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Thermo King T-1000R, Maintenance Manual

The Thermo King T-1000R Operator's Manual is a comprehensive guide that provides step-by-step instructions for operating and maintaining this powerful cooling unit. Easily downloadable and completely free, users can find this manual on our website manualshive.com, ensuring a seamless experience in maximizing the potential of their Thermo King T-1000R.

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9 Engine Maintenance

EMI 2000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2
Engine Lubrication System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2

Engine Oil Pressure Switch/Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  9-2
Engine Oil Change  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2
Oil Filter Change. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  9-3

Engine Air Cleaner (EMI 2000)  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
Crankcase Breather System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
Engine Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5

General Description  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5
Bleeding Air from the Cooling System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  9-7
ELC (Extended Life Coolant) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  9-9
Antifreeze Maintenance Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  9-9
Engine Thermostat  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  9-10
Coolant Level Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  9-11

Engine Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-12

Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  9-12
Maintenance  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  9-12
Bleeding the Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  9-13
Draining Water from Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  9-19
Fuel Filter Replacement  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  9-19
Electric Fuel Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  9-19
Injection Pump Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  9-20
Injection Pump Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  9-23
Fuel Limit Screw. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-25
Fuel Solenoid  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  9-25
Engine Speed Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  9-27

Adjust Engine Valve Clearance  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-29
Engine Mounts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-32
Belts  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-37

Belt Tensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  9-37
Water Pump Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  9-39
Engine/Electric Motor (Jackshaft) Belt - T-Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  9-41
Engine/Electric Motor (Jackshaft) Belt - T-500R/T-Dairy. . . . . . . . . . . . . . . . . . . . . . . .  9-42
Engine/Electric Motor Belt - UT-Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  9-44
Compressor/Electric Motor Belt - UT-Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  9-44
Electric Motor/Alternator Belt - UT-Series  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  9-45

Summary of Contents for T-1000R

Page 1: ...y Ltd Monivea Road Mervue Galway Ireland Maintenance Manual Self Powered Truck Units T 500R T DAIRY T 600R T 800R T 800R SPECTRUM T 1000R T 1000R SPECTRUM T 1200R T 1200R INTERMODAL T 1200R SPECTRUM UT 800 UT 1200 UT XTREME HIGH AMBIENT UT SPECTRUM ...

Page 2: ... judgment to effect its stability î No warranties express or implied including warranties of fitness for a particular purpose or merchantability or warranties arising from course or dealing or usage of trade are made regarding the information recommendations and descriptions contained herein Manufacturer is not responsible and will not be held liable in contract or in tort including negligence for...

Page 3: ...ators 4 9 Unit Description 5 1 General Description 5 2 Design Features 5 2 Unit Options 5 3 Engine 5 3 Standard HMI Control Panel 5 3 Mechanics HMI Control Panel 5 4 Premium HMI Control Panel Optional 5 4 CYCLE SENTRYTM Start Stop System 5 4 Defrost 5 5 DAS Data Acquisition System Optional except on T 500R T Dairy 5 5 Electric Standby Model 50 Units Only 5 5 Engine Compartment Components 5 5 Unit ...

Page 4: ...d UT SPECTRUM 8 9 Flywheel RPM Sensor 8 10 Glow Plugs 8 11 Unit Wiring 8 12 AC Components Model 50 Units Only 8 12 Overload Relay 8 17 Engine Maintenance 9 1 EMI 2000 9 2 Engine Lubrication System 9 2 Engine Air Cleaner EMI 2000 9 3 Crankcase Breather System 9 3 Engine Cooling System 9 5 Engine Fuel System 9 12 Adjust Engine Valve Clearance 9 29 Engine Mounts 9 32 Belts 9 37 Refrigeration Maintena...

Page 5: ... 10 44 Liquid Injection Solenoid LIS Replacement 10 44 Liquid Line Solenoid LLS and Liquid Return Check Valve Test Multi Temp Units Only 10 45 Low Pressure Cutout Switch LPCO Test T 500R T Dairy Only 10 45 Low Pressure Cutout Switch LPCO Replacement 10 45 Purge Valve PV Test 10 46 Receiver Tank Pressure Check Valve Test 10 46 Receiver Tank Pressure Solenoid RTPS Test Multi Temp Units Only 10 46 Re...

Page 6: ...s 14 1 Refrigeration System Diagnosis 15 1 Remote Evaporators 16 1 Unit Description 16 2 Electrical Maintenance 16 7 Structural Maintenance 16 7 Remote Evaporator System Diagnosis 16 7 Wiring Diagrams and Wiring Schematics 17 1 ...

Page 7: ...3 50 901426 UT 1200 SR3 400 3 50 R134A 903368 T 1000R 30 SR 901427 UT 1200 SR3 230 3 60 R134A 903385 T 1000R 50 SR 230 3 50 901428 UT SPECTRUM 208V 3 60 903360 2 ZONE T 1000R 50 SR 230 3 60 901429 UT SPECTRUM 220V 3 50 903361 2 ZONE T 1000R 50 SR 400 3 50 901431 UT SPECTRUM 230V 3 60 903362 2 ZONE T 1200R 30 SR 901432 UT SPECTRUM 400V 3 50 903363 2 ZONE T 1200R 50 SR 230 3 50 901433 UT SPECTRUM 20...

Page 8: ...SPECTRUM Parts Manual TK 54839 T 1200R SPECTRUM Parts Manual TK 54819 UT 1200 Parts Manual TK 53568 UT 800 Parts Manual TK 55366 UT SPECTRUM Parts Manual TK 61416 T Series ST Installation Manual TK 54354 T Series MT Installation Manual TK 54481 UT Series Undermount Systems Installation Manual TK 60712 UT SPECTRUM Installation Manual TK 61415 Truck TSR Single Temperature Microprocessor Control Syst...

Page 9: ...r death from suffocation 11 Use caution and follow the manufacturer s suggested practices when using ladders or scaffolds AUTO START STOP CONTROLS Units equipped with a CYCLE SENTRY Automatic Start Stop system may start automatically at any time when the unit is on and CYCLE SENTRY is the selected mode Be sure to turn the On Off switch Off before opening unit service doors or inspecting or working...

Page 10: ...he affected area rapidly and to maintain respiration EYES For contact with liquid immediately flush eyes with large amounts of water and get prompt medical attention SKIN Flush area with large amounts of lukewarm not hot water Do not apply heat Remove contaminated clothing and shoes Wrap burns with dry sterile bulky dressing to protect from infection injury Get medical attention Wash contaminated ...

Page 11: ... unit truck or truck chassis when the temperature control unit is attached it is necessary to ensure that welding currents are NOT allowed to flow through the electronic circuits of the unit These procedures must be rigidly adhered to when servicing units to avoid damage or destruction of the controller 1 Disconnect all power to the unit 2 Disconnect all wire harnesses from the controller 3 Switch...

Page 12: ... an accident First Aid IMMEDIATE action must be initiated after a person has received an electrical shock Obtain immediate medical assistance if available The source of shock must be immediately removed by either shutting down the power or removing the victim from the source If it is not possible to shut off the power the wire should be cut with either an insulated instrument e g a wooden handled ...

Page 13: ... read and follow the instructions on all warning decals T Series Refrigerant Decal Locations 1 Below the fuel filters inside the engine access door 2 On the evaporator beside the expansion valve 3 Beside the serial number plate on top of the unit frame above the switch panel 4 On the top of the condenser coil tkrsmd31 UT Series Refrigerant Decal Locations 1 On accumulator tank 2 On front of frame ...

Page 14: ...Safety Precautions 2 6 Warning Decals 2e24151g0 ...

Page 15: ... 3 7 Fuses T 500R T Dairy 3 7 Electrical Components 3 8 Evaporator Fan Motors UT Series 3 9 Electrical Standby T 1000R T 1200R T 1000R Spectrum T 1200R Spectrum Model 50 Units Only 3 9 Electrical Standby T 600R T 800R T 800R Spectrum 3 9 Electrical Standby UT Series 3 10 Electrical Standby T 500R T Dairy 3 10 Electric Heater Strips Optional 3 10 ...

Page 16: ...or Europe Oil Viscosity 10 C to 50 C SAE 15W 40 Synthetic 15 to 40 C SAE 15W 40 25 to 40 C SAE 10W 40 25 to 30 C SAE 10W 30 30 to 0 C SAE 5W 40 Synthetic Below 30 C SAE 0W 30 Synthetic Engine rpm T Series Low Speed Operation 1650 25 rpm T Series High Speed Operation except T 500R T Dairy 2250 25 rpm T 500R T Dairy High Speed Operation 2300 25 rpm UT 800 Low Speed Operation 1450 25 rpm UT 800 High ...

Page 17: ...xpansion tank 5 7 liters with coolant expansion tank 5 7 liters with coolant expansion tank 5 7 liters with coolant expansion tank 5 2 liters with coolant expansion tank Coolant Expansion Tank Cap Pressure T Series UT Series 103 kPa 15 psig 48kPa 7 psig BELT TENSION Belt Tension No on TK Gauge P N 204 427 Frequency Gauge P N 204 1903 New Hz Run In Hz Water Pump Belt 40 Engine Electric Motor Jacksh...

Page 18: ...Specifications 3 4 ENGINE CLUTCH Engagement 600 100 RPM Dynamic Torque 66 fT lb 89 5 N m minimum 1600 RPM ...

Page 19: ...procating Compressor Ester base P N 203 516 required for Scroll Compressor Suction Pressure Regulator Valve Setting T 500R T Dairy T1000R T800R T600R T1000R Spectrum T800R Spectrum 190 to 210 kPa 28 to 31 psig 140 to 160 kPa 21 to 23 psig 240 to 260 kPa 35 to 37 psig 190 to 210 kPa 28 to 31 psig 140 to 160 kPa 21 to 23 psig 240 to 260 kPa 35 to 37 psig Throttling Valve Setting T Series and UT Seri...

Page 20: ... 800 T 800R SPECTRUM T 1000R T 1200R SPECTRUM UT 1200 UT SPECTRUM 12 volt 37 amp brush type Thermo King alternator 12 volt 65 amp brush type Thermo King alternator 12 volt 65 amp brush type Thermo King alternator 12 volt 65 amp brush type Thermo King alternator 12 volt 120 amp brush type Thermo King alternator 12 volt 120 amp brush type Thermo King alternator Voltage Regulator Setting 13 8 to 14 4...

Page 21: ... F10 is installed in the lower position the unit will start and run without the HMI control panel FUSES T 500R T DAIRY Fuse Size Function F1 5A 2P Circuit Battery Power to TSD CAN Connector F2 2A 8XP Circuit Switch On Power to TSD CAN Bus F3 2A 8FC Circuit Remote Light F4 15A Power to On Off Switch F5 7 5A HPCO PHPCO Circuit F6 40A Preheat Circuit F7 40A Starter Solenoid Circuit F8 15A Damper Sole...

Page 22: ...per Solenoid 5 7 2 2 Condenser Inlet Solenoid CIS 1 8 6 9 Hot Gas Solenoid HGS 1 1 11 3 Purge Valve PV 1 1 11 3 Liquid Injection Solenoid LIS UT Only 1 1 11 3 Hot Gas Bypass Solenoid HGBS UT Spectrum Only 0 8 15 6 Electronic Throttling Valve ETV T Series Only Coil A Red EVA and Blue EVB Wires Coil B Black EVC and White EVD Wires 20 to 35 20 to 35 Starter Motor No Load Bench Test 90 Evaporator Fan ...

Page 23: ...CTRICAL STANDBY T 1000R T 1200R T 1000R SPECTRUM T 1200R SPECTRUM MODEL 50 UNITS ONLY Electric Motor and Overload Relay Voltage Phase Frequency Horsepower Kilowatts rpm Full Load amps Overload Relay Setting amps 230 3 50 10 0 7 5 1460 22 5 25 230 3 60 12 0 8 9 1750 28 8 32 400 3 50 10 0 7 5 1460 17 0 16 460 3 60 12 0 8 9 1750 14 4 16 ELECTRICAL STANDBY T 600R T 800R T 800R SPECTRUM Electric Motor ...

Page 24: ...Electric Motor and Overload Relay Voltage Phase Frequency Horsepower Kilowatts rpm Full Load amps Overload Relay Setting amps 230 3 50 6 0 4 5 1460 19 5 19 400 3 50 6 0 4 5 1460 9 8 11 ELECTRIC HEATER STRIPS OPTIONAL Number 3 Watts 750 watts each Resistance 71 ohms each Standby Power Requirements Supply Circuit Breaker T 500R T Dairy T 600R T 800R 200 230 3 50 60 T 1200 T1000R UT Series 200 230 3 ...

Page 25: ... Inspection Schedule Unit Models T Series Except T 500R and T Series Spectrum Host 4 2 Unit Models T Series Spectrum 4 4 Unit Models T 500R 4 5 Unit Models UT Series 4 7 Unit Models UT Series Remote Evaporators 4 9 ...

Page 26: ...ifoperating in very low ambients If using ELC coolant drain and refill every 12000 hrs or 60 months whichever comes first Inspect compressor fan drive water pump belts for condition Replace all belts at 4000hrs or 48 months Inspect all belt tension devices belt idler pulley for condition correct operation Inspect clutch bearings shoe wear when compressor drive belt is replaced Check water pump sea...

Page 27: ...ic motor bearings 24 months Check operating modes on electric standby Refrigeration Visually inspect condenser radiator evaporator coils for damage dirt ingress Check refrigerant level Leak test entire unit or annually or as required for F Gas control regulations Check for correct suction discharge pressures when equipped operation of ETV For ETV check use service test mode Check operating pressur...

Page 28: ...ion they should be replaced INSPECTION A SERVICE Every 1000 hours Or every 6 Months whichever comes first SERVICE B SERVICE Every 2000 hours Or every 12 Months whichever comes SERVICE C SERVICE Every 4000 hours Or every 24 Months whichever comes Check Inspect Adjust Change Replace REMOTE EVAPORATOR S Electrical Inspect wire harness for damaged wires or connections Check defrost operation including...

Page 29: ...y for condition correct operation Check water pump seal for weep age and bearing serviceability Perform Automatic Pre Trip Listen for unusual noises vibrations etc Visually inspect exhaust system for leakage and abnormal smoke or particulate emissions Check engine oil pressure hot on high speed Minimum 276 kPa 2 76 bar 40 psi Check adjust engine speeds high and low speed Change engine oil hot and ...

Page 30: ...ll battery may need to be topped up more regularly where unit is operating in high ambients for longer periods Refer to service bulletin for Silver Calcium Batteries EON battery is maintenance free and does not require topping up of electrolyte If no drain plug is available in the fuel tank the tank manufacturer should provide clear instructions for fuel cleaning For fuel supplies taken from the t...

Page 31: ...onths whichever comes first Inspect compressor fan drive water pump belts for condition and ten sion Replace all belts at 4000hrs or 24 months of belt operation Inspect all belt tension devices belt idler pulley for condition cor rect operation Inspect clutch bearings shoe wear when compressor drive belt is replaced Check water pump seal for weep age and bearing serviceability Perform Automatic Pr...

Page 32: ...cting tubing Check operating pressure of mechanical throttling valve units in heat cycle with higher than 15 C box temperature Check operating pressure of DPR valve in heat cycle Visually check compressor oil level and condition When returning to cool from heat cycle above Perform full series of pump down internal sealing point tests com pressor efficiency test Refer to diagnostic manual for pump ...

Page 33: ...on hardware security Visually inspect unit for damaged loose or broken skins parts fittings includes air ducts and bulkheads Check all unit mounting bolts external mounted equipment wiring hoses fuel lines etc Clean micro channel condenser and radiator Miscellaneous These procedures may be carried out as an addition to the standard service procedures Check calibration of return and discharge senso...

Page 34: ...Maintenance Inspection Schedule 4 10 ...

Page 35: ...nel Optional 5 4 CYCLE SENTRYTM Start Stop System 5 4 Defrost 5 5 DAS Data Acquisition System Optional except on T 500R T Dairy 5 5 Electric Standby Model 50 Units Only 5 5 Engine Compartment Components 5 5 Unit Protection Devices 5 6 Refrigeration System Components 5 11 Single Temperature Refrigeration System Diagrams 5 13 Multi Temperature Refrigeration System Diagrams 5 24 ...

Page 36: ...tarts and stops the unit according to temperature demands DESIGN FEATURES Microprocessor Controller TSD TSR 2 TSR 3 Alarm Code Display Battery Voltage Display not on TSD Continuous System Monitoring Coolant Temperature Display not on TSD CYCLE SENTRYTM Start Stop Controls Engine and Electric Model 50 Hour Display In Cab Remote Smart Defrost Symbolic Controller Interface Unit Self Check pretripping...

Page 37: ...n tank identifies units with ELC see Safety Decals and Locations The new engine coolant Texaco Extended Life Coolant is Red instead of the previous Green or Blue Green coolants Note The use of 50 50 pre mixed ELC is recommended to ensure that deionized water is being used If 100 full strength concentrate is used deionized or distilled water is recommended instead of tap water to ensure the integri...

Page 38: ...m HMI Control Panel is available as an option that replaces the Standard HMI Control Panel It is used operate the unit and display unit information It also provides access to all the controller functions and menus Refer to the relevant Truck SR 2 Single Temp Diagnostic Manual for more information about the Premium HMI Control Panel CYCLE SENTRYTM START STOP SYSTEM The CYCLE SENTRY Start Stop fuel ...

Page 39: ... 0 or higher software is used to view and analyze the data Brief reports can be printed on a microprinter connected to the serial port ELECTRIC STANDBY MODEL 50 UNITS ONLY The Electric Standby option allows the unit to be operated on either the diesel engine or external electric power Standard Model 50 Features The following features are standard equipment on units equipped with Electric Standby A...

Page 40: ...a the switch sensor signals the microprocessor to stop the engine Preheat Buzzer The preheat buzzer sounds when the CYCLE SENTRYTM system energizes the glow plugs This should warn anyone near the unit that the CYCLE SENTRYTM system is about to start the diesel engine Coolant Temperature Sensor UT Series and T 500R T Dairy This sensor provides an engine coolant temperature input to the microprocess...

Page 41: ...NTIFICATION T 1200R Front View 1 Engine Oil Dipstick on side of engine 5 Alternator 2 Engine 6 Compressor 3 Coolant Expansion Tank 7 Dehydrator Filter Drier 4 Electric Motor T Series Main Components except T 500R T Dairy AMA944 2 4 6 3 5 7 1 ...

Page 42: ...Unit Description 5 8 T 500R Front View 1 Coolant Expansion Tank 5 Dehydrator Filter Drier 2 Engine 6 Compressor 3 Electric Motor 7 On Off Switch 4 Alternator Main Components T 500R T Dairy 2 3 6 5 1 7 4 ...

Page 43: ...Shown UT 800 UT XTREME HIGH Ambient and UT SPECTRUM Similar 1 Accumulator 4 Compressor 2 Receiver Tank 5 Condenser Radiator Coil 3 Filter Drier 6 Fuel Filter Water Separator UT Series Components Front and Side Views Panels Removed 1 2 3 4 5 6 ...

Page 44: ...Unit Description 5 10 1 Compressor Pulley 3 Engine Clutch 2 Electric Motor Pulley UT Series Components Rear View Panels Removed 3 2 1 ...

Page 45: ...cool mode Purge Valve PV The purge valve is energized open in the purge mode and in heat and defrost modes to move the refrigerant out of the condenser to ensure adequate refrigerant is available This is a normally closed valve Purge Check Valve T 500R T Dairy T Series Spectrum This check valve prevents refrigerant from migrating from the accumulator back into the condenser during the heat and def...

Page 46: ... used on units equipped with an ETV It is not used on units equipped with an SPR Suction Pressure Transducer This transducer supplies the suction pressure at the compressor to the microprocessor This information is used by the microprocessor and software to determine the unit operating conditions and control the ETV The suction pressure transducer is used on units equipped with an ETV It is not us...

Page 47: ...tributor 4 High Pressure Cutout Switch HPCO 16 Evaporator Coil 5 Discharge Service Valve 17 Drain Pan Heater 6 Discharge Strainer 18 Accumulator 7 Condenser Inlet Solenoid CIS 19 Electronic Throttling Valve ETV 8 Condenser Coil 20 Suction Service Valve 9 High Pressure Relief Valve 21 Suction Pressure Transducer 10 Receiver Tank Sight Glass 22 Hot Gas Solenoid HGS 11 Receiver Tank Outlet Valve 23 R...

Page 48: ...et Solenoid CIS 19 Suction Pressure Regulator SPR 7 Condenser Coil 20 Suction Service Valve 8 High Pressure Relief Valve 21 Low Pressure Cutout Switch LPCO 9 Receiver Tank Sight Glass 22 Hot Gas Solenoid HGS 10 Receiver Tank Outlet Valve 23 Purge Check Valve 11 Dehydrator Filter Drier 24 Purge Valve PV 12 Heat Exchanger 25 Receiver Tank Pressure Check Valve 13 Expansion Valve 26 Condenser Check Va...

Page 49: ...hrough the heat exchanger accumulator and ETV T Series or SPR in T 500R T Dairy 1 Scroll Compressor 14 Expansion Valve 2 Compressor Temperature Sensor 15 Distributor 3 Compressor Sight Glass 16 Evaporator Coil 4 Liquid Injection Solenoid LIS 17 Drain Pan Heater 5 High Pressure Cutout Switch HPCO 18 Accumulator 6 Discharge Service Port 19 Mechanical Throttle Valve 7 Condenser Inlet Solenoid CIS 20 ...

Page 50: ...ies except T 500R T Dairy 1 Condenser Inlet Solenoid CIS Open De energized 2 Condenser Check Valve Open 3 Receiver Tank Pressure Check Valve Closed 4 Hot Gas Solenoid HGS Closed De energized Cool Mode T1200R Cool Mode T600 T800 and T1000R 1 2 3 4 1 2 3 4 ...

Page 51: ...essor temperature 3 Condenser Check Valve Open 4 Purge Valve PV Closed De energized 5 Hot Gas Solenoid HGS Closed De energized Cool Mode UT Series Solenoid and Check Valves T 500R T Dairy 1 Condenser Inlet Solenoid CIS Open De energized 2 Condenser Check Valve Open 3 Receiver Tank Pressure Check Valve Closed 4 Purge Valve PV Closed De energized 5 Purge Check Valve Closed 6 Hot Gas Solenoid HGS Clo...

Page 52: ...There the refrigerant heats the evaporator and returns to the compressor through the heat exchanger accumulator and ETV Some of the refrigerant flows through the receiver tank pressure check valve and forces any liquid refrigerant out of receiver tank through the drier heat exchanger and expansion valve to the evaporator From which it returns to the compressor through the heat exchanger accumulato...

Page 53: ...Most of the refrigerant flows through the hot gas line and the drain pan heater to the evaporator There the refrigerant heats the evaporator and returns to the compressor through the heat exchanger accumulator and SPR Some of the refrigerant flows through the receiver tank pressure check valve and forces any liquid refrigerant out of receiver tank through the drier heat exchanger and expansion val...

Page 54: ...rant vapor leaves the compressor and flows through the DPR which maintains a minimum discharge pressure to the hot has line The refrigerant flows through the hot gas line and the drain pan heater to the evaporator There the refrigerant heats the evaporator and returns to the compressor through the heat exchanger and accumulator Solenoid and Check Valves 1 Condenser Inlet Solenoid CIS Closed Energi...

Page 55: ...erant vapor leaves the compressor and flows through the open CIS to the condenser The PV is open so most of the refrigerant flows from the condenser through the PV and the purge check valve to the accumulator Some of the refrigerant flows through the condenser check valve receiver tank drier heat exchanger expansion valve and evaporator to the accumulator From the accumulator the refrigerant retur...

Page 56: ...essure refrigerant vapor leaves the compressor and flows through the open CIS and condenser to the receiver tank The PV is open so most of the refrigerant flows through the PV to the accumulator Some of the refrigerant flows through the drier heat exchanger expansion valve and evaporator to the accumulator From the accumulator the refrigerant returns to the compressor Solenoid and Check Valves 1 C...

Page 57: ...Unit Description 5 23 Purge Mode UT Series 1 3 4 5 2 ...

Page 58: ...Service Valve 19 Receiver Tank Pressure Solenoid RTPS 6 Discharge Strainer 20 Condenser Check Valve CCV 7 Condenser Inlet Solenoid CIS 21 Heat Exchanger Remote 8 Condenser Coil 22 Expansion Valve Remote 9 High Pressure Relief Valve 23 Distributor Remote 10 Receiver Tank Sight Glass 24 Evaporator Coil Remote 11 Receiver Tank Outlet Valve 25 Liquid Line Solenoid LLS Remote 12 Dehydrator Filter Drier...

Page 59: ...ssure vapor The refrigerant returns to the compressor through the heat exchanger SLS2 suction line SLCV2 accumulator and SPR ETV Zone 1 Evaporator 1F Zone 1 Liquid Line Solenoid LLS1 Open Energized 2F Zone 1 Liquid Return Check Valve LRCV1 Closed 3F Zone 1 Suction Line Solenoid SLS1 Open De energized 4F Zone 1 Suction Line Check Valve SLCV1 Open 5F Zone 1 Hot Gas Solenoid HGS1 Closed De energized ...

Page 60: ...Unit Description 5 26 Zone 1 Cool and Zone 2 Cool T 800R T 1000R T 1200R SPECTRUM Units Normally Open Normally Closed Zone 1 Zone 2 4F 3F 2F 1F 5F 4R 3R 2R 1R 5R 6 7 10 9 8 ...

Page 61: ... of the refrigerant flows through the Zone 2 heat exchanger expansion valve evaporator SLS2 suction line and SLCV2 to the accumulator From the accumulator the refrigerant returns to the compressor through the SPR ETV Zone 1 Evaporator 1F Zone 1 Liquid Line Solenoid LLS1 Open Energized 2F Zone 1 Liquid Return Check Valve LRCV1 Closed 3F Zone 1 Suction Line Solenoid SLS1 Open De energized 4F Zone 1 ...

Page 62: ...Unit Description 5 28 Purge Mode T 800R T 1000R T 1200R SPECTRUM Units Normally Open Normally Closed Zone 1 Zone 2 4F 3F 2F 1F 5F 4R 3R 2R 1R 5R 6 7 10 9 8 ...

Page 63: ...open continuously during heat to drain the condenser coil Zone 1 Evaporator 1F Zone 1 Liquid Line Solenoid LLS1 Open Energized 2F Zone 1 Liquid Return Check Valve LRCV1 Closed 3F Zone 1 Suction Line Solenoid SLS1 Open De energized 4F Zone 1 Suction Line Check Valve SLCV1 Open 5F Zone 1 Hot Gas Solenoid HGS1 Closed De Energized Zone 2 Evaporator 1R Zone 2 Liquid Line Solenoid LLS2 Open Energized 2R...

Page 64: ...Unit Description 5 30 Zone 1 Cool and Zone 2 Heat T 800R T 1000R T 1200R SPECTRUM Units Normally Open Normally Closed Zone 1 Zone 2 4F 3F 2F 1F 5F 4R 3R 2R 1R 5R 6 7 10 9 8 ...

Page 65: ...rge Service Port 23 Condenser Check Valve CCV 8 Condenser Inlet Solenoid CIS 24 Heat Exchanger Remote 9 Condenser Coil 25 Expansion Valve Remote 10 High Pressure Relief Valve 26 Distributor Remote 11 Receiver Tank Outlet Valve 27 Evaporator Coil Remote 12 Receiver Tank Sight Glass 28 Liquid Line Solenoid LLS Remote 13 Dehydrator Filter Drier 29 Liquid Return Check Valve LRCV Remote 14 Accumulator ...

Page 66: ... 1F Zone 1 Liquid Line Solenoid LLS1 Open Energized 2F Zone 1 Liquid Return Check Valve LRCV1 Closed 3F Zone 1 Suction Line Solenoid SLS1 Open De energized 4F Zone 1 Suction Line Check Valve SLCV1 Open 5F Zone 1 Hot Gas Solenoid HGS1 Closed De energized Zone 2 Evaporator 1R Zone 2 Liquid Line Solenoid LLS2 Open Energized 2R Zone 2 Liquid Return Check Valve LRCV2 Closed 3R Zone 2 Suction Line Solen...

Page 67: ...Unit Description 5 33 Zone 1 Cool and Zone 2 Cool UT SPECTRUM Units ...

Page 68: ...he accumulator the refrigerant returns to the compressor through the ETV Zone 1 Evaporator 1F Zone 1 Liquid Line Solenoid LLS1 Open Energized 2F Zone 1 Liquid Return Check Valve LRCV1 Closed 3F Zone 1 Suction Line Solenoid SLS1 Open De energized 4F Zone 1 Suction Line Check Valve SLCV1 Open 5F Zone 1 Hot Gas Solenoid HGS1 Closed De energized Zone 2 Evaporator 1R Zone 2 Liquid Line Solenoid LLS2 Op...

Page 69: ...Unit Description 5 35 Purge Mode UT SPECTRUM Units ...

Page 70: ...n Energized 2F Zone 1 Liquid Return Check Valve LRCV1 Closed 3F Zone 1 Suction Line Solenoid SLS1 Open De energized 4F Zone 1 Suction Line Check Valve SLCV1 Open 5F Zone 1 Hot Gas Solenoid HGS1 Closed De Energized Zone 2 Evaporator 1R Zone 2 Liquid Line Solenoid LLS2 Open Energized 2R Zone 2 Liquid Return Check Valve LRCV2 Open 3R Zone 2 Suction Line Solenoid SLS2 Closed Energized 4R Zone 2 Suctio...

Page 71: ...Unit Description 5 37 Zone 1 Cool and Zone 2 Heat UT SPECTRUM Units ...

Page 72: ...Unit Description 5 38 ...

Page 73: ... Defrost 6 11 Initiating a Manual Defrost Cycle 6 11 Terminating a Defrost Cycle 6 12 Selecting High Speed Lockout Mode If Enabled 6 12 Selecting CYCLE SENTRY or Continuous Mode 6 13 Using the Gauges Key 6 13 Using the Sensors Key 6 14 Using The Main Menu 6 15 Main Menu Choices 6 16 Languages 6 16 Alarms 6 18 Alarm Types 6 18 Log Alarms 6 18 Check Alarms 6 18 Shutdown Alarms 6 18 Prevent Alarms 6 ...

Page 74: ...Diesel Electric Menu 6 28 Adjust Brightness 6 29 Time 6 30 ...

Page 75: ...t panel using an under dash mounting kit Premium HMI Control Panel Premium Display ZIZI SPECTRUM Premium HMI Control Panel Display The HMI control panel consists of a display and 8 touch sensitive keys The display is capable of showing both text and graphics The keys on the left and right sides of the display are dedicated single function hard keys The four keys under the display are soft keys The...

Page 76: ...he MAIN MENU The other two soft keys access the GAUGES menu and SENSORS menu as shown by the labels above the keys Keys Hard Keys The keys on either side of the display are dedicated or hard keys Their function always remains the same Soft Keys Typical soft key functions MENU NEXT BACK YES NO SELECT EXIT CLEAR HELP HOUR METERS SENSORS GAUGES The Premium Display Verify the Base Controller On Off Sw...

Page 77: ...lowing differences exist when operating the unit in Single Zone Control Mode Single Zone Control Mode will appear in the Main Menu Mode Menu only if the Single Zone Control feature has been enabled in the Guarded Access Main Menu Configuration menu If Single Zone Control operation is selected then all zones will be forced on and will control to the same setpoint Unit control is based on the temper...

Page 78: ... display to appear on initial startup Thermo King Logo Then the startup screen shown in Figure appears while communications are established and the unit prepares for operation Startup Screen If More Than One Language is Enabled If more than one language has been enabled a prompt will appear to allow the desired language to be chosen as shown below Only languages enabled from the Guarded Access Men...

Page 79: ...rst and Last Soft Keys The Language Menu will appear in the current language as shown in Figure Press the or keys to select the desired language When the desired language is shown press the YES key to confirm the choice Note that all languages in the installed software can be selected using this method Language Menu When the unit is ready to run the Premium Display appears Pressing the OFF key sto...

Page 80: ...ted by pressing the YES or NO soft key within 10 seconds of changing the setpoint Failure to confirm the new setpoint by pressing YES or NO within 10 seconds of changing the setpoint will result in no setpoint change In addition Alarm Code 127 Setpoint Not Entered is set to indicate that the setpoint change was not completed Soft Keys After the YES soft key has been pressed the display briefly sho...

Page 81: ...applications Zone 1 can be turned off without affecting unit operation so long as at least one other zone is turned on IMPORTANT At least one zone must be turned on If all configured zones but one are turned off the controller will not allow the last zone to be turned off The state of each zone is retained when the unit is turned off and on For example on a three zone unit if zones 1 and 2 are tur...

Page 82: ... Display of temperature and setpoint STARTING THE ELECTRIC MOTOR Units equipped with the Electric Standby option only Electric motor starting is automatic in both Continuous Mode and CYCLE SENTRY Mode The motor will start as required when the unit is turned on If any keys are being pressed on the HMI control panel prior to the motor start the motor start will be delayed until 10 seconds after the ...

Page 83: ...igure will appear when standby power is turned off or is no longer available Prompt Screen Guarded Access Set to No If YES is selected then the display will briefly show the screen below Prompt Screen Guarded Access Set to Yes Diesel Mode operation will briefly be confirmed If unit operation is required the diesel engine will start as shown in above in STARTING THE DIESEL ENGINE DEFROST Initiating...

Page 84: ...ed operation with high speed operation locked out The time period may be from 15 minutes to 2 hours If the time period is set and is exceeded the unit will return to normal operation with high speed operation allowed If this occurs the message HIGH SPEED LOCKOUT ACTIVE at the top of the display will disappear If necessary to return to High Speed Lockout Mode press the High Speed Lockout Key again ...

Page 85: ...ision Not all gauges may appear depending on unit configuration and software revision To return to the Premium Display press the EXIT key Gauges Available NOTE Not all gauges or I O states will appear dependent upon unit type and configuration Coolant Temperature Displays the temperature of the engine coolant Coolant Level Displays the coolant level in the overflow tank as OK or LOW Oil Pressure D...

Page 86: ...units only Condenser Inlet Solenoid Drain Hose Heater Purge Valve USING THE SENSORS KEY The SENSORS key allows the operator to view the temperatures read by the unit temperature sensors To access the SENSORS menu press the SENSORS key Sensors Key The first sensor display will appear Press the NEXT and BACK keys to scroll thru the sensors as desired The Discharge Air Temperature sensor is shown in ...

Page 87: ...re Differential Zone 2 Evaporator Coil Temperature Displays the temperature of the Zone 2 Evaporator Coil sensor Zone 3 Return Air Temperature Displays the temperature of the Zone 3 Return Air Sensor Zone 3 Discharge Air Temperature Displays the temperature of the Zone 3 Discharge Air Sensor Zone 3 Temperature Differential Displays the Zone 3 Temperature Differential Zone 3 Evaporator Coil Tempera...

Page 88: ... the Diesel to Electric Auto switch feature is set NO this feature allows the operator to manually select electric mode operation This feature does not appear if the unit does not feature optional Electric Standby or if the Diesel to Electric Auto switch feature is set YES DIESEL MODE If a unit equipped with electric standby is running in electric mode and the Electric to Diesel Auto switch featur...

Page 89: ...cess to select a different language To select a different Main Menu item press the NEXT key To return to the Premium Display press the EXIT key IMPORTANT If necessary English and all other languages in the installed HMI Control Panel software revision may be accessed from the Premium Display Should it be necessary to change to another language at any time return to the Premium Display and then pre...

Page 90: ...e corrective action before a problem becomes severe The unit will run with check alarms but some features and functions may be inhibited Shutdown Alarms Shutdown alarms will be set if continued operation could cause damage to the unit or the load Shutdown Alarms are indicated by the following The Alarm Icon will appear in the display The display and backlight will flash on and off The display will...

Page 91: ...ill appear next to the affected zone If a Zone Prevent Alarm occurs in all zones then the unit will be forced into a unit level Prevent shut down Pretrip Alarm Codes If an alarm occurs during a Pretrip Test the alarm code will be displayed as Pretrip Alarm XX where XX is the alarm code Alarm Codes When Switching Between Diesel and Electric If a shutdown alarm occurs that affects only diesel mode o...

Page 92: ...red using the Alarm Menu From the Premium Display press the MENU key Figure Menu Key page 6 15 The Language Menu or Alarms Menu will appear If the Language Menu appears press the NEXT key to show the Alarm Menu When the Alarms Menu is shown press the SELECT key Select Key The Alarm Display will appear If no alarms are present NO ALARMS will be shown No Alarms If alarms are present the quantity of ...

Page 93: ...h Data Logger and DAS Data Logger if equipped are accessed using the Data Logger Menu From the Premium Display press the MENU key Figure Menu Key page 6 15 The Language Menu or Alarm Menu will appear Press the NEXT key as required to display the Data Logger Menu When the Data Logger Menu is shown press the SELECT key Select Key The first feature that appears is the Start of Trip To send a Start of...

Page 94: ...gine Run Time Maintenance Reminder 1 occurs Engine Reminder 2 User Programmable The number of hours before an Engine Run Time Maintenance Reminder 2 occurs Electric Reminder 1 User Programmable The number of hours before an Electric Run Time Maintenance Reminder 1 occurs Electric Reminder 2 User Programmable The number of hours before an Electric Run Time Maintenance Reminder 2 occurs IMPORTANT If...

Page 95: ...to wake up to be specified Hour to Wake Up This feature allows the hour the unit is to wake up to be specified Minute to Wake Up This feature allows the minute the unit is to wake up to be specified Run Pretrip on Wakeup This feature allows a Pretrip Test to be automatically run when the unit wakes up Mode changes are made using the Mode Menu From the Premium Display press the MENU key Figure Menu...

Page 96: ...argo temperatures it only keeps the engine warm and the unit battery charged This is useful in extremely cold weather or when the unit is to be out of service for an extended time Sleep mode operates in both Diesel mode and Electric mode In Diesel mode the unit will start and stop as required to maintain engine temperature and battery charge In Electric mode the unit starts and stops as necessary ...

Page 97: ...me normal operation and control to setpoint Sleep Mode Display To enter a Wake up Time verify the unit clock is set properly Then press the YES key at the Sleep Mode menu Yes Key The display will prompt the operator for the DAY the unit is to restart in normal operation In figure shown Monday has been chosen Press the YES key to confirm the DAY Day Unit is to Restart The display will now prompt th...

Page 98: ... displayed as Pretrip Alarm XX where XX is the alarm code Pretrip Test Conditions Current unit settings are saved and restored at the end of the Pretrip Test or if the unit is turned off and back on Pretrip Test can be run in either Diesel or Electric Mode The unit will auto switch from Diesel Mode to Electric Mode or from Electric Mode to Diesel Mode during a Pretrip Test if these features are en...

Page 99: ...n test in progress when the test was terminated Pretrip Tests are initiated using the Pretrip Menu From the Premium Display press the MENU key Figure Menu Key page 6 15 The Language Menu or Alarm Menu will appear Press the NEXT key as required to display the Pretrip Menu When the Pretrip Menu is shown press the SELECT key Select Key If the unit is not running a Full Pretrip Test will be initiated ...

Page 100: ...led the unit is switched using the Electric Standby Menu From the Premium Display press the MENU key Figure Menu Key page 6 15 The Language Menu or Alarm Menu will appear Press the NEXT key as required to display the Electric Standby Menu When the Electric Standby Menu is press the SELECT key Select Key NOTE This screen will not appear if diesel to electric autoswitching is enabled If the unit has...

Page 101: ... standby power fails or is disconnected ADJUST BRIGHTNESS The brightness of the HMI Control Panel display can be adjusted to allow for changing ambient light conditions The choices available to the operator are HIGH MEDIUM LOW and OFF OFF actually results in a very dim screen suitable for low light conditions Display brightness is adjusted using the Adjust Brightness Menu From the Premium Display ...

Page 102: ... cannot be changed from the Main Menu From the Premium Display press the MENU key Figure Menu Key page 6 15 The Language Menu or Alarm Menu will appear Press the NEXT key as required to display the Time Menu When the Time Menu is shown press the SELECT key Select Key The current time and date will appear and Keys ...

Page 103: ...ecting CYCLE SENTRY or Continuous Mode 7 11 Selecting the High Speed Lock Out Feature 7 11 Initiating a Manual Defrost Cycle 7 12 Terminating a Defrost Cycle 7 12 Alarms 7 13 Alarm Code Notification 7 13 Displaying Alarm Codes 7 13 Clearing Alarm Codes 7 13 Important Alarm Notes 7 13 Sending a Servicewatch Data Logger Start of Trip 7 13 Pretrip Test 7 14 Pretrip Test Conditions 7 14 Pretrip Test C...

Page 104: ...rmeters Changes unit or zone Setpoints Selects and Indicates CYCLE SENTRY or Continuous Mode Operation Selects and Indicates High Speed Lock Out Operation Initiates and Indicates a unit or zone Defrost Cycle Indicates an Alarm Condition Exists Displays and Clears Alarms Initiates and Indicates a Pretrip Test Sends a Start of Trip to the ServiceWatch data logger Changes Display Brightness Shows HMI...

Page 105: ...ms If the display is flashing on and off a shutdown alarm has occurred and the unit has been shut down Immediate action must be taken ON Key Pressing the ON Key will turn the unit on Secondary Use When the unit is on pressing this key and the PRETRIP Key at the same time will display any alarm codes that are present Secondary Use When the unit is on pressing and holding this key allows the UP ARRO...

Page 106: ...essing the DEFROST Key will initiate a manual defrost cycle if conditions allow If the evaporator coil temperature less than 45 F 7 C the unit will enter a defrost cycle The amber LED will flash while the defrost cycle is initialized and will glow during the defrost cycle The defrost cycle will terminate automatically and the amber LED will turn off when the evaporator coil temperature is greater ...

Page 107: ...trol Panel is turned on and the Base Controller On Off Switch is turned off the HMI display screen will flash on and off The unit is turned on by pressing the ON Key and off by pressing the OFF Key When the ON Key is pressed the display briefly shows dashes as the display initializes Keys and LED Indicators When two horizontal bars are present at the left side of the box temperature then Zone 2 is...

Page 108: ...nt Standard Display of Box temperature and Setpoint Pressing the OFF Key stops unit operation The unit shuts down immediately and the display goes blank To start the unit again press the ON Key Off Key The Standard Display The Standard Display is the default display that appears if no other display function is selected The Standard Display shows the box temperature and setpoint The box temperature...

Page 109: ... no other display function is selected The Standard Display shows the current zone box and the temperature and setpoint of that zone Horizontal bars to the left of the box temperature are used to indicate the zone currently shown on the display The box temperature is that measured by the return air sensor The box temperature and Box Temperature Icon are shown in the upper display The setpoint and ...

Page 110: ...can be initiated in the selected zone if zone conditions permit Turning Zones On and Off Each configured zone can be individually turned on or off The On and Off state for each zone is maintained even if the unit is turned off and back on For example if Zone 2 is turned off and the unit is then turned off and back on Zone 2 will still be off IMPORTANT At least one zone must be turned on If all con...

Page 111: ...ld setpoint and Alarm Code 127 Setpoint Not Entered will be set The Alarm Icon will appear in the display Failure to confirm the new setpoint by pressing the ENTER Key within 20 seconds of changing the setpoint will result in no setpoint change In addition Alarm Code 127 Setpoint Not Entered is set to indicate that the setpoint change was started but was not completed Alarm Icon Displayed Notice t...

Page 112: ...e TSD TSR 2 TSR 3 Standard Truck HMI Control Panel will continue to show the Standard Display The preheat buzzer at the unit located on the unit Interface Board sounds for 20 seconds before the electric motor starts Switching from Diesel to Electric Important The operation of this feature can be changed using the Guarded Access Menu Units equipped with the ELECTRIC STANDBY option only The unit wil...

Page 113: ... If the unit is running in Continuous Mode pressing this key will switch operation to Cycle Sentry Mode and the amber LED indicator will glow If the unit is running in Cycle Sentry Mode pressing this key will switch operation to Continuous Mode and the amber LED will turn off Electric Mode When running in Electric Mode the unit is forced to Cycle Sentry operation Continuous operation is not availa...

Page 114: ...again as required to select the desired zone To initiate a manual defrost cycle press the DEFROST Key If conditions allow the unit will enter a defrost cycle and the amber LED next to the DEFROST Key will glow Important During the defrost cycle the box temperature will rise toward 50 F 10 C This is normal and is caused by the defrost cycle warming the evaporator coil Since the damper door is close...

Page 115: ...o clear the alarm code currently being shown When all alarms have been cleared the display will show all zeros to indicate that no alarm codes exist The display will return to the Standard Display about 30 seconds after all alarms have been cleared Important Alarm Notes All alarms must be viewed before any of the alarms can be cleared If an alarm will not clear it may still exist If the alarm is n...

Page 116: ...ert to the Standard Display the Alarm Icon will not be displayed and the unit will continue to run as required This signifies that the unit passed the Pretrip Test If the Pretrip Test fails alarm codes will exist to direct the technician to the source of the problem Engine Running Pretrip Test Engine Running Pretrip Tests include all of the tests shown below They do not include the Amps Check or t...

Page 117: ... The box temperature will vary during the Pretrip Test This is normal operation When the Pretrip Test is complete or if a Shutdown Alarm occurs the amber Pretrip LED will turn off Stopping a Pretrip Test To stop a Pretrip Test at any time press the POWER OFF Key to turn the unit off This will generate Alarm Code 28 Pretrip Abort Other alarm codes may also be generated This is normal when the Pretr...

Page 118: ...ion is shown at the bottom of the display The HMI Control Panel Serial Number shown in Figure is 00212 The software revision shown below is Revision 2200 Software Revision and Serial Number Time and Date With all SR 2 control systems the system time and date is maintained by the HMI Control Panel The time and date held by the HMI Control Panel cannot be viewed using the Standard Truck HMI Control ...

Page 119: ... WinTrac to set the time and date See the WinTrac Manual for additional information 9 When the time and date is set and checked disconnected the cable replace the back cover and reinstall the Standard Truck HMI Control Panel as necessary 10 Turn the unit on and perform a ServiceWatch Data Logger download using WinTrac to verify the time and date are correct ...

Page 120: ...Operating Instructions Standard HMI 7 18 ...

Page 121: ...re 8 3 Field Current Test 8 5 Battery 8 5 Fuses 8 5 Interface Board LEDs 8 7 Smart FETs 8 8 SMART REEFER 2 3 SR 2 3 Microprocessor Controller 8 8 Expansion Module SPECTRUM systems ONLY T Series SPECTRUM and UT SPECTRUM 8 9 Expansion Module LEDs 8 9 Flywheel RPM Sensor 8 10 Glow Plugs 8 11 Unit Wiring 8 12 AC Components Model 50 Units Only 8 12 Electrical Contactors 8 12 Evaporator Heaters Optional...

Page 122: ...ly adjusted Be sure the belt is not loose or cracked and the pulleys are the correct size and in good condition The excitation circuit EXC circuit must supply voltage to the excite terminal of the alternator The sense circuit SENSE circuit must supply voltage to the sense terminal of the alternator The alternator must be properly grounded The unit control circuits or installed accessories may be d...

Page 123: ...ay not be readily apparent To test the alternator under load Thermo King recommends the use of a clamp on ammeter to monitor output current both on initial startup and under full unit load conditions For example on multi temp units all remote evaporators should be turned on General Diagnostic and Warranty Evaluation Procedure Complete the following diagnostic procedures before replacing an alterna...

Page 124: ...ted voltage regulator setting as shown in the table below Record the voltage The voltage regulator setting varies inversely with the temperature as shown below Regulator voltage can vary from approximately 15 2 Vdc at 40 F 40 C to approximately 13 2 Vdc at 176 F 80 C If the voltage does not increase to the anticipated voltage regulator setting the alternator is defective if there are no problems i...

Page 125: ...the battery terminals and check the electrolyte level during scheduled maintenance inspections A dead or low battery can be the cause of an ammeter indicating discharge due to lack of initial excitation of the alternator even after the unit has been boosted for starting The minimum specific gravity should be 1 235 Add distilled water as necessary to maintain the proper water level FUSES TSR 2 TSR ...

Page 126: ...ith Australian Bosch or Thermo King Alternators Install fuse F4 for Model 50 units with Prestolite Alternator F10 When fuse F10 is installed in the upper position the On Off keys on the HMI turn the unit on and off When fuse F10 is installed in the lower position the unit will start and run without the HMI control panel F15 The device identified as F15 is a poly switch These over current devices r...

Page 127: ...nator 1 Base Controller Interface Board 2 Evaporator Fan Relay Board TSD Base Controller Interface Board and Evaporator Fan Relay Board Interface Board LED Functions LED Function LED 3 K2 Preheat Circuit LED 4 K4 Damper Circuit LED 5 K3 High Speed Circuit LED 6 K1 Run Relay Circuit LED 7 K5 Diesel Electric Relay LED 8 Condenser Inlet Solenoid CIS Circuit LED 9 Receiver Tank Pressure Solenoid RTPS ...

Page 128: ...r second when the base controller is powered and operating normally Flashes several times per second when flash loading Is on without flashing during reboot and when under test Flashes twice within 1 second followed by 1 second off if a CAN communication error is present LED 22 K8 Drain Tube Heaters Remote Evaporator Not Used LED 23 K9 On Off Circuit LED 24 K6 Fuel Solenoid Pull In Circuit LED 25 ...

Page 129: ...ule via the YEL wire in the 8 pin connector The expansion module communicates with the base controller via a CAN bus connection All remote zone input and solenoid output functions are connected via the expansion module 35 pin connector harness Remote evaporator fan motor outputs are provided for 6 variable speed remote fan motors Each output is capable of operating two fans There are no user repla...

Page 130: ...tarter disengagement If the flywheel sensor fails the starter may not disengage or engage properly and a fault code will be generated HGS2 Zone 2 Hot Gas Solenoid HGS3 Zone 3 Hot Gas Solenoid SLS1 Zone 1 Suction Line Solenoid SLS2 Zone 2 Suction Line Solenoid SLS3 Zone 3 Suction Line Solenoid HBEAT Status Flashes once per second when the base controller is powered and operating normally Flashes se...

Page 131: ...tly off the voltage may be increased by turning the sensor in more and the voltage may be lowered by turning the sensor out more 5 Reconnect the FS1 and FS2 wires to the sensor If the flywheel sensor passes the above test the sensor may be considered good If the engine will not start an alternate less reliable test may be performed as follows Disconnect the sensor from all wires and measure the re...

Page 132: ...UNIT WIRING Inspect the unit wiring and the wire harnesses during scheduled maintenance inspections for loose chafed or broken wires to protect against unit malfunctions due to open or short circuits AC COMPONENTS MODEL 50 UNITS ONLY Electrical Contactors Test the contact points by checking the voltage drop across each set of points when the contactor is energized and the system is operating If th...

Page 133: ... the unit Correct rotation will hold the cloth or paper against the grille Improper rotation will blow the cloth or paper away from the grille To correct incorrect rotation check the motor and motor contactor wiring per the unit wiring diagram Phase Select Module for Truck Unit Model 50 Applications The phase select module is designed to monitor both single and 3 phase nominal input voltages betwe...

Page 134: ...e via the 8 wire and CH wire 1 Phase Select Module 2 Overload Relay 3 Base Controller Interface Board Assembly Low Voltage 4 Evaporator Fan Relay Board Low Voltage 5 MCA Motor Contactor 6 MCB Motor Contactor 7 Heater Contactor Optional Model 50 Control Box Components with High Voltage Cover Removed T 500R T Dairy Only 1 MCB Motor Contactor 2 MCA Motor Contactor 4 Overload Relay 5 Phase Select Modu...

Page 135: ...ound Inputs Input Description L1 This Brown wire supplies standby power L1 to the phase select module L2 This Gray wire supplies standby power L2 to the phase select module L3 This Black wire supplies standby power L3 to the phase select module 7EA If 12 volts DC is supplied then output 7EB or 7EC will be at 12 volts DC SP If this wire is connected to chassis ground the module will operate in sing...

Page 136: ...rcuits at the input to the terminals where the Brown Blue and Black wires are connected The voltage should be between 200 480 VAC between the circuits If not repair as necessary to supply the needed voltage to the unit 3 Check the 8 circuit to the phase select module for 12 Vdc If voltage is not present check the phase select module connector and the interface board connector for secure connection...

Page 137: ...nt When the overload relay is replaced the new overload relay must be set up to open at the correct amperage and reset automatically See the following procedure to set up a new overload relay 1 Open the clear plastic cover 2 Use a small screwdriver to set the opening amperage See Electric Motor and Overload Relay in the Specifications chapter for the correct overload relay setting 3 Use a small sc...

Page 138: ...d relay to reset automatically The new overload relay is now set up correctly Note which wires go to which terminals when removing the old overload relay so the wires are connected correctly when the new overload relay is installed 1 Set Opening Amperage 2 Remove Tab Marked H Set Amperage and Remove Tab 1 Switch Clicks into Place at Bottom of Slot Move Switch Down 2 1 1 ...

Page 139: ... Operation 9 12 Maintenance 9 12 Bleeding the Fuel System 9 13 Draining Water from Fuel Tank 9 19 Fuel Filter Replacement 9 19 Electric Fuel Pump 9 19 Injection Pump Timing 9 20 Injection Pump Removal and Installation 9 23 Fuel Limit Screw 9 25 Fuel Solenoid 9 25 Engine Speed Adjustments 9 27 Adjust Engine Valve Clearance 9 29 Engine Mounts 9 32 Belts 9 37 Belt Tensions 9 37 Water Pump Belt 9 39 E...

Page 140: ...il pump The use of improper viscosity oil will also produce low oil pressure shutdowns Engine Oil Pressure Switch Sensor The engine oil pressure switch sensor is located on the filter head above the bypass oil filter Engine oil pressure should rise immediately on starting If engine oil pressure drops below 10 2 psig 69 14 kPa the switch sensor signals the microprocessor to stop the engine See the ...

Page 141: ...n and engine life Inspect the element at every oil change Replace the EMI 2000 air cleaner filter element at 2 000 hours or 1 year whichever occurs first CRANKCASE BREATHER SYSTEM The crankcase breather system ducts crankcase gases formed in the crankcase directly to the air intake Harmful vapors that would otherwise collect in the crankcase and contaminate the oil or escape to the outside are dra...

Page 142: ...dings are significantly more positive than 0 to 11 in 0 to 279 mm H2O of vacuum you may have excess blowby past the rings A compression check should be performed to confirm this The following items can effect the crankcase pressure readings 1 Breather Cover 2 O ring 3 Baffle 4 Baffle Plate Crankcase Breather Components Unit Speed in mm H2O of vacuum Truck Low 0 to 8 in 0 to 203 mm Truck High 2 to ...

Page 143: ...omatically maintains coolant temperature within the specified temperature range All water cooled engines are shipped from the factory with a mixture of 50 percent permanent type antifreeze concentrate and 50 percent water in the engine cooling system This provides the following 1 Prevents freezing down to 30 F 34 C 2 Retards rust and mineral scale that can cause engine overheating 3 Retards corros...

Page 144: ...enance 9 6 1 Engine 5 Expansion Tank 2 Coolant Temperature Sensor 6 Coolant Level Sensor 3 Expansion Tank Cap 7 Radiator 4 Overflow Cap 8 Drain Cock T Series Engine Cooling System Components TK 270 1 2 4 7 3 5 8 6 ...

Page 145: ...oolant 1 Fill the cooling system via the expansion tank allowing the coolant level up to the overflow tank inlet passage opening 2 The recommended quantity is listed in the table below 3 To remove all air trapped in the cooling system use a custom made coolant fill tube This coolant fill tube can be manufactured locally or requested from the service department in Thermo King Galway a Install the c...

Page 146: ... on the HMI to ensure the pressure does not become excessively high potentially causing the unit to shuT down g Repeat Steps as required until the coolant level in the fill tube remains constant i e no more air bubbles in the fill tube h Then squeeze clamp the expansion tank to thermostat coolant hose to force more coolant flow through the radiator This will likely lower the temperature of the coo...

Page 147: ...onized or distilled water is recommended over tap water to insure the integrity of the cooling system is maintained Antifreeze Maintenance Procedures As with all equipment containing antifreeze periodic inspection on a regular basis is required to verify the condition of the antifreeze Inhibitors become worn out and must be replaced by changing the antifreeze Change green or blue green engine cool...

Page 148: ...ent and operate the unit in accordance with instructions of the flushing agent manufacturer c Open the drain cock to drain water and flushing solution 3 Run clear water into the radiator and allow it to drain out of the drain cock until it is clear When water has finished draining close drain cock 4 Inspect all the hoses for deterioration and the hose clamp tightness Replace if necessary 5 Loosen ...

Page 149: ...he float is in the upper position and the switch is closed When the coolant level is below the switch the float is in the lower position and the switch is open 1 Thermostat Housing 2 Gasket 3 Thermostat 4 Gasket 5 Water Pump Water Pump Assembly and Thermostat 1 Float in Upper Position Switch Closed 2 Float in Lower Position Switch Open Coolant Level Switch 1 2 3 4 5 1 2 ...

Page 150: ...ntil the coolant level is well below the switch 3 Remove unscrew the coolant level switch from the expansion tank 4 Install the new coolant level switch and position the orientation mark down as shown in the following drawing 5 Refill the expansion tank with coolant 6 Connect the wire harness connector to the coolant level switch ENGINE FUEL SYSTEM The fuel system used on these diesel engines is a...

Page 151: ...shops The following procedures can be done under field conditions Bleeding air from the fuel system Maintenance involving the fuel tank and filter system Engine speed adjustments Electric transfer pump replacement or repair 10 psig 69 kPa pump with diesel filter Injection line replacement Pump timing Nozzle spray pattern testing and adjustment Minor rebuilding of nozzles Bleeding the Fuel System T...

Page 152: ...Engine Maintenance 9 14 T Series Fuel and Oil System Components TK 376 ...

Page 153: ...21 Tee with restrictor 7 Nut 1 4 22 Switch oil pressure 8 Elbow hose fitting 1 4 23 Bushing 9 Hose 1 4 od 24 Valve Schrader 10 Tee 25 Pump fuel 12V 11 Tee with restrictor Kit filter 12 Elbow 45 degree Kit bowl gasket 13 Filter fuel EMI 2000 Gasket bowl to body 14 Adapter fuel pickup 26 Bracket fuel pump 15 Bracket fuel filter Screw bracket Screw Flatwasher Flatwasher Nut Nut 27 Tube fuel pickup T ...

Page 154: ...Engine Maintenance 9 16 T Series Fuel and Oil System Components TK 270 ...

Page 155: ...tting 1 4 Kit bowl gasket 9 Hose 1 4 od Gasket bowl to body 10 Bushing 27 Wrench fuel bowl 11 Tee with restrictor 28 Bracket fuel pump 12 Elbow 45 degree Screw bracket 13 Filter fuel EMI Flatwasher 14 Filter oil bypass EMI Nut 15 Adapter fuel filter 29 Tube fuel pickup 16 Adapter bypass oil filter 30 Hose oil drain 17 Bracket fuel filter Elbow oil hose Screw bracket Cap oil hose Flatwasher 31 Hose...

Page 156: ...Engine Maintenance 9 18 UT Series Fuel System Components AMA768 ...

Page 157: ...ing the electric pump until fuel bubbles appear at the top of filter 5 Tighten the filter until the rubber ring makes contact then tighten 1 2 turn more Electric Fuel Pump Operation The electric fuel pump must be mounted next to the fuel tank This pump is designed to push rather than pull fuel Make sure the harness plug black wire pin completes a good ground with the battery Check the voltage at t...

Page 158: ... fuel check for Air leaks in the fuel lines or connections Kinks or other restrictions in the fuel lines A leaking or distorted fuel bowl gasket A clogged or dirty filter Injection Pump Timing This is the only timing procedure for this engine It is not necessary to check the individual cylinder timing 1 Fuel Inlet 2 Fuel Filter 3 Fuel Filter Bowl 4 Fuel Filter Bowl Gasket Electric Fuel Pump CAUTIO...

Page 159: ...he number one cylinder Refer to steps a through d a Rotate the engine in the normal direction of rotation clockwise viewed from the water pump end until the number one TDC mark on the flywheel lines up with the timing mark on the starter mounting plate b Check the rocker arms on the number one cylinder to see if they are loose c If the rocker arms are loose the engine is at top dead center of the ...

Page 160: ...rees BTDC timing mark on the flywheel should be aligned with the timing mark on the starter mounting plate Repeat steps 7 through 10 to recheck the timing 11 If the timing is off by more than 1 degree 0 1 in 2 5 mm loosen the mounting nuts on the studs that fasten the injection pump to the engine and rotate the injection pump to change the timing a Pull the top of the injection pump away from the ...

Page 161: ...on pump can be returned to the same position when it is reinstalled 2 Remove the throttle linkage fuel lines wire harness and mounting hardware from the injection pump 3 Remove the injection pump timing cover from the gear case 4 Loosen the injection pump gear mounting nut but do not remove it yet 1 Index Marks Index Mark Location 1 Index Mark on Injection Pump 2 Index Mark on Gear Case Index Mark...

Page 162: ...n pump in the gear case Rotate the injection pump shaft to mate the key in the shaft with the keyway in the injection pump gear Take care to make sure the key mates with the keyway 3 Secure the injection pump to gear case with previously removed hardware Make sure to align the index marks on the injection pump and the gear case like they were in step 1 of Injection Pump Removal NOTE If a different...

Page 163: ...e microprocessor through the fuel solenoid pull in relay K6 Testing the Fuel Solenoid The fuel solenoid pull in coil will require 35 to 45 amps to turn on the fuel The unit s battery must be in good condition If the battery has enough power to crank the engine over it has enough power to energize the fuel solenoid pull in coil If you suspect that the engine does not run because the fuel solenoid i...

Page 164: ...coil a Energize the hold in coil by placing a jumper between the red wire 8D pin A in the fuel solenoid connector and the positive battery terminal b Momentarily energize the pull in coil by placing a jumper between the white wire 8DP pin B in the fuel solenoid connector and the positive battery terminal The fuel solenoid should make a definite click when the pull in coil is energized but should n...

Page 165: ...ustments with the engine fully warmed up Low Speed Adjustment 1 Start the unit and let it run until the engine is warmed up 2 Adjust the setpoint to make the engine run in low speed or use Service Test Mode LSC and check the engine speed See Specifications for the correct low speed 3 If the engine speed is not correct loosen the jam nut on the low speed adjustment screw 4 Turn the low speed adjust...

Page 166: ...the jam nuts at both ends of the high speed adjuster in the throttle linkage 4 Turn the high speed adjuster to change the engine speed 5 Set the engine speed at the correct high speed and tighten both jam nuts 6 Recheck the engine speed 1 BRACKET solenoid engine mount 9 LOCKWASHER 2 SOLENOID 10 ADJUSTER speed control 3 PLUNGER solenoid 11 NUT 1 4 28 LH thread 4 BOOT solenoid 12 BALL JOINT 5 NUT so...

Page 167: ...o cylinder engines are stamped 180 degrees apart The top dead center marks have the cylinder number stamped next to them The injection timing marks have no identification marks The index timing mark is stamped on the side of the starter mounting plate that faces the flywheel This index timing mark is on the intake side of the engine On the three cylinder engines the order for the flywheel timing m...

Page 168: ...d the exhaust valves should be 0 006 to 0 010 in 0 15 to 0 25 mm NOTE Check to make sure that the valve stem cap is in good condition and is positioned squarely on the top of the valve stem Replace the valve stem cap if it shows significant wear 4 Adjust the valves if necessary by loosening the lock nut and turning the adjustment screw until the valve clearance is correct 5 Hold the adjustment scr...

Page 169: ... and adjust both valves for the number 3 cylinder 9 Place the engine at top dead center of the compression stroke for the number 2 cylinder a Rotate the engine in the normal direction of rotation counterclockwise viewed from the flywheel end until the top dead center timing mark for the number 2 cylinder on the flywheel lines up with the index timing mark on the starter mounting plate b Check the ...

Page 170: ...Engine Maintenance 9 32 ENGINE MOUNTS The engine mounting system contains three vibration mounts and a chain restraining mount snubber T Series Engine Mounting Components for 3 Cylinder Engine ...

Page 171: ...Screw chain Screw plate bracket socket head 12 Chain 3 links Washer belleville 13 Bolt eye 1 2 in Sealer thread 14 Bracket snubber gauge 4 Screw mount Rivet bracket 5 Washer special 15 Spacer eistimer 6 Mount vibration front set of two 16 Washer special 7 Nut 17 Locknut 8 Stud snubber T Series Engine Mounting Components for 3 Cylinder Engine ...

Page 172: ...Engine Maintenance 9 34 T Series Engine Mounting Components for 2 Cylinder Engine ...

Page 173: ...olt eye Sealer thread 14 Bracket snubber 4 Screw mount 15 Spacer spring 5 Washer special 16 Washer special 6 Mount vibration 17 Nut 7 Nut 18 Plate bearing 8 Screw chain Rivet plate T Series Engine Mounting Components for 2 Cylinder Engine 1 Eye Bolt 11 Stud 2 Locknut 3 8 in 12 Locknut HH 3 Belleville Washer 3 8 in 13 Flatwasher 3 8 Galv 4 Vibration Mount 14 See Note 18 5 Screw 15 Locknut HH 6 Flat...

Page 174: ...SS Flatwasher 5 16 Nylock Nut 5 16 18 SS 4 Screw 3 8 16 SS Flatwasher 3 8 Nylock Nut 3 8 16 SS 2 Vibration Mount 5 3 Link Chain 3 Mount Frame Bracket 6 This End Through Existing Hole In Engine Flange UT Series Chain Restraining Mount Bracket ...

Page 175: ...1 Belts Only 2010 T 1200R Release 1 Belts Only 2010 T 1000R SPECTRUM Release 1 Belts Only 2010 T 1200R SPECTRUM Release 1 Belts Only 2010 UT Series 4 2 65 75 131 15 127 15 131 15 127 15 131 15 127 15 131 15 127 15 Alternator UT Series only 45 55 Note Most recent models of T Series Units now generally use plates for setting the compressor belt tension see following pages for correct belt tension pr...

Page 176: ...669 T 1000R 1E46118H90 781852 2E24751H02 930669 T 800R SPECTRUM 1E46118H89 781822 2E24751H01 930617 T 800R T 600R 1E46118H89 781822 2E24751H01 930617 T 500R T Dairy 1E46118H89 781822 1E75364H04 929604 Model Belt Part Number Plate Part Number Adjuster Brackets T 1200R SPECTRUM 1E46118H92 781854 2E24751H08 930865 44 T 1200R 1E46118H92 781854 2E24751H08 930865 44 T 1000R SPECTRUM 1E46118H90 781852 2E...

Page 177: ... necessary Model Belt Part Number Plate Part Number Adjuster Brackets T 1200R SPECTRUM 1E46118H92 781854 2E24751H08 New 44 T 1200R 1E46118H92 781854 2E24751H08 New 44 T 1000R SPECTRUM 1E46118H90 781852 2E24751H02 930669 45 5 T 1000R 1E46118H90 781852 2E24751H02 930669 45 5 T 800R SPECTRUM 1E46118H24 781688 Note T 800R Spectrum requires frame change for new routing Must use older belt instead Note ...

Page 178: ... 4 Key Woodruff 16 Electric Motor 5 Engine to Electric Motor Jackshaft Belt 17 Jackshaft 6 Clutch 18 Key square 7 Evaporator Fan Pulley Curbside 19 Fan Hub 8 Evaporator Fan Pulley Roadside 20 Condenser Fan 9 Idler Pulley 21 Water Pump Belt 10 Electric Motor Jackshaft Pulley 22 Alternator 11 Electric Motor Jackshaft to compressor Belt Measure Tension Here 23 Fan screw 12 Alternator Pulley 24 Fan sh...

Page 179: ...ulleys 4 Install the new belt Make sure it fits on the pulleys correctly 5 Release the belt tensioner tool so the belt tensioner is pressing on the belt and remove the belt tensioner tool from the belt tensioner 6 Reinstall the electric motor jackshaft compressor belt 1 Engine Electric Motor Jackshaft Belt 10 Compressor Pulley Bushing 2 Clutch 11 Compressor Pulley Key 3 Idler Pulley Tensioner 12 C...

Page 180: ...the old belt and note how it fits on the pulleys 6 Install the new belt Make sure it fits on the pulleys correctly 7 Take a straight edge place it against the side of the muffler can and mark the frame as shown below This is the unloaded engine position Mark Frame 8 Turn the adjusting bolt clockwise to make the pulley descend and tighten the belt until it is at approximately 10 Hz lower than the c...

Page 181: ...ould be adjusted to the field reset setting If the belt is replaced it should be set at the factory setting After 2 000 hours it should be adjusted to the field reset setting Use the following procedure to adjust or replace this belt 1 Loosen the alternator pivot bolt that attaches the alternator to the electric motor or jackshaft 2 Loosen the locknut on the small bolt in the alternator adjustment...

Page 182: ...mounting nut and the jam nut on the idler adjuster Compressor Electric Motor Belt UT Series 1 Loosen the idler mounting nut 2 Turn the idler adjuster to obtain a tension of 75 5 on the TK gauge P N 204 427 or a deflection of 13 mm at the center of the belt 3 Tighten the idler mounting nut 1 Idler Mounting Nut 3 Idler Adjuster 2 Jam Nut Engine Clutch Electric Motor Belt Adjustment 1 Idler Mounting ...

Page 183: ...ivot bolt and the alternator adjusting bolt 3 Position the alternator to obtain a tension of 55 5 on the TK gauge P N 204 427 or a deflection of 13 mm at the center of the belt 4 Tighten the alternator pivot bolt and the alternator adjusting bolt 1 Alternator Pivot Bolt 2 Alternator Adjusting Bolt Electric Motor Alternator Belt Adjustment AMA767 1 2 ...

Page 184: ...Engine Maintenance 9 46 ...

Page 185: ...Scroll Compressor Oil Replacement 10 27 Scroll Compressor High Temperature Switch Replacement 10 28 Scroll Compressor Liquid Injection Fitting Replacement 10 28 Condenser Check Valve Test Single Temperature Units Only 10 29 Condenser Check Valve and Purge Check Valve Test T 500R T Dairy 10 29 Condenser Check Valve Purge Check Valve and Receiver Tank Pressure Solenoid Leak Test Multi Temp Units Onl...

Page 186: ...10 45 Purge Valve PV Test 10 46 Receiver Tank Pressure Check Valve Test 10 46 Receiver Tank Pressure Solenoid RTPS Test Multi Temp Units Only 10 46 Receiver Tank Replacement 10 47 Solenoid Valve Replacement 10 47 Suction Line Check Valve Test Multi Temp Units Only 10 48 Suction Line Solenoid SLS Test Multi Temp Units Only 10 48 Suction Pressure Regulator SPR Test 10 49 Suction Pressure Regulator S...

Page 187: ...e pump is capable of pulling a deep vacuum b When the vacuum pump oil is contaminated c If the vacuum hoses and valves are leak free d If the unit is leak free e How long you should evacuate the unit f That the unit is still in a deep vacuum before any lines are disconnected or refrigerant is added NOTE The attached evacuation procedures have been written to be used with the Thermo King Evacuation...

Page 188: ...tenance 10 4 1 V 1 7 Iso Valve 2 V 2 8 To 110 Vac Power 3 V 3 9 Calibration Standard 4 V 4 10 Vacuum or Micron Gauge 5 Thermistor 11 Charging Port 6 Two Stage Vacuum Pump Evacuation Station 2 4 5 3 1 6 8 9 10 AGA654 7 11 ...

Page 189: ...s 2 500 Microns 3 1000 Microns 4 2500 Microns 5 5000 Microns 6 20 000 Microns 7 Atmospheric Pressure 8 Calibration Adjustment Screw 9 Example Meter needle shown at calibration position when Calibration Standard specifies 0 15 mm Hg Vacuum Gauge ...

Page 190: ...rn the vacuum pump Off 9 Observe the micron gauge reading The vacuum rise should not exceed 2000 microns in 5 minutes 10 If the rise is above 2000 microns in 5 minutes check all hoses and connections for leaks Hoses with moisture present will require additional evacuation time to achieve satisfactory results NOTE Dirty vacuum pump oil or a defective vacuum pump will prevent a low micron reading Ho...

Page 191: ...e lowest achievable level between 500 and 1000 microns NOTE The presence of refrigerant in the compressor oil may prevent a low micron reading from being achieved The oil can continue to outgas for long periods of time If the micron level appears to stall after 1 2 hour or 45 minutes between 1000 and 1500 microns back seat the suction service valve and observe the micron gauge A sharp drop in the ...

Page 192: ...pen the suction service valve one turn and open the discharge service valve 1 4 turn 6 Open the refrigerant supply valve for liquid 7 Start the unit and use the Service Test mode to run the unit in high speed cool See the appropriate Microprocessor Diagnostic Manual for information about the Service Test mode 8 Observe the suction pressure and slowly open the gauge manifold hand valve to allow liq...

Page 193: ...5 kPa 3 to 5 psi reading is obtained on the suction gauge Stop the unit Do not run the unit into a deep vacuum as it may damage the scroll compressor 7 Back seat close suction service valve 8 Remove the evacuation station hoses 9 Cap service valve ports backseat close suction service valve SSV Final System Charge 1 Install a calibrated gauge manifold set on the suction service valve and the discha...

Page 194: ...e evaporators The following table will help you to estimate the starting charge for the full system step 3 The following drawing refers to the combined length of refrigeration tube for adding refrigerant This is for the combined total for 1 metre of length for the three tubes not for each individual tube Irrespective of suction line size the calculation is the same For example In the case of one T...

Page 195: ...ing add charge at 0 25 kg increments until the ball floats 7 If the starting charge level is exceeded by 1 kg this indicates that the unit may now be overcharged and the installation should be checked for possible problems 8 Once the system is charged and prior to placing the unit into service ensure the correct refrigerant charge is entered into the refrigerant charge decal on the frame near the ...

Page 196: ...n of the condenser coil with a piece of cardboard 5 The suction pressure gauge should be indicating 12 to 20 psig 83 to 138 kPa gauge pressure 6 Under these conditions the ball in the receiver tank sight glass should be floating If there is no indication of refrigerant in the receiver tank sight glass the unit is low on refrigerant Testing the Refrigerant Charge with a Loaded Box Quick Check 1 Ins...

Page 197: ... line to the compressor Evacuate the compressor before opening the service valves Oil can be added to the scroll compressor through the Schrader valve on the suction adapter while the unit is running Take precautions to prevent contaminants from entering the system while adding oil Also see Scroll Compressor Replacement REFRIGERATION SYSTEM CHECKS 1 Attach a gauge manifold to the suction service v...

Page 198: ...to 14 kPa 6 Back seat the receiver tank outlet valve Perform a Refrigerant Gauge Removal procedure LOW SIDE PUMP DOWN SCROLL COMPRESSOR CAUTION Do not pull scroll compressor into a vacuum below 10 in Hg vacuum 34 kPa to perform routine maintenance procedures NOTE Operate the unit in cool for 2 to 5 minutes before performing the low side pump down 1 Attach a gauge manifold to the suction service va...

Page 199: ...ent Recommendations For Use With R 404A R 452A Dedicated Equipment Vacuum Pumps When evacuating a two stage five to seven CFM pump is recommended It is also recommended that dry nitrogen be used first Ideally a new vacuum pump should be used and dedicated for use with R 404A R 452A systems because residual refrigerants may remain in used vacuum pumps Pumps used with other Thermo King refrigerants ...

Page 200: ...re using Never use equipment that may be contaminated with automotive type Polyalkylene Glycol PAG oils Refrigerant Recovery Systems used for the recovery of R 404A R 452A should be dedicated to the recovery of this refrigerant Consult the manufacturer of your recovery equipment for details REFRIGERATION SYSTEM COMPONENT LOCATIONS The following drawings show the locations of various refrigeration ...

Page 201: ...Refrigeration Maintenance 10 17 Condenser Refrigeration Component Locations T Series Except T 500R T Dairy 1 2 3 9 10 11 12 13 14 15 7 16 17 8 4 6 5 19 18 ...

Page 202: ...r 14 Condenser Check Valve 5 Tube Defrost to evaporator 15 Condenser Inlet Solenoid CIS 6 Purge line 16 Condenser Radiator Coil 7 Hot Gas Solenoid HGS 17 Accumulator 8 Receiver Tank Pressure Check Valve 18 Discharge Service Valve 9 Dehydrator Filter Drier 19 Discharge Strainer 10 High Pressure Relief Valve Legend for Condenser Refrigeration Component Locations T Series Except T 500R T Dairy on pag...

Page 203: ...Refrigeration Maintenance 10 19 Condenser Refrigeration Component Locations T 500R T Dairy 1 2 13 3 7 8 12 6 16 5 15 4 11 17 14 10 9 18 19 ...

Page 204: ...r 14 Discharge Strainer 5 Receiver Tank Pressure Check Valve 15 Condenser Inlet Solenoid CIS 6 Hot Gas Solenoid HGS 16 Condenser Radiator Coil 7 Dehydrator Filter Drier 17 Purge Valve PV 8 High Pressure Relief Valve 18 Accumulator 9 Receiver Tank Outlet Valve 19 Purge Check Valve 10 Receiver Tank Sight Glass Legend for Condenser Refrigeration Component Locations T 500R T Dairy on page 10 19 ...

Page 205: ...Refrigeration Maintenance 10 21 Condenser Refrigeration Component Locations UT Series Multi Temp Shown Single Temp Similar 1 3 6 11 7 18 9 2 4 5 8 10 12 13 15 14 17 19 16 ...

Page 206: ...s stabilize 3 Cover the condenser to raise the discharge pressure to 300 to 350 psig 2068 to 2413 kPa 4 Keep the condenser covered and pump down the low side by front seating the receiver tank outlet valve When the low side pumps down to a 10 in Hg vacuum 34 kPa check the discharge pressure It should be 200 to 250 psig 1379 to 1724 kPa or higher The compressor is probably faulty if the discharge p...

Page 207: ...me bracket 2 Install the discharge and suction lines and attach the discharge and suction service valves to the compressor using new gaskets soaked in refrigeration oil 3 Reconnect solder the discharge and suction lines 4 Reconnect the high pressure cutout switch wires 5 Pressurize the compressor and test for refrigerant leaks 6 If no leaks are found replace the liquid line drier then evacuate the...

Page 208: ... compressor oil filter for leaks CHECKING COMPRESSOR OIL PRESSURE The oil pressure at the oil pressure access port varies with the suction pressure in the compressor Therefore we need to calculate the net oil pressure to determine the actual compressor oil pressure The net oil pressure is the pressure at the oil pressure access port minus the suction pressure after the electronic throttling valve ...

Page 209: ... the crank the engine again for 30 seconds If 10 psi 96 kPa of net oil pressure still does not develop first check the compressor oil level then check the compressor oil pump and relief valve 5 As soon as the compressor develops 10 psi 96 kPa of net oil pressure re connected the fuel solenoid wires 6 Start unit and run the engine on low speed for at least five minutes If the net oil pressure is ab...

Page 210: ... the refrigerant charge and add refrigerant if needed Scroll Compressor Shaft Seal Replacement Parts Required O ring P N 33 2998 Dust Shield P N 22 1037 Stationary Seal Member P N 22 1038 Rotating Seal Member P N 22 1039 Mounting Screws P N 55 9020 as needed To change the shaft seal 1 Remove the compressor from the unit see removal procedure above 2 Clean dirt from shaft seal cover 3 Remove key fr...

Page 211: ...emove oil filter and O ring 5 Clean any debris from oil filter cavity 6 Lubricate new O ring with compressor oil P N 203 433 7 Press oil filter and O ring over stem in compressor body until seated 8 Lubricate new cover plate gasket with compressor oil 9 Install spring gasket and cover plate using mounting studs Make sure studs are installed in their original location Install mounting screws and to...

Page 212: ...ely fill remaining void in cavity with silicone to protect against water infiltration 10 With switch wires and slot in cap facing down press new plastic cap in place on cavity Protective cap will snap into place when correctly seated Scroll Compressor Liquid Injection Fitting Replacement Parts Required O ring P N 33 2995 Liquid Injection Fitting P N 66 9056 To replace the fitting 1 Remove the refr...

Page 213: ... outlet valve and suction service valve Perform a Refrigerant Gauge Removal procedure CONDENSER CHECK VALVE AND PURGE CHECK VALVE TEST T 500R T DAIRY 1 Attach a gauge manifold to the suction service valve and the discharge service valve Attach another low pressure gauge to the suction access port located in the suction line near the accumulator inlet Attach a high pressure gauge to the service por...

Page 214: ...e Interface Board Test Mode 8 Energize the purge valve with the Interface Board Test Mode The discharge pressure and the low side pressure should equalize when the purge valve is energized 9 De energize the purge valve with the Interface Board Test Mode when the discharge pressure and the low side pressure have equalized 10 Watch the gauges attached to the discharge service port and the receiver t...

Page 215: ...iate Microprocessor Diagnostic Manual for specific information about Remote Watch If the CIS is stuck closed the unit will stop very quickly after is starts to run and will record Alarm Code 10 High Discharge Pressure Use the following procedure to check for a CIS that is stuck closed 1 Connect a high pressure gauge to the discharge service valve to monitor the discharge pressure 2 Start the unit ...

Page 216: ... at the end of the drier 3 Loosen the mounting hardware and remove the drier Installation 1 Place the new O rings in the ORS fittings on the ends of the drier 2 Install the new drier and tighten the mounting hardware 3 Install and tighten the ORS nuts Hold the drier with a back up wrench on the hex behind the ORS fitting 4 Pressurize the low side and check for leaks 5 If no leaks are found evacuat...

Page 217: ...the refrigerant charge 2 Disconnect the wires and remove the discharge pressure transducer from the discharge tube Installation 1 Apply a refrigerant Loctite to the threads of the discharge pressure transducer 2 Install and tighten the discharge pressure transducer and reconnect the wires 3 Pressurize the system and test for leaks 4 If no leaks are found evacuate the system 5 Recharge the unit wit...

Page 218: ...roprocessor Diagnostic Manual for information about testing the ETV ELECTRONIC THROTTLING VALVE ETV REPLACEMENT NOTE The Old Style ETV is being replaced with the New Style ETV starting in 09 16 There are some physical differences but they are functionally the same Removal 1 Pump down the low side and equalize the pressure to slightly positive Make sure to front seat the suction service valve to is...

Page 219: ...r motor See Reassembly of Piston and Stepper Motor on Old Style ETV 1 The new stepper motor and piston assembly is supplied with the piston in the open position In the open position the bottom edge of the piston is 0 3 to 0 7 in 8 to 18 mm from the bottom edge of the brass nut piston housing The piston retracts to open and extends to close WARNING If the ETV is stuck in the closed position much of...

Page 220: ...h backup wrench to prevent damage to the refrigeration tubing 3 New Style ETV Only a Lubricate the O rings with refrigeration oil Place one on the stepper motor and piston assembly and place the other in the valve body 1 Bottom Edge of Brass Nut Piston Housing 2 Bottom Edge of Piston Stepper Motor and Piston Assembly with Piston in Fully Open Position 1 Install O Ring on Stepper Motor and Piston A...

Page 221: ...nd Stepper Motor on Old Style ETV Use the following procedure to reassemble the piston and stepper motor if the piston has accidentally been turned off of the threaded shaft of the stepper motor 1 Disassemble the stepper motor and piston assembly by unscrewing the stepper motor small hex from the piston nut large nut 2 Insert the piston into the piston nut You must align the rectangular shaft on t...

Page 222: ...f Complete ETV Assembly 1 Clean the tubes for soldering 2 Place the new complete ETV assembly and any tubes that were removed in the same position from which the old one was removed and install the ETV mounting hardware The ETV assembly must be installed as shown below relative to the direction of refrigerant flow from the accumulator to the compressor NOTE Do not disassemble the new ETV to solder...

Page 223: ... side and equalize the pressure to slightly positive Make sure to front seat the suction service valve to isolate the low side and use the suction access port to access the low side 2 Remove the feeler bulb from the suction line clamp Note the position of the feeler bulb on the suction line 3 Unsolder the equalizer line from the expansion valve 4 Unsolder the inlet liquid line and the line to the ...

Page 224: ...ons from the condenser side of the bulkhead Remove putty from around the lines before unsoldering the connections 9 Lift the heat exchanger assembly out of the evaporator housing Installation 1 Clean the tubes for soldering 2 Place the heat exchanger assembly in the evaporator housing and install the mounting hardware loosely 3 Solder the liquid inlet and suction outlet line connections on the con...

Page 225: ...er coil air flow by covering the condenser with a piece of cardboard NOTE The discharge pressure should never be allowed to exceed a pressure of 477 psig 3289 kPa on R 404A R 452A systems 4 If the HPCO opens too soon or does not open to de energize the run relay and stop the unit it must be replaced HIGH PRESSURE CUTOUT SWITCH HPCO REPLACEMENT Removal 1 Pump down the low side to a 20 in Hg vacuum ...

Page 226: ...ischarge service port and the suction access port 2 Operate the unit with all zones in low speed cool 3 Front seat the receiver tank outlet valve and allow the low side to pump down to 0 to 5 in Hg vacuum 0 to 17 kPa 4 Turn the unit Off 5 Front seat the suction service valve to isolate the low side while it is still in a vacuum 6 Watch the low pressure gauge attached to the suction access port The...

Page 227: ...Gas Solenoid 10 Momentarily for approximately 1 second energize the HGS with the Interface Board Test Mode The low side pressure should rise slightly If the low side pressure does not rise the HGS is not opening Check the continuity of the wiring and the solenoid coil before assuming the solenoid is faulty 11 Back seat the receiver tank outlet valve and the suction service valve Perform a Refriger...

Page 228: ...ch side of the LIS by hand A temperature difference between the two sides of the LIS indicates it is leaking 7 Use the Mechanics Premium HMI Control Panel to enter the Interface Board Test Mode Refer to the appropriate Microprocessor Diagnostic Manual for specific information about the Interface Board Test Mode 8 From the Interface Board Test Mode select Liquid Injection Valve 9 Momentarily energi...

Page 229: ...ics Premium HMI Control Panel to enter the Interface Board Test Mode Refer to the appropriate Microprocessor Diagnostic Manual for specific information about the Interface Board Test Mode 10 Momentarily energize the liquid line solenoid in the zone being tested with the Interface Board Test Mode by pressing the TEMP ON key The low side pressure should rise If the low side pressure does not rise th...

Page 230: ...ce valve Attach another low pressure gauge to the suction access port located in the suction line near the accumulator inlet A low loss fitting must be used on the hose connected to the suction access port 2 Operate the unit in low speed cool 3 Front seat the receiver tank outlet valve and allow the low side to pump down to 0 to 5 in Hg vacuum 0 to 17 kPa 4 Turn the unit Off 5 Front seat the sucti...

Page 231: ... they are equal If not the receiver tank pressure solenoid is not opening Check the continuity of the wiring and the solenoid coil before assuming the solenoid is faulty 14 De energize the receiver tank pressure solenoid with the Interface Board Test Mode 15 Remove the a jumper wire from the CIS wire at the condenser inlet solenoid 16 Back seat the receiver tank outlet valve and suction service va...

Page 232: ...ate the low side 8 Watch the low pressure gauge attached to the suction access port The low side pressure should not drop It it does one or more of suction line check valves is leaking Check the temperatures of the refrigeration lines on both sides of each suction line check valve by hand A temperature difference between the two sides of a suction line check valve indicates it is leaking 9 Open th...

Page 233: ...d in the remote evaporator of the zone being tested 16 Repeat steps 10 through 15 for the other zone or zones being tested If the low side pressure rose enough to be equal with the high side pressure when the suction line solenoid was de energized open the suction service valve and repeat steps 2 through 9 before repeating steps 10 through 15 for the other zone or zones 17 Back seat the suction se...

Page 234: ...the suction pressure transducer and reconnect the wires 3 Open the refrigeration valves and check for leaks before placing the unit in operation THROTTLING VALVE TEST 1 Attach a gauge manifold to the fitting on the side of the throttling valve and the discharge service port A low loss fitting must be used on the hose connected to the discharge service port 2 Operate the unit in high speed heat unt...

Page 235: ...2 Schrader Valve And Cap Location May Vary 11 Gasket piston Housing 3 Plate Bellows End 12 Piston 4 Gasket End Plate 13 Conformance Spring Piston 5 Shim Adjusting 14 Castle Nut Adjusting 6 Spring Bellows 15 Pin Cotter 7 Bellows and Shaft assembly 16 Housing Piston 8 O ring 17 O ring Valve to Compressor 9 Housing 18 Throttling Valve Cover Throttling Valve 1 Inspect Cap 2 Inspect Spring 3 Shims Thro...

Page 236: ...ng 2 Center the spring on bellows shoulder 3 Oil the gasket same type of oil that is used in the system install on the body and place shims in end cap use same number as removed Tighten end cap in place with vent hole closest to outlet opening of the valve body 4 Install the piston spring and tighten the castle nut until firmly seated against the bottom of the piston 5 Back off the castle nut one ...

Page 237: ...w o ring soaked in compressor oil same type of oil that is used in the system Bolt the throttling valve to the compressor 2 Connect the suction hose from the throttling valve to the accumulator tank Install line from the compound gauge 3 Pressurize the system and check for leaks If no leaks are found evacuate the system 4 Open the refrigeration valves and place the unit in operation 1 Tighten Cast...

Page 238: ...Refrigeration Maintenance 10 54 ...

Page 239: ...11 Clutch Maintenance Centrifugal Clutch 11 2 Clutch Maintenance 11 4 Tools Required 11 4 Grease 11 4 Disassembly Procedure 11 4 Assembly Procedure Using New Bearings and Seal 11 5 ...

Page 240: ...Clutch Maintenance 11 2 CENTRIFUGAL CLUTCH The centrifugal clutch has three belt grooves and its engagement speed is 600 100 RPM Front View and Cross Section AGA127 ...

Page 241: ...ng 12 Pulley Housing 4 Ball Bearing 13 Elastic Stop Nuts 6 5 Large Small Spacers 14 Connector Link 6 6 Rolling Bearing 15 Spring 6 7 Lockwasher 12 16 Shoe Assembly 3 8 Bushing 6 17 Screws 6 9 Hub Centrifugal Clutch 1 2 3 4 5 6 7 8 9 8 7 10 11 12 13 14 7 8 15 16 15 8 7 14 17 aea558 3 belt grooves ...

Page 242: ...Ratchet Optional Torque Wrench Grease MobilTM Synthetic see Tool Catalog Disassembly Procedure 1 Remove retaining ring 2 Remove the 3 8 16 flat head cap screw and washer NOTE This screw was installed using Loctite see Tool Catalog and will require the use of an impact tool for removal NOTE A small amount of heat propane or acetylene torch with small heating tip applied to the cap screw head may be...

Page 243: ...the center of the housing is supported and not the outer drum of the housing Assembly Procedure Using New Bearings and Seal 1 Press bushings into hub side opposite flange NOTE It is important to press bushings in straight The bushings should also be centered in the hub socket leaving relatively equal amounts of bushing sticking out of the hub on each side A suggested simple tool for pressing in bu...

Page 244: ...Pack ball bearing with MobilTM see Tool Catalog grease 8 Apply a small amount of Loctite see Tool Catalog to O D of ball bearing and press into hub until seated against spacer Wipe excess Loctite from hub 9 Install retaining ring 10 Position shoes in a circle on flat surface and install springs on shoes 11 Position shoes on the hub 12 Install 1 4 28 x 1 3 4 in screws through links then external to...

Page 245: ...e to 110 5 in lbs 12 5 6 N m NOTE Shoes must be disengaged while tightening 6 bolts and MUST be held tightly against hub while nuts are tightened 4 Bearing Fill with MobilTM see Tool Catalog grease Approximately 0 32 oz 70 to 80 full 5 3 8 16 UNC x 1 00 Long Flat Head Socket Cap Screw with Nylox Insert Apply Loctite see Tool Catalog and Torque to 30 to 35 fT lb 41 to 48 N m 6 Serial Nameplate Clut...

Page 246: ...Clutch Maintenance 11 8 ...

Page 247: ...g Bolts 12 2 Unit Inspection 12 2 Condenser Evaporator and Radiator Coils 12 2 Micro Channel Coil Cleaning Recommendations 12 2 Fan Location 12 4 Defrost Drains UT Series 12 4 Defrost Damper 12 4 Fanshaft Assembly 12 5 Disassembly 12 6 Reassembly 12 8 ...

Page 248: ...l going with the fins across the tubes Results shown in Figure The coil will clean in a manner similar to the way lint cleans from the lint trap of a household clothes dryer Use a soft bristled brush DO NOT USE A WIRE BRUSH and brush the coil going with the fins across the tubes The coil will clean in a manner similar to the way lint cleans from the lint trap of a household clothes dryer A vacuum ...

Page 249: ...Structural Maintenance 12 3 Coil Before Cleaning Coil after Wiping Right Hand Side with Cloth Source Angle for Cleaning with Air or Water ...

Page 250: ...e defrost drains every 400 operating hours to be sure the lines remain open DEFROST DAMPER Check the damper during scheduled maintenance inspections for shaft wear end play and sealing against air flow Close the damper and check to make sure that the air flow is stopped top and bottom with the solenoid plunger bottomed If the damper blade does not seal evenly along full width of blade 1 Loosen the...

Page 251: ...haft assembly The condenser end oil seal and the evaporator end oil seal should be checked during the pretrip inspection for oil leakage If there is any sign of leakage the fanshaft assembly should be removed and repaired NOTE The fanshaft assembly requires a special lubricant P N 203 278 1 Must Contact Full Width of Blade Figure 3 Defrost Damper Adjustment 1 Oil Plug Screw with O ring 2 Housing 3...

Page 252: ...rom the bearing retainer cap Removing Bearing Retainer Bolts 3 To remove the shaft from the assembly tap the opposite end of the shaft with a soft hammer After the shaft has been removed clean all parts in clean solvent Removing Shaft 4 Using a punch remove the oil seal from the evaporator end of the assembly With the seal removed clean the housing in solvent 11 Roller Bearing 12 Splash Guard Tube...

Page 253: ...arings first remove the roll pin that is in the center of the shaft Removing Roll Pin 8 With the roll pin removed place a pipe over the shaft and drive one bearing down until the opposite bearing and bearing spacer release from the shaft 9 After removing one bearing and the bearing spacer turn the shaft upside down and drive the other bearing off using the pipe 10 The bearing races can now be driv...

Page 254: ...earings 2 When replacing the bearing race on the evaporator end of the assembly the splash guard will come out with the race Reinstall the splash guard after replacing the bearing race Installing Splash Guard 3 Install a new oil seal after replacing the bearing race and splash guard NOTE Tape shaft holes or keyway to prevent seal damage ...

Page 255: ...equal steps to 80 in lbs 9 04 N m Torquing Retainer Plate Bolts 7 Lock the assembly in a vise and set up a dial indicator to read the end play To measure the end play rotate the shaft while pushing in one direction and set the dial indicator to 0 Now rotate the shaft and pull in the opposite direction while reading the dial indicator The end play should be 0 001 to 0 005 in 0 025 to 0 127 mm If th...

Page 256: ...ponents on an assembly pin that supports the pulley 4 Install wave washer one ball bearing seal side out and bearing spacer on the pin NOTE If new bearings have two seals one seal must be removed 5 Install grease slinger and add grease Fill cavity 1 2 full between bearings Use Shell Alvania EP2 synthetic grease 6 Install second ball bearing seal side out and retaining snap ring Use arbor press to ...

Page 257: ...bly UT Series 1 Spindle 2 Retaining Snap Ring 3 Seal Side of Bearing 2 4 Bearings 2 5 Bearing Spacer 6 Fill space 1 2 Full of Grease Shell Alvania EP2 7 Wave Washer Prevents outer race from spinning 8 Pulley 9 Spindle Collar 10 Mounting Bolt afk07r ...

Page 258: ...Structural Maintenance 12 12 ...

Page 259: ... to appropriate Microprocessor Diagnostic Manual Fuel solenoid defective or stuck Replace Fuel injection pump defective Replace pump Glow plugs defective Replace No fuel or wrong fuel Fill with proper fuel Electric fuel pump not operating Check fuel pump is running and 8 to 10 psig 55 to 69 kPa Repair or replace fuel pump If the fuel will run and be audible but is not priming the system The gasket...

Page 260: ...ne coolant temperature Add coolant Check for leaks Low oil pressure Add oil Check for leaks Vent of fuel tank obstructed Remove obstruction Clogged fuel tank or fuel lines Clean fuel tank and fuel lines Electric fuel pump not operating correctly Check fuel pump is running and 8 to 10 psig 55 to 69 kPa Repair or replace fuel pump Dry air cleaner plugged Change filter element Condition Possible Caus...

Page 261: ...gasket leaking Replace gasket Compression low or unbalanced Overhaul engine Restricted exhaust system Clean or replace restricted parts Engine is sooting heavily emits thick black clouds of smoke excessive fuel to air ratio Wrong fuel Drain and refill with correct fuel Clogged air intake system Clean air cleaner Restricted exhaust system Clean or replace Opening pressure of nozzle is too low or ne...

Page 262: ...sure sensor Replace if necessary Worn oil pump camshaft main or connecting rod bearings loose oil gallery plug oil in water through crack Repair engine High oil consumption Oil leakage Check and eliminate possible causes Clogged air cleaner Clean air cleaner Damaged valve seals Replace seals on valve stem Worn valve stem or valve guides Replace valves and valve guides Broken piston rings or cylind...

Page 263: ... connections in electrical system Check all electrical connections and charging system Worn brushes in alternator Repair Voltage regulator faulty Replace Battery defective Replace Alternator defective Repair or replace Dirty battery terminals Clean and retighten Condition Possible Cause Remedy ...

Page 264: ...Mechanical Diagnosis 13 6 ...

Page 265: ...14 Electric Standby Diagnosis ...

Page 266: ...load side contactor closed 5 Overload relay 6 Motor terminals Diesel operation selected Select ELECTRIC Unit in NULL Check setpoint and box temperature Fuse F25 blown Fuse F5 T 500R T Dairy Check for short circuit and replace fuse Faulty LPCO T 500R T Dairy Check LPCO Faulty HPCO Check HPCO Open or faulty overload relay Determine cause and reset or replace overload relay Faulty run relay K1 K9 T 5...

Page 267: ...mal in rush of current Check or grounds shorts or excessive motor load current Low voltage Correct voltage condition Check momentary voltage dip during starting Foreign matter prevents contacts from closing Clean contacts Rapid cycling Check for cause of short cycling such as thermostat Short circuit Correct fault Battery is not recharging Loose alternator belt Tighten belt Loose connections in el...

Page 268: ...Electric Standby Diagnosis 14 4 ...

Page 269: ...15 Refrigeration System Diagnosis ...

Page 270: ... hot ambient Air flow through condenser restricted Air through condenser too cold ambient Air in refrigerant system Condenser fan blades bent or broken Air short cycling around evaporator coil Air through evaporator restricted Evaporator needs defrosting Compressor discharge valves leaking Compressor suction valves leaking Too much compressor oil in system Faulty oil pump in compressor Loose compr...

Page 271: ... SPR Faulty Purge Valve PV T 500R T Dairy Faulty Condenser Check Valve Faulty Receiver Tank Pressure Check Valve Rapid cycling between Cool and Heat Unit cools in Heat and Defrost cycle Unit heats in Refrigeration Cool cycle High head pressure Low head pressure No head pressure High suction pressure Low suction pressure No suction pressure Unit operating in a vacuum Receiver sight glass empty Suct...

Page 272: ...Refrigeration System Diagnosis 15 4 ...

Page 273: ...Remote Evaporators 16 1 16 Remote Evaporators Unit Description 16 2 Electrical Maintenance 16 7 Structural Maintenance 16 7 Remote Evaporator System Diagnosis 16 7 ...

Page 274: ...ooling is required the SR 2 3 Multi Temp Control System energizes a remote liquid line solenoid valve Refrigerant flows through that evaporator coil to provide cooling When the compartment temperature is near setpoint the SR 2 3 Multi Temp Control System de energizes the remote liquid line solenoid valve and switches that remote evaporator to null The SR 2 3 Multi Temp Control System energizes a r...

Page 275: ...ber Location Unit Nameplate on the end of the unit frame UTSE Remote Evaporator Serial Number Location SPECTRUM Remote Evaporator Serial Number Location 1 Nameplate on End of Unit Frame 1 Nameplate on Right End of Unit Frame 1 1 AJA985 ...

Page 276: ... Harness 16 Air Probe Hose 3 Fan Plenum 10 Fuse Connector 17 Ground Screw 4 Sealing Strip 11 Fuse 20A 18 Terminal Board 5 Evaporator Fan 12 Fuse Cover 19 Drain Pan 6 Sensor Ungraded 13 Air Pressure Switch 20 Discharge Housing 7 Sensor Graded 14 Air Switch Bracket Figure 4 UTSE Remote Evaporator Components ...

Page 277: ...s Solenoid HGS 7 Blower Housing 12 Drain Heater Resistance Wire 3 Liquid Line Solenoid LLS 8 Blower Cover 13 Return Air Sensor Graded 4 Suction Line Solenoid SLS 9 Terminal Board Bracket 14 Sensor Clamp 5 Discharge Air Sensor Graded 10 Terminal Board Figure 5 SPECTRUM Remote Evaporator Components S 3 Shown S 2 Similar ...

Page 278: ...Remote Evaporators 16 6 Figure 6 SPECTRUM Remote Evaporator Front View S 3 Shown S 2 Similar Figure 7 SPECTRUM Remote Evaporator Back View S 3 Shown S 2 Similar AJA984 AJA985 ...

Page 279: ...ing compressed air from the top side of the coil down toward the bottom the direction opposite the normal air flow Inspect the coil and fins for damage and repair if necessary REMOTE EVAPORATOR SYSTEM DIAGNOSIS CAUTION Air pressure should not be high enough to damage the coil fins Condition Possible Cause Remedy Load temperature too high Refrigerant shortage Repair leak and recharge Setpoint too h...

Page 280: ...Remote Evaporators 16 8 ...

Page 281: ...ing Wiring Model Diagram Schematic T Series T 500R T Dairy 1E73328 1E73327 T 600R 1E28187 1E28186 T 800R 1E28187 1E28186 RT 800R 1E28187 1E28186 T 1000R 1E28187 1E28186 T 1200R 1E28187 1E28186 SPECTRUM 1E28189 1E28188 UT Series UT 800 1E59998 1E59997 UT 1200 1E59998 1E59997 UT XTREME HIGH Ambient 1E59998 1E59997 UT SPECTRUM 3E02255 3E02254 ...

Page 282: ...Wiring Diagrams and Wiring Schematics 17 2 ...

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