high. Therefore, this equipment is not found in most repair shops. -
Page 59: 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 2. Turn on the electric fuel pump. The electric fuel pump is energized when the On key is pushed. Tighten the bleeder screw on the injection pump when clear flow of fuel appears. -
Page 60: Assembly
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 22. Electric Fuel Pump Fuel Inlet Fuel Filter Fuel Filter Bowl Fuel Filter Bowl Gasket... - Page 61 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 2. Remove the delivery valve spring for the number 1 cylinder by removing the delivery valve holder and the delivery valve spring, and then reinstalling the delivery valve holder without the delivery valve spring in place.
- Page 62 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 24. Injection Pump Delivery Valve Holder 9.
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Page 63: Injection Pump Removal And Installation
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 reconnect the 8S wire to the starter solenoid when finished with the procedure. Injection Pump Removal and Installation Injection Pump Removal 1. - Page 64 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. Remove the injection pump timing cover from the gear case. 4.
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Page 65: Injection Pump Installation
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 Installation 1. Place a new O-ring on the injection pump and lubricate it with engine oil. 2. -
Page 66: Testing The 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 Figure 31. Fuel Solenoid Location Fuel Solenoid Testing the Fuel Solenoid N N o o t t e e : : The fuel solenoid pull-in coil will require 35 to 45 amps to turn on the fuel. -
Page 67: 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 Figure 32. Fuel Solenoid Connector Pin Identification RAJ528 Red (8D) White (8DP) -
Page 68: Engine Speed Adjustments
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 2. Connect the new fuel solenoid wire connector to the main wire harness. 3. -
Page 69: Speed Setting Of The Engine Via Wintrac
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 4. Snap the ball joint off of the throttle lever and turn it to adjust the engine speed. Reinstall the ball joint on the throttle lever. -
Page 70: Adjust Engine Valve Clearance
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 Adjust Engine Valve Clearance The valve clearance should be checked after every 1,000 operating hours, maximum. It is important that valves be adjusted to the correct specifications for satisfactory engine operation. - 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 36. Timing Marks Top Dead Center Timing Mark for Number 1 Cylinder Index Timing Mark on Starter Mounting Plate b.
- 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 Figure 38. Adjusting Valves 6. Recheck the valve clearance. 7.
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Page 73: 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 Belts Belts should be regularly inspected during unit pre-trip inspections for wear, scuffing or cracking, and belt tension. Belts that are too loose will whip, and belts that are too tight put too much strain on the belt fibers and bearings. -
Page 74: Engine/Compressor 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 Engine/Compressor Belt Tensioner Pulley Machined Slot Slider Retainer Ring Tensioner Bracket... -
Page 75: Evacuation, Dehydration, And Charging
That the unit is still in a deep vacuum before any lines are disconnected or refrigerant is added. N N o o t t e e : : The attached evacuation procedures have been written to be used with the Thermo King Evacuation System (P/N 2040725). - Page 76 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 P P r r o o c c e e d d u u r r e e s s Figure 40.
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Page 77: Set Up And Test Of Evacuation Equipment
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 P P r r o o c c e e d d u u r r e e s s Figure 41. -
Page 78: Using Evacuation Mode
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 P P r r o o c c e e d d u u r r e e s s N N o o t t e e : : If the vacuum pump is okay, and there are no leaks between V-1 and V-3, the micron gauge should show less than 500 microns. -
Page 79: Unit Evacuation
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 P P r r o o c c e e d d u u r r e e s s Figure 44. -
Page 80: Unit Charging
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 P P r r o o c c e e d d u u r r e e s s required. -
Page 81: Refrigerant Gauge Removal
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 P P r r o o c c e e d d u u r r e e s s 12. -
Page 82: Checking Compressor Oil
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 P P r r o o c c e e d d u u r r e e s s 4. -
Page 83: Refrigeration System 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 P P r r o o c c e e d d u u r r e e s s 3. -
Page 84: Unit Identification
Compressor Oil Thermo King Corporation has chosen to use a compressor oil called Polyol Ester (POE)—also called ester based oil. POE oil is compatible with R-452A and can be used in low temperature applications. This oil is available from service parts (P/N 2030513) TK 62055–1–MM-EN... -
Page 85: Compressors Shipped With Poe Oil
Ideally, a new vacuum pump should be used and dedicated for use with R-452A systems because residual refrigerants may remain in used vacuum pumps. Pumps used with other Thermo King refrigerants may be used but extreme care should be taken to prevent contamination of R-452A systems with other refrigerants. -
Page 86: Refrigeration System Component Locations
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 P P r r o o c c e e d d u u r r e e s s Refrigeration System Component Locations The following drawings show the locations of various refrigeration system components. -
Page 87: Accumulator Replacement
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 P P r r o o c c e e d d u u r r e e s s Accumulator Replacement Removal 1. -
Page 88: Compressor Coupling Installation (Standard Units)
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 P P r r o o c c e e d d u u r r e e s s N 2040991 to loosen the center bolt which holds the coupling to the compressor shaft. -
Page 89: 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 P P r r o o c c e e d d u u r r e e s s bolt and washer. -
Page 90: Hex Drive Compressor Seal Replacement
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 P P r r o o c c e e d d u u r r e e s s Figure 52. - Page 91 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 P P r r o o c c e e d d u u r r e e s s 4.
- Page 92 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 P P r r o o c c e e d d u u r r e e s s Figure 56.
- Page 93 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 P P r r o o c c e e d d u u r r e e s s Figure 58.
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Page 94: Condenser Check Valve Test
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 P P r r o o c c e e d d u u r r e e s s crankshaft during assembly. -
Page 95: Condenser/Radiator Coil Replacement
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 P P r r o o c c e e d d u u r r e e s s •... -
Page 96: Dehydrator (Filter-Drier) Replacement
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 P P r r o o c c e e d d u u r r e e s s 6. -
Page 97: Electronic Throttling Valve (Etv) Replacement
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 P P r r o o c c e e d d u u r r e e s s Electronic Throttling Valve (ETV) Replacement Removal 1. -
Page 98: 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 P P r r o o c c e e d d u u r r e e s s Figure 62. - Page 99 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 P P r r o o c c e e d d u u r r e e s s Figure 63.
- Page 100 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 P P r r o o c c e e d d u u r r e e s s Figure 65.
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Page 101: 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 P P r r o o c c e e d d u u r r e e s s Figure 66. -
Page 102: Evaporator Coil Replacement - S-3
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 P P r r o o c c e e d d u u r r e e s s Evaporator Coil Replacement –... -
Page 103: Expansion Valve Replacement
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 P P r r o o c c e e d d u u r r e e s s 5. -
Page 104: Heat Exchanger Replacement
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 P P r r o o c c e e d d u u r r e e s s 5. -
Page 105: High Pressure Cutout Switch (Hpco) Replacement
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 P P r r o o c c e e d d u u r r e e s s Figure 70. -
Page 106: High Pressure Relief Valve Replacement
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 P P r r o o c c e e d d u u r r e e s s 3. -
Page 107: Removal
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 P P r r o o c c e e d d u u r r e e s s Figure 71. -
Page 108: Receiver Tank Replacement
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 P P r r o o c c e e d d u u r r e e s s 9. -
Page 109: Suction Pressure Transducer Testing
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 P P r r o o c c e e d d u u r r e e s s 7. -
Page 110: Centrifugal Clutch
Clutch Maintenance Centrifugal Clutch The centrifugal clutch has three belt grooves and its engagement speed is 600 ± 100 RPM. Figure 72. Front View and Cross Section TK 62055–1–MM-EN... -
Page 111: Clutch Inspection
C C l l u u t t c c h h M M a a i i n n t t e e n n a a n n c c e e Figure 73. Centrifugal Clutch Screw Grease Seal Washer Roller Bearing Inner Race Snap-Ring... -
Page 112: Check Condition Of Belts
1. Check to make sure that the belts are TK recommended or the equivalent. If not, the belt or belts must be replaced. 2. Use a Continental Elite Gauge to check the condition of the Engine/Electric Motor Belt. 3. Contact the Thermo King Service Department if you cannot find a supplier for the Continental Elite Gauge. Check the Clutch 1. - Page 113 C C l l u u t t c c h h M M a a i i n n t t e e n n a a n n c c e e Figure 76. Clutch Removed from Failed Engine Figure 77.
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Page 114: Clutch Maintenance
C C l l u u t t c c h h M M a a i i n n t t e e n n a a n n c c e e After a short run time in electric mode have them check the heat in the clutch. If the temperature is rising there may be a shoe dragging. - Page 115 C C l l u u t t c c h h M M a a i i n n t t e e n n a a n n c c e e Figure 78. Housing Removal 4. Remove the nuts from six 1/4-28 link screws and remove screws, links, and lockwashers. 5.
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Page 116: Assembly Procedure (Using New Bearings And Seal)
C C l l u u t t c c h h M M a a i i n n t t e e n n a a n n c c e e Assembly Procedure (Using New Bearings and Seal) 1. - Page 117 C C l l u u t t c c h h M M a a i i n n t t e e n n a a n n c c e e 15. Apply Loctite (see Tool Catalog) to 3/8-16 x 1 in. screw and install through washer into housing shaft. The housing and hub will be drawn together to the proper relative position as the screw is tightened.
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Page 118: Unit Inspection
Structural Maintenance 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 replacement of parts. TK 62055–1–MM-EN... -
Page 119: Unit And Engine Mounting Bolts
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 Unit and Engine Mounting Bolts Periodically check and tighten all unit and engine mounting bolts. -
Page 120: Condenser, Evaporator, And Radiator Coils
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 I I m m p p o o r r t t a a n n t t : : •... -
Page 121: 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 •... - Page 122 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...
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Page 123: 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
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 reach full power Air or dirt in fuel system... - Page 124 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 runs hot Engine coolant is low...
- Page 125 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 Check HMI Harness...
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Page 126: E E L L E E C C T T R R I I C C S S T T A A N N D D B B Y Y ( ( O O P P T T I I O O N N A A L L ) ) D D I I A A G G N N O O S S I I S
E E l l e e c c t t r r i i c c S S t t a a n n d d b b y y ( ( O O p p t t i i o o n n 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... - Page 127 Refrigeration Diagnosis Possible Causes Overcharge of refrigerant • • • • Shortage of refrigerant • • • • • • No refrigerant • • • • • • Air through condenser too hot (ambient) • Air flow through condenser restricted •...
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Page 128: 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
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 Faulty Condenser Inlet Solenoid (CIS) •... - Page 129 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 4E04691 Schematic Diagram 4E04692 Wiring Diagram TK 62055–1–MM-EN...
- Page 130 N N o o t t e e s s TK 62055–1–MM-EN...
- Page 131 N N o o t t e e s s TK 62055–1–MM-EN...
- Page 132 1938. For more information, visit www.thermoking.com or www.tranetechnologies.com. Thermo King has a policy of continuous product and product data improvements and reserves the right to change design and specifications without notice. We are committed to using environmentally conscious print practices.