Related Manuals for Thermo King UT-1400R & UT-R EXTREME
Summarization of Contents
Introduction
Manual Overview and References
Covers unit models, related documentation, and refrigerant handling advice.
Introduction
Service Tools and Procedures
Details essential tools, recovery equipment, and procedures for refrigeration service.
Customer Feedback
Invites feedback on the manual for improvement purposes.
Safety Precautions
Hazard Advisory Definitions
Defines advisory types (Danger, Warning, Caution, Notice) for safe operation.
General Safety Practices
Outlines essential safety practices for handling potential hazards like explosions and gases.
Safety Precautions
Refrigerant and Confined Space Hazards
Warns about refrigerant vapor inhalation and confined space risks.
Electrical and Equipment Safety
Covers explosion risks, proper equipment condition, and PPE/ladder safety.
Unit Operation Safety
Recommends turning off the unit and disconnecting the battery before inspections.
Safety Precautions
Coil Handling and Battery Safety
Warns about sharp coil fins and details battery installation safety precautions.
Safety Precautions
Battery Removal and Refrigerant Hazards
Covers safe battery removal and hazards related to refrigerant pressure and gases.
Safety Precautions
Refrigerant Oil Hazards and PPE
Details PPE requirements and hazards associated with refrigerant oil handling.
Safety Precautions
High Voltage Electrical Safety
Warns about lethal voltage potentials and extreme care needed during servicing.
Safety Precautions
Capacitor, Low Voltage, and Controller Safety
Warns about capacitor discharge, low voltage hazards, and controller service precautions.
Welding Safety
Outlines precautions to prevent damage to electronic circuits during welding.
Safety Precautions
Welding Procedures
Provides specific steps and recommendations for safe welding practices.
Safety Precautions
First Aid Measures
Details first aid for refrigerant, oil, coolant, battery acid, electrical shock, and asphyxiation.
Specifications
Engine Specifications
Lists technical specifications for the engine, including fuel, oil, RPM, and pressures.
Specifications
Clutch, Belt Tension, and Refrigeration Specs
Provides specifications for the engine clutch, belt tension, and refrigeration system components.
Specifications
Electrical System Specifications
Details specifications for the electrical control system, fuses, and components.
Specifications
Fan Motor and Standby Power Specs
Lists specifications for evaporator fan motors and standby power requirements.
Unit Description
General Unit Overview
Provides an overview of the UT-R Series units, their design features, and optional components.
Unit Description
HMI Controller and Cycle-Sentry System
Describes Basic, Mechanics, and Premium HMI controllers and the CYCLE-SENTRY system.
Unit Description
Unit Protection Devices
Details various protective devices like fuses, sensors, and relays for unit safety.
Refrigeration System Diagrams
Cool Mode Operation
Explains refrigerant flow and component states during Cool Mode operation.
Refrigeration System Diagrams
Purge Mode Operation
Describes refrigerant flow and component states during Purge Mode operation.
Refrigeration System Diagrams
Heat/Defrost Mode Operation
Explains refrigerant flow and component states during Heat/Defrost Mode.
Electrical Maintenance
Alternator Diagnostics and Identification
Covers alternator diagnostic procedures and identification methods.
Electrical Maintenance
Base Controller Fuse F4 and Test Equipment
Explains Fuse F4 function, test equipment, and alternator load testing.
General Alternator Diagnostic Procedure
Outlines a procedure for diagnosing alternator/regulator issues before replacement.
Electrical Maintenance
Alternator Diode Quick Check and Voltage Readings
Details diode quick check and voltage reading procedures for alternator testing.
Electrical Maintenance
Field Current Test and Battery Maintenance
Covers field current test for alternators and battery inspection/maintenance.
Battery Load Test and Fuse Information
Details battery load testing and general information about fuses.
Electrical Maintenance
Base Controller Fuses and LED Functions
Lists base controller fuses, their functions, and LED indicators.
Electrical Maintenance
Smart FET Outputs and Fan Fuses
Explains Smart FET outputs and specifies fan fuse details.
Electrical Maintenance
Fan Relay/Fuse and Microprocessor Controller
Covers fan relay/fuse testing and refers to controller service manual.
Flywheel (RPM) Sensor Function
Describes the function and mounting of the flywheel sensor.
Electrical Maintenance
Flywheel Sensor Testing and Glow Plugs
Details testing the flywheel sensor and procedures for glow plugs.
Electrical Maintenance
Unit Wiring and AC Components Safety
Advises on unit wiring inspection and covers safety for AC components in Model 50 units.
Electrical Maintenance
Phase Select Module Diagnostics
Details diagnostic steps for the phase select module, including voltage checks.
Electrical Maintenance
Overload Relay Function and Replacement
Explains the overload relay's function and the procedure for its replacement.
Electrical Maintenance
Overload Relay Setup Procedures
Details steps for opening the cover, setting amperage, and enabling automatic reset.
Electrical Maintenance
Overload Relay Switch Adjustment
Explains how to move the slide switch for automatic reset.
Engine Maintenance
EMI 2000 Package and Lubrication System
Describes the EMI 2000 package and the engine lubrication system.
Engine Oil Change Procedure
Details the procedure for changing engine oil, emphasizing draining when hot.
Engine Maintenance
Oil Filter Change and Breather System
Outlines oil filter change procedure and explains the crankcase breather system.
Engine Maintenance
Crankcase Breather Components and Pressure
Identifies breather components and normal crankcase pressures.
Engine Maintenance
Engine Air Cleaner (EMI 2000) Maintenance
Describes the EMI 2000 air cleaner, its function, and replacement intervals.
Engine Maintenance
Engine Cooling System Overview
Explains the closed, circulating cooling system, its components, and antifreeze benefits.
Engine Maintenance
Cooling System Components and ELC
Identifies cooling system components and discusses Extended Life Coolant (ELC).
Engine Maintenance
Antifreeze Maintenance and Coolant Types
Details antifreeze inspection, changing intervals, approved coolants, and mixture recommendations.
Engine Maintenance
Antifreeze Change Procedure
Provides detailed steps for changing antifreeze, including flushing and refilling.
Engine Thermostat Specification
Specifies the recommended thermostat temperature for optimal engine operation.
Engine Maintenance
Engine Fuel System Overview
Explains the high-pressure fuel system and its components.
Engine Maintenance
Fuel System Maintenance and Bleeding
Covers fuel system maintenance, contamination prevention, and bleeding air from the system.
Engine Maintenance
Fuel Tank Draining and Filter Replacement
Details draining fuel tank water and replacing the fuel filter.
Electric Fuel Pump Procedures
Describes electric fuel pump operation, maintenance, disassembly, and cleaning.
Engine Maintenance
Electric Fuel Pump Assembly and Timing
Details fuel pump assembly and injection pump timing procedures.
Engine Maintenance
Injection Pump Timing Procedure Details
Provides detailed steps for setting injection pump timing, including flywheel marks.
Engine Maintenance
Correct Injection Timing Mark Alignment
Illustrates and describes the alignment of timing marks for correct injection timing.
Engine Maintenance
Injection Pump Removal
Outlines the steps for removing the injection pump, including noting index marks.
Engine Maintenance
Injection Pump Removal and Installation
Details the procedure for removing and installing the injection pump, including gear case and timing cover.
Engine Maintenance
Injection Pump Installation and Fuel Limit Screw
Provides steps for installing the injection pump and information on the fuel limit screw.
Engine Maintenance
Fuel Solenoid Function and Testing
Describes the fuel solenoid's function and procedures for testing its operation.
Engine Maintenance
Fuel Solenoid Connector and Replacement
Shows fuel solenoid connector pin identification and replacement steps.
Engine Maintenance
Engine Speed Adjustment Procedures
Outlines checks and procedures for adjusting engine speed, including low speed.
Engine Maintenance
High Speed Adjustment and Wintrac Settings
Details high speed adjustment and engine speed setting via Wintrac.
Engine Maintenance
Adjust Engine Valve Clearance
Explains the importance of valve clearance and the procedure for adjustment.
Engine Maintenance
Valve Clearance Adjustment Details
Details checking and adjusting valve clearance using a feeler gauge and adjusting screw.
Engine Maintenance
Valve Clearance for Cylinders 3 and 2
Covers checking and adjusting valve clearance for cylinders 3 and 2.
Engine Maintenance
Belt Inspection and Condition Check
Advises on inspecting belts for wear, tension, and proper installation, and checking their condition.
Clutch Check Guidance
Refers to further sections for detailed clutch inspection procedures.
Engine Maintenance
Belt Tension Adjustment Procedures
Details engine/compressor and water pump belt tension adjustment.
Refrigeration Service Procedures
Evacuation, Dehydration, and Charging Importance
Emphasizes the critical importance of evacuation, dehydration, and charging for system performance.
Refrigeration Service Procedures
Evacuation Station Components
Shows a diagram of the evacuation station and its components like valves and pump.
Refrigeration Service Procedures
Vacuum Gauge and Evacuation Setup
Explains the vacuum gauge and the setup procedure for evacuation equipment.
Refrigeration Service Procedures
Using Evacuation Mode
Details how to access and use the unit's Evacuation Mode via the HMI controller.
Refrigeration Service Procedures
Unit Evacuation Procedure
Provides steps for evacuating the unit, including leak checking and micron level targets.
Refrigeration Service Procedures
Unit Charging Procedure
Details the steps for charging the system with refrigerant, including pressure and sight glass checks.
Refrigeration Service Procedures
Refrigerant Gauge Removal and Leak Detection
Outlines gauge removal and refrigerant leak detection methods.
Refrigerant Charge Testing Methods
Explains methods for checking refrigerant charge using controlled and quick checks.
Refrigeration Service Procedures
Compressor Oil Level Check and Addition
Details how to check and add compressor oil under different ambient temperatures.
Refrigeration Service Procedures
Refrigeration System Checks and Low Side Pump Down
Describes system checks, pressure monitoring, and low side pump down procedure.
Refrigeration Service Procedures
R-452A Refrigerant and Oil Information
Provides information on R-452A refrigerant, unit identification, and compressor oil.
Refrigeration Service Procedures
R-452A Equipment Recommendations
Lists recommended equipment, vacuum pumps, and precautions for R-452A systems.
Refrigeration Service Procedures
Accumulator and Compressor Replacement
Details procedures for replacing the accumulator and the compressor, including oil checks.
Refrigeration Service Procedures
Compressor Coupling Installation (Standard Units)
Details the procedure for installing the compressor coupling, including cleaning tapers and aligning keyways.
Refrigeration Service Procedures
Compressor Coupling Installation and Pressurized Seal Cavity
Continues coupling installation and identifies compressors with pressurized seal cavities.
Refrigeration Service Procedures
Hex Drive Compressor Seal Replacement
Provides steps for replacing the hex drive compressor seal, including removing the seal plate.
Refrigeration Service Procedures
Lip Seal and Hard Ring Installation
Details the installation of the lip seal and hard ring, including lubrication and tool usage.
Refrigeration Service Procedures
Hex Drive Bellows and Seal Installation
Details the installation of hex drive bellows, including cleaning seal faces and applying oil.
Refrigeration Service Procedures
Hex Drive Bellows Seal Assembly
Details the assembly of hex drive bellows seal, cleaning seal faces, and applying oil.
Refrigeration Service Procedures
Condenser Check Valve and CIS Test
Describes testing the condenser check valve and the Condenser Inlet Solenoid (CIS).
Refrigeration Service Procedures
Condenser/Radiator Coil Replacement
Provides steps for removing and installing the condenser/radiator coil, noting micro-channel coil care.
Refrigeration Service Procedures
Dehydrator Replacement and Transducer Tests
Details dehydrator replacement and testing of discharge pressure transducer.
ETV Testing and Diagnostics
Refers to diagnostic manual for testing the ETV, referencing alarm codes.
Refrigeration Service Procedures
Electronic Throttling Valve (ETV) Replacement
Details procedures for removing the ETV, emphasizing safe refrigerant recovery if stuck.
Refrigeration Service Procedures
ETV Service Kit Installation
Explains the installation of the ETV service kit, including stepper motor and piston assembly.
Refrigeration Service Procedures
ETV Piston and Actuator Installation
Details lubrication and installation steps for Round and Square style ETVs.
Refrigeration Service Procedures
ETV Actuator Alignment and Assembly
Describes aligning the actuator tab with the valve body slot and arrowhead marks.
Refrigeration Service Procedures
Complete ETV Assembly Installation
Covers installing the complete ETV assembly, including soldering tubing and connecting harness.
Refrigeration Service Procedures
Evaporator Coil Replacement (S-3 and E-Evap/ES800)
Provides steps for replacing evaporator coils for different models.
Refrigeration Service Procedures
Expansion Valve Replacement Procedure
Outlines the procedure for replacing the expansion valve, including feeler bulb placement.
Refrigeration Service Procedures
Heat Exchanger Replacement and HPCO Test
Details heat exchanger replacement and testing the High Pressure Cutout Switch (HPCO).
Refrigeration Service Procedures
HPCO Replacement Procedure
Details the removal and installation of the High Pressure Cutout Switch (HPCO).
Refrigeration Service Procedures
High Pressure Relief Valve Replacement and HGS Test
Covers relief valve replacement and testing the Hot Gas Solenoid (HGS).
Refrigeration Service Procedures
In-Line Check Valve and Purge Valve (PV) Test
Details in-line check valve replacement and testing the Purge Valve (PV).
Refrigeration Service Procedures
Receiver Tank and Solenoid Valve Replacement
Outlines receiver tank and solenoid valve replacement procedures.
Refrigeration Service Procedures
Suction Pressure Transducer Testing and Replacement
Details testing and replacement of the suction pressure transducer.
Clutch Maintenance
Centrifugal Clutch Overview
Describes the centrifugal clutch, its belt grooves, and engagement speed.
Clutch Maintenance
Centrifugal Clutch Components and Inspection
Identifies clutch components and discusses potential defects and inspection.
Clutch Maintenance
Belt and Clutch Checks
Covers checking and adjusting belt tensions and performing a visual clutch check.
Clutch Maintenance
Clutch Spin Check and Operational Tests
Explains how to perform a spin check and operational checks for clutch functionality.
Clutch Maintenance
Additional Clutch Checks and Maintenance Schedule
Outlines additional checks, maintenance schedule, tools, and grease for clutch.
Clutch Disassembly Procedure
Details the steps for disassembling the clutch, starting with removing the retaining ring.
Clutch Maintenance
Clutch Housing and Bearing Removal
Provides steps for removing the clutch housing and bearings.
Clutch Maintenance
Clutch Assembly with New Bearings and Seal
Details the assembly of the clutch using new bearings and seal, including bushing insertion.
Clutch Maintenance
Clutch Assembly Steps and Torque
Continues clutch assembly, covering bearing lubrication, component installation, and torque specifications.
Structural Maintenance
Unit Inspection for Damage
Advises inspecting the unit for loose wires, hardware, or physical damage affecting performance.
Structural Maintenance
Mounting Bolt Torque Specifications
Specifies torque values for unit and engine mounting bolts.
Structural Maintenance
Coil Cleaning Recommendations
Details procedures for cleaning coils, removing debris, and checking cleaning intervals.
Structural Maintenance
Coil Cleaning Methods and Defrost Drains
Describes coil cleaning methods and maintenance for defrost drains.
Mechanical Diagnosis
Engine Crank and Start Failure Diagnosis
Lists causes and remedies for engine not cranking, or cranking but not starting.
Mechanical Diagnosis
Engine Power, Sooting, and Knocking Diagnosis
Addresses engine power loss, heavy sooting, and knocking issues.
Mechanical Diagnosis
Engine Temperature, Oil Pressure, and Consumption Diagnosis
Covers engine running hot, low oil pressure, and high oil consumption issues.
Battery Recharging Diagnosis
Lists causes and remedies for battery not recharging.
Electric Standby (Optional) Diagnosis
Display and Motor Not Running Diagnosis
Diagnoses issues with the microprocessor display not appearing or the electric motor not running.
Electric Standby (Optional) Diagnosis
Motor Hums, Contact Chatter, and Battery Recharging Diagnosis
Addresses motor humming, contact chatter, and battery recharging issues.
Refrigeration Diagnosis
Symptom-Based Refrigeration Troubleshooting
Provides a diagnostic guide linking symptoms to possible causes in the refrigeration system.
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