Trane technologies Thermo king e-200 series User manual

Revision C

June 2023 TTKK 6611771177--1188--MMMM--EENN

Truck Edition

E-200 Series

Maintenance Manual

Introduction

This manual is published or in ormational purposes only. Thermo King®makes no representations warranties express

or implied, with respect to the in ormation recommendations and descriptions contained herein. In ormation provided

should not be regarded as all-inclusive or covering all contingencies. I urther in ormation is required, Thermo King

Service Department should be consulted.

TThheerrmmoo KKiinngg’’ss wwaarrrraannttyy sshhaallll nnoott aappppllyy ttoo aannyy eeqquuiippmmeenntt wwhhiicchh hhaass bbeeeenn ““ssoo iinnssttaalllleedd,, mmaaiinnttaaiinneedd,, rreeppaaiirreedd

oorr aalltteerreedd aass,, iinn tthhee mmaannuu aaccttuurreerr’’ss jjuuddggmmeenntt,, ttoo aa eecctt iittss iinntteeggrriittyy..””

MMaannuuffaaccttuurreerr sshhaallll hhaavvee nnoo lliiaabbiilliittyy ttoo aannyy ppeerrssoonn oorr eennttiittyy ffoorr aannyy ppeerrssoonnaall iinnjjuurryy,, pprrooppeerrttyy ddaammaaggee oorr aannyy

ootthheerr ddiirreecctt,, iinnddiirreecctt,, ssppeecciiaall,, oorr ccoonnsseeqquueennttiiaall ddaammaaggeess wwhhaattssooeevveerr,, aarriissiinngg oouutt ooff tthhee uussee ooff tthhiiss mmaannuuaall oorr

aannyy iinnffoorrmmaattiioonn,, rreeccoommmmeennddaattiioonnss oorr ddeessccrriippttiioonnss ccoonnttaaiinneedd hheerreeiinn.. TThhee pprroocceedduurreess ddeessccrriibbeedd hheerreeiinn sshhoouulldd

oonnllyy bbee uunnddeerrttaakkeenn bbyy ssuuiittaabbllyy qquuaalliiffiieedd ppeerrssoonnnneell.. FFaaiilluurree ttoo iimmpplleemmeenntt tthheessee pprroocceedduurreess ccoorrrreeccttllyy mmaayy ccaauussee

ddaammaaggee ttoo tthhee TThheerrmmoo KKiinngg uunniitt oorr ootthheerr pprrooppeerrttyy oorr ppeerrssoonnaall iinnjjuurryy..

Revision History

Revision A (01/20) Original release

Revision B (11/20) TK Holdover Battery Recycling information

Revision C (06/23) Removed DVDT Filter

General Information

The maintenance information in this manual covers unit models:

E–Series System Numbers TKE200

For further information, refer to:

E-200 Parts Manual TK 61702

E-200 Operator’s Manual TK 61652

E-200 Installation Manual TK 61694

Lithium Ion Battery Safety Manual TK 61900

Direct Smart Reefer IV Microprocessor Control System Diagnostic Manual TK 61714

Direct Smart Reefer III Microprocessor Control System Diagnostic Manual TK 61096

Vehicle Powered Truck Installation Standards and Procedures TK 61588

Diagnosing Thermo King Truck and Trailer Refrigeration Systems TK 5984

Evacuation Station Operation and Field Application TK 40612

Silver Brazing & Soft Soldering TK 7949

Tool Catalog TK 5955

The information in this manual is provided to assist owners, operators and service people in the proper upkeep and maintenance of Thermo

King units.

Recover Refrigerant

NNoottee In the USA, EPA Section 608 Certification is required to work on refrigeration systems. In the EU, local F-gas

Regulations must be observed when working on refrigeration systems.

At Thermo King®, we recognize the need to preserve the environment and limit the potential harm to the ozone layer

that can result rom allowing re rigerant to escape into the atmosphere.

TK 61717-18-MM-EN 3

We strictly adhere to a policy that promotes the recovery and limits the loss o re rigerant into the atmosphere.

When working on transport temperature control systems, a recovery process that prevents or minimizes re rigerant

loss to the atmosphere is required by law. In addition, service personnel must be aware o the applicable European

Union, National, Federal, State, and/or Local regulations governing the use o re rigerants and certi ication o

technicians. For additional in ormation on regulations and technician programs, contact your local THERMO KING

dealer.

SSeerrvviiccee TToooollss - Use the proper service tools. Gauge mani old sets should include appropriate shuto valves or

disconnects near the end o each service line.

RReeccoovveerryy EEqquuiippmmeenntt - Recovery equipment must be used. Proper recovering, storing and recycling o re rigerants is

an important part o all service work.

SSeerrvviiccee PPrroocceedduurreess - Recommended procedures must be used to minimize re rigerant loss.

CCoommppoonneennttss mmaayy bbee iissoollaatteedd by closing service valves and per orming system pump-downs.

CCoommppoonneennttss uunnaabbllee ttoo bbee iissoollaatteedd or service must be repaired only a ter re rigerant is properly recovered.

R-1 4a/R-404A/R-452A

NNOOTTIICCEE

EEqquuiippmmeenntt DDaammaaggee!!

UUnnlliikkee ootthheerr TThheerrmmoo KKiinngg uunniittss,, PPoollyyvviinnyyll eetthheerr ((PPVVEE)) iiss tthhee oonnllyy ooiill aapppprroovveedd oorr uussee iinn TTHHIISS TThheerrmmoo KKiinngg

uunniitt.. IItt sshhoouulldd nnoott bbee mmiixxeedd wwiitthh aannyy ootthheerr ttyyppee..

NNOOTTIICCEE

SSyysstteemm CCoonnttaammiinnaattiioonn!!

DDoo nnoott mmiixx PPoollyyvviinnyyll eetthheerr ((PPVVEE)) aanndd ssttaannddaarrdd ssyynntthheettiicc ccoommpprreessssoorr ooiillss.. BBeeiinngg eetthheerr--bbaasseedd,, PPVVEE ddooeess nnoott

hhyyddrroollyyzzee,, ssoo tthhee uussuuaall pprreeccaauuttiioonnss ddoo nnoott aappppllyy oorr mmooiissttuurree ccoonnttaammiinnaattiioonn,, hhoowweevveerr iitt iiss ssttiillll ggoooodd pprraaccttiiccee

ttoo kkeeeepp PPoollyyvviinnyyll eetthheerr ccoommpprreessssoorr ooiill iinn ttiigghhttllyy sseeaalleedd ccoonnttaaiinneerrss.. II PPoollyyvviinnyyll eetthheerr ooiill bbeeccoommeess

ccoonnttaammiinnaatteedd wwiitthh ssttaannddaarrdd ooiillss,, ddiissppoossee oo pprrooppeerrllyy––DDOO NNOOTT UUSSEE..

NNOOTTIICCEE

SSyysstteemm CCoonnttaammiinnaattiioonn!!

WWhheenn sseerrvviicciinngg TThheerrmmoo KKiinngg RR--113344aa,, RR--440044AA oorr RR--445522AA uunniittss,, uussee oonnllyy tthhoossee sseerrvviiccee ttoooollss cceerrttii iieedd oorr aanndd

ddeeddiiccaatteedd ttoo RR--113344aa//RR--440044AA//RR--445522AA rree rriiggeerraanntt aanndd PPoollyyvviinnyyll eetthheerr ccoommpprreessssoorr ooiillss.. RReessiidduuaall nnoonn--HHFFCC

rree rriiggeerraannttss oorr ooiillss wwiillll ccoonnttaammiinnaattee RR--113344aa//RR--440044AA//RR--445522AA ssyysstteemmss..

IInnttrroodduuccttiioonn

4TK 61717-18-MM-EN

SSaa eettyy PPrreeccaauuttiioonnss ............................................................................................................................................................ 88

Danger, Warning, Caution, and Notice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Auto Start/Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Battery Installation and Cable Routing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

TK Lithium Ion Battery Sa ety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Re rigerant Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Re rigerant Oil Hazards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Electrical Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

High Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

LowVoltage............................................................................... 13

Controller/Microprocessor Service Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Welding Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

FirstAid....................................................................................... 13

SSppeeccii iiccaattiioonnss .. .. .... .. .... .. .... .. .......... .... .. .... .. .... .. .......... .... .. .......... .... .. .... ...... .... .. ...... .... .. .......... .... .. .... .. .... .. .... .. ...... .... .. .... .. .. 1155

Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Electric Standby Power Supply Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Re rigeration System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Compressors.................................................................................. 17

Solder Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

UUnniitt DDeessccrriippttiioonn .... .... .. .... .. .... ...... .... .... .. .... .. .... ...... .... .. .... .......... .... ...... .... .. .... .......... .... ...... .... .. .... .......... .... ...... .... .. .... ........ 1199

Unit Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Standard Unit Features. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Options....................................................................................... 19

System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Compressor(s) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Condenser................................................................................. 20

Evaporator ................................................................................ 20

Oil Separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Re rigerant ................................................................................ 20

Liquid Injection System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Evaporator Drain Line Heaters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Electric Standby Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

TK Lithium Ion Batteries (i equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Unit Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

StandardFeatures ......................................................................... 21

OptionalFeatures.......................................................................... 21

Protection Features. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

DSR Control System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

ControlBox............................................................................... 22

Description............................................................................... 22

UnitControls.............................................................................. 23

Table of Contents

TK 61717-18-MM-EN 5

Standby Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Re rigeration System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Solenoids and Valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

HotGasSolenoid(HGS) .................................................................... 26

Liquid Injection Solenoid (LIS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Condenser Inlet Solenoid (CIS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Suction Pressure Regulator Valve (SPR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Discharge Pressure Regulator Valve (DPR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

LiquidLineCheckValve..................................................................... 26

Switches and Transducers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Unit Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Operation ................................................................................. 28

CoolMode................................................................................ 28

NullMode................................................................................ 33

HeatMode................................................................................ 33

DerostMode ............................................................................. 33

Serial Number Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Unit Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

MMaaiinntteennaannccee IInnssppeeccttiioonn SScchheedduullee .... .. .......... .... .. .......... .... ...... .... .. .... .. ...... .... .. .......... .... .. .... ...... .... .. ...... .... .. .......... 3399

EElleeccttrriiccaall MMaaiinntteennaannccee.. .. .......... .... .. .... .. .... .. .......... .... .. .......... .... .. .... ...... .... .. ...... .... .. .......... .... .. .... .. .... .. .... .. ...... .... .. .... .. .. 4400

Auto Start Hard Stop / Disable Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Electronic Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

De rost System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

De rost Termination Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

De rost Termination Switch Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Removal ................................................................................. 41

Installation ............................................................................... 41

Liquid Injection System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Condenser Fan Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Condenser Fan Motor Removal and Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Removal ................................................................................. 42

Installation ............................................................................... 42

Evaporator Fan Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Evaporator Fan Motor Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Removal ................................................................................. 43

Installation ............................................................................... 43

Drain Line Heaters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Drain Line Heater Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Removal ................................................................................. 43

Installation ............................................................................... 43

Fuses......................................................................................... 45

Fuses: Printed Circuit Boards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Harness Fuses: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46