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Thermo King RD-II SR 50 380-460/3/50-6 User Manual

Thermo King RD-II SR 50 380-460/3/50-6
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RD-II SR
TK 41131-1-MM (Rev. 04/03)
Copyright
©
1996 Thermo King Corp., Minneapolis, MN, U.S.A.
Printed in U.S.A.

Table of Contents

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Thermo King RD-II SR 50 380-460/3/50-6 Specifications

General IconGeneral
BrandThermo King
ModelRD-II SR 50 380-460/3/50-6
CategoryRefrigerator
LanguageEnglish

Summary

Safety Precautions

General Practices

Essential safety rules for unit operation and maintenance.

Auto Start/Stop Procedures

Safety information regarding the unit's automatic start and stop functions.

Refrigerant Handling and Safety

Guidelines for safe handling of refrigerants and environmental protection.

First Aid for Refrigerant Exposure

Immediate medical assistance procedures for refrigerant-related injuries.

Refrigeration Oil Handling and Safety

Safe practices for handling refrigeration oil and related first aid.

Electrical Hazards and High Voltage Safety

Precautions and first aid for high voltage electrical hazards.

Low Voltage and Microprocessor Safety

Safety considerations for low voltage circuits and microprocessor handling.

Specifications

Engine Specifications and Belt Tension

Key engine data and procedures for setting belt tension.

Refrigerant System Specifications

Technical data for R-134a and R-404A refrigeration systems.

Engine Clutch and Electrical System Specs

Details on the engine clutch and electrical control system components.

Electrical Components and Standby Power

Details on electrical parts, standby operation, and power requirements.

Maintenance Inspection Schedule

Engine Maintenance Checks

Scheduled inspections and service for the engine system.

Electrical System Checks

Scheduled inspections and service for the electrical system.

Refrigeration System Checks

Scheduled inspections and service for the refrigeration system.

Structural Component Checks

Scheduled inspections for structural integrity and parts.

Unit Description

RD-II SR System Overview

General description of the RD-II SR unit and its capabilities.

Thermo King X426 Compressor Details

Information about the X426 compressor used in the RD-II SR unit.

Unit Instruments and Displays

Explanation of the unit's instruments and optional remote indicator lights.

Unit Protection, Operation, and Modes

Details on system protection, operation, self-checks, and operating modes.

Unit Restart, Loading, and Post-Load Procedures

Steps for restarting, loading, and post-load checks.

Microprocessor Control System (µP-T)

General System Description

Overview of the µP-T microprocessor control system.

µP-T Control System Components

Key components of the µP-T control system.

Microprocessor Power Switch Operation

Function and location of the microprocessor power switch.

Optional Electric Standby Features

Details on the electric standby option for Model 50 units.

Model 50 Standard and Optional Features

Features available on Model 50 units, standard and optional.

Remote Control Panel Features

Remote Control Panel Keypad and Buttons

Description of the keypad, its keys, and their functions.

Remote Control Panel Display and Icons

Explanation of the display layout, indicators, and status icons.

Standard Display and Changing Setpoint

How to view the standard display and adjust the unit's setpoint.

Selecting Operating Modes

Procedures for choosing between CYCLE-SENTRY and Continuous modes.

Engine Start, Manual Defrost, and Software Revision

Starting the engine, manual defrost, and checking software version.

Viewing Screens, Locking Display, Alarms, and Self-Check

Navigating prompts, locking display, managing alarms, and performing unit self-checks.

Electrical Maintenance

Service Precautions

General safety precautions for electrical maintenance tasks.

Alternator and Charging System

Details on alternators, voltage output, and charging system diagnostics.

Battery, Wiring, and Contacts

Maintenance for battery, unit wiring, and electrical contacts.

Charging System, Preheat Buzzer, and RPM Sensor

Information on the 12 VDC charging system, preheat buzzer, and RPM sensor.

RPM Sensor Testing, Glow Plugs, and Fan Rotation

Testing RPM sensor, servicing glow plugs, and checking fan rotation.

Defrost Air Switch Checkout and Adjustment

Procedures for checking and adjusting the defrost air switch.

Air Switch and Heating System Operation

Maintenance for air switch and TherMax™ heating system operation.

Engine Maintenance

Lubrication System, Oil Filter, Crankcase Breather, and Air Cleaner

Maintenance for oil systems, filters, breather, and air cleaner.

Engine Cooling System and Antifreeze Procedures

Details on the cooling system, antifreeze checks, and replacement procedures.

Fuel System, Fuel Filter Replacement, and Electric Fuel Pump

Details on the fuel system, filter replacement, and electric fuel pump.

Injection Pump Adjustments and Timing

Procedures for adjusting and timing the diesel engine's injection pump.

Engine Valve Clearance and Fuel Limit Screw

Procedures for adjusting valve clearance and information on the fuel limit screw.

Engine Mounts and Idler Assembly

Details on engine mounting system and idler assembly components.

Belt Tension Adjustments and Fuel Solenoid

Procedures for adjusting belt tensions and servicing the fuel solenoid.

TK 3.95 Engine Operation and Fuel Solenoid Diagnostics

Operation of the TK 3.95 engine and troubleshooting the fuel solenoid.

Refrigeration Maintenance

System Evacuation Overview and Equipment Setup

Introduction to evacuation, and procedures for setting up and testing equipment.

Unit Evacuation and Unit Charging

Procedures for evacuating the refrigeration system and charging it with refrigerant.

Hose Removal, Leak Testing, and Refrigerant Charge Testing

Procedures for removing hoses, leak detection, and testing refrigerant charge.

Compressor Oil Check, High Pressure Cutout, and Compressor Pump Down

Procedures for checking compressor oil, testing high pressure cutout, and pump down.

Three-Way Valve Operations and Repair

Information on three-way valve operations and repair procedures.

Condenser/Radiator Coil, Liquid Line Check Valve, and Dehydrator Maintenance

Procedures for servicing coils, check valves, and dehydrators.

Evaporator Coil and Expansion Valve Assembly

Procedures for removing and installing evaporator coils and expansion valve assemblies.

Heat Exchanger Removal and In-line Screen Cleaning

Procedures for removing the heat exchanger and cleaning the in-line screen.

High Pressure Cutout Switch, Relief Valve, and Pilot Solenoid

Procedures for removing and installing pressure cutout switches, relief valves, and pilot solenoids.

Pressure Regulator Valve, Receiver Tank, and Three-Way Valve Bypass Check Valve Repair

Procedures for servicing pressure regulator valves, receiver tanks, and three-way valve bypass check valves.

Three-Way Valve Repair

Three-Way Valve Repair Procedures

Detailed procedures for repairing the three-way valve.

Structural Maintenance

Unit and Engine Mounting Bolts

Procedures for checking and tightening unit and engine mounting bolts.

Unit Inspection

Guidelines for inspecting the unit for damage or loose components.

Evaporator and Condenser Coil Cleaning

Methods for cleaning evaporator and condenser coils.

Fan Location and Mounting

Proper positioning of the fan and hub assembly for optimal performance.

Defrost Damper Checks and Adjustments

Procedures for checking and adjusting the defrost damper for proper operation.

Jackshaft Assembly Disassembly and Reassembly

Step-by-step instructions for disassembling and reassembling the jackshaft assembly.

Fanshaft Assembly Overhaul

Procedures for overhauling the fanshaft assembly, including disassembly and reassembly.

Checking End Play

Method for checking and adjusting end play in assemblies.

RD-II SR Idler Pulley Seal Installation

Step-by-step procedure for installing the RD-II SR idler pulley seal.

Mechanical Diagnosis

Unit Switch ON - Nothing Happens

Troubleshooting for when the unit switch is ON but no response.

Unit Switch ON - Lights On, Engine No Crank

Troubleshooting for when indicator lights are on but the engine does not crank.

Engine Cranks but Fails to Start

Troubleshooting steps when the engine cranks but fails to start.

Engine Stops After Starting

Troubleshooting for when the engine stops after initial starting.

Engine Does Not Reach Full Power or Emits Smoke

Troubleshooting for when the engine lacks power or emits smoke.

Engine Knocks, Runs Hot, Low Oil Pressure, or High Oil Consumption

Troubleshooting for engine knocking, overheating, low oil pressure, or high oil consumption.

Smoke Conditions and Battery Not Recharging

Troubleshooting for smoke emissions and battery recharging issues.

Electric Standby (Optional) Diagnosis

Unit Switch ON - Indicator Lights Do Not Come On

Troubleshooting for no power or indicator lights on the electric standby system.

Unit Switch ON - Lights On, Motor Does Not Run

Troubleshooting for when the electric motor fails to run despite indicator lights.

Electric Motor Hums But Does Not Run

Troubleshooting for electric motors that hum but do not operate.

Contact Chatter, Heater Issues, and Battery Recharging

Troubleshooting for contact issues, heater problems, and battery recharging in standby mode.

Refrigeration Diagnosis

Symptom and Cause Cross-Reference

A diagnostic table linking symptoms to possible causes for refrigeration issues.

Refrigeration Symptom Analysis

Further analysis of refrigeration symptoms and their potential causes.

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