User Manuals: Thermo King TK40956 Refrigeration System

Manuals and User Guides for Thermo King TK40956 Refrigeration System. We have 1 Thermo King TK40956 Refrigeration System manual available for free PDF download: Manual

Thermo King TK40956 Manual (142 pages)

Brand: Thermo King | Category: Refrigerator | Size: 13 MB

Table of Contents
5
List of Figures
9
Safety Precautions
11
General Practices
11
Auto Start/Stop
11
Refrigerant
11
First Aid
11
Refrigeration Oil
12
First Aid
12
Electrical Hazards
12
Microprocessor Service
12
Welding of Units or Truck Bodies
13
High Voltage
13
Low Voltage
14
Specifications
15
Maintenance Inspection Schedule
19
Unit Description
21
General Description
21
Unit Instruments
22
Unit Protection Devices
23
Unit Operation
24
Pre-Trip Inspection (before Starting Unit)
24
Starting Unit (Full Unit Self Check)
24
Selection of Operating Modes on CYCLE-SENTRY Equipped Units
25
Products Requiring Continuous Run Operation for Air Flow
25
Products Acceptable for CYCLE-SENTRY Operation
25
Continuous Run Operation
25
Auto Start-Stop Operation
25
Restarting the Unit
26
After Start Inspection
26
Loading Procedure
27
Post Load Procedure
27
Post Trip Checks
27
Unit Photographs
28
Figure 1: Front Curbside View-MD-200
28
Figure 2: Front Roadside View-MD-200
28
Figure 3: X214 Compressor
29
Figure 4: X214 Compressor
30
Figure 5: Access Panel Open (Curbside)-MD-200
31
Figure 6: Rear View (Curbside)-MD-200
31
Figure 7: Side View (Roadside)
32
Figure 8: Top View
33
Figure 9: Control Box
34
Figure 10: Power Receptacle Box-MD-200 50
35
Figure 11: THERMOGUARD Remote Control Panel
36
Μp-T System Description
37
General Description
37
Μp-T Control System
37
Microprocessor Power Switch
37
Optional Electric Standby (Model 50 Units Only)
37
Figure 12: Microprocessor Power Switch
37
Standard Model 50 Features
38
Optional Model 50 Features
38
Figure 13: High Voltage Tray no Options
38
Figure 14: High Voltage Tray with Phase Correction
38
Figure 15: High Voltage Tray with Electric Heat
39
Figure 16: High Voltage Tray with Phase Correction and Electric Heat
39
Figure 17: High Voltage Tray with Single Phase Power and Electric Heater
39
Remote Control Panel Features
41
Keypad Keys
41
Understanding the Display
41
Display Icons
42
Reading a Typical Display
42
The Standard Display
43
Changing the Setpoint
43
Selecting CYCLE-SENTRY or Continuous Mode
44
Starting the Engine
44
Initiating a Manual Defrost Cycle
45
Checking the Software Revision
45
Viewing Prompt and Display Screens
46
Viewing and Clearing Alarm Codes
47
Remote Control Panel Features (Continued)
47
To View Alarm Codes
47
To Clear Alarm Codes
47
Μp-T Alarms
47
Μp-T Unit Self Check Test
50
Electrical Maintenance
51
Alternator (Prestolite) Charging System Diagnostic Procedures
51
Figure 18: Prestolite Terminal Locations
51
Excessive Voltage Output
52
Battery
52
Unit Wiring
53
Electrical Contacts
53
Charging System (12 VDC)
53
Preheat Buzzer
53
RPM Sensor
53
Figure 19: Flywheel (RPM) Sensor
53
Figure 20: RPM+ and RPM- Wires
53
Glow Plugs
54
Defrost Air Switch Checkout and Adjustment
54
Figure 21: Glow Plug Test
54
Figure 22: Testing Air Switch
55
Figure 23: Air Switch
55
High Capacity Thermax
56
TM Heating System
56
Cool Mode
56
Heat/Condenser Evacuation Mode
56
Defrost Mode
56
Start up Mode
56
Units Equipped with a Three-Phase Electric Motor and a Phase Converter that Operates on Single-Phase Power
57
Conversion System
57
Start System
57
Figure 24: First and Second-Phase Connections
58
Figure 25: Motor Start Contactor Control Coil Circuit
59
Run System
60
Figure 26: Third Phase Connection During a Start
60
Figure 27: Third Phase Connection During a Start
61
Troubleshooting the Phase Conversion System
62
Troubleshooting Chart
64
Engine Maintenance
69
Emi 2000
69
Engine Lubrication System
69
Engine Oil Pressure Switch
69
Figure 28: Engine Oil Pressure Switch
69
Engine Oil Change
70
Oil Filter Change
70
Crankcase Vent
70
Engine Air Cleaner (EMI 2000)
70
Figure 29: Oil Filter Parts
70
Figure 30: Dry Type Air Cleaner
70
Engine Cooling System
71
General Description
71
Figure 31: Engine Cooling Components
71
ELC (Extended Life Coolant)
72
Figure 32: ELC Nameplate-Located on Expansion Tank
72
Antifreeze Maintenance Procedure
73
Checking the Antifreeze
73
Engine Thermostat
74
Engine Fuel System
74
Figure 33: Water Pump Assembly and Thermostat
74
Bleeding the Fuel System
75
Figure 34: Fuel and Oil System Components
76
Figure 35: Fuel and Oil System Components for Figure 122
77
Draining Water from Fuel Tank
78
Fuel Filter Replacement
78
Electric Fuel Pump
78
Figure 36: Electric Fuel Pump
78
Injection Pump
79
Figure 37: Timing Marks
80
Figure 38: Individual Cylinder Timing and Firing Order
81
Adjust Engine Valve Clearance
82
Fuel Limit Screw
82
Integral Fuel Solenoid
82
Figure 39: Emission Control Label
82
Fuel Solenoid Diagnostic and Replacement
83
Belt Tensions
83
Figure 40: Integral Fuel Solenoid Components
83
Auto Start/Stop
84
Figure 41: MD-II SR Belt Arrangement
84
Figure 42: Idler Assembly
85
Figure 43: New Idler Assembly
86
Figure 44: Belt Layout
87
Figure 45: Alternator Mounting and Belt Tension Screws
88
Engine Speed Adjustments
89
Low Speed Adjustment
89
High Speed Adjustment
89
Refrigeration Maintenance
91
Evacuation
91
Figure 46: Evacuation Station
92
Figure 47: Vacuum Gauge
93
Set up and Test of Evacuation Equipment
94
Figure 48: Leak
94
Figure 49: Moisture
94
Unit Evacuation
95
Refrigerant Leaks
95
Unit Charging
95
Figure 50: Unit Charging
97
Refrigerant Charge
98
Testing the Refrigerant Charge with an Empty Box
98
Testing the Refrigerant Charge with a Loaded Box
98
Checking Compressor Oil
98
High Pressure Cutout (HPCO)
99
Figure 51: X214 Compressor
99
Figure 52: High Pressure Cutout Manifold
99
Compressor Pump down and Checkout
100
Low Side Pump down
100
Figure 53: Install Gauge Manifold
100
Figure 54: Compound Gauge Indicating 20 In. Vacuum
100
Three-Way Valve Condenser Pressure Bypass Check Valve
101
Figure 55: Three-Way Valve Condenser Pressure Bypass Check Valve
101
Refrigeration Service Operations
103
Accumulator
103
Removal
103
Installation
103
Compressor
103
Condenser/Radiator Coil
103
Installation
104
Liquid Line Check Valve Replacement
104
Removal
104
Dehydrator (Filter-Drier)
104
Evaporator Coil
104
Expansion Valve Assembly
105
Removal
105
Installation
105
Cleaning In-Line Screen
105
Figure 56: Location of Expansion Valve Bulb
105
Figure 57: Completely Wrap Bulb with Tape
105
Heat Exchanger
106
Removal
106
Installation
106
Figure 58: Expansion Valve
106
High Pressure Cutout Switch
107
Removal
107
Installation
107
High Pressure Relief Valve
107
Pilot Solenoid
107
Pressure Regulator Valve
107
Receiver Tank
108
Removal
108
Installation
108
Three-Way Valve Condenser Pressure Bypass Check Valve Repair
108
Refrigeration Service Operations (Continued)
108
Figure 59: Condenser Pressure Bypass Check Valve
108
Three-Way Valve Repair
109
Removal
109
Installation
110
Compressor Pulley Removal and Installation
110
Figure 60: Three-Way Valve Assembly
110
Oil Filter Maintenance
111
Figure 61: Anti-Seize Lubricant Application
111
Figure 62: Compressor Oil Filter
112
Equipment Recommendations for Use with R-404A
113
Hilliard Clutch Maintenance
115
Large Truck Unit Centrifugal Clutch Change
115
Figure 63: Front View and Cross Section
115
Figure 64: Hilliard Centrifugal Clutch
116
Clutch Maintenance
117
Tools Required
117
Grease
117
Disassembly Procedure
117
Figure 65: Housing Removal
117
Figure 66: Bearing Removal
117
Assembly Procedure (Using New Bearings and Seal)
118
Figure 67: Bushing Removal
118
Figure 68: Bushing Insertion
118
Figure 69: Clutch
119
Structural Maintenance
121
Unit and Engine Mounting Bolts
121
Lift Points
121
Unit Inspection
121
Evaporator Coil
121
Condenser Coil
121
Defrost Damper
121
Figure 70: Check Bolts for Tightness
121
Figure 71: Lift Points
121
Jackshaft Assembly
122
Figure 72: Defrost Damper Adjustment
122
Fanshaft Assembly
124
Fanshaft Assembly Overhaul
124
Disassembly
124
Figure 73: Jackshaft Assembly
124
Figure 74: Removing Bearing Retainer Bolts
124
Figure 75: Removing Shaft
124
Figure 76: Removing Oil Seal
124
Reassembly
125
Figure 77: Removing Roll Pin
125
Figure 78: Installing Bearings
125
Figure 79: Installing Splash Guard
125
Figure 80: Installing Oil Seal
125
Figure 81: Shims and O-Ring
125
Figure 82: Torquing Retainer Plate Bolts
126
Figure 83: Checking End Play
126
Figure 84: Fan Shaft Assembly
126
Mechanical Diagnosis
127
Electric Standby (Optional) Diagnosis
131
Refrigeration Diagnosis
133
Index
135
Wiring and Schematic Diagrams Index
137

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User Manuals: Thermo King TK40956 Refrigeration System

Thermo King TK40956 Manual (142 pages)

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