Page 1 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 HIGH UT XTREME AMBIENT UT SPECTRUM TK 60484-1 (Rev. 6, 09-2016) Ingersoll Rand Company Ltd. • Monivea Road • Mervue, Galway • Ireland...
Page 2 Recover Refrigerant At Thermo King we recognise the need to preserve the environment and limit the potential harm to the ozone layer that can result from allowing refrigerant to escape into the atmosphere. We strictly adhere to a policy that promotes the recovery and limits the loss of refrigerant into the atmosphere.
Page 3: Table Of Contents
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 Protection Devices ........................5-6 Refrigeration System Components ....................5-11...
Page 4 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 Datalogger ............................ 6-21 Hourmeters ........................... 6-21 Mode............................. 6-22 Pretrip ............................6-26 Diesel/Electric Menu ........................6-28 Adjust Brightness .........................
Page 5 Suction Line Solenoid (SLS) Test (Multi-Temp Units Only) ............10-48 Suction Pressure Regulator (SPR) Test ..................10-49 Suction Pressure Regulator (SPR) Replacement ................10-49 Suction Pressure Transducer Testing (UT-Series and T-Series except T-500R/T-Dairy) ...10-50 Suction Pressure Transducer Replacement...................10-50 Throttling Valve Test........................10-50 Throttling Valve Replacement and Repair ...................10-50 Clutch Maintenance .
Page 6 Electric Standby Diagnosis ......... . . 14-1 Refrigeration System Diagnosis .
Page 7: Introduction
The information in this manual is provided to assist owners, operators and service people in the proper upkeep and maintenance of Thermo King units. Each unit family includes many specific models. When maintenance information differs between models within a unit family, this manual uses specific unit model nomenclature. When maintenance information for specific models within a unit family is the same, this manual uses unit family nomenclature.
Page 8 OTHER REFERENCE MANUALS For detailed descriptions of Thermo King engines, compressors or temperature control systems, refer to the appropriate Thermo King manual: Operating Manuals Self-Powered Truck Units T-500R, T-600R, T-800R, TK 60483 T-1000R, T-1200R, T-Series SPECTRUM Self-Powered Undermount Truck Units UT-800, UT-1200,...
Page 9: Safety Precautions
2 Safety Precautions Thermo King recommends that all service be performed by a Thermo King dealer. However, you should be aware of several general safety practices: GENERAL PRACTICES 1. ALWAYS WEAR GOGGLES OR SAFETY GLASSES. Refrigerant liquid and battery acid can permanently damage the eyes (see First Aid).
Page 10 BATTERY REMOVAL DANGER: Disconnect the negative battery terminal (-) first when removing a battery. Connect the positive terminal (+) first when installing a battery. This order is important because the frame is grounded to the negative battery terminal. If the negative terminal is still connected, a complete circuit exists from the positive terminal of the battery to the frame.
Page 11 ELECTRICAL Microprocessor Service Precautions must be taken to prevent electrostatic discharge when servicing the microprocessor controller and related components. Potential differences considerably lower than those which produce a small spark from a finger to a door knob can severely damage or destroy solid-state integrated circuit components. The following procedures must be rigidly adhered to when servicing units to avoid microprocessor damage or destruction.
Page 12 Precautions 1. Be certain the unit On/Off switch is turned OFF before connecting or disconnecting the standby power plug. Never attempt to stop the unit by disconnecting the power plug. 2. Be certain the unit power plug is clean and dry before connecting it to a power source. 3.
Page 13 UNIT DECALS Serial number decals, refrigerant type decals and warning decals appear on all Thermo King equipment. These decals provide information that may be needed to service or repair the unit. Service technicians should especially read and follow the instructions on all warning decals.
Page 14 2e24151g0 Warning Decals Safety Precautions...
Page 15: Specifications
Electrical Standby T-500R/T-Dairy ........3-10...
Page 16: Engine
T-Series Low Speed Operation 1650 ± 25 rpm T-Series High Speed Operation (except T-500R/ 2250 ± 25 rpm T-Dairy) T-500R/T-Dairy High Speed Operation 2300 ± 25 rpm UT-800 Low Speed Operation 1450 ± 25 rpm* UT-800 High Speed Operation 2200 ± 25 rpm HIGH...
Page 17: Belt Tension
Coolant System Capacity T-1200R, T-1000R 6.2 liters with coolant expansion tank Coolant System Capacity T-800R, T-600R 5.7 liters with coolant expansion tank Coolant System Capacity T-500R 5.7 liters with coolant expansion tank Coolant System Capacity T-Dairy 5.7 liters with coolant expansion tank Coolant System Capacity UT-Series 5.2 liters with coolant expansion tank...
Page 18: Engine Clutch
ENGINE CLUTCH Engagement 600 ± 100 RPM Dynamic Torque 66 fT-lb (89.5 N•m) minimum @ 1600 RPM Specifications...
Page 19: Refrigeration System
NOTE: Please take note of your refrigerant type (label on outside of unit), and make sure not to cross-contaminate. Refrigerant R-404A 3922 R-452A 2140 Compressor Model T-500R/T-Dairy, T-600R, T-800R, Thermo King X214 Deep Sump T-1000R Thermo King X426 LSC5 T-1200R Thermo King X430 LSC5 UT-Series TK06 Scroll 6 HP Refrigerant Charge T-800R/T-1000R/T-1200R SPECTRUM (Host) 4.11 kg (9.06 lb) **...
Page 20: Electrical Control System
UT-1200/UT SPECTRUM 12 volt, 120 amp, brush type, Thermo King alternator Voltage Regulator Setting 13.8 to 14.4 volts @ 25 C (77 F) NOTE: Fuse F4 (Bypass resistor for Prestolite Alternator) must be removed for the Thermo King Alternator. Specifications...
Page 21: Fuses - (Except T-500R/T-Dairy)
HPCO/Run Circuit CAN Connector J98 F4 Remove fuse F4 for Model 30 units with 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.
Page 22: Electrical Components
Coil A (Red [EVA] and Blue [EVB] Wires) — 20 to 35 Coil B (Black [EVC] and White [EVD] Wires) — 20 to 35 Starter Motor (No Load Bench Test) Evaporator Fan Motors (Each) (T-500R/T-Dairy 7.0 to 7.6 Only) Specifications...
Page 23: Evaporator Fan Motors (Ut-Series)
EVAPORATOR FAN MOTORS (UT-SERIES) UTSE Evaporator: Number Used Power Rating 0.17 hp (0.12 kW) each 2860 Full Load Current Each 9.2 amps each Spectrum Evaporator (2 evaps used): Number Used 6 (3 per evaporator unit) Power Rating 0.13 hp (0.09 kW) each 2450 Full Load Current Each 7.0 amps/motor...
Page 24: Electrical Standby Ut-Series
Number 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 30 amps T-1200, T1000R, UT-Series 200-230/3/50-60 50 amps All 380-460/3/50-60 20 amps Extension Cord Size: Up to 50 ft—10 gauge (Up to 25 ft for UT-Series and T-500R/T-Dairy) 50 to 75 ft—8 gauge...
Page 25: Maintenance Inspection Schedule
Unit Models: T-500R........
Page 26: Unit Models: T-Series (Except T-500R) And T-Series Spectrum Host
UNIT MODELS: T-SERIES (EXCEPT T-500R) AND T-SERIES SPECTRUM HOST The service technician is responsible for assessing the condition of all parts & components found during any service operation to be in a condition suitable for further operation up to the next scheduled service. If parts not considered in suitable condition they should be replaced.
Page 27 The service technician is responsible for assessing the condition of all parts & components found during any service operation to be in a condition suitable for further operation up to the next scheduled service. If parts not considered in suitable condition they should be replaced. SERVICE SERVICE INSPECTION...
Page 28: Unit Models: T-Series Spectrum
*Do not mix antifreeze types. ** Wet cell 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.
Page 29: Unit Models: T-500R
  & take corrective action as required Check HMI & Controller software revision - InstalI latest revision if   customer approved or approved by Thermo King for upgrade.    Check fuel supply.  Check engine oil level.
Page 30 The service technician is responsible for assessing the condition of all parts & components found during any service operation to be in a condition suitable for further operation up to the next scheduled service. If parts not considered in suitable condition they should be replaced.
Page 31: Unit Models: Ut-Series
UNIT MODELS: UT-SERIES The service technician is responsible for assessing the condition of all parts & components found during any service operation to be in a condition suitable for further operation up to the next scheduled service. If parts not considered in suitable condition they should be replaced.
Page 32 Electrical Check alternator connections for corrosion and clean and protect as   required.  Inspect alternator brushes Check defrost initiation and termination. Check evaporator fans function  during defrost (fans should be stopped during defrost) **Inspect battery terminals, and electrolyte level. ***If EON battery ...
Page 33: Unit Models: Ut-Series Remote Evaporators
UNIT MODELS: UT-SERIES REMOTE EVAPORATORS Electrical   Inspect wire harness for damaged wires or connections. Check defrost operation, including drain heaters operation & defrost ter-   mination.   Check fan motor start speed sequence and operation. Refrigeration Leak test remote evaporator &...
Page 34 Maintenance Inspection Schedule 4-10...
Page 35: Unit Description
Defrost............5-5 DAS - Data Acquisition System (Optional - except on T-500R/T-Dairy) ..5-5 Electric Standby (Model 50 Units Only) .
Page 36: General Description
The T-600, T-800, T-1000, T-1200R, UT-800, UT-1200 unit is a microprocessor based transport temperature control system that uses the SR-2/SR-3 (UT-Series - SR-3 only) Truck HMI microcontroller to manage system functions. The T-500R/T-Dairy is a microprocessor based transport temperature control system that uses the TSD Control Panel to manage system functions.
Page 37: Unit Options
The clutch isolates the engine from the belt drive system during electric standby operation on Model 50 units. Compressor The T- Series units feature reliable four-cylinder reciprocating compressors. T-500R/T-Dairy, T-600R and T-800R - X214, T-1000R - X426 and T-1200R - X430 compressors The UT-Series features a TKO Scroll Compressor STANDARD HMI CONTROL PANEL The Standard HMI Control Panel (Human/Machine Interface) is used to operate the unit and display unit information.
Page 38: Mechanics Hmi Control Panel
Premium HMI Control Panel Standard HMI Control Panel - SPECTRUM Premium HMI Control Panel - SPECTRUM MECHANICS HMI CONTROL PANEL The Mechanics HMI Control Panel is available as a hand held diagnostic tool. It is used on units with a Standard HMI Control Panel if it is necessary to access the Maintenance Menu or the Guarded Access Menu to service the unit.
Page 39: Defrost
EFROST Cycle.” DAS - DATA ACQUISITION SYSTEM (OPTIONAL - EXCEPT ON T-500R/T-DAIRY) The DAS (Data Acquisition System) monitors and records 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 ®...
Page 40: Unit Protection Devices
Coolant Temperature Sensor (UT-Series and T-500R/T-Dairy)): This sensor provides an engine coolant temperature input to the microprocessor. If the engine coolant temperature is too high, the controller stops the unit and records an alarm.
Page 41 UNIT COMPONENT IDENTIFICATION AMA944 T-1200R Front View Engine Oil Dipstick (on side of engine) Alternator Engine Compressor Coolant Expansion Tank Dehydrator (Filter-Drier) Electric Motor T-Series Main Components (except T-500R/T-Dairy) Unit Description...
Page 42 T-500R Front View Coolant Expansion Tank Dehydrator (Filter-Drier) Engine Compressor Electric Motor On/Off Switch Alternator Main Components T-500R/T-Dairy Unit Description...
Page 43 HIGH Front View (UT-1200 Shown, UT-800, UT XTREME Ambient, and UT SPECTRUM Similar) Accumulator Compressor Receiver Tank Condenser/Radiator Coil Filter/Drier Fuel Filter/Water Separator UT-Series Components, Front and Side Views (Panels Removed) Unit Description...
Page 44 Compressor Pulley Engine Clutch Electric Motor Pulley UT-Series Components, Rear View (Panels Removed) Unit Description 5-10...
Page 45: Refrigeration System Components
The ETV system also uses discharge and suction pressure transducers. The ETV is not used if the unit is equipped with an SPR. Suction Pressure Regulator (SPR) (T-500R/T-Dairy/T-Series Except T-1200R) This component is a mechanical control device used to limit the suction pressure to the compressor. The valve controls suction pressure based on the actual system pressure.
Page 46 This normally closed switch monitors the discharge pressure at the compressor. It opens on high discharge pressure to shut the unit down to prevent damage. Low Pressure Cutout Switch (LPCO) (T-500R/T-Dairy) This normally closed switch monitors the suction pressure at the compressor. It opens on low suction pressure to shut the unit down to prevent damage.
Page 47: Single Temperature Refrigeration System Diagrams
SINGLE TEMPERATURE REFRIGERATION SYSTEM DIAGRAMS The following pages show the refrigeration system and examples of the refrigerant flow in the various modes for T600/T800/T1000 and T1200R. Compressor 13. Heat Exchanger Compressor Sight Glass 14. Expansion Valve Discharge Pressure Transducer 15. Distributor High Pressure Cutout Switch (HPCO) 16.
Page 48 22. Hot Gas Solenoid (HGS) 10. Receiver Tank Outlet Valve 23. Purge Check Valve Dehydrator (Filter-Drier) 24. Purge Valve (PV) 12. Heat Exchanger 25. Receiver Tank Pressure Check Valve 13. Expansion Valve 26. Condenser Check Valve Refrigeration System Components T-500R/T-Dairy Unit Description 5-14...
Page 49 There, liquid refrigerant absorbs heat as it evaporates into low pressure vapor. The refrigerant returns to the compressor through the heat exchanger, accumulator, (and ETV - T-Series or SPR in T-500R/T-Dairy). Unit Description...
Page 50 Solenoid and Check Valves T-Series (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 Unit Description...
Page 51 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.
Page 52 Cool Mode T-500R/T-Dairy Heat/Defrost Mode T-Series (except T-500R/T-Dairy) The refrigerant flow in Heat/Defrost Mode is a conventional hot gas heat cycle. The CIS is closed and the HGS is open so high pressure refrigerant vapor leaves the compressor and flows through the HGS to the hot has line. Most of the refrigerant flows through the hot gas line and the drain pan heater to the evaporator.
Page 53 Heat/Defrost Mode T1200R Heat/Defrost Mode T600, T800 and T1000R T-500R/T-Dairy The refrigerant flow in Heat/Defrost Mode is a conventional hot gas heat cycle. The CIS is closed and the HGS is open so high pressure refrigerant vapor leaves the compressor and flows through the HGS to the hot has line. Most of the refrigerant flows through the hot gas line and the drain pan heater to the evaporator.
Page 54 4. Purge Valve (PV)-Open/Energized 5. Purge Check Valve-Closed 6. Hot Gas Solenoid (HGS)-Open/Energized Heat/Defrost Mode T-500R/T-Dairy UT-Series The refrigerant flow in Heat/Defrost Mode is a conventional hot gas heat cycle. The CIS is closed and the HGS is open so high pressure refrigerant vapor leaves the compressor and flows through the DPR (which maintains a minimum discharge pressure) to the hot has line.
Page 55 Heat/Defrost Mode UT-Series Purge Mode (T-500R/T-Dairy) Purge Mode is similar to Condenser Evacuation Mode in previous systems. It is used to move the refrigerant out of the condenser into the accumulator when the unit shifts from Cool (or Null) to Heat. The unit goes into Purge Mode for 20 to 100 seconds before shifting to Heat.
Page 56 Purge Mode T-500R/T-Dairy Purge Mode (UT-Series) Purge Mode is similar to Condenser Evacuation Mode in previous systems. It is used to move the refrigerant out of the condenser into the accumulator when the unit shifts from Cool (or Null) to Heat or Defrost. The unit goes into Purge Mode for 20 to 100 seconds before shifting to Heat or Defrost.
Page 57 Purge Mode UT-Series Unit Description 5-23...
Page 58: Multi-Temperature Refrigeration System Diagrams
MULTI-TEMPERATURE REFRIGERATION SYSTEM DIAGRAMS The following pages show the refrigeration systems and examples of the refrigerant flow in the various modes for T-800R/T-1000R/T-1200R and UT SPECTRUM units. The examples show two zone systems. The three zone systems are similar with a Zone 3 evaporator and its components added. T-800R/T-1000R/T-1200R SPECTRUM Units Normally Open Normally Closed...
Page 59 Zone 1 Cool and Zone 2 Cool T-800R/T-1000R/T-1200R SPECTRUM Units High pressure refrigerant vapor leaves the compressor and flows through the open CIS to the condenser where the refrigerant releases heat and condenses into high pressure liquid. The liquid refrigerant flows through the CCV, receiver tank, and drier, into the liquid lines.
Page 60 Zone 1 Normally Open Zone 2 Normally Closed Zone 1 Cool and Zone 2 Cool T-800R/T-1000R/T-1200R SPECTRUM Units Unit Description 5-26...
Page 61 Purge Mode T-800R/T-1000R/T-1200R SPECTRUM Units Purge Mode is used to move the refrigerant out of the condenser into the accumulator when the unit shifts from all zones in Cool (or Null) to any zone in Heat. The unit goes into Purge Mode for 20 to 100 seconds before shifting to Heat. The ambient and return air temperatures determine the duration.
Page 62 Zone 1 Normally Open Zone 2 Normally Closed Purge Mode T-800R/T-1000R/T-1200R SPECTRUM Units Unit Description 5-28...
Page 63 Zone 1 Cool and Zone 2 Heat T-800R/T-1000R/T-1200R SPECTRUM Units The CIS is closed so high pressure refrigerant vapor leaves the compressor and flows into the hot gas lines. The HGS2 is open so most of the refrigerant flows through it into the Zone 2 evaporator. There, the refrigerant heats the Zone 2 evaporator and condenses into high pressure liquid.
Page 64 Zone 1 Normally Open Zone 2 Normally Closed Zone 1 Cool and Zone 2 Heat T-800R/T-1000R/T-1200R SPECTRUM Units Unit Description 5-30...
Page 65 UT SPECTRUM Unit Scroll Compressor 17. Suction Pressure Transducer Compressor Temperature Sensor 18. Discharge Pressure Regulator (DPR) Compressor Sight Glass 19. Hot Gas Bypass Solenoid (HGBS) Liquid Injection Solenoid (LIS) 20. Purge Check Valve (PCV) High Pressure Cutout Switch (HPCO) 21.
Page 66 Zone 1 Cool and Zone 2 Cool UT SPECTRUM Units High pressure refrigerant vapor leaves the compressor and flows through the open CIS to the condenser where the refrigerant releases heat and condenses into high pressure liquid. The liquid refrigerant flows through the CCV, receiver tank, and drier, into the liquid lines.
Page 67 Zone 1 Cool and Zone 2 Cool UT SPECTRUM Units Unit Description 5-33...
Page 68 Purge Mode UT SPECTRUM Units Purge Mode is used to move the refrigerant out of the condenser into the accumulator when the unit shifts from all zones in Cool (or Null) to any zone in Heat. The unit goes into Purge Mode for 20 to 100 seconds before shifting to Heat. The ambient and return air temperatures determine the duration.
Page 69 Purge Mode UT SPECTRUM Units Unit Description 5-35...
Page 70 Zone 1 Cool and Zone 2 Heat UT SPECTRUM Units The CIS is closed so high pressure refrigerant vapor leaves the compressor and flows through the DPR (which maintains a minimum discharge pressure) to the hot gas lines. The HGS2 is open so most of the refrigerant flows through it into the Zone 2 evaporator. There, the refrigerant heats the Zone 2 evaporator and condenses into high pressure liquid.
Page 71 Zone 1 Cool and Zone 2 Heat UT SPECTRUM Units Unit Description 5-37...
Page 72 Unit Description 5-38...
Page 73: Operating Instructions Premium Hmi
6 Operating Instructions Premium HMI Controller Description ..........6-3 Controller Features .
Page 74 Diesel/Electric Menu ..........6-28 Adjust Brightness .
Page 75: Controller Description
CONTROLLER DESCRIPTION The Premium Truck HMI (Human/Machine Interface) Control Panel is available as an option on TSR-2/3 Truck applications. It is used to operate the unit, display unit information and access all TSR-2/3 Maintenance and Guarded Access Menus. The Premium HMI Control Panel communicates with the base controller via the CAN (Controller Area Network) bus. It is connected to the base controller via CAN Connector J14 on the interface board.
Page 76: Controller Features
Controller Features • 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 • Selects and Indicates CYCLE-SENTRY or Continuous Mode Operation •...
Page 77: Operating The Unit In Single Zone Control Mode (Spectrum)
Pressing the left soft key allows the user to change the SETPOINT, and pressing the right soft key accesses the MAIN MENU. The other two soft keys access the GAUGES menu and the SENSORS menu. The Two Zone Premium Display 2 Zone Premium Display The 2 Zone Premium Display in a figure shows the return air temperature and setpoint for two zones.
Page 78: Turning The Unit On And Off
THERMO KING Logo as the display initializes. Important: The ON key must be held down until the Thermo King Logo appears. If the ON key is not held down long enough (approximately ½ second), the display may flicker but the unit will not start up. If this occurs, hold the ON key down until the Thermo King logo appears.
Page 79 The new language is confirmed, and then the Premium Display will appear in the new language as shown below. The unit is ready to run. Premium Display Should it be necessary to change to another language at any time, return to the Premium Display and then press and hold the first and last soft keys for 5 seconds as shown in Figure .
Page 80: Changing The Setpoint
Changing the Setpoint From the Premium Display, press the SETPOINT soft key. SETPOINT Key The setpoint display appears as shown below Setpoint Display The "-" and "+" soft keys are used to increase or decrease the setpoint until the desire setpoint is shown. In Figure the setpoint has been changed to 40 F using the "+"...
Page 81: Changing The Setpoint (Spectrum)
Premium Display, New Setpoint Important: If the setpoint is changed using 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 is accepted, the setpoint changes, and the display returns to the Premium Display.
Page 82: Starting The Diesel Engine
Zone 2 is OFF STARTING THE DIESEL ENGINE Diesel engine preheats and starts are automatic in both Continuous Mode and CYCLE-SENTRY Mode. The engine will preheat and start as required when the unit is turned on. The engine preheat and start will be delayed in CYCLE-SENTRY mode if there is no current need for the engine to run.
Page 83: Switching From Electric To Diesel (Premium Hmi Only)
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 Electric Mode operation will briefly be confirmed. If unit operation is required the electric motor will start as shown in STARTING THE ELECTRIC MOTOR.
Page 84: Selecting High Speed Lockout Mode (If Enabled)
Prompt Screen, Guarded Access Set to Yes The display then shows the Defrost display. The bar indicator shows approximately how much time remains to complete the defrost cycle. The bar indicator in Figure shows that the defrost cycle is about 25% complete. Defrost Display Terminating a Defrost Cycle The defrost cycle terminates automatically when the coil temperature is greater than or equal to 52 F (11 C) or the defrost timer...
Page 85: Selecting Cycle-Sentry Or Continuous Mode
SELECTING CYCLE-SENTRY OR CONTINUOUS MODE With Thermo King Truck unit applications, CYCLE-SENTRY Mode or Continuous Mode operation is selected from the Main Menu - Mode Submenu. See the Main Menu - Mode Submenu material later in this section for complete details.
Page 86: Using The Sensors Key
I/O (Input/Output State) - Displays the current state of the input/output devices listed below as ON or OFF. • High Speed Relay/Electric Heat • Run Relay • Run Relay Feedback • Alternator Excite Output • Defrost Damper • Hot Gas Solenoid •...
Page 87: Using The Main Menu
Sensors Available Return Air Temperature - Displays the temperature of the control return air sensor. Discharge Air Temperature - Displays the temperature of the control discharge air sensor. Temperature Differential - Displays the calculated difference between the control return air sensor and the control discharge air sensor.
Page 88: Main Menu Choices
MAIN MENU OVERVIEW (SPECTRUM) Truck TSR-2/3 SPECTRUM M/T Operator and Main Menu. MAIN MENU CHOICES LANGUAGE - If more than one language is enabled, this will be the first menu item to appear. If only one language is enabled, this menu will not appear. The Language Menu allows the operator to select a language from a list of up to 11 languages at one time.
Page 89 If enabled, the Language Menu is the first menu item to appear as shown in Figure below. Press the SELECT key to choose the Language menu. Select Key The Language menu will appear 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.
Page 90: Alarms
When the unit is turned on the display will show the Thermo King Logo and then the "Configuring System" message. If log alarm(s) are present the Log Alarm notice will appear on the display for 60 seconds as shown. The amber K symbol of the remote indicator alarm light (if installed) will also be on during this period.
Page 91: Prevent Alarms
Alarm Code Notification The Alarm Icon used in previous Thermo King controllers has been incorporated. If a Check alarm condition occurs the Alarm Icon will appear in the display as shown.
Page 92: Displaying And Clearing Alarm Codes
The following alarm codes clear automatically. • Alarm Code 64 Pretrip Reminder - Clears when a Pretrip Test is performed. • Alarm Code 84 Restart Null - Clears when the unit is no longer in a restart null due to a Prevent Alarm. •...
Page 93: Datalogger
A help message will appear. For the alarm shown, the message "CHECK OIL LEVEL. IF UNIT IS SHUT DOWN, REPAIR IMMEDIATELY. OTHERWISE, REPORT ALARM AT END OF THE DAY" will be shown on the display. Check the oil level and add oil as required, clear the alarm and restart the engine. To select a different Main Menu item press the NEXT key.
Page 94: Mode
Hourmeter Display Press the NEXT or PREVIOUS key to scroll through the enabled hourmeters. Scroll Through Hourmeters Hourmeter names and definitions are shown in the table below in the order they appear. Only hourmeters enabled in the Guarded Access Menu will be shown. To return to the Premium Display, press the EXIT key. Hourmeter Names and Definitions Total number of hours the unit has been turned on (protection hours).
Page 95: Start Sleep Mode
Single Zone Control – Multi Zone Control (SPECTRUM) If enabled in Guarded Access, Single Zone Control allow single temperature operation. If Single Zone Control operation is selected then all zones will be forced on and will control to the same setpoint. All bulkheads should be down to create one large compartment.
Page 96: Selecting Sleep Mode
Turn Off/Turn On CYCLE-SENTRY Screen Pressing the Select key will change the mode from CYCLE-SENTRY to Continuous. Select Key The display will confirm the change as shown below. Mode Change Confirmed The new mode is then confirmed for 10 seconds. Mode Confirmed The display then returns to the Mode Menu.
Page 97 Sleep Mode Menu The screen shown will appear.. Start of Sleep Mode Menu The operator can now choose a Sleep Mode Wake-up Time or simply enter Sleep Mode immediately. If NO is pressed the unit will immediately enter Sleep Mode. Select No to Enter Sleep Mode The display will show SLEEP and the unit will start and stop as required to keep the engine warm and/or the battery charged.
Page 98: Pretrip
Confirm Minute The display will now prompt for a Pretrip Test on Wake-up. Press the YES key to perform a Pretrip Test on Wake-up. If the No key is pressed the unit will resume normal operation on Wake-up. Press Yes Key for Pretrip Test The display will show SLEEP and the unit will start and stop as required to keep the engine warm and/or the battery charged.
Page 99: Performing A Pretrip Test
Pretrip Test Considerations When performing a Pretrip Test, the following issues should be considered. • If running a Pretrip Test on a truck or trailer loaded with dry cargo, insure that proper airflow can occur around the load. If the load restricts airflow, false test results may occur.
Page 100: Diesel/Electric Menu
Performing Cool Test When all tests are complete, the results are reported as PASS, CHECK or FAIL. If the results are CHECK or FAIL, the accompanying alarm codes will direct the technician to the cause of the problem. 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 service.
Page 101: Adjust Brightness
Switching from Electric to Diesel If the unit is running in electric and manual switching to diesel mode is enabled, the unit is switched using the Diesel Mode Menu. From the Premium Display, press the MENU key. (Figure "Menu Key" page 6-15) The Language Menu or Alarm Menu will appear.
Page 102: Time
TIME The system time and date is viewed using the Main Menu. Time and Date 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.
Page 103: Operating Instructions Standard Hmi
7 Operating Instructions Standard HMI Controller Description ..........7-2 Controller Features .
Page 104: Controller Description
• 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 will also glow if a 15 pin Thermo King data cable is connected to the serial port on the back of the controller (DPD).
Page 105: Keys And Led Indicators
A red indicator LED is located between the ON Key and OFF Key at the left side of the display. This indicator will glow if Alarm Code 91 Check Electric Ready Input occurs. It will also light if a 15 pin Thermo King data cable is connected to the serial port on the back of the controller (DPD).
Page 106: The Multi-Temperature Display And Zone Indicators
ENTER Key If the setpoint has been changed using the UP ARROW Key and/or DOWN ARROW Key, pressing the ENTER Key enters the setpoint into the base controllers memory. Secondary Use - When alarms are being displayed, pressing this key will clear the alarm shown on the display.
Page 107 When two horizontal bars are present at the left side of the box temperature, then Zone 2 is being shown on the display. The display will automatically scroll through all configured zones, showing each zone for 10 seconds. When three horizontal bar is present at the left side of the box temperature, then Zone 1 is being shown on the display.
Page 108: The Standard Display
Then the unit running time hourmeters are shown for 30 seconds. The diesel engine run time hours and Diesel Icon are shown in the upper display. If the optional Electric Standby Feature is installed, the electric motor run time hours and Electric Icon are shown in the lower display.
Page 109 When the desired setpoint has been selected using the UP ARROW Key or DOWN ARROW Key, the ENTER Key must be pressed to confirm and load the new setpoint. • If the setpoint is changed using the UP ARROW Key and DOWN ARROW Key, the setpoint display will begin to flash 10 seconds after the last press of the UP ARROW or DOWN ARROW key as a reminder to press the ENTER Key.
Page 110 Zone 1 Display Manual Zone Selection Mode Manual Zone Selection mode allows the operator to select a desired zone when the Standard Display is being shown. Once a zone is selected, the zone can be turned on or off, the zone setpoint can be changed or a manual defrost cycle can be initiated. To manually select a zone when the Standard Display is being shown, press the Enter Key once.
Page 111: Changing The Zone Setpoint
Changing the Zone Setpoint From the Standard Display, press the Enter Key to put the unit in Manual Zone Selection mode. Press the Enter Key again as required to select the desired zone. Zone 2 Selected When the desired zone is selected, press the UP ARROW Key and/or DOWN ARROW Key until the desired setpoint is shown. The setpoint has been increased to 4°C using the UP ARROW Key.
Page 112: Starting The Diesel Engine
Starting the Diesel Engine Verify the Base Controller On/Off switch is in the ON position. Diesel engine preheats and starts are automatic in both Continuous Mode and CYCLE-SENTRY Mode. The engine will preheat and start as required when the unit is turned on. The engine pre-heat and start sequence will be delayed in Cycle Sentry mode if there is no current need for the engine to run.
Page 113: Selecting Cycle-Sentry Or Continuous Mode
Preferred Method for Manually Switching from Electric Mode to Diesel Mode 1. Press the Standard Truck HMI Control Panel OFF Key to turn the unit off. 2. Turn off the standby power and disconnect the cord. 3. Press the Standard Truck HMI Control Panel ON Key to turn the unit on. The Hourmeters display will briefly appear and then the screen will appear as shown below.
Page 114: Initiating A Manual Defrost Cycle
Initiating a Manual Defrost Cycle Defrost cycles are usually initiated automatically based on time or demand. Manual defrost may also be available. Defrost is only available if the unit is running and the evaporator coil temperature is less than 7 C. Other features such as door switch settings may not allow manual defrost under some conditions.
Page 115: Alarms
ALARMS Alarm Code Notification If an alarm condition occurs, the Alarm Icon will appear on the display. If the alarm is a Check Alarm, the Alarm Icon will turn on but the unit will continue to run. If the alarm is a Shutdown Alarm, the Alarm Icon and the display will flash on and off and the unit will shut down.
Page 116: Pretrip Test
PRETRIP TEST A Pretrip Test verifies unit operation. The PRETRIP Key allows either a Full Pretrip Test or an Engine Running Pretrip Test to be initiated by the operator. Pretrip Test Conditions • The current unit settings are saved and restored at the end of the Pretrip Test or if the unit is turned off and back on. •...
Page 117: Starting A Pretrip Test
PERFORMING A PRETRIP TEST Starting a Pretrip Test 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 shown on the display. When the unit running time hourmeters are shown on the display, press and hold the PRETRIP Key for 5 seconds.
Page 118: Checking Truck Hmi Control Panel Software Revision And Serial Number
3. Remove the back cover from the Standard 4. Connect a Thermo King 9 to 15 pin serial cable from the PC computer to the 15 pin connector on the back of the Standard Truck HMI Control Panel shown below “D”...
Page 119 Red LED Indicator of WinTrac will not work. 6. Open WinTrac 4.8.1 or later. Earlier versions 7. Select Seek Device. 8. Use 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.
Page 120 Operating Instructions Standard HMI 7-18...
Page 121: Electrical Maintenance
8 Electrical Maintenance Alternator Charging System Diagnostic Procedures ..... . 8-2 General Information ............8-2 Alternator Identification .
Page 122: Alternator Charging System Diagnostic Procedures
An overcharged battery is usually caused by a defective voltage regulator. Alternator Identification • These units use Thermo King Alternators (see below), which are painted black. B+ Terminal (Positive Output - 2A Wire) F2 Terminal (Do Not Ground) B- Terminal (Negative Ground - CH Wire)
Page 123: Interface Board Fuse F4
NOTE: The F4 fuse must be removed from the interface board on units equipped with Thermo King alternators. The voltage regulator on the Thermo King alternators will be damaged if the unit is turned On with the F4 fuse in place on the interface board.
Page 124 6. With the unit off, check the voltage at the B+ terminal on the alternator. Battery voltage must be present. If not, check the 2A circuit. 7. Disconnect the main wire harness from the voltage regulator. On Thermo King alternators, carefully push on the spring clip to release the plug lock.
Page 125: Battery
1. Attach a clamp-on ammeter to the 2A wire near the B+ terminal on the alternator. 2. Energize the field on the Thermo King 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.
Page 126 HPCO/Run Circuit Power to CAN Connector J98 F4 Remove fuse F4 for Model 30 units with 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.
Page 127: Interface Board Leds
When fuse F11 is installed in the upper position the unit will start and run without the TSD control panel F14 Remove fuse F4 for units with Australian Bosch or Thermo King Alternators. Install fuse F4 for units with Prestolite Alternator.
Page 128: Smart Reefer 2/3 (Sr-2/3) Microprocessor Controller
Interface Board LED Functions (Continued) LED # Function LED 20 (Not Used) Status – Flashes once per 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.
Page 129: Expansion Module (Spectrum Systems Only [T-Series Spectrum And Ut Spectrum])
EXPANSION MODULE (SPECTRUM SYSTEMS ONLY [T-SERIES SPECTRUM AND UT SPECTRUM]) The expansion module allows for up to three temperature controlled zones. The module provides the interface between the base controller and the Zone 1, Zone 2, and Zone 3 (if used) multi-temperature components such as sensors, solenoids, valves, and fan motors.
Page 130: Flywheel (Rpm) Sensor
Expansion Module LED Functions (Continued) Function 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 Status – Flashes once per second when the base controller is powered and operating normally. Flashes several time per second when flash loading.
Page 131: Glow Plugs
Testing the Flywheel (RPM) Sensor: The following equipment is required: • AC voltmeter capable of reading up to 10 volts • Ohmmeter The flywheel sensor may be checked as follows: 1. Position the flywheel so a ring gear tooth is in the center of the sensor mount hole. 2.
Page 132: Unit Wiring
A shorted glow plug will show excessive current draw (more than 13 amps) during preheat, and may cause fuse F5 (40 A) to blow. Check each glow plug individually. EVAPORATOR FAN MOTORS (T-500R/T-DAIRY ONLY) NOTE: Non-repairable fan motor assemblies are used. If a motor malfunctions, it must be replaced.
Page 133: Evaporator Heaters (Optional)
The phase select module is designed to monitor both single and 3 phase nominal input voltages between 200 and 480 volts AC. MCB–Motor Contactor MCA–Motor Contactor Base Controller/Interface Board Assembly Overload Relay Phase Select Module Model 50 Control Box Components with High Voltage Cover Removed - T-Series (Except T-500R/T-Dairy) Electrical Maintenance 8-13...
Page 134 (Low Voltage) Evaporator Fan Relay Board (Low Voltage) MCA–Motor Contactor MCB–Motor Contactor Heater Contactor (Optional) Model 50 Control Box Components with High Voltage Cover Removed (T-500R/T-Dairy Only) MCB–Motor Contactor MCA–Motor Contactor Overload Relay Phase Select Module Model 50 High Voltage Box Components with High Voltage Cover Removed - UT-Series Operation The phase select module will detect missing phases, phase orientation and low voltage on three phase or single phase power.
Page 135 When the voltage sensed rises above 165 volts AC and all three phases are present, the module ER wire will output 12 volts DC after the conditions exist for 2 to 4 seconds. This signal informs the microprocessor that electric standby operation is possible. If the voltage drops below 160 volts AC or a phase is lost, the ER output is turned off after the condition exists for 3 seconds.
Page 136 Connector Pinout Wire Description Power to Module CH/CHV Chassis ground AC Power OK, output to microprocessor 7EA/7E Power for 7EB or 7EC output Output to MCA Output to MCB SP-GND Internal ground to enable a jumper circuit for SP logic Grounded for single phase mode Unused Removal and Replacement...
Page 137: Overload Relay
OVERLOAD RELAY The overload relay protects the standby electric motor. It is located in the control box under the high voltage cover. The overload relay opens the circuit to the electric motor if the current exceeds the overload relay setting. The overload relay resets automatically.
Page 138 Set Opening Amperage Remove Tab Marked “H” Set Amperage and Remove Tab 4. Move the slide switch down until it clicks into place at the bottom of the slot (from which the tab marked “H” was removed). This sets the overload relay to reset automatically. Switch Clicks into Place at Bottom of Slot Move Switch Down The new overload relay is now set up correctly.
Page 139: Engine Maintenance
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 .
Page 140: Emi 2000
Five Year or 12,000 Hour ELC (Extended Life Coolant). The EMI package allows standard maintenance intervals to be extended to 2,000 hours, or 1 year, whichever occurs first. NOTE: Units equipped with the EMI 2000 package do require regular inspection in accordance with Thermo King's maintenance recommendations.
Page 141: Engine Air Cleaner (Emi 2000)
Add oil as necessary to reach the full mark. See the “Specifications” chapter of this manual for correct type of oil. Oil Filter Change Both oil filters should be changed along with the engine oil. Use genuine Thermo King extended maintenance oil filters. 1. Remove the filter.
Page 142 Breather Cover O-ring Baffle Baffle Plate Crankcase Breather Components Normal crankcase pressures with a new air cleaner are shown below: Unit/Speed in. (mm) H 2 O of vacuum Truck/Low 0 to 8 in. (0 to 203 mm) Truck/High 2 to 11 in. (51 to 279 mm) TriPac 0 to 8 in.
Page 143: Engine Cooling System
ENGINE COOLING SYSTEM General Description The engine employs a closed, circulating type, pressurized cooling system. Correct engine temperatures are controlled and maintained by a radiator, fan and thermostat. The coolant is circulated through the system by a belT-driven centrifugal pump. The pump draws the coolant from the side of the radiator (large header), circulates it through the cylinder block and head, then back to the radiator.
Page 144 Engine Expansion Tank Coolant Temperature Sensor Coolant Level Sensor Expansion Tank Cap Radiator Overflow Cap Drain Cock T-Series Engine Cooling System Components TK 270 Engine Maintenance...
Page 145: Bleeding Air From The Cooling System
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. Install the coolant fill tube assembly to the expansion tank as shown in the following images:...
Page 146 Install Coolant Fill Tube Assembly (T-Series Shown, UT-Series Similar) Lock HMI to read engine coolant temperature (if Standard HMI a service tool should be used). As the coolant temperature increases, air bubbles will escape through the coolant fill tube as the thermostat begins to open (approximately 72°C).
Page 147: Elc (Extended Life Coolant)
The new engine coolant, Texaco Extended Life Coolant, is Red in color instead of the current Green or Blue-Green colored coolants. AJA1947 ELC Nameplate Located On Expansion Tank The following are the Extended Life Coolants currently approved by Thermo King for use in ELC units for five years or 12,000 hours: • Chevron Dex-Cool •...
Page 148: Engine Thermostat
Checking the Antifreeze Check the solution concentration by using a temperature compensated antifreeze hydrometer or a refractometer designed for testing antifreeze. Maintain a minimum of 50 percent permanent type antifreeze concentrate and 50 percent water solution to provide protection to -30 F (-34 C). Do not mix antifreeze stronger than 68 percent permanent type coolant concentrate and 32 percent water for use in extreme temperatures.
Page 149: Coolant Level Switch
Thermostat Housing Gasket Thermostat Gasket Water Pump Water Pump Assembly and Thermostat Coolant Level Switch The coolant expansion tank uses a magnetic float type coolant level switch. When the coolant level is at or above the switch, the 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.
Page 150: Engine Fuel System
Testing the Coolant Level Switch You can test the switch in the unit by adjusting the coolant level. You can also remove the coolant level switch from the expansion tank and test the switch by moving the float up and down. 1.
Page 151: Bleeding The Fuel System
Overhaul Manual TK 53163 for injection nozzle testing and repair procedures. Thermo King recommends that any major injection pump or nozzle repairs be done by a quality diesel injection service specialty shop. The investment in equipment and facilities to service these components is quite high. Therefore, this equipment is not found in most repair shops.
Page 152 T-Series Fuel and Oil System Components TK 376 Engine Maintenance 9-14...
Page 153 Elbow - hose fitting (3/8) 16. Plug - pipe Kit - sleeve & eyelet (3/8) 17. Plug - pipe Nut (3/8) 18. Filter - oil bypass (EMI 2000) Hose (3/8 od) 19. Stud - bypass filter Adapter - oil line 20.
Page 154 T-Series Fuel and Oil System Components TK 270 Engine Maintenance 9-16...
Page 155 Elbow - hose fitting (3/8) 21. Tee (with restrictor) Kit - sleeve & eyelet (3/8) 22. Switch - oil pressure Nut (3/8) 23. Adapter - oil hose Hose (3/8 od) 24. Adapter (3/8) Fitting - hose fitting (1/4) 25. Eye - lifting Kit - sleeve &...
Page 156 AMA768 UT-Series Fuel System Components Engine Maintenance 9-18...
Page 157: Draining Water From Fuel Tank
HEAD - filter 13. HOSE - fuel (3/8 x 35 ft) SPUD - filter 14. JOINT - fuel SHAFT - water bleed 15. JOINT - fuel FILTER - fuel 16. PUMP - fuel injection HOSE - fuel (1/4 od x 35 ft lg) 17.
Page 158: Injection Pump Timing
AMA703 AMA703 Fuel Inlet Fuel Filter Fuel Filter Bowl Fuel Filter Bowl Gasket Electric Fuel Pump Assembly 1. Screw the fuel filter back into the pump housing (finger tight). 2. Place the fuel filter bowl gasket in place and hand tighten (or 100 in-lb [11.3 N•m]) the fuel filter bowl. If the pump does not operate, check for: •...
Page 159 Number One Cylinder Injection Line Timing Mark Component Location CAUTION: Loosen all of the injection lines at the injection nozzles to prevent the possibility of the engine firing while it is being rotated. 1. Remove the injection line for the number one cylinder from the delivery valve on the injection pump and from the injection nozzle.
Page 160 If the rocker arms are tight, the engine is at top dead center of the exhaust stroke for the number one cylinder. Rotate the engine 360 degrees to place the engine at top dead center of the compression stroke for the number one cylinder. 5.
Page 161: Injection Pump Removal And Installation
Injection Pump Removal and Installation Injection Pump Removal 1. Note the alignment of the index marks on the injection pump and the gear case. If they are not marked, mark them so the injection pump can be returned to the same position when it is reinstalled. Index Marks Index Mark Location Index Mark on Injection Pump...
Page 162 NOTE: The injection pump gear assembly is made of two pieces, the flange and the gear. Do not loosen or remove the four bolts that fasten the gear to the flange because that changes the timing. 5. Use a suitable puller to loosen the injection pump gear from the injection pump shaft. 6.
Page 163: Fuel Limit Screw
Fuel Limit Screw The fuel limit screw is not adjustable. It is equipped with an anti-tamper cap to fulfill requirements for CARB (California Air Resources Board) emission regulations. Service technicians must be CARB certified to perform service on the fuel limit screw for equipment operating in California.
Page 164 NOTE: The fuel solenoid may be removed from the injection pump to visually check its operation. The fuel solenoid must be energized when it is re-installed in the injection pump. If it is not, the plunger and the linkage may not line up correctly and the fuel solenoid will not function properly. 5.
Page 165: Engine Speed Adjustments
6. Place the O-ring in the groove in the end of the fuel injection pump. Make sure that the O-ring is positioned correctly during installation to avoid damage and leaks. AEA635 Fuel Solenoid O-ring Groove in Fuel Injection Pump Fuel Solenoid Components 7.
Page 166 BRACKET - solenoid/engine mount LOCKWASHER SOLENOID 10. ADJUSTER - speed control PLUNGER - solenoid NUT (1/4-28 LH thread) BOOT - solenoid 12. BALL JOINT NUT - solenoid 13. LINK - throttle DIODE 14. LOCKWASHER ROD - throttle 15. NUT UT-Series High Speed Solenoid Components High Speed Adjustment 1.
Page 167: Adjust Engine Valve Clearance
ADJUST ENGINE VALVE CLEARANCE The valve clearance should be checked after every 2000 operating hours, maximum. It is important that valves be adjusted to the correct specifications for satisfactory engine operation. Insufficient valve clearance will result in compression loss and misfiring of cylinders resulting in burned valves and seats.
Page 168 Top Dead Center Timing Mark for Number 1 Cylinder Index Timing Mark on Starter Mounting Plate Timing Marks Check the rocker arms on the number 1 cylinder to see if they are loose. If the rocker arms are loose, the engine is at top dead center of the compression stroke for the number 1 cylinder. If the rocker arms are tight, the engine is at top dead center of the exhaust stroke for the number 1 cylinder.
Page 169 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 3 cylinder on the flywheel lines up with the index timing mark on the starter mounting plate.
Page 170: Engine Mounts
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 Engine Maintenance 9-32...
Page 171 Bracket - engine (upper rear) Bracket - engine (compressor side) 10. Washer - belleville Bracket - engine (door side) Screw - chain Screw - plate & bracket (socket head) 12. Chain - 3 links Washer - belleville 13. Bolt - eye 1/2 in. Sealer - thread 14.
Page 172 T-Series Engine Mounting Components for 2 Cylinder Engine Engine Maintenance 9-34...
Page 173 Bracket - engine (upper rear) Washer - belleville Bracket - engine (compressor side) 10. Flatwasher Bracket - engine (door side) Screw - plate & bracket (socket head) 12. Chain Washer - belleville 13. Bolt - eye Sealer - thread 14. Bracket - snubber Screw - mount 15.
Page 174 Screw (5/16-18 SS); Flatwasher (5/16); Screw (3/8-16 SS); Flatwasher (3/8); Nylock Nut (5/16-18 SS) Nylock Nut (3/8-16 SS) Vibration Mount 3-Link Chain Mount Frame Bracket This End Through Existing Hole In Engine Flange UT-Series Chain/Restraining Mount Bracket Engine Maintenance 9-36...
Page 175: Belts
BELTS The unit uses only two belts to transfer power from the engine and the electric motor to the alternator, compressor, and evaporator fans. BELT TENSIONS NOTE: See SB 1068 for more information about belt tensions for the T-1000R, T-1200R, T-1000R SPECTRUM, and T-1000R SPECTRUM units.
Page 176 2E24751H01 930617 T-800R & T-600R 1E46118H89 781822 2E24751H01 930617 T-500R/T-Dairy 1E46118H89 781822 1E75364H04 929604 TO UPGRADE UNITS FROM RELEASE 2 BELT ROUTING TO SIMILAR ROUTING OF RELEASE 3 The part numbers below will be required. See belt routing below also.
Page 177: Water Pump Belt
UPGRADE RELEASE 2 TO UPDATE TO RELEASE 3 DRIVE TO LATEST REROUTED BELTS, PULLEYS, BRACKETS, MOTOR ETC.** *Adjuster Model Belt Part Number Plate Part Number Brackets T-1200R SPECTRUM 1E46118H92 781854 2E24751H08 T-1200R 1E46118H92 781854 2E24751H08 T-1000R SPECTRUM 1E46118H90 781852 2E24751H02 930669 45.5 T-1000R...
Page 178 Evaporator Fans 13. Compressor Pulley Hub Clip (M6 or M8*) 14. Compressor Key (U-shaped **) Fan Shaft 15. Compressor Key - Woodruff 16. Electric Motor Engine to Electric Motor/(Jackshaft) Belt 17. Jackshaft Clutch 18. Key - square Evaporator Fan Pulley (Curbside) 19.
Page 179: Engine/Electric Motor (Jackshaft) Belt - T-Series
17. Condenser Fan Compressor Pulley (Tensioner) 18. Water Pump Belt Belt Layout T-500R Engine/Electric Motor (Jackshaft) Belt - T-Series The engine/electric motor (jackshaft) belt is a 3V belt that also drives the engine side evaporator fan. A belt tensioner keeps the belt at the proper tension.
Page 180: Engine/Electric Motor (Jackshaft) Belt - T-500R/T-Dairy
Engine/Electric Motor (Jackshaft) Belt - T-500R/T-Dairy The engine/electric motor (jackshaft) belt is a 3V belt. A static belt tensioner keeps the belt at the proper tension. Use the following procedure to replace this belt or adjust the belt tension. 1. If replacing the belt, remove the electric motor (jackshaft)/compressor belt.
Page 181 9. Tighten the pulley mounting nut. 10. Place the straight edge against the side of the muffler can. 11. Tighten the locknut to compress the restraining mount (snubber) until the top of the washer is aligned with the top of the gauge bracket.
Page 182: Engine/Electric Motor Belt - Ut-Series
Engine/Electric Motor Belt - UT-Series 1. Loosen the idler mounting nut and the jam nut on the idler adjuster. 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.
Page 183: Electric Motor/Alternator Belt - Ut-Series
Electric Motor/Alternator Belt - UT-Series 1. Remove the lower condenser panel to access the alternator. 2. Loosen the alternator pivot 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.
Page 184 Engine Maintenance 9-46...
Page 185: 10 Refrigeration Maintenance
Set Up and Test of Evacuation Equipment ........10-6 Using Evacuation Mode (Not on T-500R/T-Dairy) ......10-6 Unit Evacuation.
Page 186 T-500R/T-Dairy) ........
Page 187: Evacuation, Dehydration, And Charging
204-725). However, the principles of 3-point evacuation and the use of a micron gauge during evacuation should always be practiced and can be applied when using normal workshop evacuation and micron gauge equipment. See the diagram of the Thermo King Evacuation Station (Figure on page 10-4) and note the location of the valves and other components.
Page 188 AGA654 Iso-Valve To 110 Vac Power Calibration Standard 10. Vacuum or Micron Gauge Thermistor Charging Port Two Stage Vacuum Pump Evacuation Station Refrigeration Maintenance 10-4...
Page 189 100 Microns 500 Microns 1000 Microns 2500 Microns 5000 Microns 20,000 Microns Atmospheric Pressure Calibration Adjustment Screw Example: Meter needle shown at calibration position when Calibration Standard specifies 0.15 mm Hg. Vacuum Gauge Refrigeration Maintenance 10-5...
Page 190: Set Up And Test Of Evacuation Equipment
NOTE: Dirty vacuum pump oil or a defective vacuum pump will prevent a low micron reading. Hoses and fittings can be isolated individually to identify leaks. Using Evacuation Mode (Not on T-500R/T-Dairy) A Graphics HMI is required to access the Evacuation Mode. On units equipped with the standard Truck HMI, it must be disconnected and have a Graphics HMI connected instead.
Page 191: Unit Evacuation
CAUTION: Do not attempt to evacuate a unit until you are certain that the unit is leak free. A unit with less than a full refrigerant charge should be thoroughly leak checked and all leaks must be repaired. 2. Put the unit into the Evacuation Mode (see “Using Evacuation Mode (Not on T-500R/T-Dairy)” on page 10-6). (Not on T-500R/T-Dairy) 3.
Page 192: Unit Charging (T-Series)
Moisture Leak Isolate the pump from the system by closing the Should the needle show a pressure rise but proper valve. Watch the movement of the vacuum finally level off to practically a constant mark, gauge needle. If the needle continues to rise, this is an indication that the system is vacuum tight but is still too wet, requiring additional this is an indication that a leak exists in the unit...
Page 193 Unit Charging (UT-Series) Initial System Charge The UT-Series utilizes a receiver tank sight glass. This is used in order to attain an optimum charge given varied installations (suction/ liquid line lengths vary). Before charging the system, make sure that the refrigerant lines from the gauge manifold to the refrigerant supply bottle have been evacuated or purged.
Page 194: Charging Procedure For T-Spectrum & Ut Units
Charging procedure for T-Spectrum & UT units. Prior to charging, it is necessary to make a rough estimate of the charge requirements of the unit. The correct quantity of refrigerant required for an installation will depend on the type of unit, the type and number of remote evaporators used, and the refrigerant line route between the condenser area and the remote evaporators.
Page 195: Refrigerant Gauge Removal
3. Make a quick calculation of the approximate required refrigerant charge. Refer to the table above for initial charge calculations. 4. Liquid charge the unit as per Thermo King procedures with the exact calculated amount from step 3, utilising weighing scales to ensure accurate measurement.
Page 196: Refrigerant Leaks
REFRIGERANT LEAKS Use a reliable leak detector (e.g., electronic detector) to leak test the refrigeration system. Inspect for signs of oil leakage which is the first sign of a leak in the refrigeration system. It is normal for compressor shaft seals to have a slightly oily film. REFRIGERANT CHARGE Testing the Refrigerant Charge with an Empty Box (Controlled Check) If the unit has an insufficient charge of refrigerant, the evaporator will be “starved”...
Page 197: Refrigeration System Checks
Compressor Oil Sight Glass Location Compressor To check compressor oil level with 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 pressure for 15 minutes or more.
Page 198: Low Side Pump Down
NOTE: If the low side will not pump down into a vacuum, the hot gas solenoid, or the receiver tank pressure check valve may be stuck open. See the individual component tests for more information. 6. Continue pumping down the low side until it reaches a 25 in. Hg vacuum (-85 kPa), then turn the unit Off. 7.
Page 199 Compressor Oil Thermo King Corporation has chosen to use a compressor oil called Polyol Ester (POE)—also called ester based oil. POE oil is compatible with R-404A/R-452A and can be used in low temperature applications. This oil is available from service parts (P/N 203-513).
Page 200: Refrigeration System Component Locations
Gauge manifold sets that show the correct pressure-temperature relationship should be used. Gauge manifolds and manifold hoses used with other Thermo King refrigerants maybe used but extreme care should be taken to prevent contamination of the R-404A/R-452A systems with other refrigerants. Purge manifold and hoses with dry nitrogen before using. Never use equipment that may be contaminated with automotive type Polyalkylene Glycol (PAG) oils.
Page 201 Condenser Refrigeration Component Locations T-Series (Except T-500R/T-Dairy) Refrigeration Maintenance 10-17...
Page 202 16. Condenser/Radiator Coil Hot Gas Solenoid (HGS) 17. Accumulator Receiver Tank Pressure Check Valve Discharge Service Valve Dehydrator (Filter-Drier) Discharge Strainer 10. High Pressure Relief Valve Legend for “Condenser Refrigeration Component Locations T-Series (Except T-500R/T-Dairy)” on page 10-17 Refrigeration Maintenance 10-18...
Page 203 Condenser Refrigeration Component Locations T-500R/T-Dairy Refrigeration Maintenance 10-19...
Page 204 16. Condenser/Radiator Coil Dehydrator (Filter-Drier) 17. Purge Valve (PV) High Pressure Relief Valve 18. Accumulator 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 Refrigeration Maintenance 10-20...
Page 205 Condenser Refrigeration Component Locations UT-Series (Multi-Temp Shown, Single Temp Similar) Refrigeration Maintenance 10-21...
Page 206: Accumulator Replacement
Mechanical Throttling Valve High Pressure Cutout Switch (HPCO) Suction Service Valve 12. Condenser Check Valve Compressor 13. Liquid Injection Solenoid (LIS) Purge Check Valve (PCV) 14. Receiver Tank Sight Glass Hot Gas Bypass Solenoid (HGBS) 15. High Pressure Relief Valve Receiver Tank Pressure Solenoid (RTPS) 16.
Page 207: Reciprocating Compressor Replacement (T-Series)
RECIPROCATING COMPRESSOR REPLACEMENT (T-SERIES) Removal 1. Perform a “Low Side Pump Down” to prepare unit to perform service. 2. Front seat the discharge and suction service valves. 3. Open both service manifold hand valves to bleed the pressure in the head into the compressor crankcase. 4.
Page 208: Checking Compressor Oil Pressure
1. Oil Pressure Access Port 2. Inlet Fitting 3. Outlet Fitting Compressor Oil Filter Use the following procedure to change the compressor oil filter. 1. Pump down the low side and equalize the pressure to slightly positive. 2. Front seat the discharge and suction service valves. 3.
Page 209: Tko Scroll Compressor (Ut-Series)
PRIMING NEW COMPRESSOR INSTALLATIONS Thermo King remanufactured compressors have had a special break in process to assure that the oil pump is primed, functioning, and broken in. The following procedure is recommended, but not required for factory-remanufactured compressors.
Page 210: Scroll Compressor Shaft Seal Replacement
Installation 1. Lift the compressor into the unit and install the mounting bolts. 2. Clean tubes for soldering. Solder discharge line to compressor. 3. Install the suction valve using a new gasket soaked in refrigerant oil. 4. Solder the liquid injection tube to injection fitting. NOTE: Use a heat sink or wrap the injection fitting with wet rags before soldering the connection to prevent damage to the O-ring in the fitting.
Page 211: Scroll Compressor Oil Filter Replacement
8. Make sure the spacer is correctly located on the shaft flat. Slide new seal member onto shaft without touching the bronze surface with fingers. 9. Torque set screws to 4.8 to 5.4 Nm. 10. Remove stationary member, O-ring and dust shield from seal cover. 11.
Page 212: Scroll Compressor High Temperature Switch Replacement
12. Replace SAE plug in compressor body. Torque mounting screws to 11 to 12.5 Nm. 13. Add compressor oil through the fitting at the oil filter cover. Add the same amount of oil that was removed. If the compressor oil removed from the compressor was NOT measured and step 1 of the compressor removal procedure was followed to return as much oil as possible to the compressor, then add 1.2 litres of compressor oil.
Page 213: Condenser Check Valve Test (Single Temperature Units Only)
12. Back seat the receiver tank 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.
Page 214: Condenser Check Valve, Purge Check Valve, And Receiver Tank Pressure Solenoid Leak Test (Multi-Temp Units Only)
CONDENSER CHECK VALVE, PURGE CHECK VALVE, AND RECEIVER TANK PRESSURE SOLENOID LEAK TEST (MULTI-TEMP UNITS ONLY) The condenser check valve and the purge check valve prevent refrigerant from moving into the condenser when one or more zones are in heat. A unit with a leaking condenser check valve or purge check valve will have good heating capacity when a zone first goes into the heat mode.
Page 215: Condenser Inlet Solenoid (Cis) Test
12. Back seat the suction service valve and perform a “Refrigerant Gauge Removal” procedure. For T-500R/T-Dairy - replace points 7 thru’ 9 above with the following: Use “Remote Watch” - Relay Test - Condenser Inlet Solenoid (or jumper wires) to energize the CIS. Refer to the appropriate Microprocessor Diagnostic Manual for specific information about “Remote Watch”.
Page 216: Dehydrator (Filter-Drier) Replacement
Installation 1. Clean the tubes for soldering. 2. Place the coil in the unit and install the mounting hardware. 3. Solder the hot gas inlet and liquid outlet refrigerant line connections. IMPORTANT: Micro-channel coils are made of aluminum but have copper stub tubes at the inlet and outlet connections. Make sure to use a heat sink on the copper stub tubes to prevent damage to the brazed connections (and the aluminum) that attached the copper stub tubes to the aluminum micro-channel coil.
Page 217: Discharge Pressure Transducer Testing
Installation 1. Clean the tubes for soldering. 2. Place the new DPR in the same position from which the old one was removed. 3. Use a heat sink or wrap the DPR with a wet rag to prevent damage and solder the tubing connections. 4.
Page 218: Discharge Strainer Replacement
DISCHARGE STRAINER REPLACEMENT Removal 1. Recover the refrigerant charge. 2. Remove the discharge strainer mounting clamp. 3. Unsolder the refrigeration lines from the discharge strainer and remove the discharge strainer from the unit. Installation 1. Clean the tubes for soldering. 2.
Page 219 WARNING: If the ETV is stuck in the closed position, much of the refrigerant charge may be trapped in the evaporator. If you hear refrigerant begin to flow through the valve when the stepper motor and piston assembly are loosened, unscrew the Old Style ETV stepper motor and piston assembly no more than four turns, or unscrew the four screws on New Style ETV stepper motor no more than four turns each, and check the suction (low side) pressure on the gauge manifold.
Page 220 ARA2501 0.3 in. (8 mm) Bottom Edge of Brass Nut/Piston Housing Bottom Edge of Piston Stepper Motor and Piston Assembly with Piston in Fully Open Position 2. Old Style ETV Only: a. Lubricate the piston and threads on the new stepper motor and piston assembly with refrigeration oil. b.
Page 221 b.Place stepper motor and piston assembly into the valve body and make sure the arrowhead marks on them are aligned as shown below. ARA2504 Align Arrowhead Marks c. Install the four screws and torque them to 4.43 ± 0.37 fT-lb (6.0 ± 0.5 N•m). 4.
Page 222 3. Push the piston into the piston nut until the end of the rectangular shaft is about even with the top of the piston nut. Position End of Rectangular Shaft about Even with Top of Piston Nut Push Piston into Piston Nut 4.
Page 223: Evaporator Coil Replacement
EVAPORATOR COIL REPLACEMENT Removal 1. Recover the refrigerant charge. 2. Remove the evaporator top panel. 3. Unsolder the hot gas line and the line to the expansion valve from the distributor. 4. Unsolder the suction line from the evaporator coil. 5.
Page 224: Heat Exchanger Replacement
Top View Completely Wrap Bulb with Tape 5. Pressurize the low side and check for leaks. 6. If no leaks are found, replace the liquid line drier then evacuate the low side. 7. Open the refrigeration valves and place the unit in operation. 8.
Page 225: High Pressure Cutout Switch (Hpco) Test
HIGH PRESSURE CUTOUT SWITCH (HPCO) TEST The HPCO is located on the compressor discharge manifold. If the discharge pressure rises above 470 ± 7 psig (3241 ± 48 kPa), the switch opens the HPCO circuit the to run relay and stops the unit. To test the switch, rework a gauge manifold per the following illustration.
Page 226: High Pressure Relief Valve Replacement
Installation 1. Apply a refrigerant Loctite to the threads of the HPCO. 2. Install and tighten the HPCO and reconnect the wires. 3. Pressurize the compressor and test for leaks. 4. If no leaks are found, back seat the refrigeration service valves and place the unit in operation. Check the refrigerant charge. 5.
Page 227: Hot Gas Solenoid (Hgs) Test
11. Back seat the receiver tank outlet valve and the suction service valve. Perform a “Refrigerant Gauge Removal” procedure. Note: For T-500R/T-Dairy, instead of points 8 thru’ 11 above, please use the following: Use “Remote Watch” - Relay Test - Hot Gas Solenoid Test (or jumper wires) to momentarily (for approximately 1 second) energize the HGS.
Page 228: Liquid Injection Solenoid (Lis) Test
Installation A heat sink must be used on the in-line check valve when it is being soldered in place to prevent damage to the neoprene seal. 1. Clean the tubes for soldering. 2. Place the check valve in position. The arrow on the valve body indicates the direction of refrigerant flow through the valve. 3.
Page 229: Liquid Line Solenoid (Lls) And Liquid Return Check Valve Test (Multi-Temp Units Only)
12. Back seat the suction service valve. Perform a “Refrigerant Gauge Removal” procedure. LOW PRESSURE CUTOUT SWITCH (LPCO) TEST (T-500R/T-DAIRY ONLY) The LPCO is used in these units starting in June 2012. If the suction pressure drops to 13 ± 3 in. Hg of vacuum (-44 ± 10 kPa), the switch opens the LPCO/HPCO circuit to stop the unit.
Page 230: Purge Valve (Pv) Test
PURGE VALVE (PV) TEST 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. A low loss fitting must be used on the hose connected to the suction access port.
Page 231: Receiver Tank Replacement
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). CAUTION: Do not run scroll compressor in a vacuum for more than 1 minute. 4.
Page 232: Suction Line Check Valve Test (Multi-Temp Units Only)
Installation 1. Clean the tubes for soldering. 2. Remove the coil and place the valve in position. 3. Install the valve mounting hardware if used. 4. Solder the inlet and outlet connections. After the valve cools, install the coil. CAUTION: Use a heat sink to prevent damage. 5.
Page 233: Suction Pressure Regulator (Spr) Test
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 low side pressure should not rise. It it does, there could be a leak through one (or more) of following components: hot gas solenoids, purge valve, or hot gas bypass solenoid.
Page 234: Suction Pressure Transducer Testing (Ut-Series And T-Series Except T-500R/T-Dairy)
SUCTION PRESSURE TRANSDUCER TESTING (UT-SERIES AND T-SERIES EXCEPT T-500R/T-DAIRY) The suction pressure transducer is located on the suction adapter on the compressor. It supplies pressure information to the SR-3 Microprocessor Control System. Alarm Code 87 (Check Suction Pressure Sensor) indicates a possible problem with the pressing suction pressure transducer.
Page 235 Screw—Plate And Flatwasher 10. Test Port—Schrader Valve Schrader Valve And Cap (Location May Vary) Gasket—piston Housing Plate—Bellows End 12. Piston Gasket—End Plate 13. Conformance Spring—Piston Shim—Adjusting 14. Castle Nut—Adjusting Spring—Bellows 15. Pin—Cotter Bellows and Shaft—assembly 16. Housing—Piston O-ring 17. O-ring—Valve to Compressor Housing 18.
Page 236 8. Inspect all the parts (replace if excess wear is found). Piston and cap for wear (scuff marks) Body for stripped threads Bellows end cap for damage in pilot hole NOTE: Bellows is normally replaced. Inspect for Wear Throttle Valve Piston Inspect for Damage Throttle Valve Housing 9.
Page 237 Tighten Castle Nut to Bottom—Then Back Off 1 Turn Only. Insert Cotter Pin. Throttle Valve Piston Assembly 7. Oil the gasket and install the end cap. 8. Throttling valve will have to be recalibrated on operating unit. (Refer to “Specifications” chapter for setting.) 9.
Page 238 Refrigeration Maintenance 10-54...
Page 239: 11 Clutch Maintenance
11 Clutch Maintenance Centrifugal Clutch ..........11-2 Clutch Maintenance .
Page 240: Centrifugal Clutch
CENTRIFUGAL CLUTCH The centrifugal clutch has three belt grooves and its engagement speed is 600 ± 100 RPM. AGA127 Front View and Cross Section Clutch Maintenance 11-2...
Page 241 aea558 (3 belt grooves) Screw Grease Seal Washer Roller Bearing Inner Race Snap-Ring Pulley Housing Ball Bearing Elastic Stop Nuts (6) Large & Small Spacers Connector Link (6) Rolling Bearing Spring (6) Lockwasher (12) Shoe Assembly (3) Bushing (6) Screws (6) Centrifugal Clutch Clutch Maintenance 11-3...
Page 242: Clutch Maintenance
CLUTCH MAINTENANCE Using an inspection mirror, inspect the clutch every 1000 hours of operation or yearly, whichever occurs first. If shoe wear is uneven on different shoes, remove the clutch, clean the shoes and drum, regrease bearings or replace if they are worn. Inspect anchor bushings, shoe lining and springs for wear and replace if necessary.
Page 243 Bearing Removal NOTE: Press tool should be slightly smaller than hub bore. NOTE: Make sure the center of the hub is supported and not the outer rim of the hub, when pressing bearing out. 7. Press bushings out of hub. Bushing Removal 8.
Page 244 Bushing Insertion *DO NOT USE SOAP OR OIL TO LUBRICATE BUSHING PRIOR TO ASSEMBLY. 2. Remove the inner race from the roller bearing, apply a small amount of Loctite (see Tool Catalog) to race I.D. and press onto the housing shaft, seating against the step. CAUTION: During all bearing assembly, care must be taken to prevent Loctite from entering bearing.
Page 245 Roller Bearing, Pack with Mobil (see Tool Catalog) grease Pack These Areas with Mobil (see Tool Catalog) grease at Assembly HEX HD Cap Screw (6X), 1-4/28 UNF X 1.75 Long. Torque 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.
Page 246 Clutch Maintenance 11-8...
Page 247: 12 Structural Maintenance
12 Structural Maintenance Unit and Engine Mounting Bolts........12-2 Unit Inspection .
Page 248: Unit And Engine Mounting Bolts
UNIT AND ENGINE MOUNTING BOLTS Periodically check and tighten all unit and engine mounting bolts. T-Series:Torque the unit mounting bolts to 60 fT-lb (81 N•m). Torque the engine mounting bolts to 64 fT-lb (87 N•m). UT-Series: Torque the condenser section mounting bolts to 130-170 fT-lb (176-230 N•m). Torque the evaporating mounting bolts to 60 fT-lb (81 N•m).
Page 249 Coil Before Cleaning => Coil after Wiping Right Hand Side with Cloth Source Angle for Cleaning with Air or Water Structural Maintenance 12-3...
Page 250: Fan Location
FAN LOCATION When mounting the fan and hub assembly on the fanshaft, position the assembly in the orifice as follows for proper fan performance: • For the ten-blade condenser fan, position the fan with 50 percent of the blade width to the air discharge side. NOTE:One evaporator fan rotates clockwise (CW) and one evaporator fan rotates counterclockwise (CCW—on engine side of unit, viewed from inside the box).
Page 251: Fanshaft Assembly
Must Contact Full Width of Blade Figure 3: Defrost Damper Adjustment FANSHAFT ASSEMBLY The unit is equipped with one-piece fanshaft assemblies that contain tapered roller bearings in a sealed oil reservoir. A fanshaft assembly does not require any maintenance. There is a level plug and a fill plug, but they are not normally utilized except after removal and repair of the fanshaft assembly.
Page 252: Disassembly
Roller Bearing 12. Splash Guard Tube Fan Shaft Assembly Disassembly 1. Remove the fanshaft assembly from the unit. Remove both oil plugs and drain the oil from the housing. 2. After draining the oil from the housing, remove the four retaining bolts from the bearing retainer cap. Removing Bearing Retainer Bolts 3.
Page 253 Removing Oil Seal 5. Check the condition of the vent. If it is loose or damaged, it must be repaired or replaced. 6. After all the parts are cleaned, inspect the bearings and bearing races for wear or damage. 7. To replace the bearings, first remove the roll pin that is in the center of the shaft. Removing Roll Pin 8.
Page 254: Reassembly
Reassembly 1. Install the new bearings on the shaft with a pipe in the same way they were removed. Installing Bearings 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.
Page 255 Installing Oil Seal 4. Place the shaft in the housing. Install a new seal in the retainer cap. Use the original shims and replace the o-ring if necessary. NOTE: Tape shaft holes or keyway to prevent seal damage. Shims and O-ring 5.
Page 256 Checking End Play IDLER PULLEY Seal Installation — UT-Series NOTE: The idler pulley uses seal assembly P/N 77-1575. See diagram below. Installation Procedure To perform a seal change the following procedure is recommended: 1. Remove idler pulley from the unit. 2.
Page 257 afk07r Idler Pulley Assembly—UT-Series Spindle Retaining (Snap) Ring Seal Side of Bearing (2) Bearings (2) Bearing Spacer Fill space 1/2 Full of Grease (Shell Alvania EP2) Wave Washer (Prevents outer race from spinning) Pulley Spindle Collar Mounting Bolt Structural Maintenance 12-11...
Page 258 Structural Maintenance 12-12...
Page 259: 13 Mechanical Diagnosis
13 Mechanical Diagnosis Condition Possible Cause Remedy Engine will not crank Electrical problem Check and repair electrical system Defective starter solenoid Replace solenoid Defective starter Repair starter Water in cylinders Check for hydrostatic lock. Remove injectors and turn engine slowly Starter motor turns but engine does Starter clutch defective Replace...
Page 260 Condition Possible Cause Remedy Engine stops after starting Air in injection pump Bleed fuel system Fuel filter obstructed Replace filter element High head pressure Eliminate cause of high head pressure High engine coolant temperature Add coolant. Check for leaks Low oil pressure Add oil.
Page 261 Condition Possible Cause Remedy Engine does not reach full power Air or dirt in fuel system Repair Fuel line leaks Tighten connections of fuel lines. If necessary, replace damaged lines Speed adjustment wrong Adjust speed Electric fuel pump does not run Check voltage.
Page 262 Condition Possible Cause Remedy Engine runs hot Engine coolant is low Add coolant slowly while engine is in operation Dirty or plugged radiator Clean radiator Cooling system heavily scaled Clean cooling system Water pump leaks Repair or replace water pump Worn or loose belt Replace belt or adjust Cylinder head gasket leaks (bubbles...
Page 263 Condition Possible Cause Remedy Battery is not recharging Loose alternator belt Tighten belt Loose connections in electrical Check all electrical connections and system 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 Mechanical Diagnosis...
Page 264 Mechanical Diagnosis 13-6...
Page 265: 14 Electric Standby Diagnosis
14 Electric Standby Diagnosis...
Page 266 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/ Check for short circuit and replace T-Dairy) fuse Faulty LPCO (T-500R/T-Dairy) Check LPCO Faulty HPCO...
Page 267 Condition Possible Cause Remedy Low line voltage or no voltage on Bring voltage up to within 10% of one leg motor rating Contact Chatter Low battery voltage Check voltage condition. Check momentary voltage dip during starting—low voltage prevents magnet sealing Defective or incorrect coil Replace coil Poor contact in control circuit...
Page 268 Electric Standby Diagnosis 14-4...
Page 269: Refrigeration System Diagnosis
15 Refrigeration System Diagnosis...
Page 270 Refrigeration Diagnosis Possible Causes • • • • Overcharge of refrigerant • • • • • • Shortage of refrigerant • • • • • • No refrigerant • Air through condenser too hot (ambient) • Air flow through condenser restricted •...
Page 271 • • • Faulty Suction Pressure Regulator (SPR) • • • • • • • Faulty Purge Valve (PV) (T-500R/T-Dairy) • Faulty Condenser Check Valve • • • • • • Faulty Receiver Tank Pressure Check Valve Refrigeration System Diagnosis...
Page 272 Refrigeration System Diagnosis 15-4...
Page 273 16 Remote Evaporators Unit Description ........... 16-2 Electrical Maintenance .
Page 274: Unit Description
UNIT DESCRIPTION The SPECTRUM SR-2/3 multi-temperature refrigeration system provides heavy duty temperature control for multiple compartment trucks. The system provides direct expansion cooling in all cargo compartments. Heat and defrost is provided in all compartments by circulating hot refrigerant gas through the remote evaporators. The remote evaporators are controlled by the SR-2/3 Multi-Temp Control System directly and through the expansion module.
Page 275 Serial Number Location Unit: Nameplate on the end of the unit frame. Nameplate on End of Unit Frame UTSE Remote Evaporator Serial Number Location AJA985 Nameplate on Right End of Unit Frame SPECTRUM Remote Evaporator Serial Number Location Remote Evaporators 16-3...
Page 276 Evaporator Coil Sensor Clamp 15. Air Switch Probe Sealing Strip Evaporator Harness 16. Air Probe Hose Fan Plenum 10. Fuse Connector 17. Ground Screw Sealing Strip Fuse - 20A 18. Terminal Board Evaporator Fan 12. Fuse Cover 19. Drain Pan Sensor (Ungraded) 13.
Page 277 Coil Temperature Sensor (Ungraded) 6. Variable Blower (12 V) Terminal Board Markstrip Hot Gas Solenoid (HGS) Blower Housing 12. Drain Heater (Resistance Wire) Liquid Line Solenoid (LLS) Blower Cover 13. Return Air Sensor (Graded) Suction Line Solenoid (SLS( Terminal Board Bracket 14.
Page 278 AJA984 Figure 6: SPECTRUM Remote Evaporator - Front View (S-3 Shown, S-2 Similar) AJA985 Figure 7: SPECTRUM Remote Evaporator - Back View (S-3 Shown, S-2 Similar) Remote Evaporators 16-6...
Page 279: Electrical Maintenance
ELECTRICAL MAINTENANCE SR-2/3 Multi-Temp Microprocessor Controlled Components Refer to the Truck SR-2/3 Multi-Temp Diagnostic Manual TK 54293 for information about maintenance of the microprocessor controlled components. Unit Wiring Inspect the unit wiring and wire harnesses during scheduled maintenance inspections for loose, chaffed or broken wires to protect against unit malfunction due to opens or shorts.
Page 280 Remote Evaporators 16-8...
Page 281: Wiring Diagrams And Wiring Schematics
17 Wiring Diagrams and Wiring Schematics The wiring diagrams and schematics indexed here can be found in the ESA Sharepoint Infocentral. Wiring 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:...
Page 282 Wiring Diagrams and Wiring Schematics 17-2...

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Thermo King T-500R Maintenance Manual

Table of Contents

3 Specifications

4 Maintenance Inspection Schedule

5 Unit Description

6 Operating Instructions Premium Hmi

7 Operating Instructions Standard Hmi

8 Electrical Maintenance

9 Engine Maintenance

10 Refrigeration Maintenance

12 Structural Maintenance

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Summary of Contents for Thermo King T-500R