Thermo King T-500R User manual

TK 60484-1 (Rev. 6, 09-2016)
Ingersoll Rand Company Ltd. • Monivea Road • Mervue, Galway • Ireland
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
UT XTREME HIGH AMBIENT
UT SPECTRUM

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©2012-2016 Thermo King Ingersoll Rand Ltd., Monivea Road, Mervue, Galway • Ireland. All rights reserved.
Printed in Ireland.
The contents of this manual are the property of Thermo King and are copyrighted. No part of this document may be
reproduced or transmitted in any form or by an means, electronic or mechanical, for any purpose, without the express
written permission of Thermo King.
This maintenance manual is published for informational purposes only and the information should not be considered
as all-inclusive or covering all contingencies. If further information is required, Thermo King Europe should be
consulted. Information in this document is subject to change without notice.
Sale of product shown in this Maintenance Manual is subject to Thermo Kingís terms and conditions including, but
not limited to, the THERMO KING WARRANTY. Such terms and conditions are available on request.
The Thermo King warranty will not apply to any equipment which has been ìso repaired or altered outside the
manufacturerís plants as, in the manufacturerís judgment, to effect its stability.î
No warranties, express or implied, including warranties of fitness for a particular purpose or merchantability, or
warranties arising from course or dealing or usage of trade, are made regarding the information, recommendations
and descriptions contained herein. Manufacturer is not responsible and will not be held liable in contract or in tort
(including negligence) for any special, indirect or consequential damages, including injury or damage caused to
vehicles, contents or persons, by reason of the installation of any Thermo King product or its mechanical failure.
All other trademarks are the property of their respective owners.
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.
In addition, service personnel must be aware of Federal regulations concerning the use of refrigerants and the certification
of technicians. For additional information on regulations and technician certification programmes, contact your local
THERMO KING dealer.

Table of Contents
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Engine ...........................................................................................................................................3-2
Belt Tension..................................................................................................................................3-3
Engine Clutch ...............................................................................................................................3-4
Refrigeration System ....................................................................................................................3-5
Electrical Control System .............................................................................................................3-6
Fuses - (except T-500R/T-Dairy) .................................................................................................3-7
Fuses T-500R/T-Dairy..................................................................................................................3-7
Electrical Components..................................................................................................................3-8
Evaporator Fan Motors (UT-Series) .............................................................................................3-9
Electrical Standby T-Series (except T-500R/T-Dairy) (Model 50 Units Only) ...........................3-9
Electrical Standby UT-Series........................................................................................................3-10
Electrical Standby T-500R/T-Dairy..............................................................................................3-10
Electric Heater Strips (Optional) ..................................................................................................3-10
Maintenance Inspection Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Unit Models: T-Series (Except T-500R) and T-Series Spectrum Host ........................................4-2
Unit Models: T-Series Spectrum ..................................................................................................4-4
Unit Models: T-500R....................................................................................................................4-5
Unit Models: UT1200 and UT-800 ..............................................................................................4-7
Unit Models: UT1200 and UT-800 Remote Evaporators.............................................................4-9
Unit Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
General Description ......................................................................................................................5-2
Design Features.............................................................................................................................5-2
Unit Options..................................................................................................................................5-3
Engine ...........................................................................................................................................5-3
Standard HMI Control Panel ........................................................................................................5-3
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
Single Temperature Refrigeration System Diagrams ...................................................................5-13
Multi-Temperature Refrigeration System Diagrams ....................................................................5-24
Operating Instructions Premium HMI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Controller Description ..................................................................................................................6-3
Starting the Diesel Engine ............................................................................................................6-10
Starting the Electric Motor ...........................................................................................................6-10
Switching from Diesel to Electric (Premium HMI only) .............................................................6-10
Switching from Electric to Diesel (Premium HMI only) .............................................................6-11
Defrost ..........................................................................................................................................6-11
Selecting High Speed Lockout Mode (If Enabled).......................................................................6-12
Selecting CYCLE-SENTRY or Continuous Mode ......................................................................6-13

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 ......................................................................................................................... 6-29
Time.............................................................................................................................................. 6-30
Operating Instructions Standard HMI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Controller Description .................................................................................................................. 7-2
Alarms .......................................................................................................................................... 7-13
Pretrip Test ................................................................................................................................... 7-14
Checking Truck HMI Control Panel Software Revision and Serial Number............................... 7-16
Electrical Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Alternator Charging System Diagnostic Procedures .................................................................... 8-2
Battery .......................................................................................................................................... 8-5
Fuses ............................................................................................................................................. 8-5
Smart FETs................................................................................................................................... 8-8
SMART REEFER 2/3 (SR-2/3) Microprocessor Controller........................................................ 8-8
Expansion Module (SPECTRUM systems ONLY [T-Series SPECTRUM
and UT SPECTRUM]) ................................................................................................................. 8-9
Flywheel (RPM) Sensor ............................................................................................................... 8-10
Glow Plugs ................................................................................................................................... 8-11
Unit Wiring................................................................................................................................... 8-12
AC Components (Model 50 Units Only)...................................................................................... 8-12
Overload Relay............................................................................................................................. 8-17
Engine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
EMI 2000...................................................................................................................................... 9-2
Engine Lubrication System .......................................................................................................... 9-2
Engine Air Cleaner (EMI 2000) ...................................................................................................9-3
Crankcase Breather System .......................................................................................................... 9-3
Engine Cooling System ................................................................................................................ 9-5
Engine Fuel System...................................................................................................................... 9-12
Adjust Engine Valve Clearance.................................................................................................... 9-29
Engine Mounts.............................................................................................................................. 9-32
Belts.............................................................................................................................................. 9-37
Refrigeration Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
Evacuation, Dehydration, and Charging ...................................................................................... 10-3
Refrigerant Leaks ......................................................................................................................... 10-12
Refrigerant Charge ....................................................................................................................... 10-12
Checking Compressor Oil ............................................................................................................ 10-12
Refrigeration System Checks ....................................................................................................... 10-13
Low Side Pump Down.................................................................................................................. 10-14
R-404A/R-452A/R-134A ............................................................................................................. 10-14
Refrigeration System Component Locations................................................................................ 10-16
Accumulator Replacement ........................................................................................................... 10-22
Reciprocating Compressor Replacement (T-Series) .................................................................... 10-23
TKO Scroll Compressor (UT-Series)........................................................................................... 10-25
Condenser Check Valve Test (Single Temperature Units Only) ................................................. 10-29

Condenser Check Valve and Purge Check Valve Test (T-500R/T-Dairy)...................................10-29
Condenser Check Valve, Purge Check Valve, and Receiver Tank Pressure Solenoid Leak
Test (Multi-Temp Units Only)......................................................................................................10-30
Condenser Inlet Solenoid (CIS) Test ............................................................................................10-31
Condenser/Radiator Coil Replacement.........................................................................................10-31
Dehydrator (Filter-Drier) Replacement ........................................................................................10-32
Discharge Pressure Regulator (DPR) Test....................................................................................10-32
Discharge Pressure Regulator (DPR) Replacement......................................................................10-30
Discharge Pressure Transducer Testing........................................................................................10-33
Discharge Pressure Transducer Replacement...............................................................................10-33
Discharge Strainer Test.................................................................................................................10-33
Discharge Strainer Replacement...................................................................................................10-34
Electronic Throttling Valve (ETV) Testing..................................................................................10-34
Electronic Throttling Valve (ETV) Replacement.........................................................................10-34
Evaporator Coil Replacement.......................................................................................................10-39
Expansion Valve Replacement .....................................................................................................10-40
Heat Exchanger Replacement.......................................................................................................10-41
High Pressure Cutout Switch (HPCO) Test..................................................................................10-41
High Pressure Cutout Switch (HPCO) Replacement....................................................................10-41
High Pressure Relief Valve Replacement.....................................................................................10-42
Hot Gas Bypass Solenoid (HGBS) Test .......................................................................................10-43
Hot Gas Solenoid (HGS) Test ......................................................................................................10-43
In-Line Check Valve Replacement...............................................................................................10-43
Liquid Injection Solenoid (LIS) Test............................................................................................10-44
Liquid Injection Solenoid (LIS) Replacement..............................................................................10-44
Liquid Line Solenoid (LLS) and Liquid Return Check Valve Test (Multi-Temp Units Only)....10-45
Low Pressure Cutout Switch (LPCO) Test (T-500R/T-Dairy Only)............................................10-45
Low Pressure Cutout Switch (LPCO) Replacement.....................................................................10-45
Purge Valve (PV) Test..................................................................................................................10-46
Receiver Tank Pressure Check Valve Test...................................................................................10-46
Receiver Tank Pressure Solenoid (RTPS) Test (Multi-Temp Units Only) ..................................10-46
Receiver Tank Replacement .........................................................................................................10-47
Solenoid Valve Replacement........................................................................................................10-47
Suction Line Check Valve Test (Multi-Temp Units Only) ..........................................................10-48
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1
Centrifugal Clutch.........................................................................................................................11-2
Clutch Maintenance ......................................................................................................................11-4
Structural Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-1
Unit and Engine Mounting Bolts ..................................................................................................12-2
Unit Inspection..............................................................................................................................12-2
Condenser, Evaporator and Radiator Coils...................................................................................12-2
Micro-Channel Coil Cleaning Recommendations........................................................................12-2
Fan Location .................................................................................................................................12-4
Defrost Drains (UT-Series)...........................................................................................................12-4
Defrost Damper.............................................................................................................................12-4
Fanshaft Assembly........................................................................................................................12-5
Mechanical Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-1