Thermo King 902391 Manuals

Manuals and User Guides for Thermo King 902391. We have 1 Thermo King 902391 manual available for free PDF download: Maintenance Manual

Thermo King 902391 Maintenance Manual (191 pages)

Brand: Thermo King | Category: Refrigerator | Size: 7 MB

Table of Contents
6
Safety Precautions
12
General Practices
12
Auto Start/Stop
13
Battery Installation and Cable Routing
13
Battery Removal
13
Refrigerant Hazards
13
Refrigerant Oil Hazards
14
Electrical Hazards
14
High Voltage
14
Low Voltage
15
Microprocessor Service Precautions
15
Welding Precautions
15
First Aid
16
First Aid, Refrigerant
16
First Aid, Refrigerant Oil
16
First Aid, Engine Coolant
16
First Aid, Electrical Shock
16
Specifications
17
Engine
17
Belt Tension
18
Engine Clutch
18
Refrigeration System
18
Electrical Control System
18
Fuses
19
Electrical Components
19
Electrical Standby (Model 50 Units Only)
20
T-680S and T-880S Electric Motor and Overload Relay
20
T-1080S Electric Motor and Overload Relay
20
Electric Heater Strips (Optional)
20
Standby Power Requirements
20
Maintenance Inspection Schedule
21
Unit Description
23
General Description
23
Design Features
23
Unit Options
24
Engine
24
ELC (Extended Life Coolant)
24
Clutch
24
Scroll Compressor
24
Standard HMI Control Panel
24
Mechanics HMI Control Panel
25
Premium HMI Control Panel (Optional)
25
CYCLE-SENTRYTM Start/Stop System
25
Defrost
25
DAS - Data Acquisition System (Optional)
25
Cargolink™ (Optional)
26
Electric Standby (Model 50 Units Only)
26
Standard Model 50 Features
26
Optional Model 50 Features
26
Engine Compartment Components
26
Unit Protection Devices
26
Refrigeration System Components
29
Solenoids and Valves
29
Sensors, Switches, and Transducers
29
Refrigeration System Diagrams
30
Cool Mode
31
Purge Mode
32
Heat/Defrost Mode
33
Operating Instructions for Standard HMI Control Panel
34
Truck HMI Controller Description
34
SR-3 Truck HMI Controller
34
Display
34
Keys and LED Indicators
36
Turning the Unit on and off
38
The Standard Display
38
Changing the Setpoint
39
Starting the Diesel Engine
39
Starting the Electric Motor
40
Switching from Diesel to Electric
40
Switching from Electric to Diesel
40
Selecting CYCLE-SENTRY or Continuous Mode
41
Selecting the High Speed Lock-Out Feature
42
Initiating a Manual Defrost Cycle
42
Alarms
43
Sending a Servicewatch Data Logger Start of Trip
44
Pretrip Test
44
Pretrip Test Conditions
44
Conditions Where Pretrip Tests Are Not Allowed
44
Pretrip Test Sequence
44
Pretrip Test Considerations
45
Performing a Pretrip Test
45
Starting a Pretrip Test
45
Pretrip Test Results
46
Display Brightness
46
Checking Truck HMI Control Panel Software Revision and Serial Number
47
Operating Instructions for Premium HMI Control Panel
48
Truck Premium HMI Controller Description
48
Premium HMI Control Panel
48
Display
48
Keys
49
Hard Keys
49
Soft Keys
49
Turning the Unit on and off
49
If more than One Language Is Enabled
50
The Standard Display
51
Changing the Setpoint
51
Starting the Diesel Engine
52
Starting the Electric Motor
53
Switching from Diesel to Electric
53
Switching from Electric to Diesel
54
Initiating a Manual Defrost Cycle
54
Terminating a Defrost Cycle
55
Selecting High Speed Lockout Mode (if Enabled)
55
Selecting CYCLE-SENTRY or Continuous Mode
56
Using the Gauges Key
56
Using the Sensors Key
57
Using the Main Menu
57
Main Menu Choices
58
Languages
58
Alarms
60
Datalogger
63
Hourmeters
63
Mode
64
Selecting CYCLE-SENTRY or Continuous Mode
65
Selecting Sleep Mode
66
Pretrip
68
Diesel/Electric Menu
70
Adjust Brightness
71
Time
72
Electrical Maintenance
73
Alternator Charging System Diagnostic Procedures
73
General Information
73
Alternator Identification
73
Interface Board Fuse F4
74
Test Equipment for Checking Voltage and Current
74
Alternator Load Test
74
General Diagnostic and Warranty Evaluation Procedure
74
Field Current Test
76
Battery
76
Fuses
77
Base Controller Leds
78
Smart Fets
78
SMART REEFER 3 (SR-3) Microprocessor Controller
78
Flywheel (RPM) Sensor
78
Glow Plugs
79
Unit Wiring
80
AC Components (Model 50 Units Only)
80
Electrical Contactors
80
Evaporator Heaters (Optional)
80
Condenser Fan Rotation
80
Phase Select Module for Truck Unit Model 50 Applications
80
Overload Relay
83
Engine Maintenance
85
Emi 2000
85
Engine Lubrication System
85
Engine Oil Pressure Switch/Sensor
85
Engine Oil Change
85
Oil Filter Change
86
Engine Air Cleaner (EMI 2000)
86
Crankcase Breather System
87
Engine Cooling System
88
General Description
88
ELC (Extended Life Coolant)
90
Antifreeze Maintenance Procedures
90
Bleeding Air from the Cooling System for Units with Coolant Expansion Tank Only (Ending 10/16)
91
Engine Thermostat
99
Coolant Level Switch for Units with Coolant Expansion Tank Only (Ending 10/16)
99
Coolant Level Switch for Units with Coolant Expansion Tank and Overflow Bottle (Starting 10/16)
100
Engine Fuel System
101
Operation
101
Maintenance
101
Bleeding the Fuel System
104
Draining Water from Fuel Tank
104
Fuel Filter Replacement
104
Electric Fuel Pump
105
Injection Pump Timing
105
Injection Pump Removal and Installation
107
Fuel Limit Screw
109
Fuel Solenoid
109
Engine Speed Adjustments
111
Adjust Engine Valve Clearance
112
Engine Mounts
115
Restraining Mount (Snubber) Adjustment
116
Belts
117
Engine/Electric Motor (Jackshaft) Belt
118
Electric Motor (Jackshaft)/ Compressor Belt
120
Water Pump Belt
120
Refrigeration Service Procedures
121
Evacuation, Dehydration, and Charging
121
Set up and Test of Evacuation Equipment
124
Using Evacuation Mode
124
Unit Evacuation
125
Unit Charging
126
Refrigerant Gauge Removal
127
Refrigerant Leaks
127
Refrigerant Charge
127
Testing the Refrigerant Charge with an Empty Box (Controlled Check)
127
Testing the Refrigerant Charge with a Loaded Box (Quick Check)
127
Checking Compressor Oil
128
Refrigeration System Checks
128
Low Side Pump down
129
R404A
130
Unit Identification
130
Availability
130
Leak Detection
130
Compressor Oil
130
Compressors Shipped with POE Oil
130
Equipment Recommendations for Use with R404A
130
Refrigerant Recovery
131
Refrigeration System Component Locations
132
Accumulator Replacement
134
Removal
134
Installation
134
Compressor Test
134
Compressor Replacement
134
Compressor Shaft Seal Change Procedure
137
Compressor Oil Filter Replacement
139
Compressor Oil Change
139
Compressor Temperature Sensor Testing
140
Compressor Temperature Sensor Replacement
140
Condenser Check Valve and Purge Check Valve Test
140
Condenser Inlet Solenoid (CIS) Test
141
Condenser/Radiator Coil Replacement
142
Removal
142
Installation
142
Dehydrator (Filter-Drier) Replacement
143
Removal
143
Installation
143
Discharge Pressure Regulator (DPR) Test
143
Discharge Pressure Regulator (DPR) Replacement
143
Discharge Pressure Transducer Testing
144
Discharge Pressure Transducer Replacement
144
Removal
144
Installation
144
Discharge Strainer Test
144
Discharge Strainer Replacement
144
Electronic Throttling Valve (ETV) Testing
145
Electronic Throttling Valve (ETV) Replacement
145
Removal
145
Installation of Service Kit
147
Reassembly of Piston and Stepper Motor on Old Style ETV
148
Installation of Complete ETV Assembly
149
Evaporator Coil Replacement
149
Removal
149
Installation
149
Expansion Valve Replacement
149
Installation
150
Heat Exchanger Replacement
150
Removal
150
High Pressure Cutout Switch (HPCO) Test
151
High Pressure Cutout Switch (HPCO) Replacement
151
Removal
151
Installation
152
High Pressure Relief Valve Replacement
152
Removal
152
Hot Gas Solenoid (HGS) Test
152
In-Line Check Valve Replacement
152
Removal
153
Installation
153
Liquid Injection Solenoid (LIS) Test
153
Liquid Injection Solenoid (LIS) Replacement
153
Installation
154
Purge Valve (PV) Test
154
Receiver Tank Pressure Check Valve Test
154
Receiver Tank Replacement
155
Removal
155
Installation
155
Solenoid Valve Replacement
155
Suction Pressure Transducer Testing
156
Suction Pressure Transducer Replacement
156
Removal
156
Installation
156
Clutch Maintenance
157
Centrifugal Clutch
157
Clutch Inspection
159
Check Condition of Belts
159
Check the Clutch
159
Clutch Maintenance
161
Tools Required
161
Grease
161
Disassembly Procedure
161
Assembly Procedure (Using New Bearings and Seal)
162
Structural Maintenance
164
Unit and Engine Mounting Bolts
164
Unit Inspection
164
Condenser, Evaporator and Radiator Coils
164
Micro-Channel Coil Cleaning Recommendations
164
Fan Location
165
Plastic Defrost Damper
166
Fanshaft Assembly
167
Disassembly
167
Reassembly
169
Jackshaft Assembly
170
Disassembly
170
Reassembly
171
Mechanical Diagnosis
172
Electric Standby (Optional) Diagnosis
176
Refrigeration Diagnosis
178
Index
180
Wiring and Schematic Diagrams Index
183

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