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Engine Maintenance

2. Turn on the electric fuel pump. The electric

fuel pump is energized when the

ON key is

pushed. Tighten the bleeder screw on the

injection pump when clear flow of fuel

appears.

NOTE: At initial start-up, open the bleeder

screw at the injection pump and bleed fuel

until a clear flow is noted.

3. Loosen the injector lines on the injection

nozzles.

4. Crank the engine until fuel appears at the

nozzles. Tighten the injector lines, and start

the engine.

NOTE: Fuel will not appear at the nozzles by

merely running the electric pump. The

engine must be cranked.

1. Injector Line 2. Bleeder Screw

Figure 166: Injection Pump

Table of Contents5
List of Figures11
Safety Precautions15
General Practices15
Auto Start/Stop16
Battery Installation and Cable Routing16
Battery Removal16
Refrigerant Hazards16
Refrigerant Oil Hazards17
Electrical Hazards17
High Voltage17
Low Voltage18
Microprocessor Service Precautions18
Welding Precautions18
First Aid19
First Aid, Refrigerant19
First Aid, Refrigerant Oil19
First Aid, Engine Coolant19
First Aid, Electrical Shock19
Specifications21
Engine21
Engine Clutch22
Belt Tension22
Refrigeration System22
Electrical Control System22
Fuses23
Electrical Components23
Evaporator Fan Motors24
Electrical Standby24
Standby Power Requirements24
Maintenance Inspection Schedule25
Unit Description27
General Description27
Unit Features27
Unit Options27
Standard HMI Control Panel27
Figure 1: Standard HMI Control Panel27
Mechanics HMI Control Panel28
Premium HMI Control Panel (Optional)28
CYCLE-SENTRYTM Start/Stop System28
DAS - Data Acquisition System (Optional)28
Unit Protection Devices28
Figure 2: Mechanics/Premium HMI Control Panel28
Unit Component Identification29
Figure 3: Front View (UT-1200 Shown, UT-800 Similar)29
Figure 4: UT-800/UT-1200 Components, Front and Side Views (Panels Removed)30
Figure 5: UT-800/UT-1200 Components, Rear View (Panels Removed)30
Refrigeration System Components31
Solenoids and Valves31
Sensors, Switches, and Transducers31
Refrigeration System Diagrams33
Figure 6: Refrigeration System Components33
Cool Mode34
Figure 7: Cool Mode34
Purge Mode35
Figure 8: Purge Mode35
Heat/Defrost Mode36
Figure 9: Heat/Defrost Mode36
Operating Instructions for Standard HMI Control Panel37
Truck HMI Controller Description37
SR-3 Truck HMI Controller37
Display37
Figure 10: SR-3 Truck HMI Controller37
Figure 11: Display37
Keys and LED Indicators39
Figure 12: Keys and LED Indicators39
Turning the Unit on and off41
The Standard Display41
Figure 13: Keys and LED Indicators41
Figure 14: Electric Motor Run Time Hours and Electric Icon41
Figure 15: Standard Display of Box Temperature and Setpoint41
Figure 16: on Key41
Figure 17: Standard Display41
Changing the Setpoint42
Starting the Diesel Engine42
Figure 18: up ARROW Key42
Figure 19: ENTER Key42
Figure 20: Alarm Icon and Setpoint42
Starting the Electric Motor43
Switching from Diesel to Electric43
Switching from Electric to Diesel43
Figure 21: Standard Display43
Figure 22: Standard Display43
Selecting CYCLE-SENTRY or Continuous Mode44
Figure 23: Alarm Icon44
Figure 24: Press on Key44
Figure 25: Display, Preferred Method for Manually Switching from Electric Mode to Diesel Mode44
Selecting the High Speed Lock-Out Feature45
Initiating a Manual Defrost Cycle45
Figure 26: CYCLE-Sentry/Continuous Key45
Figure 27: HIGH SPEED LOCKOUT Key45
Figure 28: DEFROST Key45
Alarms46
Figure 29: Box Temperature will Rise Toward 50 F (10 C)46
Figure 30: Alarm Icon46
Figure 31: on and PRETRIP TEST Keys46
Figure 32: ENTER Key46
Figure 33: Standard Display46
Sending a Servicewatch Data Logger Start of Trip47
Pretrip Test47
Pretrip Test Conditions47
Conditions Where Pretrip Tests Are Not Allowed47
Pretrip Test Sequence47
Figure 34: ENTER Key47
Pretrip Test Considerations48
Performing a Pretrip Test48
Starting a Pretrip Test48
Figure 35: Pretrip Test48
Figure 36: PRETRIP Key48
Pretrip Test Results49
Display Brightness49
Figure 37: on Key, UP/DOWN Arrow Keys49
Checking Truck HMI Control Panel Software Revision and Serial Number50
Figure 38: PRETRIP Key50
Figure 39: Software Revision and Serial Number50
Operating Instructions for Premium HMI Control Panel51
Truck Premium HMI Controller Description51
Premium HMI Control Panel51
Display51
Figure 40: Premium HMI Control Panel51
Keys52
Hard Keys52
Soft Keys52
Turning the Unit on and off52
Figure 41: Display52
Figure 42: Keys52
Figure 43: Soft Keys52
If more than One Language Is Enabled53
Figure 44: Thermo King Logo53
Figure 45: Startup Screen53
Figure 46: no Key53
Figure 47: YES Key53
Figure 48: Programming Language53
Figure 49: Standard Display53
Figure 50: First and Last Soft Keys53
The Standard Display54
Changing the Setpoint54
Figure 51: Language Menu54
Figure 52: Standard Display54
Figure 53: Power down Message54
Figure 54: off Display54
Figure 55: Standard Display54
Figure 56: SETPOINT Key54
Figure 57: Setpoint Display54
Starting the Diesel Engine55
Figure 58: Increase Setpoint55
Figure 59: Soft Keys55
Figure 60: New Setpoint55
Figure 61: Standard Display, New Setpoint55
Starting the Electric Motor56
Switching from Diesel to Electric56
Figure 62: Engine Start Screen56
Figure 63: Standard Display of Temperature and Setpoint56
Figure 64: Motor Start Screen56
Figure 65: Standard Display of Temperature and Setpoint56
Figure 66: Prompt Screen, Guarded Access Set to no56
Figure 67: Prompt Screen, Guarded Access Set to Yes56
Switching from Electric to Diesel57
Initiating a Manual Defrost Cycle57
Figure 68: Prompt Screen, Standby Power Is Turned off or Is no Longer Available57
Figure 69: Prompt Screen, after off and on57
Figure 70: Display Is YES Is Selected57
Figure 71: Press Defrost Key57
Figure 72: Prompt Screen, Guarded Access Set to Yes57
Terminating a Defrost Cycle58
Selecting High Speed Lockout Mode (if Enabled)58
Figure 73: Defrost Display58
Figure 74: High Speed Lockout Key58
Figure 75: PROGRAMMING HIGH SPEED LOCKOUT - PLEASE WAIT58
Figure 76: High Speed Lockout Display58
Figure 77: Standard Display, High Speed Lockout Active58
Selecting CYCLE-SENTRY or Continuous Mode59
Using the Gauges Key59
Figure 78: Gauges Key59
Figure 79: Next, Back, Lock Keys59
Using the Sensors Key60
Using the Main Menu60
Figure 80: Sensors Key60
Figure 81: Next, Back, Lock Keys60
Figure 82: Menu Key60
Figure 83: Pretrip Submenu60
Main Menu Choices61
Languages61
Figure 84: Menu Key62
Figure 85: Select Key62
Figure 86: + or - Keys, Yes Key62
Figure 87: New Language62
Figure 88: Standard Display in New Language62
Figure 89: Standard Display in New Language62
Figure 90: Language Menu62
Alarms63
Figure 91: Log Alarm Notice63
Figure 92: Alarm Icon64
Figure 93: Menu Key65
Figure 94: Select Key65
Figure 95: no Alarms65
Figure 96: Alarm Code 665
Figure 97: Next Key65
Figure 98: Help Key65
Datalogger66
Hourmeters66
Figure 99: Menu Key66
Figure 100: Select Key66
Figure 101: Start of Trip66
Figure 102: Select Key66
Mode67
Figure 103: Menu Key67
Figure 104: Hourmeter Display67
Figure 105: Scroll through Hourmeters67
Selecting CYCLE-SENTRY or Continuous Mode68
Figure 106: Menu Key68
Figure 107: Select Key68
Figure 108: Select and Next Keys68
Figure 109: Menu Key68
Figure 110: Select Key68
Selecting Sleep Mode69
Figure 111: Turn Off/Turn on CYCLE-SENTRY Screen69
Figure 112: Select Key69
Figure 113: Mode Change Confirmed69
Figure 114: Mode Confirmed69
Figure 115: Mode Menu69
Figure 116: Menu Key69
Figure 117: Select Key70
Figure 118: Sleep Mode Menu70
Figure 119: Start of Sleep Mode Menu70
Figure 120: Select no to Enter Sleep Mode70
Figure 121: Sleep Mode Display70
Figure 122: Yes Key70
Figure 123: Day Unit Is to Restart70
Figure 124: Confirm Hour70
Pretrip71
Figure 125: Confirm Minute71
Figure 126: Press Yes Key for Pretrip Test71
Figure 127: Sleep Mode71
Figure 128: Menu Key72
Figure 129: Select Key72
Figure 130: Running Pretrip72
Figure 131: no Pretrip Prompt72
Diesel/Electric Menu73
Figure 132: Pretrip Test Display73
Figure 133: Performing Cool Test73
Figure 134: Pass, Check or Fail73
Figure 135: Standby Power Connected & Available73
Figure 136: Display When YES Is Selected73
Adjust Brightness74
Figure 137: Display When Standby Power Not Available74
Figure 138: Prompt for Switch to Diesel74
Figure 139: Display When YES Is Selected74
Figure 140: Menu Key74
Figure 141: Select Key74
Time75
Figure 142: + and - Keys75
Figure 143: Adjusting Brightness75
Figure 144: Menu Key75
Figure 145: Select Key75
Figure 146: + and - Keys75
Electrical Maintenance77
Alternator Charging System Diagnostic Procedures77
General Information77
Alternator Identification77
Figure 147: Thermo King Alternator Terminal and Component Locations77
Interface Board Fuse F478
Test Equipment for Checking Voltage and Current78
Alternator Load Test78
General Diagnostic and Warranty Evaluation Procedure78
Field Current Test80
Battery80
Fuses81
Figure 148: Base Controller81
Base Controller Leds82
Smart Fets82
SMART REEFER 3 (SR-3) Microprocessor Controller82
Flywheel (RPM) Sensor82
Glow Plugs83
Figure 149: Flywheel (RPM) Sensor83
Figure 150: Flywheel (RPM) Sensor Wires83
Figure 151: Glow Plug Ohm Test83
Unit Wiring84
AC Components84
Electrical Contactors84
Condenser Fan Rotation84
Phase Select Module for Truck Unit Model 50 Applications84
Figure 152: High Voltage Box with Cover Removed84
Overload Relay86
Figure 153: Typical Overload Relay86
Figure 154: Open Cover87
Figure 155: Set Amperage and Remove Tab87
Figure 156: Move Switch down87
Engine Maintenance89
Emi 200089
Engine Lubrication System89
Engine Oil Pressure Switch/Sensor89
Engine Oil Change89
Figure 157: TK376U89
Oil Filter Change90
Crankcase Breather System90
Figure 158: Oil Filter Parts90
Figure 159: Crankcase Breather Components90
Engine Air Cleaner (EMI 2000)91
Figure 160: Dry Type Air Cleaner91
Engine Cooling System92
General Description92
Figure 161: Engine Cooling System Components92
ELC (Extended Life Coolant)93
Antifreeze Maintenance Procedures93
Figure 162: ELC Nameplate Located on Expansion Tank93
Bleeding Air from the Cooling System94
Figure 163: Remove Bleeder Set Screw94
Engine Thermostat95
Figure 164: Checking Temperature95
Figure 165: Water Pump Assembly and Thermostat95
Engine Fuel System96
Operation96
Maintenance96
Bleeding the Fuel System96
Figure 166: Injection Pump97
Figure 167: Fuel Components98
Draining Water from Fuel Tank99
Fuel Filter Replacement99
Electric Fuel Pump100
Figure 168: Electric Fuel Pump100
Injection Pump Timing101
Figure 169: Component Location101
Figure 170: Timing Marks101
Figure 171: Injection Pump102
Figure 172: Correct Injection Timing Mark Alignment102
Injection Pump Removal and Installation103
Figure 173: Index Mark Location103
Figure 174: Index Mark Alignment103
Figure 175: Injection Pump Removal and Installation104
Fuel Limit Screw105
Fuel Solenoid105
Figure 176: Emission Control Label105
Figure 177: Fuel Solenoid Location105
Figure 178: Fuel Solenoid Connector Pin Identification106
Engine Speed Adjustments107
Figure 179: Fuel Solenoid Components107
Figure 180: Low Speed Adjustment Screw Location107
Figure 181: High Speed Solenoid Components108
Adjust Engine Valve Clearance109
Figure 182: Valve Adjustment and Firing Order109
Figure 183: Timing Marks109
Figure 184: Valve Clearance110
Figure 185: Adjusting Valves110
Restraining Mount Adjustment111
Figure 186: Chain/Restraining Mount111
Figure 187: Chain/Restraining Mount Bracket112
Belts113
Engine/Electric Motor Belt113
Compressor/Electric Motor Belt113
Figure 188: Engine Clutch-Electric Motor Belt Adjustment113
Figure 189: Electric Motor-Compressor Belt Adjustment113
Electric Motor/Alternator Belt114
Water Pump/Engine Belt114
Figure 190: Electric Motor-Alternator Belt Adjustment114
Refrigeration Service Procedures115
Evacuation, Dehydration, and Charging115
Figure 191: Evacuation Station116
Figure 192: Vacuum Gauge117
Set up and Test of Evacuation Equipment118
Using Evacuation Mode118
Figure 193: Press Menu Key118
Figure 194: Press and Hold Exit and Unlabeled Keys118
Unit Evacuation119
Figure 195: Select Evacuation Test119
Figure 196: Programming119
Unit Charging120
Figure 197: Pressure Rise Graphs120
Refrigerant Gauge Removal121
Refrigerant Leaks121
Refrigerant Charge121
Testing the Refrigerant Charge with an Empty Box (Controlled Check)121
Testing the Refrigerant Charge with a Loaded Box (Quick Check)122
Checking Compressor Oil122
Refrigeration System Checks122
Figure 198: Scroll Compressor122
Low Side Pump down123
R404A124
Unit Identification124
Availability124
Leak Detection124
Compressor Oil124
Compressors Shipped with POE Oil124
Equipment Recommendations for Use with R404A124
Figure 199: R404A Decal124
Refrigerant Recovery125
Accumulator Replacement125
Removal125
Installation125
Compressor Test125
Compressor Replacement126
Removal126
Installation126
Figure 200: Compressor Components127
Compressor Shaft Seal Change Procedure128
Figure 201: Cross Section of Set Screw Type Bellows128
Figure 202: Set Screw Type Bellows Seal128
Figure 203: Bellows Installation with Tool129
Figure 204: Lip Seal and Hard Ring Installation129
Compressor Oil Filter Replacement130
Compressor Oil Change130
Compressor Temperature Sensor Testing131
Compressor Temperature Sensor Replacement131
Condenser Check Valve and Purge Check Valve Test131
Condenser Inlet Solenoid (CIS) Test132
Condenser/Radiator Coil Replacement133
Removal133
Installation133
Dehydrator (Filter-Drier) Replacement133
Discharge Pressure Regulator (DPR) Test133
Discharge Pressure Regulator (DPR) Replacement134
Removal134
Installation134
Discharge Pressure Transducer Testing134
Discharge Pressure Transducer Replacement134
Discharge Strainer Test134
Discharge Strainer Replacement135
Removal135
Installation135
Evaporator Coil Replacement (URDE Only)135
Expansion Valve Replacement135
Installation136
Heat Exchanger Replacement136
Removal136
Figure 205: Location of Expansion Valve Bulb136
Figure 206: Completely Wrap Bulb with Tape136
High Pressure Cutout Switch (HPCO) Test137
High Pressure Cutout Switch (HPCO) Replacement137
Removal137
Installation137
High Pressure Relief Valve Replacement137
Figure 207: High Pressure Cutout Manifold137
Hot Gas Solenoid (HGS) Test138
In-Line Check Valve Replacement138
Removal138
Installation138
Figure 208: Cross Section of In-Line Check Valve138
Liquid Injection Solenoid (LIS) Test139
Liquid Injection Solenoid (LIS) Replacement139
Removal139
Installation139
Purge Valve (PV) Test139
Receiver Tank Pressure Check Valve Test140
Receiver Tank Replacement140
Removal140
Installation140
Solenoid Valve Replacement141
Removal141
Installation141
Suction Pressure Regulator (SPR) Test141
Clutch Maintenance143
Centrifugal Clutch143
Figure 209: Front View and Cross Section143
Figure 210: Centrifugal Clutch144
Clutch Maintenance145
Tools Required145
Grease145
Disassembly Procedure145
Figure 211: Housing Removal145
Figure 212: Bearing Removal145
Assembly Procedure (Using New Bearings and Seal)146
Figure 213: Bushing Removal146
Figure 214: Bushing Insertion146
Figure 215: Clutch147
Structural Maintenance149
Unit Inspection149
Unit and Engine Mounting Bolts149
Condenser, Evaporator and Radiator Coils149
Defrost Drains149
Figure 216: Condenser Unit and Engine Mounting Bolts149
Figure 217: Evaporator Mounting Bolts149
Mechanical Diagnosis151
Electric Standby Diagnosis155
Refrigeration Diagnosis157
Index159
Wiring and Schematic Diagrams Index161

Thermo King UT-800 User Manual

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Brand	Thermo King
Model	UT-800
Category	Refrigerator
Language	English