User Manuals: Thermo King 902041 Control Device

Manuals and User Guides for Thermo King 902041 Control Device. We have 1 Thermo King 902041 Control Device manual available for free PDF download: Maintenance Manual

Thermo King 902041 Maintenance Manual (120 pages)

Brand: Thermo King | Category: Air Conditioner | Size: 5 MB

Table of Contents
6
Danger, Warning, Caution, and Notice
12
General Practices
12
Personal Protective Equipment (PPE)
14
Auto Start/Stop
14
Battery Installation and Cable Routing
14
Refrigerant Hazards
15
Refrigerant Oil Hazards
16
Electrical Hazards
16
High Voltage
16
Low Voltage
18
Controller / Microprocessor Service Precautions
18
Welding Precautions
18
First Aid
18
Electrical System
21
Refrigeration System
23
Compressors
24
Belt Tension
24
AC Semi-Hermetic Compressor
24
Contactors
25
Capacitors
25
Transformer
25
Start Relay
25
Electric Standby Power Supply Requirements
25
Optional Electric Heaters
25
Solder Applications
26
Introduction
27
Standard Features
27
Optional Features
27
Condenser
27
Evaporator
28
Compressor
28
Control Circuits
28
DSR Control System
28
Oil Separator
28
Refrigerant
29
Liquid Injection System
29
Evaporator Drain Line Heaters
29
Electric Standby Operation
29
Protection Features
29
Control Box
30
P.C. Boards
30
Electronic Control Module (ECM)
30
Refrigeration System Components
30
Solenoids and Valves
30
Hot Gas Solenoid (HGS)
30
Switches and Transducers
30
Low Pressure Cutout Switch (LPCO)
30
Liquid Injection Switch (LISW)
30
Discharge Pressure Transducer (DPT)
30
Unit Operation
31
Operation
32
Cool Mode
32
Null Mode - Single Temperature Units
44
Null Mode - SPECTRUM Multi-Temp Units
44
Purge Mode - Model 30 and Model 50 Units Only
44
Heat Mode - Model 30 and Model 50 Single Temperature Units Only
44
Heat Mode - Model 50 SPECTRUM Multi-Temp Units Only
48
Defrost Mode - Single Temperature Units
50
Defrost Mode - SPECTRUM Multi-Temp Units
53
Serial Number Locations
56
Unit Components
56
Electrical
59
Refrigeration/Heating
59
Structural
60
Maintenance Inspection Schedule Checklist Authentication
60
Electronic Control System
61
Defrost System
61
Defrost Termination Switch
61
Defrost Termination Switch Replacement
61
Removal
61
Installation
61
Liquid Injection System
62
Testing Liquid Injection Solenoid Valve and Metering Orifice
62
Testing Liquid Injection Switch (LISW)
62
Liquid Injection Switch (LISW) Replacement
62
Removal
62
Installation
62
Condenser Fan Motor
63
Condenser Fan Motor Removal and Installation
63
Removal
63
Installation
63
Evaporator Fan Motors
63
Evaporator Fan Motor Removal and Installation
64
Removal
64
Installation
64
Drain Line Heaters
64
Drain Line Heater Replacement
64
Fuses
66
Relays
67
Relay Testing
67
Relay Replacement
68
AC Components Model 20 and Model 50 Units Only
68
Electrical Contactors
71
Compressor Motor Contactor
71
Compressor Motor Contactor Replacement
71
Electric Heat Contactor - HC (Model 20 Option Only)
72
Electric Heat Contactor Replacement
72
Thermal Motor Protector
72
Thermal Motor Protector Replacement
72
Transformer - T1
72
Transformer Testing
73
Transformer Replacement
73
Rectifier Bridge
73
Capacitors
73
Capacitor Testing
74
Capacitor Replacement
74
Start Relay
74
Start Relay Testing
74
Start Relay Replacement
75
Compressor Motor
75
Testing 230/1/60 Units
75
Testing 230/3/60 Units
75
Electric Standby Circuits
76
Heat Option - Truck Engine Coolant
77
Heat Option - Truck Engine Coolant and Electric Standby Heater Strip
78
Evacuating and Charging the Refrigeration System
80
Checking the Refrigerant Charge
80
Testing the Refrigerant Charge with an Empty Box
80
Testing the Refrigerant Charge with a Loaded Box
80
Suction (Low Side) Bump Charging
81
Checking Compressor Oil Charge
81
Refrigeration System Checks
82
Cleanup Procedure for Small Truck Units
82
Tools Required
82
Clean-Up Procedure
82
Putting the Unit Back into Operation
83
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
86
Engine Driven Compressor
91
Removal
91
Installation
91
Electric Standby Compressor
91
Condenser Coil
91
Installation
92
Drier
92
Removal
92
Discharge Pressure Transducer (DPT)
92
Hot Gas Solenoid (HGS) Test
92
Liquid Injection Solenoid (LIS) Test
93
Condenser Inlet Solenoid (CIS) Test
93
Liquid Line Solenoid Test (SPECTRUM Only)
93
CPR Bypass Solenoid Test (SPECTRUM Only)
94
Solenoid Valve Replacement
94
Removal
94
Installation
94
Oil Separator
94
Removal
95
Installation
95
Liquid Injection Metering Orifice
95
Liquid Line Check Valve (Model 30 and 50 Single Temp Only)
95
Liquid Line Check Valve Test
95
Liquid Line Check Valve Replacement
96
Removal
96
Installation
96
Discharge Check Valve (Model 20 and 50 Only)
96
Testing the Discharge Check Valve
96
Discharge Check Valve Replacement
97
Removal
97
Installation
97
Suction Pressure Regulator Valve (Model 20 and 50 Only)
97
Suction Pressure Regulator Valve Test
97
Suction Pressure Regulator Valve Replacement
97
Evaporator Coil
98
Removal
98
Installation
98
Expansion Valve Assembly
98
Checking Superheat
98
Expansion Valve Replacement
99
Removal
99
Low Pressure Cutout Switch (LPCO)
100
Low Pressure Cutout Switch Test
100
Low Pressure Cutout Switch Replacement
101
Removal
101
Installation
101
Compressor Pressure Regulator Valve in Model 30 and 50 Single Temp Units
101
Compressor Pressure Regulator Valve Test
102
Compressor Pressure Regulator Valve Replacement
103
Removal
103
Installation
103
Compressor Pressure Regulator Valve in SPECTRUM Units
103
SPECTRUM Advanced Control System
103
Advanced Control System Components and Operation
103
Compressor Pressure Regulator Valve Setup Procedure
104
Compressor Pressure Regulator Valve Replacement
104
Removal
104
Installation
104
Accumulator
104
Replacing Refrigerant Hoses (Speedy Clip System)
105
Compressor Failures
106
Compressor Test
106
Engine Driven Compressor Belt and Pulleys
107
Condenser and Evaporator Coils
108
Coil Cleaning Recommendations
108
Cleaning Intervals
108
Cleaning Methods
108
Unit Mounting Bolts
109

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