Thermo King UT-1000R Manuals

Manuals and User Guides for Thermo King UT-1000R. We have 1 Thermo King UT-1000R manual available for free PDF download: Maintenance Manual

Thermo King UT-1000R Maintenance Manual

Thermo King UT-1000R Maintenance Manual (132 pages)

Self Powered Truck Edition

Brand: Thermo King | Category: Automobile Accessories | Size: 8 MB

Table of Contents

Table of Contents
4
Danger, Warning, Caution, and Notice
10
General Practices
10
Battery Installation and Cable Routing
12
Battery Removal
13
Refrigerant Hazards
13
Refrigerant Oil Hazards
14
Electrical Hazards
15
- High Voltage
  15
- Low Voltage
  16
Controller / Microprocessor Service Precautions
16
Welding Precautions
16
First Aid
18
Engine
19
Engine Clutch
20
Belt Tension
20
Refrigeration System
20
Electrical Control System
20
Fuses
21
Electrical Components
21
Evaporator Fan Motor
22
Electrical Standby
22
- Electric Motor and Overload Relay
  22
- Standby Power Requirements
  22
General Description
24
Design Features
24
Unit Options
24
Basic HMI Controller
25
Mechanics HMI Controller
25
Premium HMI Control Panel (Optional)
25
CYCLE-SENTRY™ Start/Stop System
25
Unit Protection Devices
26
Unit Component Identification
27
Refrigeration System Components
29
- Solenoids and Valves
  29
  - Condenser Inlet Solenoid (CIS)
    29
  - Hot Gas Solenoid (HGS)
    29
  - Purge Valve (PV)
    29
  - Electronic Throttling Valve (ETV)
    29
  - Condenser Check Valve
    29
  - Purge Check Valve
    29
- Sensors, Switches, and Transducers
  29
  - High Pressure Cutout Switch (HPCO)
    29
Refrigeration System Diagrams
30
- Cool Mode
  31
  - Solenoid and Check Valves
    31
- Purge Mode
  32
  - Solenoid and Check Valves
    32
- Heat/Defrost Mode
  33
  - Solenoid and Check Valves
    33
Alternator Diagnostic Procedures
35
Battery
38
- Filler Cap Batteries
  38
- Maintenance Free Batteries
  38
- Battery Load Test
  38
Fuses
38
Base Controller
39
- Base Controller Fuse Size & Function
  40
  - Fuse F10
    40
  - Fuse F15
    40
- LED Functions
  40
- Smart FET Outputs
  41
Fan Fuses
41
Fan Relay
42
SMART REEFER 3 (SR-3) Microprocessor Controller
42
Flywheel (RPM) Sensor
42
- Testing the Flywheel (RPM) Sensor
  43
Glow Plugs
43
Unit Wiring
44
AC Components (Model 50 Units Only)
44
- Electrical Contactors
  44
- Condenser Fan Rotation
  44
- Phase Select Module for Truck Unit Model 50 Applications
  44
  - Operation
    44
  - Removal and Replacement
    45
  - Diagnostics
    45
- Overload Relay
  46
  - Overload Relay Replacement
    46
Emi 2000
49
Engine Lubrication System
49
- Engine Oil Pressure Switch/Sensor
  49
- Engine Oil Change
  49
- Oil Filter Change
  50
Crankcase Breather System
50
Engine Air Cleaner (EMI 2000)
52
Engine Cooling System
53
- Extended Life Coolant (ELC)
  54
- Antifreeze Maintenance Procedures
  55
  - Checking the Antifreeze
    55
  - Changing the Antifreeze
    55
- Engine Thermostat
  56
Engine Fuel System
57
- Operation
  57
- Maintenance
  58
- Bleeding the Fuel System
  58
- Draining Water from Fuel Tank
  59
- Fuel Filter Replacement
  59
- Electric Fuel Pump
  59
  - Operation
    59
  - Maintenance
    59
  - Disassembly
    59
  - Assembly
    60
- Injection Pump Timing
  60
- Injection Pump Removal and Installation
  63
  - Injection Pump Removal
    63
  - Injection Pump Installation
    65
- Fuel Limit Screw
  65
- Fuel Solenoid
  65
  - Testing the Fuel Solenoid
    66
  - Fuel Solenoid Replacement
    67
- Engine Speed Adjustments
  68
Adjust Engine Valve Clearance
70
Belts
73
- Engine/Compressor Belt
  74
- Water Pump Belt
  74
Evacuation, Dehydration, and Charging
75
- Set up and Test of Evacuation Equipment
  77
- Using Evacuation Mode
  78
- Unit Evacuation
  79
- Unit Charging
  80
- Refrigerant Gauge Removal
  81
Refrigerant Leaks
81
Refrigerant Charge
81
- Testing the Refrigerant Charge with an Empty Box (Controlled Check)
  81
- Testing the Refrigerant Charge with a Loaded Box (Quick Check)
  81
Checking Compressor Oil
82
Refrigeration System Checks
83
Low Side Pump down
83
- Unit Identification
  84
- Availability
  84
- Refrigerant Leaks
  84
- Compressor Oil
  84
- Compressors Shipped with POE Oil
  85
- Equipment Recommendations for Use with R-452A
  85
  - Dedicated Equipment
    85
  - Vacuum Pumps
    85
  - Gauge Manifold Sets
    85
  - Refrigerant Recovery
    85
Refrigeration System Component Locations
86
Accumulator Replacement
87
- Removal
  87
- Installation
  87
Compressor
87
Condenser Inlet Solenoid (CIS) Test
94
Condenser Check Valve Test
94
Condenser/Radiator Coil Replacement
95
- Removal
  95
- Installation
  95
Dehydrator (Filter-Drier) Replacement
96
- Removal
  96
- Installation
  96
Discharge Pressure Transducer Testing
96
Discharge Pressure Transducer Replacement
96
Electronic Throttling Valve (ETV) Testing
96
Electronic Throttling Valve (ETV) Replacement
97
- Removal
  97
- Installation of Service Kit
  98
- Installation of Complete ETV Assembly
  101
Evaporator Coil Replacement - S-3
102
- Removal
  102
- Installation
  102
Evaporator Coil Replacement - E-Evap/Es800
102
Expansion Valve Replacement
103
- Removal
  103
- Installation
  103
Heat Exchanger Replacement
104
- Removal
  104
- Installation
  104
High Pressure Cutout Switch (HPCO) Test
104
High Pressure Cutout Switch (HPCO) Replacement
105
- Removal
  105
- Installation
  105
High Pressure Relief Valve Replacement
106
- Removal
  106
- Installation
  106
Hot Gas Solenoid (HGS) Test
106
In-Line Check Valve Replacement
106
- Removal
  107
- Installation
  107
Purge Valve (PV) Test
107
Solenoid Valve Replacement
108
Receiver Tank Replacement
108
- Removal
  108
- Installation
  108
Suction Pressure Transducer Testing
109
Suction Pressure Transducer Replacement
109
- Removal
  109
- Installation
  109
Centrifugal Clutch
110
Clutch Inspection
111
- Check Condition of Belts
  112
- Check the Clutch
  112
Clutch Maintenance
114
- Tools Required
  114
- Grease
  114
- Disassembly Procedure
  114
- Assembly Procedure (Using New Bearings and Seal)
  116
Unit Inspection
118
Unit and Engine Mounting Bolts
119
Condenser, Evaporator, and Radiator Coils
120
- Micro-Channel Coil Cleaning Recommendations
  120
  - Cleaning Intervals
    120
  - Cleaning Methods (Listed in Order of Recommended Method)
    120
Defrost Drains
121
M M E E C C H H a a N N I I C C a a L L D D I I a a G G N N O O S S I I S
123
- E E L L E E C C T T R R I I C C S S T T a a N N D D B B y y ( ( O O P P T T I I O O N N a a L L ) ) D D I I a a G G N N O O S S I I S
  126
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 D D I I a a G G N N O O S S I I S
128

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