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Table of Contents
Related Manuals for Thermo King T-1080S 30 SR
Summarization of Contents
Safety Precautions
General Practices
General guidelines and warnings for safe operation and maintenance of Thermo King units.
Battery Installation and Cable Routing
Instructions for safely installing and routing battery cables to prevent hazards.
Battery Removal
Procedures for safely removing the battery, emphasizing terminal disconnection order.
Refrigerant Hazards
Warnings related to handling refrigerants, including toxic gas production and storage.
Refrigerant Oil Hazards
Hazards associated with refrigerant oil, including eye protection and proper handling.
Electrical Hazards
Dangers associated with electrical shock, emphasizing caution with high voltage.
High Voltage
Warnings about potential lethal injury from electrical shock during service.
Low Voltage
Information on low voltage control circuits and potential amperage hazards.
Microprocessor Service Precautions
Steps to prevent electrostatic discharge (ESD) when servicing electronic components.
Welding Precautions
Safety measures to prevent damage to electronic circuits during welding operations.
First Aid
First Aid, Refrigerant
Procedures for frostbite, refrigerant contact with eyes/skin, and inhalation.
First Aid, Refrigerant Oil
First aid for contact with refrigerant oil (eyes, ingestion).
First Aid, Engine Coolant
First aid for engine coolant contact (eyes, ingestion).
First Aid, Electrical Shock
Immediate actions and medical assistance for electrical shock victims.
Specifications
Engine
Technical details and specifications for the unit's engine.
Belt Tension
Specifications for belt tension settings using gauges.
Engine Clutch
Specifications for clutch engagement and dynamic torque.
Refrigeration System
Specifications for the refrigeration system, including refrigerant charge and oil.
Electrical Control System
Specifications for voltage, charging system, and voltage regulator settings.
Fuses
Table listing fuse sizes and their functions in the unit's circuits.
Electrical Components
Table detailing current draw and resistance of various electrical components.
Electrical Standby (Model 50 Units Only)
Specifications for electric motor and overload relay settings for Model 50 units.
Electric Heater Strips (Optional)
Specifications for optional electric heater strips.
Standby Power Requirements
Requirements for supply circuit breakers and extension cord size for standby power.
Maintenance Inspection Schedule
Microprocessor
Pretrip test procedure for the microprocessor.
Engine
Engine inspection and service items based on operating hours.
Electrical
Electrical system checks and inspections based on operating hours.
Refrigeration
Refrigeration system checks and component replacement intervals.
Structural
Structural component inspections and cleaning requirements.
Unit Description
General Description
Overview of the T-680S, T-880S, T-1080S units and their basic models.
Design Features
Key design elements and features of the unit's system.
Unit Options
List of available optional features and systems for the unit.
Engine
Details on the diesel engines used in the T-680S/T-880S and T-1080S models.
ELC (Extended Life Coolant)
Information on Extended Life Coolant, its interval, and type.
Clutch
Description of the centrifugal clutch engagement and isolation function.
Scroll Compressor
Information on the high-performance scroll compressors used in the units.
Standard HMI Control Panel
Description of the Standard Human/Machine Interface control panel.
Mechanics HMI Control Panel
Description of the Mechanics HMI Control Panel as a diagnostic tool.
Premium HMI Control Panel (Optional)
Description of the Premium HMI Control Panel as an optional upgrade.
CYCLE-SENTRY
TM
Start/Stop System
Explanation of the CYCLE-SENTRY system for fuel saving and optimal operation.
Defrost
Explanation of how frost is melted and removed from evaporator coils.
DAS - Data Acquisition System (Optional)
Description of the DAS for monitoring and recording sensor data.
CargoLink
TM
(Optional)
Description of the wireless sensor system and its components.
Electric Standby (Model 50 Units Only)
Information on operating the unit on diesel or external electric power.
Standard Model 50 Features
Standard features on units equipped with Electric Standby.
Optional Model 50 Features
Optional features available for units equipped with Electric Standby.
Engine Compartment Components
Components located within the engine compartment and their functions.
Unit Protection Devices
Devices that protect the unit from damage due to various conditions.
Preheat Buzzer
Function of the preheat buzzer in the CYCLE-SENTRY system.
Coolant Temperature Sensor
Role of the coolant temperature sensor in monitoring and controlling the unit.
Electric Motor Overload Relay (Model 50)
Function of the overload relay in protecting the electric standby motor.
Fuses
Reference to fuse sizes and functions in the Specifications section.
Refrigeration System Components
Descriptions of key components within the refrigeration system.
Refrigeration Service Procedures
Evacuation, Dehydration, and Charging
Importance and principles of evacuating, dehydrating, and charging refrigeration systems.
Evacuation Station
Diagram and identification of components on the Thermo King Evacuation Station.
Valves V-1, V-2, V-3, V-4
Description of the function of valves V-1 through V-4 in the evacuation process.
Iso-Valve
TM
Description of the Iso-Valve and its use in evacuation.
Vacuum Gauge
Explanation of the Hastings vacuum gauge scale and readings.
Set Up and Test of Evacuation Equipment
Steps for connecting, testing, and verifying evacuation equipment.
Using Evacuation Mode
How to access and use the Evacuation Mode on the HMI control panel.
Unit Evacuation
Procedure for evacuating the unit, including refrigerant recovery and leak checking.
Unit Charging
Procedure for charging the system with refrigerant, including liquid and vapor methods.
Refrigerant Gauge Removal
Procedure for safely removing refrigerant gauges.
Refrigerant Leaks
Methods for detecting refrigerant leaks and signs of oil leakage.
Refrigerant Charge
Testing refrigerant charge using controlled and quick checks.
Checking Compressor Oil
Procedure for checking compressor oil level under different ambient temperatures.
Refrigeration System Checks
Steps for checking system pressures and refrigerant flow.
Low Side Pump Down
Procedure for pumping down the low side of the refrigeration system.
R404A
Information about R404A refrigerant, its classification, and handling precautions.
Unit Identification
How units charged with R404A are identified.
Availability
Information on R404A refrigerant availability.
Leak Detection
Methods and tools for detecting refrigerant leaks.
Compressor Oil
Information about Polyol Ester (POE) oil used with R404A and Scroll compressors.
Compressors Shipped with POE Oil
Note that Scroll compressors are shipped with Polyol Ester oil.
Gauge Manifold Sets
Guidelines for using gauge manifold sets with R404A systems.
Refrigerant Recovery
Recommendation for dedicated equipment for R404A recovery.
Accumulator Replacement
Procedures for removing and installing the accumulator.
Compressor Test
Procedure for testing the scroll compressor's efficiency.
Compressor Replacement
Procedures for removing and installing a compressor.
Compressor Shaft Seal Change Procedure
Steps for changing the compressor shaft seal, recommending oil and filter change.
Compressor Oil Filter Replacement
Procedure for replacing the compressor oil filter and oil.
Compressor Oil Change
Procedure for draining and refilling the compressor oil.
Compressor Temperature Sensor Testing
Information on testing the compressor temperature sensor and associated alarms.
Compressor Temperature Sensor Replacement
Steps for replacing the compressor temperature sensor.
Condenser Check Valve and Purge Check Valve Test
Procedure to test the condenser and purge check valves for leaks.
Discharge Pressure Transducer Testing
How to test the discharge pressure transducer and compare readings.
Discharge Pressure Transducer Replacement
Procedures for removing and installing the discharge pressure transducer.
Discharge Strainer Test
How to test for a plugged discharge strainer or faulty HPCO.
Discharge Strainer Replacement
Procedures for removing and installing the discharge strainer.
Electronic Throttling Valve (ETV) Testing
How to test the Electronic Throttling Valve (ETV) and associated alarms.
Electronic Throttling Valve (ETV) Replacement
Procedures for replacing Old Style and New Style ETVs.
Installation of Service Kit
Steps for installing the ETV service kit, including stepper motor and piston assembly.
Reassembly of Piston and Stepper Motor on Old Style ETV
Procedure to reassemble the piston and stepper motor if misaligned.
Installation of Complete ETV Assembly
Steps for installing a complete ETV assembly, including soldering and connecting the harness.
Evaporator Coil Replacement
Procedures for removing and installing the evaporator coil.
Expansion Valve Replacement
Procedures for removing and installing the expansion valve.
Heat Exchanger Replacement
Procedure for replacing the heat exchanger, with a caution about its rarity of failure.
High Pressure Cutout Switch (HPCO) Test
How to test the HPCO switch by monitoring discharge pressure.
High Pressure Cutout Switch (HPCO) Replacement
Procedures for removing and installing the HPCO switch.
High Pressure Relief Valve Replacement
Procedures for replacing the high pressure relief valve.
Hot Gas Solenoid (HGS) Test
How to test the HGS by checking pressure rise and solenoid continuity.
In-Line Check Valve Replacement
Procedure for replacing in-line check valves, noting the need for a heat sink.
Liquid Injection Solenoid (LIS) Test
How to test the LIS for proper opening and potential leaks.
Liquid Injection Solenoid (LIS) Replacement
Procedures for removing and installing the LIS.
Purge Valve (PV) Test
How to test the PV for proper opening and potential leaks.
Receiver Tank Pressure Check Valve Test
How to test the receiver tank pressure check valve for leaks.
Receiver Tank Replacement
Procedures for removing and installing the receiver tank.
Solenoid Valve Replacement
Procedures for replacing solenoid valves.
Suction Pressure Transducer Testing
How to test the suction pressure transducer by comparing readings.
Suction Pressure Transducer Replacement
Procedures for removing and installing the suction pressure transducer.
Clutch Maintenance
Centrifugal Clutch
Description of the centrifugal clutch, its belt grooves, and engagement speed.
Clutch Inspection
Inspection steps for potential clutch defects causing engine damage.
Check the Clutch
Visual checks for clutch condition, including rust and shoe wear.
Check Condition of Belts
How to check belts for proper type, condition, and tension.
Clutch Maintenance
General maintenance recommendations for the clutch, including cleaning and inspection.
Tools Required
List of tools needed for clutch maintenance.
Grease
Specification for the type of grease to be used.
Disassembly Procedure
Step-by-step instructions for disassembling the clutch.
Assembly Procedure (Using New Bearings and Seal)
Steps for reassembling the clutch with new bearings and seal.
Torquing Retainer Plate Bolts
Procedure for torquing retainer plate bolts.
Checking End Play
How to measure and adjust end play for the jackshaft assembly.
Jackshaft Assembly
Information on the jackshaft assembly and bearing checks.
Disassembly
Steps for disassembling the jackshaft assembly.
Reassembly
Steps for reassembling the jackshaft assembly.
Structural Maintenance
Unit and Engine Mounting Bolts
Periodic checks and tightening of unit and engine mounting bolts.
Unit Inspection
Inspection of the unit for loose wires, oil leaks, or physical damage.
Condenser, Evaporator and Radiator Coils
Cleaning procedures for coils to ensure proper airflow.
Micro-Channel Coil Cleaning Recommendations
Recommendations for cleaning micro-channel coils, including intervals and methods.
Fan Location
How to position the fan and hub assembly for proper fan performance.
Plastic Defrost Damper
Information on the plastic defrost damper and its adjustment.
Fanshaft Assembly
Information on the fanshaft assembly, its maintenance, and oil seals.
Disassembly
Steps for disassembling the fanshaft assembly.
Reassembly
Steps for reassembling the fanshaft assembly.
Torquing Retainer Plate Bolts
Procedure for torquing retainer plate bolts.
Checking End Play
How to measure and adjust end play for the jackshaft assembly.
Jackshaft Assembly
Information on the jackshaft assembly and bearing checks.
Disassembly
Steps for disassembling the jackshaft assembly.
Reassembly
Steps for reassembling the jackshaft assembly.
Mechanical Diagnosis
Engine will not crank
Possible causes and remedies for an engine that fails to crank.
Starter motor turns but engine does not crank
Possible causes and remedies when the starter operates but the engine doesn't crank.
Engine cranks but fails to start
Possible causes and remedies when the engine cranks but does not start.
Engine stops after starting
Possible causes and remedies for the engine stopping after starting.
Engine does not reach full power
Possible causes and remedies for the engine failing to reach full power.
Engine is sooting heavily, emits thick black clouds of smoke
Causes and remedies for heavy sooting and black smoke from the engine.
Engine knocks
Possible causes and remedies for engine knocking.
Engine runs hot
Causes and remedies for the engine overheating.
Oil pressure too low or drops suddenly
Causes and remedies for sudden drops in oil pressure.
High oil consumption
Possible causes of high oil consumption.
Blue Smoke (oil consumption)
Causes and remedies for blue smoke indicating oil consumption.
White Smoke (fuel is not burning)
Causes and remedies for white smoke indicating unburnt fuel.
Battery is not recharging
Possible causes and remedies for the battery not recharging.
Electric Standby (Optional) Diagnosis
Unit turned On—Microprocessor display does not come on
Troubleshooting steps when the display does not activate.
Unit turned On—Microprocessor display comes on but electric motor does not run
Troubleshooting steps when the electric motor fails to run.
Electric motor hums but does not run
Possible causes and remedies when the electric motor hums but doesn't run.
Contact chatter
Causes and remedies for contact chatter in control circuits.
Contact welding or freezing
Causes and remedies for contact welding or freezing.
Battery is not recharging
Possible causes and remedies for the battery not recharging.
Refrigeration Diagnosis
Possible Causes
Table correlating symptoms with possible causes of refrigeration issues.
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