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Thermo King UT-1200, Manual

The Thermo King UT-1200 is a reliable refrigeration unit designed for transport trucks. Ensure optimal performance by downloading the free user manual from manualshive.com. The manual provides detailed instructions on operating and maintaining the unit, helping you get the most out of your investment.

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Table of Contents

7

Alternator Load Test  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
General Diagnostic and Warranty Evaluation Procedure  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Field Current Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Fuses   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Base Controller LEDs  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Smart FETs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
SMART REEFER 3 (SR-3) Microprocessor Controller  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Flywheel (RPM) Sensor   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Glow Plugs  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Unit Wiring   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
AC Components  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

Electrical Contactors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Condenser Fan Rotation   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Phase Select Module for Truck Unit Model 50 Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Overload Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

Engine Maintenance  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

EMI 2000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Engine Lubrication System  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

Engine Oil Pressure Switch/Sensor  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Engine Oil Change  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Oil Filter Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

Crankcase Breather System  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Engine Air Cleaner (EMI 2000)  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Engine Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92

General Description  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92

ELC (Extended Life Coolant)   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

Antifreeze Maintenance Procedures   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Bleeding Air from the Cooling System  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Engine Thermostat  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

Engine Fuel System  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96

Operation  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Maintenance  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Bleeding the Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Draining Water from Fuel Tank   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Fuel Filter Replacement  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Electric Fuel Pump  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Injection Pump Timing   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Injection Pump Removal and Installation  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Fuel Limit Screw  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Fuel Solenoid  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Engine Speed Adjustments   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

Adjust Engine Valve Clearance   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Restraining Mount Adjustment  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Belts   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113

Engine/Electric Motor Belt   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Compressor/Electric Motor Belt  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Electric Motor/Alternator Belt  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Water Pump/Engine Belt   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114

Refrigeration Service Procedures  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115

Evacuation, Dehydration, and Charging  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115

Set Up and Test of Evacuation Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
Using Evacuation Mode  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
Unit Evacuation   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Unit Charging  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
Refrigerant Gauge Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121

Refrigerant Leaks  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Refrigerant Charge  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121

Testing the Refrigerant Charge with an Empty Box (Controlled Check)   . . . . . . . . . . . . . . . . . . . . . . . . . . 121

Summary of Contents for UT-1200

Page 1: ...UT 800 and UT 1200 TK 55385 1 MM Rev 0 05 12 Copyright 2012 Thermo King Corp Minneapolis MN U S A Printed in U S A...

Page 2: ...e in contract or in tort including negligence for any special indirect or consequential damages including injury or damage caused to vehicles contents or persons by reason of the installation of any T...

Page 3: ...formation on regulations and technician certification programs contact your local Thermo King dealer R 404A WARNING Use only Polyol Ester based refrigeration compressor oil in R 404A See Thermo King P...

Page 4: ..._________________________________________ ________________________________________________________________________ ________________________________________________________________________ ____________...

Page 5: ...24 Electrical Standby 24 Standby Power Requirements 24 Maintenance Inspection Schedule 25 Unit Description 27 General Description 27 Unit Features 27 Unit Options 27 Standard HMI Control Panel 27 Mech...

Page 6: ...um HMI Control Panel 51 Display 51 Keys 52 Hard Keys 52 Soft Keys 52 Turning the Unit On and Off 52 If More Than One Language is Enabled 53 The Standard Display 54 Changing the Setpoint 54 Starting th...

Page 7: ...intenance Procedures 93 Bleeding Air from the Cooling System 94 Engine Thermostat 95 Engine Fuel System 96 Operation 96 Maintenance 96 Bleeding the Fuel System 96 Draining Water from Fuel Tank 99 Fuel...

Page 8: ...nd Purge Check Valve Test 131 Condenser Inlet Solenoid CIS Test 132 Condenser Radiator Coil Replacement 133 Removal 133 Installation 133 Dehydrator Filter Drier Replacement 133 Removal 133 Installatio...

Page 9: ...Solenoid Valve Replacement 141 Removal 141 Installation 141 Suction Pressure Regulator SPR Test 141 Clutch Maintenance 143 Centrifugal Clutch 143 Clutch Maintenance 145 Tools Required 145 Grease 145...

Page 10: ...Table of Contents 10...

Page 11: ...ress ON Key 44 Figure 25 Display Preferred Method for Manually Switching from Electric Mode to Diesel Mode 44 Figure 26 CYCLE SENTRY Continuous Key 45 Figure 27 HIGH SPEED LOCKOUT Key 45 Figure 28 DEF...

Page 12: ...k Lock Keys 59 Figure 80 Sensors Key 60 Figure 81 Next Back Lock Keys 60 Figure 82 Menu Key 60 Figure 83 Pretrip Submenu 60 Figure 84 Menu Key 62 Figure 85 Select Key 62 Figure 86 or Keys Yes Key 62 F...

Page 13: ...ent Locations 77 Figure 148 Base Controller 81 Figure 149 Flywheel RPM Sensor 83 Figure 150 Flywheel RPM Sensor Wires 83 Figure 151 Glow Plug Ohm Test 83 Figure 152 High Voltage Box with Cover Removed...

Page 14: ...gure 195 Select Evacuation Test 119 Figure 196 Programming 119 Figure 197 Pressure Rise Graphs 120 Figure 198 Scroll Compressor 122 Figure 199 R404A Decal 124 Figure 200 Compressor Components 127 Figu...

Page 15: ...etion resulting in suffocation and possible death DANGER Avoid engine operation in confined spaces and areas or circumstances where fumes from the engine could become trapped and cause serious injury...

Page 16: ...r rotating components WARNING Do not attach fuel lines or any additional wiring harnesses to the battery cables as this could cause an electrical fire CAUTION Do not connect other manufacturer s equip...

Page 17: ...Store refrigerant oil in an approved sealed container to avoid moisture contamination CAUTION Do not expose the refrigerant oil to the air any longer than necessary The oil will absorb moisture which...

Page 18: ...utions Take precautions before electrically welding any portion of the unit or the vehicle to which it is attached Ensure that welding currents are not allowed to flow through the unit s electronic ci...

Page 19: ...ntact local poison control center or physician First Aid Engine Coolant EYES Immediately flush with water for at least 15 minutes CALL A PHYSICIAN Wash skin with soap and water INGESTION Do not induce...

Page 20: ...Safety Precautions 20...

Page 21: ...o 0 010 in 0 15 to 0 25 mm Exhaust Valve Clearance 0 006 to 0 010 in 0 15 to 0 25 mm Valve Setting Temperature 70 F 21 C Fuel Injection Timing 16 1 degrees BTDC Injection Nozzle Pressure 12 3 MPa 0 98...

Page 22: ...Ester base P N 203 516 required for Scroll compressor Throttling Valve Setting 32 to 34 psig 220 to 234 kPa Discharge Pressure Regulator Valve Setting 350 5 psig 2413 34 kPa High Pressure Cutout Switc...

Page 23: ...5A HPCO Switch Circuit F26 5A Power to CAN Connector J98 F4 Remove fuse F4 for units with Australian Bosch or Thermo King Alternators Install fuse F4 for units with Prestolite Alternator F10 When fus...

Page 24: ...oad Current Each 7 0 amps motor Electrical Standby Voltage Phase Frequency Horsepower Kilowatts rpm Full Load amps Overload Relay Setting amps 208 3 60 12 8 9 1735 31 4 32 220 3 50 10 7 5 1445 25 1 28...

Page 25: ...ir cleaner element Inspect clean electric fuel pump filter Check air cleaner hose for damage Check and adjust engine speeds Check condition of engine mounts Check restraining mount snubber pre load ad...

Page 26: ...ructural Check for oil fuel coolant and refrigerant leaks Visually inspect unit for damaged loose or broken parts includes air ducts and bulkheads Inspect tapered roller bearing idlers for leakage and...

Page 27: ...m Monitoring Coolant Temperature Display CYCLE SENTRYTM Start Stop Controls Engine and Electric Model 50 Hour Display In Cab Remote Smart Defrost Symbolic Controller Interface Unit Self Check pretripp...

Page 28: ...the temperatures of up to six additional sensors The sensors are independent from the microprocessor controller and are normally located in the truck box to monitor load temperatures DAS data can be d...

Page 29: ...ergizes the glow plugs This should warn anyone near the unit that the CYCLE SENTRYTM system is about to start the diesel engine Electric Motor Overload Relay The overload relay protects the electric s...

Page 30: ...ox 3 Filter Drier 7 Electric Standby Power Receptacle 4 Fuel Filter Water Separator 8 Microprocessor Power Switch Figure 4 UT 800 UT 1200 Components Front and Side Views Panels Removed 2 1 3 AMA756 1...

Page 31: ...rol device used to maintain a minimum discharge pressure during heat and defrost The valve controls discharge pressure based on the actual system pressure Throttling Valve This component is a mechanic...

Page 32: ...2 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 op...

Page 33: ...Injection Solenoid LIS 19 Drain Pan Heater 5 High Pressure Cutout Switch HPCO 20 Suction Access Port 6 Discharge Strainer 21 Accumulator 7 Discharge Pressure Transducer 22 Suction Pressure Regulator S...

Page 34: ...to the evaporator There liquid refrigerant absorbs heat as it evaporates into low pressure vapor The refrigerant returns to the compressor through the heat exchanger and accumulator Solenoid and Check...

Page 35: ...e 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 ta...

Page 36: ...r and SPR or 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 valv...

Page 37: ...the display The LED will light when that function is active A red indicator LED is located between the ON Key and OFF Key This indicator will glow if Alarm Code 91 Check Electric Ready Input occurs It...

Page 38: ...etpoint When this icon is present the upper display is showing the diesel engine run time When this icon is present the lower display is showing the electric motor run time if the unit equipped with o...

Page 39: ...y to increase or decrease the display brightness Secondary Use When the unit is on pressing this key will return to the Standard Display of box temperature and setpoint POWER OFF Key Pressing the OFF...

Page 40: ...cle will terminate automatically and the amber LED will turn off when the evaporator coil temperature is greater than 52 F 11 C To manually terminate a defrost cycle turn the unit off and back on PRET...

Page 41: ...in the lower display as shown in Figure 14 A Full Pretrip Test is initiated from this display by pressing and holding the Pretrip Key as shown later in this section Figure 14 Electric Motor Run Time...

Page 42: ...Figure 20 Alarm Icon and Setpoint Notice that the setpoint has returned to the old setpoint of 35 F 1 6 C and the Alarm Icon has lighted indicating that Alarm Code 127 Setpoint Not Entered is set IMPO...

Page 43: ...details The Diesel to Electric Auto Switch Enabled feature should be set YES on units equipped with the Standard Truck HMI Control panel Diesel to Electric Auto Switch Enabled set YES Default If this...

Page 44: ...off Press the Standard Truck HMI Control Panel ON Key again to clear Alarm Code 91 Check Electric Ready Input and turn the unit back on in Diesel Mode If the Standard Truck HMI Control Panel OFF Key...

Page 45: ...No further high speed operation is allowed until this feature is turned off or the High Speed Lockout Timer is exceeded IMPORTANT HIGH SPEED LOCKOUT TIMER If High Speed Lockout Mode is selected the H...

Page 46: ...a Shutdown Alarm the Alarm Icon and the display will flash on and off and the unit will shut down Figure 30 Alarm Icon Displaying Alarm Codes Alarms are displayed by simultaneously pressing and holdi...

Page 47: ...Pretrip Test if these features are enabled and the auto switch conditions occur Conditions where Pretrip Tests are not allowed Pretrip Tests are not allowed if any shutdown alarms are present Pretrip...

Page 48: ...est The Full Pretrip Test must be started with the unit not running Turn the unit on and clear all alarm codes Turn the unit off Turn the unit on and wait for the unit running time hourmeters to be sh...

Page 49: ...Pretrip Test will continue to run unless a Shutdown Alarm occurs The amber Pretrip Test LED will turn off at the completion of the test but the Alarm Icon will remain lit This indicates that one or mo...

Page 50: ...ry To display the serial number and software revision press and hold the PRETRIP key for 5 seconds when the unit is turned off Figure 38 PRETRIP Key The serial number is shown at the top of the displa...

Page 51: ...atures Displays Box Temperature and Setpoint in Fahrenheit or Celsius Displays Engine Running and Motor Running Hourmeters Changes Setpoint Indicates Alarm Condition Exists Displays and Clears Alarms...

Page 52: ...display will briefly show the Thermo King Logo and then the statement Configuring System Please Wait When the power up sequence is complete the display shows the Standard Display of box temperature an...

Page 53: ...the NO key as shown in Figure 46 Figure 46 NO key The Language menu will appear as shown in Figure 47 Press the or keys to select the desired language When the desired language is shown press the YES...

Page 54: ...ture in Figure 55 is 35 8 F with a 35 F setpoint Figure 55 Standard Display The CYCLE SENTRY Icon in the upper right corner of the display shows that the unit is operating in CYCLE SENTRY Mode If the...

Page 55: ...g the or keys the change must be confirmed or rejected by pressing the YES or NO soft key within 10 seconds of changing the setpoint If the YES key is pressed the setpoint change made with the or key...

Page 56: ...aring to start the HMI control panel will display the motor start screen as shown in Figure 64 The preheat buzzer sounds for 20 seconds before the electric motor starts Figure 64 Motor Start Screen Af...

Page 57: ...ll appear Figure 69 Prompt Screen after OFF and ON If YES is selected then the display will briefly show the screen in Figure 70 Then Diesel Mode operation will briefly be confirmed Figure 70 Display...

Page 58: ...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...

Page 59: ...ates 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 LO...

Page 60: ...tor coil sensor Ambient Air Temperature Displays the temperature of the ambient air sensor Data Logger Sensor 1 Temperature Display the temperature of Data Logger Sensor 1 Data Logger Sensor 2 Tempera...

Page 61: ...rator is prompted to clear the alarm s ELECTRIC STANDBY If the Electric Standby option is present and the Diesel to Electric Auto switch feature is set NO this feature allows the operator to manually...

Page 62: ...pear in the new language as shown in Figure 88 The unit is ready to run Figure 88 Standard Display in New Language Repeat the process to select a different language To select a different Main Menu ite...

Page 63: ...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...

Page 64: ...t affects only electric mode operation and the unit is switched to diesel the electric mode shutdown alarm becomes a diesel mode log alarm to allow diesel mode operation If the unit is switched back t...

Page 65: ...alarms are present the quantity of alarms if more than one and the most recent alarm code number will be shown In the example in Figure 96 there are two alarms present The most recent is Alarm Code 5...

Page 66: ...The ServiceWatch Data Logger and DAS Data Logger if equipped are accessed using the Data Logger Menu From the Standard Display press the MENU key Figure 99 Menu Key The Language Menu or Alarm Menu wil...

Page 67: ...On Total hours the controller and HMI control panel have been turned on Pretrip Reminder User Programmable number of hours before a Pretrip Reminder occurs Engine Reminder 1 User Programmable The num...

Page 68: ...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 un...

Page 69: ...leep Mode Normal CYCLE SENTRY mode starts and stops the unit as required to maintain the desired setpoint temperature maintain the unit battery in a charged condition and keep the unit engine warm in...

Page 70: ...mode does not consider setpoint or maintain cargo temperatures To exit Sleep Mode press the EXIT key or turn the unit off and back on The unit will resume normal operation and control to setpoint Fig...

Page 71: ...ice amp checks will be performed If the Pretrip Test is entered with the unit running in either diesel or electric mode a Running Pretrip Test is performed but the device amps checks are not performed...

Page 72: ...load temperature during the test as normal temperature control is suspended during a Pretrip Test Always perform Pretrip Tests with the truck or trailer cargo doors closed to prevent false test failur...

Page 73: ...e technician to the cause of the problem Figure 134 Pass Check or Fail If the Pretrip Test results are CHECK or FAIL the problem should be diagnosed and corrected before the unit is released for servi...

Page 74: ...Soft Key will not clear these two alarms Then the prompt screen shown in Figure 138 will appear Figure 138 Prompt for Switch to Diesel If YES is selected then the display will briefly show the screen...

Page 75: ...w setting Time The system time and date is viewed using the Main Menu Time and Date cannot be changed from the Main Menu From the Standard Display press the MENU key Figure 144 Menu Key The Language M...

Page 76: ...Operating Instructions for Premium HMI Control Panel 76...

Page 77: ...t is not properly 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 term...

Page 78: ...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 rem...

Page 79: ...s charge current to the unit battery typically 5 10 amps A reading on the clamp on ammeter at or near 0 amps indicates the alternator is not charging Checking the unit ammeter will show a discharge co...

Page 80: ...ng alternator by connecting a jumper wire between the F2 terminal and the B terminal Do not connect the F2 terminal to ground or the alternator will be damaged 3 Note the ammeter reading The ammeter r...

Page 81: ...F20 2A Alternator Sense F25 7 5A HPCO Run Circuit F26 5A Power to CAN Connector J98 F4 Remove fuse F4 for units with Australian Bosch or Thermo King Alternators Install fuse F4 for units with Prestoli...

Page 82: ...engine speed and precisely control the timing of the starter disengagement If the flywheel sensor fails the starter may not disengage or engage properly and a fault code will be generated Interface B...

Page 83: ...e 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 en...

Page 84: ...ll 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 Applica...

Page 85: ...e will operate in single phase mode SP GND This is an internal ground for the module If SP GND is jumpered to SP then the module will be set to operate on single phase Outputs Output Description 7EB I...

Page 86: ...nd 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 selec...

Page 87: ...the H and the A to access the switch used to set the overload relay to reset automatically 4 Move the slide switch down until it clicks into place at the bottom of the slot from which the tab marked H...

Page 88: ...Electrical Maintenance 88...

Page 89: ...il will also produce low oil pressure shutdowns Engine Oil Pressure Switch Sensor Engine oil pressure should rise immediately on starting If engine oil pressure drops below 10 2 psig 69 14 kPa the swi...

Page 90: ...e from getting too low Normal crankcase pressures with a new air cleaner are shown below The vacuum will increase as the air cleaner gets dirty and becomes more restrictive Remove the breather cover a...

Page 91: ...r entering the engine Excessive restriction of the air intake system affects horsepower fuel consumption and engine life Inspect the element at every oil change Replace the EMI 2000 air cleaner filter...

Page 92: ...r head to the radiator automatically maintains coolant temperature within the specified temperature range All water cooled engines are shipped from the factory with a mixture of 50 percent permanent t...

Page 93: ...ired 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 coolant every two years Change ELC red engin...

Page 94: ...o the unit This procedure may not give a true 50 50 mixture because the exact cooling system capacity may not always be known 8 Refill the radiator with the 50 50 mixture Bleeding Air from the Cooling...

Page 95: ...t soak and open completely to purge air out of block head and water pump Figure 164 Checking Temperature 8 After 2 minutes re start the engine and run it in low speed while filling the expansion tank...

Page 96: ...completed in the shortest time possible NOTE The injection nozzles must be tested and repaired if necessary at least every 3 000 hours in accordance with EPA 40 CFR Part 89 Normal conditions are consi...

Page 97: ...art up open the bleeder screw at the injection pump and bleed fuel until a clear flow is noted 3 Loosen the injector lines on the injection nozzles 4 Crank the engine until fuel appears at the nozzles...

Page 98: ...Engine Maintenance 98 Figure 167 Fuel Components...

Page 99: ...er and fuel do not drain freely the vent may be plugged If so clean or replace the vent 4 Install the drain plug Fuel Filter Replacement Replace the fuel filter at intervals according to the Maintenan...

Page 100: ...cleaning solvent and blow out the dirt and cleaning solvent with compressed air 4 Clean the fuel filter bowl 5 Check the fuel filter bowl gasket and replace if necessary Assembly 1 Screw the fuel fil...

Page 101: ...ker 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 compression stroke for the number one cylinder d If the rocker arms...

Page 102: ...han 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 aw...

Page 103: ...ar case 7 Remove the injection pump from the gear case but leave the injection pump gear in the gear case This keeps the teeth on the injection pump gear aligned properly with the teeth on the idler g...

Page 104: ...e nut to 43 5 to 50 9 ft lb 59 0 to 69 0 N m 5 Install the injection pump timing cover on the gear case cover and reinstall all components removed previously to facilitate the injection pump removal 1...

Page 105: ...o 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 t...

Page 106: ...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 d...

Page 107: ...t loosen the jam nut on the low speed adjustment screw 4 Turn the low speed adjustment screw to change the engine speed Turn the screw in to increase the engine speed Turn the screw out to decrease th...

Page 108: ...unt 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 solenoid 13 LINK throttle 6 DIODE 14 LOCKWASHER 7 ROD throttle 15 N...

Page 109: ...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 marks is 1 2 3 but the firing order is 1 3 2 The reason for thi...

Page 110: ...l lines up with the index timing mark on the starter mounting plate b Check the rocker arms on the number 3 cylinder to see if they are loose c If the rocker arms are loose the engine is at top dead c...

Page 111: ...a straight edge Install chain on Depressed side of eye bolt 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...

Page 112: ...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 Fi...

Page 113: ...uster 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 and the jam nut on the idler...

Page 114: ...split type Adjust the tension by adding or removing shims between the pulley sheaves to obtain a reading of 40 on the TK Gauge P N 204 427 or a deflection of 13 mm at the center of the belt 1 Remove...

Page 115: ...e micron gauge will help determine a If the 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 fre...

Page 116: ...ures 116 2 4 5 3 1 6 8 9 10 AGA654 7 11 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 Fi...

Page 117: ...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 S...

Page 118: ...eached close valve V 1 to the pump Turn 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 min...

Page 119: ...tart the vacuum pump and open valves V 1 V 2 V 3 V 4 7 Evacuate the refrigeration system to 500 microns or the lowest achievable level between 500 and 1000 microns NOTE The presence of refrigerant in...

Page 120: ...refrigerant is added close the gauge manifold hand valve 4 Remove hose from discharge line A low loss fitting on this hose will prevent excessive loss of refrigerant 5 Back seat close the receiver tan...

Page 121: ...priate Microprocessor Diagnostic Manual for information about the Service Test mode 4 Open both service manifold hand valves 5 Front seat the receiver tank outlet valve 6 Run the unit until a 3 to 5 p...

Page 122: ...h an ambient air temperature above 50 F 10 C Install a gauge manifold Operate the unit on high speed cool with a 10 psig 69 kPa minimum suction pressure and 185 psig 1275 kPa minimum discharge pressur...

Page 123: ...de while it is still in a vacuum 9 Turn the unit Off 10 Watch the low pressure gauge attached to the suction access port The low side pressure should not rise If the low side pressure rises to 0 psig...

Page 124: ...available from wholesalers The price will depend upon the quantity purchased Thirty 30 50 and 125 containers are available Leak Detection Leaks can be detected by an electronic leak detector such as t...

Page 125: ...ed for the recovery of R404A should be dedicated to the recovery of this refrigerant Consult the manufacturer of your recovery equipment for details Accumulator Replacement Removal 1 Pump down the low...

Page 126: ...ompressor into the unit and install the mounting bolts NOTE New compressors are shipped with a full oil charge Install the new compressor with the full oil charge and check the oil level after operati...

Page 127: ...lve 7 Shaft Seal Assembly 2 Suction Service Valve 8 Pulley 3 Oil Filter under Oil Filter Cover Plate 9 Oil Filter Cover Plate 4 High Temperature Cutout Switch 10 Schraeder Valve 5 Cap 11 Low Pressure...

Page 128: ...seal cover 8 Loosen the set screws that secure the bellows to the shaft These set screws typically use an 1 8 inch Allen wrench which is provided with the new seal 9 Remove the old bellows from the sh...

Page 129: ...ubstitute installation tool should have a diameter approximately the same size as the I D of the polished surface NOTE The following illustration shows the seal installation tool being used on a recip...

Page 130: ...positive 2 Clean oil drain cap area bottom and bottom rear of compressor of excess dirt 3 Remove oil drain plug from bottom rear of compressor to drain oil Measure amount of oil drained from compress...

Page 131: ...heat A unit with a leaking condenser check valve or purge check valve will have good heating capacity when it first goes into the heat mode But it will gradually lose heating capacity as refrigerant...

Page 132: ...t 1 Attach a gauge manifold to the suction service valve and the discharge service port Attach another low pressure gauge to the suction access port located in the suction line near the accumulator in...

Page 133: ...ks 5 If no leaks are found replace the liquid line drier then evacuate the system 6 Connect the coolant hoses to the radiator and refill the engine cooling system with the 50 50 antifreeze water solut...

Page 134: ...n the discharge line near the discharge service port The discharge pressure transducer supplies pressure information to the SR 3 Microprocessor Control System Alarm Code 86 Check Discharge Pressure Se...

Page 135: ...then evacuate the system 7 Recharge the unit with proper refrigerant and check the compressor oil Evaporator Coil Replacement URDE Only Removal 1 Pump down the low side and equalize the pressure to sl...

Page 136: ...is properly installed Heat Exchanger Replacement NOTE It unlikely that the heat exchanger is defective Carefully review your refrigeration system diagnosis to eliminate all other system components bef...

Page 137: ...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 Recover the refrigerant charge 2 Disconnect the wires an...

Page 138: ...Test Mode Refer to the appropriate Microprocessor Diagnostic Manual for specific information about the Interface Board Test Mode 9 From the Interface Board Test Mode select Hot Gas Solenoid 10 Momenta...

Page 139: ...ond energize the LIS with the Interface Board Test Mode The suction pressure should rise slightly If the suction pressure does not rise the LIS is not opening Check the continuity of the wiring and th...

Page 140: ...e used on the hoses connected to the discharge service port and 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...

Page 141: ...l 5 Pressurize the refrigeration system and test for leaks 6 If no leaks are found replace the liquid line drier then evacuate the system 7 Recharge the unit with proper refrigerant and check the comp...

Page 142: ...Refrigeration Service Procedures 142...

Page 143: ...143 Clutch Maintenance Centrifugal Clutch The centrifugal clutch has three belt grooves and its engagement speed is 600 100 RPM Figure 209 Front View and Cross Section AGA127...

Page 144: ...oves 1 Screw 10 Grease Seal 2 Washer 11 Roller Bearing Inner Race 3 Snap Ring 12 Pulley Housing 4 Ball Bearing 13 Elastic Stop Nuts 6 5 Large Small Spacers 14 Connector Link 6 6 Rolling Bearing 15 Spr...

Page 145: ...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 amou...

Page 146: ...n nut Thread nut onto screw approximately 3 4 to 1 in Insert threaded end of screw into bushing Lubricate bushing by dipping in clean water only Then press into place Figure 214 Bushing Insertion DO N...

Page 147: ...6 N m NOTE Shoes MUST be held tightly against hub while nuts are tightened 14 Place the hub and shoe assembly into the housing and place flatwasher over the bearing 15 Apply Loctite see Tool Catalog t...

Page 148: ...Clutch Maintenance 148...

Page 149: ...m Condenser Evaporator and Radiator Coils Clean the coils during scheduled maintenance inspections Remove any debris e g leaves or plastic wrap that reduces the air flow Clean dirty coils with compres...

Page 150: ...Structural Maintenance 150...

Page 151: ...ce 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 Air in fuel system Bleed air Compre...

Page 152: ...asket 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 exces...

Page 153: ...re 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 elimina...

Page 154: ...onnections in electrical system Check all electrical connections and charging system Worn brushes in alternator Repair Voltage regulator faulty Replace Battery defective Replace Alternator defective R...

Page 155: ...C Unit in NULL Check setpoint and box temperature Fuse F25 blown Check for short circuit and replace fuse Faulty HPCO Check HPCO Open or faulty overload relay Determine cause and reset or replace over...

Page 156: ...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...

Page 157: ...hrough 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 restric...

Page 158: ...ator SPR Faulty Liquid Injection Solenoid LIS Faulty Purge Valve PV Faulty Condenser Check Valve Faulty Receiver Tank Pressure Check Valve Rapid cycling between Cool and Heat Unit cools in Heat and De...

Page 159: ...osis mechanical 151 diagnosis refrigeration 157 discharge pressure regulator DPR replacement 134 test 133 discharge pressure transducer replacement 134 testing 134 discharge strainer test 134 135 drai...

Page 160: ...124 radiator coil 133 149 receiver tank replacement 140 receiver tank pressure check valve test 140 refrigerant charge 121 refrigerant gauge removal 121 refrigerant leaks 121 refrigeration diagnosis...

Page 161: ...161 Wiring and Schematic Diagrams Index Dwg No Drawing Title Page 1E59997 Schematic Diagram 163 164 1E59998 Wiring Diagram 165 169...

Page 162: ...Wiring and Schematic Diagrams Index 162...

Page 163: ...163 Schematic Diagram Page 1 of 2...

Page 164: ...164 Schematic Diagram Page 2 of 2...

Page 165: ...165 Wiring Diagram Page 1 of 5...

Page 166: ...166 Wiring Diagram Page 2 of 5...

Page 167: ...167 Wiring Diagram Page 3 of 5...

Page 168: ...168 Wiring Diagram Page 4 of 5...

Page 169: ...169 Wiring Diagram Page 5 of 5...

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