Thermo King 919202 Manuals

Manuals and User Guides for Thermo King 919202. We have 1 Thermo King 919202 manual available for free PDF download: Manual

Thermo King 919202 Manual (152 pages)

Brand: Thermo King | Category: Refrigerator | Size: 11 MB

Table of Contents
5
List of Figures
11
Safety Precautions
13
General Practices
13
Auto Start/Stop
13
Refrigerant
13
First Aid
13
Refrigeration Oil
14
First Aid
14
Electrical Hazards
14
Microprocessor Service
14
Welding of Units or Truck Bodies
15
High Voltage
15
Low Voltage
16
Unit Decals
16
Figure 1: Refrigerant Decal Locations
16
Figure 2: Refrigerant Decal
16
Specifications
17
Engine
17
Belt Tension
18
Refrigeration System
18
Engine Clutch - Hilliard
18
Electrical Control System
19
Defrost Timer
19
Thermostat
19
Electrical Components
19
Electric Standby (Model 50 Unit Only)
20
Standby Power Requirements
20
Air Switch
20
Maintenance Inspection Schedule
21
Unit Description
23
Thermoguard Μp-T Controller
23
Data Acquisition System (Optional)
23
Clutch
23
Unit Features
24
Unit Instruments
25
Unit Protection Devices
25
Unit Operation
26
Pretrip Inspection (before Starting Unit)
26
Thermoguard Μp-T Smart Reefer
27
TM (SR) Microprocessor
27
Displaying Operating Data
27
Entering Setpoint Temperature
27
Starting Unit (Full Unit Self Check)
28
Selection of Operating Modes on CYCLE-SENTRY Equipped Units
28
Products Requiring Continuous Run Operation for Air Flow
28
Products Acceptable for CYCLE-SENTRY Operation
29
Selecting CYCLE-SENTRY or Continuous Run Mode (Diesel or Electric Operation)
29
Initiating Manual Defrost
29
Displaying and Clearing Alarm Codes
30
Restarting the Unit
30
After Start Inspection
31
Loading Procedure
31
Post Load Procedure
31
Post Trip Checks
31
Unit Photographs
32
Figure 3: Front View
32
Figure 4: Back View
32
Figure 5: Side View
33
Figure 6: Components
34
Figure 7: Control Box with High Voltage Shield in Place
35
Figure 8: Power Receptacle Box-Model 50
36
Figure 9: Thermoguard Remote Control Panel
37
Figure 10: Remote Light Display Kit
37
P-T System Description
39
General Description
39
P-T Control System
39
Microprocessor Power Switch
39
Optional Electric Standby (Model 50 Units Only)
39
Figure 11: Microprocessor Power Switch
39
Standard Model 50 Features
40
Optional Model 50 Features
40
Figure 12: High Voltage Contactors with Shield Removed
41
Remote Control Panel Features
43
Keypad Keys
43
Figure 13: Remote Control Panel
43
Understanding the Display
44
Display Icons
44
Reading a Typical Display
44
Figure 14: Display Screen Features
44
Figure 15: Typical Display
44
The Standard Display
45
Changing the Setpoint
45
Figure 16: Standard Display
45
Figure 17: Changing the Setpoint
45
Selecting CYCLE-SENTRY or Continuous Mode
46
Starting the Engine
46
Figure 18: Selecting CYCLE-SENTRY or Continuous Mode
46
Figure 19: Starting the Engine
46
Initiating a Manual Defrost Cycle
47
Checking the Software Revision
47
Figure 20: Initiating a Manual Defrost Cycle
47
Figure 21: Software Revision
47
Viewing Prompt and Display Screens
48
Figure 22: Viewing Prompt and Display Screens
48
Viewing and Clearing Alarm Codes
49
Figure 23: Alarm Code Display
49
P-T Unit Self Check Test
52
Electrical Maintenance
53
Alternator (Prestolite) Charging System Diagnostic Procedures
53
Figure 24: Prestolite Terminal Locations
53
Excessive Voltage Output
54
Battery
55
Unit Wiring
55
Electrical Contacts
55
Charging System (12 VDC)
55
Preheat Buzzer
55
RPM Sensor
55
Figure 25: Flywheel (RPM) Sensor
55
Glow Plugs
56
Figure 26: RPM+ and RPM- Wires
56
Figure 27: Glow Plug Test
56
Condenser/Evaporator Fan Rotation (Electric Standby Operation)
57
Defrost Air Switch Checkout and Adjustment
57
Figure 28: Testing Air Switch
57
Figure 29: Air Switch
57
High Capacity Thermax
58
TM Heating System
58
Cool Mode
58
Heat/Condenser Evacuation Mode
58
Defrost Mode
59
Start up Mode
59
Engine Maintenance
61
Emi 2000
61
Engine Lubrication System
61
Engine Oil Pressure Sensor
61
Engine Oil Change
61
Oil Filter Change
62
Crankcase Breather
62
Engine Air Cleaner (EMI 2000)
62
Figure 30: Oil Filter Parts
62
Figure 31: Dry Type Air Cleaner
62
Engine Cooling System
63
General Description
63
Figure 32: Engine Cooling Components
63
ELC (Extended Life Coolant)
64
Figure 33: ELC Nameplate-Located on Expansion Tank
64
Engine Thermostat
66
Engine Fuel System
66
Figure 34: Water Pump Assembly and Thermostat
66
Bleeding the Fuel System
67
Figure 35: Fuel and Oil System Components
68
Draining Water from Fuel Tank
70
Fuel Filter Replacement
70
Electric Fuel Pump
70
Figure 36: Electric Fuel Pump
70
Injection Pump
71
Engine Maintenance (Continued)
71
Figure 37: Timing Marks
72
Figure 38: Individual Cylinder Timing and Firing Order
73
Adjust Engine Valve Clearance
74
Fuel Limit Screw
74
Engine Mounts
75
Figure 39: Engine Mounting Components
75
Restraining Mount Adjustment
77
Figure 40: Chain/Restraining Mount
77
Figure 41: Chain/Restraining Mount Bracket
78
Integral Fuel Solenoid
79
Fuel Solenoid Diagnostic and Replacement
79
Figure 42: Integral Fuel Solenoid Components
79
Engine Speed Adjustments
80
Low Speed Adjustment
80
High Speed Adjustment
80
Belts
81
Engine/Electric Motor Belt
81
Figure 43: Front View Belt Arrangement
81
Electric Motor/Compressor Belt
82
Alternator Adjustment
83
Figure 44: Alternator Mounting and Belt Tension Adjustment
83
Idler Pulley Bearing and Seal Installation
84
Figure 45: Idler Pulley Assembly
84
Assembly Instructions
85
Refrigeration Maintenance
87
Evacuation
87
Figure 46: Evacuation Station
88
Figure 47: Vacuum Gauge
89
Set up and Test of Evacuation Equipment
90
Unit Evacuation
91
Unit Charging
91
Remove Refrigerant Hoses
92
Refrigerant Leaks
92
Refrigerant Charge
92
Testing the Refrigerant Charge with an Empty Box
92
Testing the Refrigerant Charge with a Loaded Box
93
Checking Compressor Oil
93
Figure 48: Scroll Compressor
93
High Pressure Cutout (HPCO)
94
Low Side Pump down
94
Figure 49: High Pressure Cutout Manifold
94
Refrigeration System Checks
95
Three-Way Valve Condenser Pressure Bypass Check Valve
95
Figure 50: Gauge Manifold Installation
95
Figure 51: Three-Way Valve Condenser Pressure Bypass Check Valve
96
Discharge Pressure Regulator Valve
97
Figure 52: Discharge Pressure Regulator Valve Assembly
97
Refrigeration Service Operations
99
Accumulator
99
Removal
99
Installation
99
Compressor
99
Figure 53: Compressor Components
100
Shaft Seal Change Procedure
101
Figure 54: Cross Section of Set Screw Type Bellows
101
Figure 55: Set Screw Type Bellows Seal
101
Figure 56: Bellows Installation with Tool
102
Figure 57: Lip Seal and Hard Ring Installation
102
Compressor Oil Filter Replacement
103
Scroll Compressor Oil Change
103
High Temperature Cutout Switch Change Procedure
104
Liquid Injection Fitting Change Procedure
104
Condenser/Radiator Coil
105
Removal
105
Installation
105
Receiver Outlet Check Valve
105
Liquid Injection Valve
105
Installation
106
Dehydrator (Filter-Drier)
106
Removal
106
Refrigeration Service Operations (Continued)
106
Evaporator Coil
106
Figure 58: Location of Injection Valve Bulb
106
Figure 59: Completely Wrap Bulb with Tape
106
Installation
107
Expansion Valve Assembly
107
Removal
107
Figure 60: Location of Expansion Valve Bulb
107
Figure 61: Completely Wrap Bulb with Tape
107
Cleaning In-Line Screen
108
Heat Exchanger
108
Removal
108
Installation
108
Figure 62: Expansion Valve
108
High Pressure Cutout Switch
109
Removal
109
Installation
109
High Pressure Relief Valve
109
Pilot Solenoid
109
Receiver Tank
109
Three-Way Valve Condenser Pressure Bypass Check Valve Repair
110
Removal
110
Installation
110
Figure 63: Condenser Pressure Bypass Check Valve
110
Three-Way Valve Repair
111
Removal
111
Figure 64: Three-Way Valve Assembly
111
Installation
112
Unit Identification
112
Availability
112
Leak Detection
112
Figure 65: R404A Decal
112
Compressor Oil
113
Compressors Shipped with POE Oil
113
Equipment Recommendations for Use with R-404A
113
Gauge Manifold Sets
113
Refrigerant Recovery
114
Throttling Valve
114
Removal
114
Disassembly
114
Figure 66: Throttle Valve, Cap and Spring
114
Figure 67: Throttle Valve Piston
114
Reassembly
115
Installation
115
Figure 68: Throttle Valve Housing
115
Figure 69: Throttle Valve Piston Assembly
115
Figure 70: Throttling Valve
116
Hilliard Clutch Maintenance
117
Large Truck Unit Centrifugal Clutch Change
117
Figure 71: Front View and Cross Section
117
Figure 72: Hilliard Centrifugal Clutch
118
Clutch Maintenance
119
Tools Required
119
Grease
119
Disassembly Procedure
119
Figure 73: Housing Removal
119
Figure 74: Bearing Removal
119
Assembly Procedure (Using New Bearings and Seal)
120
Figure 75: Bushing Removal
120
Figure 76: Bushing Insertion
120
Figure 77: Clutch
121
Structural Maintenance
123
Unit and Engine Mounting Bolts
123
Unit Inspection
123
Condenser, Evaporator and Radiator Coils
123
Fan Location
123
Figure 78: Fan Blade Position in Orifice
123
Defrost Damper
124
Figure 79: Defrost Damper Adjustment
124
Fanshaft Assembly
125
Disassembly
125
Figure 80: Fan Shaft Assembly
125
Figure 81: Removing Bearing Retainer Bolts
125
Figure 82: Removing Shaft
125
Reassembly
126
Figure 83: Removing Oil Seal
126
Figure 84: Removing Roll Pin
126
Figure 85: Installing Bearings
126
Figure 86: Installing Splash Guard
126
Figure 87: Installing Oil Seal
127
Figure 88: Shims and O-Ring
127
Figure 89: Torquing Retainer Plate Bolts
127
Figure 90: Checking End Play
127
Mechanical Diagnosis
129
Electric Standby (Optional) Diagnosis
133
Refrigeration Diagnosis
135
Cycle Diagrams
137
Cool Cycle
137
Figure 91: Cool Cycle Diagram
137
Condenser Evacuation Cycle
138
Figure 92: Condenser Evacuation Cycle Diagram
138
Heat/Defrost Cycle
139
Figure 93: Heat/Defrost Cycle Diagram
139
Index
141
Wiring and Schematic Diagrams Index
143

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Thermo King 919202 Manual (152 pages)

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