Thermo King 002010 Manuals

Manuals and User Guides for Thermo King 002010. We have 1 Thermo King 002010 manual available for free PDF download: Manual

Thermo King 002010 Manual (155 pages)

Brand: Thermo King | Category: Refrigerator | Size: 17 MB

Table of Contents
5
List of Figures
9
Safety Precautions
11
General Practices
11
Refrigerant
11
Refrigerant Oil
11
Electrical Hazards
11
High Voltage
11
Low Voltage
12
Specifications
13
Engine
13
Belt Tension
14
Refrigeration System
14
Electrical Control System
15
Electrical Components
15
Smart Reefer Multi-Temp Μp-IV Microprocessor Temperature Controller
16
Electric Standby (Model 50 Units Only)
16
Maintenance Inspection Schedule
17
Unit Description
19
General Description
19
Host Unit
19
Spectrum Remote Evaporators
19
Thermo King TK 486 Engine
19
Figure 1:Front View
19
Figure 2:S-3 Spectrum Remote Evaporator
19
Thermo King X430L Compressor
20
Smart Reefer Multi-Temp Μp-IV Microprocessor
20
CYCLE-SENTRY Start-Stop Controls
20
DAS (Optional)
21
Remote Control Box (Optional)
21
Sequence of Operation
21
Defrost
21
System Operation
22
Refrigeration System Diagrams
23
Zone 1 Cool, Zone 2 Cool, and Zone 3 Cool
24
Figure 3:Zone 1 Cool, Zone 2 Cool, and Zone 3 Cool
25
Zone 1 Cool, Zone 2 Cool, and Zone 3 Heat
26
Figure 4:Zone 1 Cool, Zone 2 Cool, and Zone 3 Heat
27
Design Features
28
Serial Number Locations
29
Figure 5:Compressor Serial Number Location
29
Figure 6:Engine Serial Number Location
29
Figure 7:Unit Serial Number Locations
29
Figure 8:Laminated Serial Number Plate (Located Where Shown Above)
29
Figure 9:Front View
30
Figure 10:Back View
31
Figure 11:Engine Compartment
32
Figure 12:Control Panel
33
Figure 13:Typical Components Inside Control Box
34
Operating Instructions
35
Control Panel
35
Zone 1/Host On/Off Switch
35
Figure 14:Control Panel
35
Zone 2 On/Off Switch
36
Zone 3 On/Off Switch
36
Diesel/Electric Switch (Model 50 Only)
36
Display
36
Keypad
36
Computer Port
37
Printer Port
37
Unit Indicators
37
Unit Protection Devices
37
Unit Operation
38
Manual Pretrip Inspection (before Starting Unit)
38
Starting Unit with Electronic Full Pretrip Test
39
Selection of Operating Modes
39
Restarting Unit-Diesel Operation
40
Restarting Unit-Electric Operation
40
After Start Inspection
41
Operating Instructions (Continued)
41
Loading Procedure
41
Single Temperature Loading Procedures
41
Figure 15:Single Temperature Load, Host on and Remote Off, Bulkhead Open/Removed
41
Post Load Procedure
42
Post Trip Checks
42
Figure 16:Same Temperatures in each Compartment, Host and Remote Running, Bulkhead Closed
42
Electrical Maintenance
43
Australian Bosch Alternator - Model 30
43
Amp Charging System Diagnostic Procedures
43
Figure 17:Check Points for Alternator Test
43
Field Current Test
45
Prestolite Alternator - Model 50
46
Amp Charging System Diagnostic Procedures
46
Figure 18:Prestolite Terminal Locations
46
Battery
48
Fuses
48
Figure 19:Control Box
48
Fuse Link
49
Air Heater
49
Smart Reefer Multi-Temp Μp-IV Microprocessor Controller
49
Unit Wiring
49
AC Components (Model 50 Units Only)
49
Electrical Contactors
49
Evaporator Heaters
49
Figure 20:Air Heater
49
Auto Phase System
50
Figure 21:Host Unit Air Flow
50
Figure 22:High Voltage Tray
51
Engine Maintenance
53
Emi 3000
53
Engine Lubrication System
53
Engine Oil Change
53
Oil Filter Change
53
Low Oil Pressure
53
Engine Cooling System
55
ELC (Extended Life Coolant)
55
Figure 23:ELC Nameplate Located on Expansion Tank
55
Antifreeze Maintenance Procedure
56
Figure 24:Engine Cooling System
56
Bleeding Air from the Cooling System
57
Engine Thermostat
58
Engine Fuel System
58
Operation
58
Maintenance
58
Figure 25:Engine Fuel System
59
Bleeding the Fuel System
60
Draining Water from Fuel Tank
60
Fuel Filter/Water Separator
60
Fuel Filter/Water Separator Replacement
60
Figure 26:Fuel Tank
60
Figure 27:Injection Pump
60
Engine Speed Adjustments
61
Figure 28:Filling Fuel Filter/Water Separator
61
Figure 29:Engine Speed Adjustments
61
Injection Pump Timing
62
Figure 30:Component Location
62
Figure 31:Top Dead Center One and Four
62
Injection Pump Removal
63
Figure 32:Timing Mark Alignment
63
Figure 33:Correct Injection Timing Mark Alignment
63
Injection Pump Reinstallation
64
Figure 34:Injection Pump Gear Tool
64
Fuel Solenoid System
65
Figure 35:Fuel Solenoid Location
65
Figure 36:Fuel Solenoid Timer
65
Figure 37:Simplified Schematic Diagram of Fuel Solenoid System
66
Figure 38:Main Wire Harness Connector Pin Identification
66
Figure 39:Fuel Solenoid Connector Pin Identification
66
Figure 40:Relay Socket Terminal Identification
67
Engine Valve Clearance Adjustment
68
Figure 41:Fuel Solenoid Components
68
Figure 42:Top Dead Center One and Four
68
Figure 43:Adjusting the Valve Clearance
69
Crankcase Breather
70
Air Cleaner
70
EMI 3000 Air Cleaner
70
Figure 44:Crankcase Breather
70
Figure 45:EMI 3000 Air Cleaner Assembly
70
Figure 46:EMI 3000 Air Filter Element
70
Air Restriction Indicator
71
Belts
71
Figure 47:EMI 3000 Air Cleaner System Model 30 Shown Model 50 Similar
71
Figure 48:Air Restriction Indicator
71
Model 30 Belt Adjustments
72
Figure 49:Model 30 Belt Arrangement
72
Model 30 Fan Belt Replacement
73
Model 50 Belt Adjustments
74
Figure 50:Condenser Blower Alignment
74
Model 50 Compressor Belt Replacement
75
Figure 51:Model 50 Belt Arrangement
75
Model 50 Fan Belt Replacement
76
Clutch (Model 50)
76
Figure 52:Clutch
78
Refrigeration Maintenance
79
Refrigerant Charge
79
Testing the Refrigerant Charge with an Empty Trailer
79
Testing the Refrigerant Charge with a Loaded Trailer
79
Testing for an Overcharge
79
Adjusting Refrigerant Level
80
Moisture Indicating Sight Glass
80
Refrigerant Leaks
80
Figure 53:Moisture Indicating Sight Glass
80
Compressor Sump Sizes
81
Figure 54:Compressor with 4-Quart Sump
81
Figure 55:Compressor with 7-Quart Sump
81
Checking Compressor Oil
82
High Pressure Cutout Switch (HPCO)
82
High Pressure Switch (HPSW) Test
83
Figure 56:High Pressure Cutout Manifold
83
Evacuating and Charging Smart Reefer Multi-Temp Systems
84
Set-Up Unit
84
Evacuating the System
84
Figure 57:Multi-Temp Evacuation and Charging (Two Zone Unit Shown Other Units Similar)
85
Charging the System
86
Refrigeration Service Operations
87
Low Side Pump down
87
Compressor
87
Compressor Coupling Removal
88
Compressor Coupling Installation
89
Figure 58:Compressor Coupling Removal Tool
89
Condenser Coil
90
Figure 59:Keyway Tool P/N 204-972
90
Figure 60:Compressor Coupling Installation
90
Discharge Vibrasorber
91
In-Line Check Valves
91
Figure 61:Cross Section of In-Line Check Valve
91
Receiver Tank
92
Filter Drier
92
Expansion Valve Assembly
92
Heat Exchanger
93
Evaporator Coil
93
Figure 62:Location of Expansion Valve Bulb
93
Accumulator
94
Suction Vibrasorber
94
High Pressure Cutout Switch and High Pressure Switch
94
Discharge Pressure Sensor
95
High Pressure Relief Valve
95
Throttling Valve
95
Removal
95
Figure 63:Throttling Valve Assembly
96
Disassembly
97
Reassembly
97
Figure 64:Inspect the Parts
97
Figure 65:Inspect for Wear
97
Figure 66:Inspect for Damage
97
Installation
98
Liquid Line Solenoid Valve (LLS)
98
Figure 67:Throttling Valve Reassembly
98
Hot Gas Solenoid Valve (HGS)
99
Suction Line Solenoid Valve (SLS)
99
Check Valve Repair (SLCV, SLCV2, SLCV3, LRCV, and PVC)
100
Figure 68:Suction Line Check Valve
100
Figure 69:Check Valve with Cap Nut
100
Check Valve Replacement (SLCV, SLCV2, SLCV3, LRCV, and PVC)
101
Condenser Inlet Solenoid Valve (CIS)
101
Installation
101
Condenser Inlet Check Valve (CICV) Repair
101
Condenser Inlet Check Valve (CICV) Replacement
102
Receiver Tank Pressure Solenoid Valve (RTPS)
102
Purge Valve (PV)
102
Compressor Oil Filter
103
Checking Compressor Oil Pressure
103
Figure 70:Compressor Oil Filter
103
Priming New Compressor Installations
104
Structural Maintenance
105
Unit and Engine Mounting Bolts
105
Unit Inspection
105
Condenser, Evaporator, and Radiator Coils
105
Defrost Drains
105
Unit Installation
105
Figure 71:Unit and Engine Mounting Bolts
105
Defrost Damper
106
Figure 72:Defrost Damper Adjustment
106
Condenser and Evaporator Fan Location
107
Condenser Fan Blower
107
Evaporator Fan Blower
107
Figure 73:Condenser Blower Alignment
107
Figure 74:Evaporator Fan Location
107
Fan Shaft Assembly
108
Fan Shaft Assembly Overhaul
108
Figure 75:Fan Shaft Assembly
108
Idler Assembly
109
Idler Assembly Overhaul
109
Figure 76:Idler Assembly
110
Mechanical Diagnosis
111
Electric Standby Diagnosis
115
Refrigeration Diagnosis
117
Remote Evaporator Specifications
119
Refrigeration System
119
Electrical
119
Remote Evaporator Maintenance Inspection Schedule
121
Remote Evaporator Unit Description
123
Figure 77:Spectrum S-3 Evaporator Components
123
Figure 78:Spectrum S-3 Evaporator - Front View
124
Figure 79:Spectrum S-3 Evaporator - Back View
124
Unit Operation
125
Defrost
125
Operating Modes
125
Unit Features
125
Unit Protection Devices
126
Serial Number Location
126
Figure 80:Serial Number Location
126
Remote Evaporator Electrical Maintenance
127
Smart Reefer Multi-Temp Μp-IV Microprocessor Controlled Components
127
Unit Wiring
127
Remote Evaporator Refrigeration Service Operations
129
Expansion Valve Assembly
129
Evaporator Coil
129
Solenoid Valves
130
Liquid Return Check Valve Repair
130
Figure 81:Check Valve with Cap Nut
130
Liquid Return Valve Replacement
131
Heat Exchanger
131
Remote Evaporator Structural Maintenance
133
Unit Inspection
133
Defrost Drains
133
Evaporator Coil
133
Remote Evaporator System Diagnosis
135
Index
137
Wiring Diagrams Index
141

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Thermo King 002010 Manual (155 pages)

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