The provided document is a maintenance manual for the Thermo King UT-1000R, UT-1400R & UT-R EXTREME Self Powered Truck Edition Single Temperature Units.
Device Description
The Thermo King UT-R Series units are microprocessor-based transport temperature control systems designed for truck applications. These two-piece refrigeration units feature a condenser unit mounted underneath the truck and an evaporator unit inside the truck body. The system utilizes an SR-3 Truck HMI microcontroller to manage various system functions. Engine power is supplied by a TK376U diesel engine, with a belt drive system transferring energy to the compressor, unit fans, and alternator. A centrifugal clutch on the diesel engine isolates the engine during electric standby operation, engaging fully at 600 ± 100 RPM on engine operation.
Important Technical Specifications
Engine:
- Model: TK376U
- Fuel Type: Diesel Fuel (conforms to EN 590, No. 2 for normal conditions, No. 1 for cold weather).
- Oil Capacity: 11.6 quarts (11.0 liters) for crankcase and oil filter; 12.8 quarts (12.1 liters) with bypass oil filter. Fill to full mark on dipstick.
- Oil Type: API Classification CJ-4 or CK-4, ACEA Rating E6. API Classification FA-4 oils are not approved.
- Oil Viscosity:
- 14 F to 122 F (-10 C to 50 C): SAE 15W-40 (Synthetic)
- 5 to 104 F (-15 C to 40 C): SAE 15W-40
- 5 to 104 F (-15 C to 40 C): SAE 10W-30 (Synthetic or Synthetic Blend)
- -13 to 104 F (-25 C to 40 C): SAE 10W-40
- -13 to 86 F (-25 C to 30 C): SAE 10W-30
- -22 to 122 F (-30 C to 50 C): SAE 5W-40 (Synthetic)
- Below -22 F (-30 C): SAE 0W-30 (Synthetic)
- Engine RPM:
- UT-1000R Low Speed Operation: 1500 ± 50 RPM
- UT-1000R High Speed Operation: 2050 ± 50 RPM
- UT-1400R/UT-R EXTREME Low Speed Operation: 1500 ± 50 RPM
- UT-1400R/UT-R EXTREME High Speed Operation: 2150 ± 50 RPM
- Engine Oil Pressure: 20 to 50 psig (138 to 345 kPa) in low speed; 40 to 60 psig (276 to 414 kPa) in high speed.
- Valve Clearance: Intake and Exhaust: 0.006 to 0.010 in. (0.15 to 0.25 mm) at 70 F (21 C).
- Fuel Injection Timing: 16 ± 1 degrees BTDC.
- Fuel Injection Nozzle Opening Pressure: 12.3 MPa + 0.98 MPa (1784 psig +142 psig) - 0.
- Low Oil Pressure Switch/Sensor: 10 ± 2 psig (69 ± 14 kPa) - shutdown.
- High Coolant Temperature Sensor: 220 ± 5 F (104 ± 3 C) - shutdown.
- Engine Thermostat: 160 F (71 C).
- Engine Coolant Type: ELC (Extended Life Coolant), "RED" 50/50 concentration. Approved equivalents include Chevron Dex-Cool, Texaco ELC, Havoline Dex-Cool®, Shell Dexcool®, Caterpillar ELC, and Detroit Diesel POWERCOOL® Plus.
- Coolant Expansion Tank Cap Pressure: 7 psig (48 kPa).
Engine Clutch:
- Engagement: 600 ± 100 RPM.
- Dynamic Torque: 66 ft-lb (89.5 N•m) minimum @ 1600 RPM.
Belt Tension (TK Gauge P/N 2040427):
- Engine/Electric Motor: New Belt: 62 Hz, Field Reset: 53 Hz.
- Compressor/Electric Motor: New Belt: 109 Hz, Field Reset: 92 Hz.
Refrigeration System:
- Compressor Model: Thermo King X430P®.
- Refrigerant Charge:
- All Except UTR EXTREME: Approximately 6 lb (2.7 kg) R-452A.
- UTR EXTREME: Approximately 6 lb (2.7 kg) R-134A.
- Compressor Oil Charge: 3.9 liters/litres (4.1 quarts).
- Compressor Oil Type: Polyol Ester.
- High Pressure Cutout Switch: Open: 470 ± 7 psig (3241 ± 48 kPa), Close: 375 ± 38 psig (2586 ± 262 kPa).
Electrical Control System:
- Control System Voltage: 12.5 Vdc (nominal).
- Battery: 12 volt, 75 AHrs, 640 Cold Cranking Amps at 0 F (-18 C) (ENCCA).
- Battery Charging System:
- UT-1000R: 12 volt, 65 amp, brush type, Thermo King Alternator.
- UT-1400R/UT-R EXTREME: 12 volt, 120 amp, brush type, Thermo King Alternator.
- Voltage Regulator Setting: 13.8 to 14.4 volts @ 77 F (25 C).
Fuses:
- F2 (15A): Power to On/Off Switch.
- F3 (40A): Fuel Sol Pull-In/Starter Circuit.
- F4 (None/2A): No Fuse for Bosch/Thermo King Alternators; 2A Fuse for Prestolite Alternators.
- F5 (40A): Preheat Circuit.
- F6 (15A): Power to Damper and High Speed Solenoids.
- F7 (2A): Switch On Power to CAN Bus.
- F8 (5A): 2A power to CAN Connector J12.
- F9 (5A): 2A power to CAN Connector J14.
- F10 (10A): Power to On Relay (Right Position); Bypass HMI Control of Power (Left Position).
- F11 (10A): Power to Drain Tube Heaters in Remote Evaporators.
- F12 (5A): 2A power to CAN Connector J13.
- F13 (2A): Power to Remote Lights.
- F15 (P/S): On/Off Relay (Polyswitch, auto-resetting).
- F20 (2A): Power to Alternator Sense.
- F21 (60A): Main Fuse (2 Circuit).
- F25 (7.5A): Power to HPCO.
- F26 (5A).
Electrical Components (Current Draw at 12.5 Vdc / Resistance):
- Glow Plugs (3) Each: 5.5 ± 0.5 Amps / 2.3 ± 0.2 Ohms.
- Fuel Solenoid: Pull-in Coil: 35 to 45 Amps / 0.2 to 0.3 Ohms; Hold-in Coil: 0.5 Amps / 24 to 29 Ohms.
- High Speed (Throttle) Solenoid: 3.3 Amps / 3.8 Ohms.
- Condenser Inlet Solenoid (CIS): 1.8 Amps / 6.9 Ohms.
- Hot Gas Solenoid (HGS): 1.1 Amps / 11.3 Ohms.
- Purge Valve (PV): 1.1 Amps / 11.3 Ohms.
- Liquid Injection Solenoid (LIS): 1.1 Amps / 11.3 Ohms.
- Fan Relay: 0.9 Amps / 13.5 Ohms.
- Starter Motor (No Load Bench Test): 90 Amps.
Evaporator Fan Motor:
- ES800 Evaporator (3 used): 0.17 hp (0.12 kW) each, 2860 RPM, 9.2 amps each.
- E-Evaporator (3 used): 0.13 hp (0.097 kW) each, 2350 RPM, 7.5 amps each.
- Spectrum Evaporator (6 used, 3 per evaporator unit): 0.13 hp (0.09 kW) each, 2450 RPM, 7.0 amps/motor.
Electrical Standby - Electric Motor and Overload Relay:
- 200/3/60: 10.0 hp, 7.5 kW, 1445 RPM, 25.1 Full Load (amps), 38 Overload Relay Setting (amps).
- 230/3/60: 12.0 hp, 8.9 kW, 1750 RPM, 28.8 Full Load (amps), 32 Overload Relay Setting (amps).
- 400/3/50: 10.0 hp, 7.5 kW, 1445 RPM, 14.5 Full Load (amps), 16 Overload Relay Setting (amps).
- 460/3/60: 12.0 hp, 8.9 kW, 1750 RPM, 14.4 Full Load (amps), 16 Overload Relay Setting (amps).
Standby Power Requirements:
- Supply Circuit Breaker: 200-230/3/50-60: 50 amps; All 380-460/3/50-60: 20 amps.
- Extension Cord Size: Up to 25 ft (7.6 m): 10 gauge; 50 to 75 ft (15.2 to 22.9 m): 8 gauge; Greater than 75 ft: Not recommended.
Usage Features
The UT-R Series units offer a range of features designed for efficient and reliable temperature control:
- Microprocessor Controller, SR-3 Truck: Provides advanced control and monitoring capabilities, including alarm code display, battery voltage display, continuous system monitoring, coolant temperature display, and engine and electric hour display.
- CYCLE-SENTRY™ Start/Stop System: Optimizes fuel economy by automatically starting and stopping the unit based on microprocessor demand, compartment temperature, engine block temperature, and battery charge levels.
- In-Cab Remote: Allows convenient control and monitoring from within the vehicle's cab.
- Smart Defrost: An intelligent defrost system for efficient operation.
- Symbolic Controller Interface: User-friendly interface for easy operation.
- Unit Self Check-pretripping: Enables pre-trip checks to ensure the unit is ready for operation.
- Automatic Phase Correction: Ensures proper operation during electric standby.
- Diesel/Electric Autoswitching: Seamlessly transitions between diesel and electric power sources.
- Economy Mode: Reduces fuel consumption during periods of lower demand.
- Fahrenheit and Celsius Scales: Provides temperature readings in both units.
- R-452A Chlorine-free Refrigerant: Utilizes an environmentally friendly refrigerant.
- ETV (Electronic Throttling Valve): Electronically controls suction pressure to the compressor for precise temperature management.
- Optional Features: TouchLog Datalogger, Door Switch, Battery Box Kit, Remote Body-Mount Box Kit, and Premium HMI Control Panel.
- Premium HMI Control Panel: An optional upgrade that replaces the standard HMI, offering access to all controller functions and menus.
- Telematics: Enables remote monitoring and management of the unit.
Maintenance Features
The manual outlines comprehensive maintenance procedures to ensure the longevity and optimal performance of the UT-R Series units:
- Extended Maintenance Interval (EMI 2000) Package: Standard equipment that extends maintenance intervals to 2,000 hours or 1 year, whichever comes first. This package includes a cyclonic air cleaner assembly and element, a fuel filter (black with gold lettering), API Classification CJ-4 or CK-4 oil, and Extended Life Coolant (ELC) with a five-year or 12,000-hour lifespan.
- Regular Inspections: Emphasizes the importance of regular inspections for wear, scuffing, cracking of belts, and proper belt tension.
- Refrigerant Recovery and Charging: Strict adherence to recovery policies to minimize refrigerant loss and prevent environmental harm. Detailed procedures for evacuation, dehydration, and charging, including the use of a micron vacuum gauge and 3-point evacuation.
- Component-Specific Maintenance: Instructions for checking and replacing various components such as alternators, batteries, fuses, fan relays, flywheel (RPM) sensors, glow plugs, electrical contactors, phase select modules, overload relays, oil filters, air cleaners, engine coolant, fuel pumps, injection pumps, expansion valves, heat exchangers, high pressure cutout switches, in-line check valves, purge valves, receiver tanks, and solenoid valves.
- Engine Maintenance: Procedures for engine oil changes, crankcase breather system inspection, and antifreeze maintenance (checking concentration, changing).
- Clutch Maintenance: Detailed instructions for inspecting, disassembling, and assembling the centrifugal clutch, including checking for wear, proper engagement, and lubrication.
- Structural Maintenance: Periodic checks and tightening of unit and engine mounting bolts, and cleaning of condenser, evaporator, and radiator coils.
- Diagnostic Procedures: Provides diagnostic information for electrical and refrigeration systems, including troubleshooting tables for various conditions like engine not cranking, engine failing to start, engine running hot, low oil pressure, high oil consumption, and battery not recharging.
- Safety Precautions: Extensive safety advisories covering hazards such as explosion, hazardous gases, refrigerant vapor, confined spaces, electrical shock (high and low voltage), sharp edges, and equipment damage. Emphasizes the use of Personal Protective Equipment (PPE) and proper handling of chemicals and refrigerants.
- First Aid Information: Provides detailed first aid instructions for exposure to refrigerant, refrigerant oil, engine coolant, battery acid, electrical shock, and asphyxiation.
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