Page 2 If further information is required, Thermo King Corporation should be consulted. Sale of product shown in this manual is subject to Thermo King’s terms and conditions including, but not limited to, the Thermo King Limited Express Warranty. Such terms and conditions are available upon request.
Page 3 Ester compressor oil in tightly sealed containers. If Polyol Ester oil becomes contaminated with moisture or standard oils, dispose of properly–DO NOT USE. When servicing Thermo King R-404A unit, use only those service tools certified for and dedicated to R-404A refrigerant and Polyol Ester compressor oils.
Page 5: Table Of Contents
TS-200 ........
Page 6 Table of Contents µ P-T System Description ..............39 General Description .
Page 7 Table of Contents Engine Maintenance (continued) Fuel Limit Screw ............... . . 72 Engine Mounts .
Page 8 Table of Contents Refrigeration Service Operations (continued) Expansion Valve Assembly ..............105 Removal .
Page 9 Table of Contents Mechanical Diagnosis ..............125 Electric Standby (Optional) Diagnosis .
Page 10 Table of Contents...
Page 11: List Of Figures
List of Figures Figure 1: Refrigerant Decal Locations ............16 Figure 2: Refrigerant Decal .
Page 12 List of Figures Figure 50: Vacuum Gauge ..............87 Figure 51: Scroll Compressor .
Page 13: Safety Precautions
Safety Precautions General Practices Auto Start/Stop 1. Always wear goggles or safety glasses. CAUTION: The unit may start Refrigerant liquid, refrigeration oil, and automatically and at any time when the battery acid can permanently damage the eyes. unit On/Off switch is in the On position. 2.
Page 14: Refrigeration Oil
Safety Precautions Refrigeration Oil The following procedures must be rigidly adhered to when servicing units to avoid microprocessor Observe the following precautions when working damage or destruction. with or around synthetic or polyol ester refrigerant 1. Disconnect all power to the unit. oil: 2.
Page 15: Welding Of Units Or Truck Bodies
Safety Precautions Welding of Units or Truck Bodies Precautions When electric welding is to be performed on any 1. Be certain the Unit On/Off switch is turned portion of the temperature control unit, truck or Off before connecting or disconnecting the truck chassis when the temperature control unit is standby power plug.
Page 16: Low Voltage
Serial number decals, refrigerant type decals and Use the victim’s coat, a rope, wood, or loop your warning decals appear on all Thermo King belt around the victim’s leg or arm and pull the equipment. These decals provide information that victim off.
Page 17: Specifications
Specifications Engine Engine TK 3.74 Fuel Type No. 2 Diesel fuel under normal conditions No. 1 Diesel fuel is acceptable cold weather fuel Oil Capacity: Crankcase & Oil Filter 9.1 quarts (8.6 liters) w/Bypass Oil Filter 10.1 quarts (9.5 liters) Fill to full mark on dipstick Oil Type API Classification CG-4 or better Oil Viscosity...
Page 18: Belt Tension
Compressor Oil Type: R-404A (Solest 35) Ester base required for Scroll compressor (See Tool Catalog) Suction Pressure Regulator Valve Setting: TS-200 28 to 30 psig (193 to 207 kPa) TS-300 36 to 38 psig (248 to 262 kPa) High Pressure Cutout Switch: Open 470 ±...
Page 19: Electrical Control System
Specifications Electrical Control System Control System Voltage 12.5 Vdc Battery Charging System 12 volts 23 amp brush type integral alternator Voltage Regulator Setting 14 volts @ 70 F (21.1 C) 4.7 µ fd 50 Vdc Alternator/Regulator Capacitor 0.5 µ fd 100 Vdc Alternator/Output Capacitor NOTE: Disconnect components from unit circuit to check resistance.
Page 20: Electric Standby (Model 50 Unit Only
Specifications Electric Standby (Model 50 Unit Only) TS-200 Voltage/Phase/Frequency Horsepower Kilowatts Full Load Overload Relay Setting (Amps) (Amps) 230/3/60 1760 16.4 460/3/60 1760 TS-300 Voltage/Phase/Frequency Horsepower Kilowatts Full Load Overload Relay Setting (Amps) (Amps) 230/3/60 1750 17.8 460/3/60 1750 Standby Power Requirements...
Page 21: Maintenance Inspection Schedule
Maintenance Inspection Schedule Pretrip 1,200 2,000 Annual/ Inspect/Service These Items Hours Hours 3,000 NOTE: The 1,200 hour maintenance interval may be Hours extended to 2,000 hours or 1 year (whichever occurs first) when equipped with EMI fuel filter and EMI bypass oil filter. Microprocessor •...
Page 22 Maintenance Inspection Schedule Pretrip 1,200 2,000 Annual/ Inspect/Service These Items Hours Hours 3,000 NOTE: The 1,200 hour maintenance interval may be Hours extended to 2,000 hours or 1 year (whichever occurs first) when equipped with EMI fuel filter and EMI bypass oil filter. Electrical •...
Page 23: Unit Description
Unit Description The TS-200 and TS-300 are microprocessor The built-in CYCLE-SENTRY , an exclusive controlled transport temperature control systems, Thermo King feature, automatically starts and µP-T which utilize the ThermoGuard ® stops the unit according to temperature demands. microcontroller to manage system functions.
Page 24: Unit Features
Unit Description Unit Features Feature S = Standard; O = Option; — = Does not Apply TK 3.74 Diesel Engine TKO Scroll Compressor Electric Standby Motor, 230/3/60 ThermoGuard µ P-T Microprocessor Controller Three-way Valve Refrigeration System Dry Element Air Cleaner Electric Fuel Pump with Fuel Prefilter Spin-on Fuel Filter Fuel Heater...
Page 25: Unit Instruments
Unit Description Unit Instruments Unit Protection Devices The display screen A number of fuses are located on the relay Microprocessor LCD Display: Fuses: normally shows the setpoint, the return air board. The sizes and functions are shown in the temperature, and any active icons, which are: following table.
Page 26: Unit Operation
Unit Description The high pressure Unit Operation High Pressure Relief Valve: relief valve is designed to relieve excess pressure within the refrigeration system. The valve is a Pretrip Inspection (Before Starting spring-loaded piston that lifts off its seat when Unit) refrigerant pressure exceeds 500 psig (3447 kPa).
Page 27: Thermoguard Μp-T Smart Reefer
Unit Description Visually inspect the unit for leaks, Displaying Operating Data Structural: loose or broken parts and other damage. The Unit operational information appears on display condenser and evaporator coils should be clean screen. During normal operation, the Standard and free of debris. Check the defrost drain hoses Display appears on the screen.
Page 28: Starting Unit (Full Unit Self Check)
Enter the new setpoint by pressing the key within 5 seconds. NTER The Thermo King CYCLE-SENTRY system is 3. Initiate a Unit Self Check (see the Operation designed to save refrigeration fuel costs. The Manual or the µP-T Microprocessor...
Page 29: Selecting Cycle-Sentry Or Continuous Run Mode (Diesel Or Electric Operation)
Unit Description Products Acceptable for CYCLE-SENTRY Initiating Manual Defrost Operation 1. With the Standard Display on the display, • Frozen foods (in adequately insulated press the key. EFROST trucks) NOTE: The coil temperature must be below • Boxed or processed meats 42 F (7 C) and the unit must be operating to initiate a Defrost cycle.
Page 30: Displaying And Clearing Alarm Codes
Unit Description Displaying and Clearing Alarm 4. While the alarm screen is showing, press the Codes key. The alarm will clear and the NTER standard display will appear on the screen. If When the controller senses an alarm condition, an more than one alarm code is present, Alarm icon appears on the display.
Page 31: After Start Inspection
Check the refrigerant charge. See Refrigerant: 4. Products should be pre-cooled before loading. “Refrigerant Charge” in the Refrigeration Thermo King units are designed to maintain Maintenance chapter of this manual. loads at the temperature at which they were loaded. Transport refrigeration units are not...
Page 32: Unit Photographs
Unit Description Unit Photographs AJA584 Figure 3: Front View AJA585 Figure 4: Back View...
Page 33: Figure 5: Left Side View
Unit Description AJA586 Figure 5: Left Side View AJA58 Figure 6: Right Side View...
Page 34: Figure 7: Components
Unit Description AJA58 Engine (Not Shown) Suction Pressure Regulator Electric Motor Alternator Pilot Solenoid Air Switch Liquid Injection Valve Three-way Valve Receiver Tank 10. Discharge Service Port (Not Shown) Scroll Compressor (Not Shown) 12. Accumulator (Not Shown) 13. Muffler 14. Engine Coolant Drain Figure 7: Components...
Page 35: Figure 8: North American Power Receptacle Box
Unit Description AJA58 Figure 8: North American Power Receptacle Box...
Page 36: Figure 9: Control Box
Unit Description AJA408 Motor Contactor A (Behind Cover Plate) K1 Relay Overload Contactor (Behind Cover Plate) K3 Relay Overload Reset Solenoid (Behind Cover Plate) 11. K2 Relay Remote Control Cab Box Harness Connector K5 Relay Preheat Buzzer K6 Relay K8 Relay K4 Relay K7 Relay Caution High Voltage Module...
Page 37: Figure 10: Thermoguard Remote Control Panel
Unit Description Keypad LED Display Figure 10: ThermoGuard Remote Control Panel AEA103 Figure 11: Remote Light Display...
Page 38 Unit Description...
Page 39: P-T System Description
µP-T System Description General Description Microprocessor Power Switch The µP-T microprocessor controllers are self The Microprocessor Power switch applies 12 Vdc contained temperature control units designed for control power to the microprocessor and must be Smart Reefer (SR) truck units. On to operate the unit.
Page 40: Optional Model 50 Features
µ P-T System Description CAUTION: The Electric Power Icon will not appear in the display if electric power is not present (the unit is not plugged in), or if there are electrical voltage or phase problems while the power cord is connected to a power outlet.
Page 41: Remote Control Panel Features
Remote Control Panel Features The remote panel is connected to the the dashboard using the supplied plastic mounting microprocessor and is used to operate the unit. It strips. An optional body mount enclosure kit is may be located in the truck dashboard using the available to mount the remote control panel on the supplied DIN mounting ring, under the dashboard truck box.
Page 42: Understanding The Display
Remote Control Panel Features Understanding the Display Appears when an alarm Alarm Icon: The display normally shows the Standard Display condition has been detected by the of return air temperature and setpoint. In addition, microprocessor. the icons located at the sides of the display indicate the operating mode of the unit and shows if any alarm codes are present.
Page 43: The Standard Display
Remote Control Panel Features The Standard Display temperature of 35.8 F and a setpoint of 35 F. The Standard Display is the starting point used to The Standard Display appears when the unit is reach all other prompts and displays. To return to turned On and no other functions have been this display from any other prompts or display, selected.
Page 44: Selecting Cycle-Sentry Or Continuous Mode
Remote Control Panel Features Selecting CYCLE-SENTRY or Continuous Mode Figure 20: Selecting CYCLE-SENTRY or Continuous Mode [no] = Continuous mode. 1. Press the key to turn the unit On. 4. Press the key to load the new NTER 2. Press the key to display operating mode selection into the ELECT...
Page 45: Initiating A Manual Defrost Cycle
Remote Control Panel Features Initiating a Manual Defrost Cycle Figure 22: Initiating a Manual Defrost Cycle 1. The unit must be running in either in the display when the unit starts a Defrost CYCLE-SENTRY or Continuous mode and cycle. The Defrost cycle will terminate the coil temperature must be below 45 F (7 C).
Page 46: Viewing Prompt And Display Screens
Remote Control Panel Features Viewing Prompt And Display Screens Figure 24: Viewing Prompt And Display Screens Total accumulated hours on hourmeter 5 [Hr5]: (only appears if this hourmeter is set to Type 1, 2 1. Press the key to turn the unit On. or 3).
Page 47: Viewing And Clearing Alarm Codes
Remote Control Panel Features Viewing and Clearing Alarm Codes Figure 25: Alarm Code Display µP-T Alarms 1. Press the key to turn the unit On. Alarms and Alarm Codes: If an abnormal condition is sensed by the 2. If the Alarm icon is present, one or microprocessor, an alarm code is generated and saved in memory.
Page 48 Remote Control Panel Features Notice to take corrective action Types of Alarms Check Alarm: before an abnormal condition becomes severe. There are three types of alarms. They may occur The Alarm icon will appear and remain On. individually or along with other alarms. There can Indicates conditions that may Shutdown Alarm: be more than one alarm present at one time.
Page 49 Remote Control Panel Features µP-T Alarm Codes Stored Check Shutdown Code Description Heating Cycle Check Cooling Cycle Fault Heating Cycle Fault Alternator Check Unit Self Check Abort Oil Pressure Sensor Refrigeration Capacity Low Check Engine RPM Run Relay Circuit; High Compressor Temperature Still Open Electric Motor Failed to Run Check Engine Water Level Electric Phase Reversed or Motor Overload Tripped...
Page 50: P-T Unit Self Check Test
Remote Control Panel Features µP-T Unit Self Check Test Defrost Check The Unit Self Check is a functional test of the The operation of the damper door is checked. unit’s operating capability. Once the test is started RPM Check by the operator, it is fully automatic and requires no operator attendance.
Page 51: Electrical Maintenance
Electrical Maintenance Alternator (Prestolite) Charging CAUTION: Full-fielding alternators System Diagnostic Procedures with the integral regulator is NOTE: Units manufactured with accomplished by installing a jumper from CYCLE-SENTRY and alternators with integral terminal F2 to ground. Attempting to regulators MUST use replacement alternators full-field the alternator by applying battery with integral regulators.
Page 52: Excessive Voltage Output
12 Volt Alternators With Internal Regular Setting: not, check the EXC circuit. When a Thermo King unit is installed on a truck, 7. Attach a clamp-on ammeter to the 2A wire it is often connected to a truck battery. When both connected to the B+ terminal on the alternator.
Page 53: Battery
Electrical Maintenance Battery Preheat Buzzer NOTE: The Microprocessor Power switch must The preheat buzzer module on the circuit board is be placed in the Off position before connecting designed to indicate preheat is in operation. or disconnecting the battery terminals. The Microprocessor Power switch is located on the RPM Sensor control box side of the unit.
Page 54: Glow Plugs
Electrical Maintenance Glow Plugs 2. Disconnect wires RPM+ and RPM- from the sensor. Glow plugs heat the combustion chamber to aid in quick starting. The glow plugs are energized when the microprocessor initiates unit start-up. A defective glow plug (burned out) can be detected by placing an external ammeter in series with the plugs.
Page 55: Condenser/Evaporator Fan Rotation (Electric Standby Operation)
Electrical Maintenance Condenser/Evaporator Fan Rotation (Electric Standby Operation) The condenser and evaporator fans are belt driven. On electric standby operation, check for correct fan rotation by placing a small cloth or sheet of paper against the condenser fan grille on the front of the unit.
Page 56: High Capacity Thermax
Electrical Maintenance 6. Repeat test procedure several times to be sure The components that have been added to the the setting is correct. system are: 7. Remove the test equipment. Install wire on • the TherMax solenoid switch terminal and air sensing tubes on air •...
Page 57: Defrost Mode
Electrical Maintenance Defrost Mode The Condenser Evacuation mode is not used before the Defrost mode. The TherMax solenoid, the hot gas solenoid, and the condenser inlet solenoid are all energized at the same time. The TherMax solenoid remains open while the unit is in the Defrost mode.
Page 58 Electrical Maintenance...
Page 59: Engine Maintenance
NOTE: Units equipped with the EMI 2000 ThermoGuard µP-T Microprocessor Controller package do require regular inspection in Diagnosis Manual. accordance with Thermo King’s maintenance recommendations. Engine Oil Change NOTE: The new EMI 2000 oil filters and new The engine oil should be changed according to the EMI 2000 air cleaners are NOT interchangeable “Maintenance Inspection Schedule”.
Page 60: Oil Filter Change
25 in. (635 mm) of vacuum, or at 2,000 hours, or 1 year, whichever occurs first. It cannot be interchanged with air filter elements used on previous Thermo King truck units. Spin-on Oil Filter Pressure Valve Nut...
Page 61: Engine Cooling System
Engine Maintenance Engine Cooling System All water-cooled engines are shipped from the factory with a mixture of 50% permanent type antifreeze concentrate and 50% water in the General Description engine cooling system. The engine employs a closed, circulating type, This provides the following: pressurized cooling system.
Page 62: Elc (Extended Life Coolant)
To upgrade new production engines for ELC use, The following are the Extended Life Coolants all water pump seal bellows were changed from currently approved by Thermo King for use in NBR to HNBR elastomer, and the o-rings ELC units for five years or 12,000 hours: upgraded from NBR to EPDM elastomer.
Page 63 Engine Maintenance Antifreeze Maintenance Procedure b. Close the drain cock and install a commercially available radiator and block As with all equipment containing antifreeze, flushing agent, and operate the unit in periodic inspection on a regular basis is required accordance with instructions of the to verify the condition of the antifreeze.
Page 64: Engine Thermostat
Engine Thermostat Engine Fuel System For the best engine operation, use a 180 F (82 C) The fuel system used on the Thermo King thermostat year round. TK 3.74 diesel is a high pressure system used in conjunction with a prechamber.
Page 65: Bleeding The Fuel System
Proceed as follows: Thermo King recommends that any major 1. Loosen the bleeder screw on the inlet fuel injection pump or nozzle repairs be done by a fitting of the injection pump.
Page 66: Figure 37: Fuel And Oil System Components
Engine Maintenance Figure 37: Fuel and Oil System Components...
Page 67 Engine Maintenance Elbow—hose fitting (3/8) Lockwasher Kit—sleeve & eyelet (3/8) Flatwasher Nut (3/8) Washer (nylon) Hose (3/8 od x 35 ft lg) Sensor—oil pressure Not Used Nut—sensor Kit—sleeve & eyelet (1/4) Lockwasher Nut (1/4) Flatwasher Elbow Fitting—engine (3.0 in lg) Hose Pump—fuel (12V) 10.
Page 68: Draining Water From Fuel Tank
Engine Maintenance Draining Water from Fuel Tank Electric Fuel Pump Water run through the system may damage the Operation injection pump or nozzles. Damage to the fuel system will subsequently cause more expensive The electric fuel pump must be mounted next to damage to the engine.
Page 69: Injection Pump
Engine Maintenance Reassembly Timing the Injection Pump to the Engine Place the cover gasket on the bottom cover and There are two different types of timing procedures install the filter and cover assembly. Replace the used on the engine. One procedure involves three screws.
Page 70: Figure 39: Timing Marks
Engine Maintenance TDC Mark File V-Notch Here Injection Timing Mark Timing Mark Round Notch Figure 39: Timing Marks 1. Rotate the engine in the direction of rotation The timing mark on the starter mounting (clockwise as viewed from the water pump plate is a line stamped on the side of the plate end) until the number 1 cylinder (closest to facing the flywheel.
Page 71: Figure 40: Individual Cylinder Timing And Firing Order
Engine Maintenance 4. Energize the fuel pump and fuel solenoid by 13. Reinstall the injector lines, bleed the air from using the Interface Board Test mode to the nozzles, and test run the engine. energize the Fuel On Relay (K9). See the µP-T Microprocessor Diagnosis Manual, for Timing Individual Cylinder Injection information about the Interface Board Test...
Page 72: Adjust Engine Valve Clearance
California. All other equipment can be serviced per recent service bulletins with special tools and CAUTION: Make sure the fuel rack is off procedures. California service technicians should to prevent the engine from starting. see your local Thermo King dealer for recent bulletins.
Page 73: Engine Mounts
Engine Maintenance Engine Mounts The engine mounting system contains three vibration mounts, two snubber mounts, and a chain restraining mount. AGA648 0.2 in. (5 mm) Air Gap Between Lower Snubber and Engine Bracket When Assembled (Snubbers Only) NOTE: For details see “Chain/Restraining Mount”...
Page 74 Engine Maintenance Restraining Bracket 14. Mount Screw Bracket Screw 15. Flatwasher Belleville Washer 16. Wear Plate Mount Wear Plate Rivet 17. Engine Screw Belleville Washer 18. Belleville Washer Vibration Mount 19. Vibration Engine Mount (set of two) Engine Mount (roadside) 20.
Page 75: Restraining Mount Adjustment
Engine Maintenance Restraining Mount Adjustment edge to verify. Next, retighten belts using TK Gauge (see Tool Catalog). Set belt tension to a Install belts and remove slack. After belt tension reading of 55 to 60. Recheck restraining mount has been set (no slack). Check seating in pulleys. alignment using a straight edge.
Page 76: Figure 43: Chain/Restraining Mount Bracket
Engine Maintenance AGA650 Screw (5/16-18 SS); Flatwasher (5/16); Screw (3/8-16 SS); Flatwasher (3/8); Nylock Nut (5/16-18 SS) Nylock Nut (3/8-16 SS) Vibration Mount 2-Link Chain Mount Frame Bracket This End Through Existing Hole In Engine Flange Figure 43: Chain/Restraining Mount Bracket...
Page 77: Integral Fuel Solenoid
Engine Maintenance Integral Fuel Solenoid “pulled-in” position, the plunger releases tension on the governor linkage. The governor linkage The fuel solenoid is located on the end of the fuel then moves the fuel injector rack, thus controlling injection pump. the fuel flow and placing it in the “Fuel On” position.
Page 78: Engine Speed Adjustments
Engine Maintenance Engine Speed Adjustments High Speed Adjustment 1. Start the unit and let it run until the engine is Low Speed Adjustment warmed up. 1. Start the unit and let it run until the engine is 2. Run the engine in high speed and check the warmed up.
Page 79: Belts
Engine Maintenance Belts 2. Loosen the locknut on the idler pulley adjustment bolt. This bolt is located directly The unit uses only two belts to transfer power above the idler pulley on the idler pulley from the engine and the electric motor to the mounting bracket.
Page 80: Electric Motor/Compressor Belt
Engine Maintenance AGA652 Scroll Compressor Engine—Clutch Alternator Evaporator Fan Pulley Electric Motor Evaporator Fan Pulley Idler Pulley—Belt Tension Compressor Pulley Engine Figure 46: Rear View Belt and Pulley Layout Electric Motor/Compressor Belt 3. Turn the locknut above the adjusting bracket on the eye bolt to obtain the proper belt The electric motor/compressor belt is a poly-v belt tension (field reset—55 to 60 on TK gauge).
Page 81: Alternator Adjustment
Engine Maintenance Alternator Adjustment Shims may be used to facilitate alignment during alternator installation. Use adjustment strap and eye bolt to ensure belt tension reading is between 55 to 65 on TK gauge. AGA643 NOTE: It is critical that the belt be correctly seated in pulley.
Page 82: Idler Pulley Bearing And Seal Installation
Engine Maintenance Idler Pulley Bearing and Seal To perform a bearing and seal change the following procedure is recommended. Installation 1. Remove idler pulley from unit. NOTE: See the Parts manual for the bearing assembly part number. 2. Remove retaining snap ring and discard the two bearings.
Page 83: Assembly Instructions
Engine Maintenance Assembly Instructions 1. Stack items on an assembly pin that supports pulley. 2. Install wave washer, one ball bearing (seal side out) and bearing spacer on pin. 3. Install grease slinger and add grease. Fill cavity 1/2 full between bearings. Use Shell Alvania EP2 (see Tool Catalog).
Page 84 Engine Maintenance...
Page 85: Refrigeration Maintenance
See the diagram of the Thermo King Evacuation be overcharged with refrigerant when charged Station and note the location of the valves.
Page 86: Figure 49: Evacuation Station
Refrigeration Maintenance AGA654 Two Stage Vacuum Pump Thermistor To 110 Vac Power Calibration Standard Vacuum or Micron Gauge Figure 49: Evacuation Station...
Page 87: Figure 50: Vacuum Gauge
Refrigeration Maintenance 100 Microns 500 Microns 1000 Microns 2500 Microns 5000 Microns 20,000 Microns Atmospheric Pressure Calibration Adjustment Screw Example: Meter needle shown at calibration position when Calibration Standard specifies 0.15 mm Hg. Figure 50: Vacuum Gauge...
Page 88: Set Up And Test Of Evacuation Equipment
Refrigeration Maintenance Set Up and Test of Evacuation NOTE: If the vacuum pump is okay, and Equipment there are no leaks between V-1 and V-3, the micron gauge should show less than 500 NOTE: See the previous two pages for the microns.
Page 89: Unit Evacuation
Refrigeration Maintenance 7. Evacuate hoses to 100 microns or lowest NOTE: The presence of refrigerant in the achievable level below 500 microns. compressor oil may prevent a low micron reading from being achieved. The oil can 8. Once 100 microns is reached, close valve V-1 continue to “outgas”...
Page 90: Remove Refrigerant Hoses
Refrigeration Maintenance Refrigerant Leaks 5. If the unit is not fully charged, attach the gauge manifold set to the suction service valve Use a reliable leak detector (e.g., electronic and the discharge service port (see Figure 53 detector) to leak test the refrigeration system. on page 93).
Page 91: Testing The Refrigerant Charge With A Loaded Box
Refrigeration Maintenance Testing the Refrigerant Charge with To check compressor oil level with an ambient air temperature above 50 F (10 C): a Loaded Box Install a gauge manifold (see Figure 53 on page 1. Install a gauge manifold (optional). 93).
Page 92: High Pressure Cutout (Hpco)
Refrigeration Maintenance High Pressure Cutout (HPCO) 3. Raise the discharge pressure of the compressor by blocking the condenser coil air The high pressure cutout is located on the flow by covering the roadside condenser grille discharge line. If the discharge pressure rises with a piece of cardboard.
Page 93: Refrigeration System Checks
Refrigeration Maintenance Refrigeration System Checks 4. Cover the condenser and check the head pressure. The compressor should be able to NOTE: The Scroll compressor can not be increase the head pressure at least 100 psig pumped down. Check the compressor efficiency (689 kPa).
Page 94: Figure 54: Three-Way Valve Condenser Pressure Bypass Check Valve
Refrigeration Maintenance 5. Operate the unit on cool, and pump down the 8. Gauges will remain in this position low side to 0 in. (0 kPa) of vacuum. (approximately 30 to 50 psig [207 to 345 kPa]) if the three-way valve seals 6.
Page 95: Discharge Pressure Regulator Valve
Refrigeration Maintenance Discharge Pressure Regulator Valve This unit is equipped with a discharge pressure regulator valve, which is located in the hot gas line between the hot gas valve and the evaporator coil distributor head. The discharge pressure regulator valve maintains the compressor discharge pressure at 340 to 400 psig (2344 to 2758 kPa) during heat and defrost operation.
Page 96 Refrigeration Maintenance...
Page 97: Refrigeration Service Operations
Refrigeration Service Operations NOTE: It is generally good practice to replace 4. Disconnect the high temperature cutout the filter drier whenever the high side is opened switch, the pilot solenoid line, and unsolder or when the low side is opened for an extended liquid injection line.
Page 98: Figure 56: Compressor Components
Refrigeration Service Operations AGA660 AGA661 Pulley Shaft Seal Assembly Oil Filter Cover Plate Suction Adapter Oil Filter Compressor Stabilization Bracket High Temperature Cutout Switch Oil Drain Cap Figure 56: Compressor Components...
Page 99: Shaft Seal Change Procedure
When the shaft seal is changed, Thermo King also recommends changing the oil and oil filter. The steps for changing the shaft seal are as...
Page 100: Figure 59: Bellows Installation With Tool
Refrigeration Service Operations 13. Use seal installation tool (see Tool Catalog) to If the installation tool is not available, use the pad install the bellows squarely on the shaft. Clean in the new seal packaging to protect the polished the seal installation tool and place it on the surface of the hard ring during assembly.
Page 101: Compressor Oil Filter Replacement
Measure amount of total loss of refrigerant charge. When the oil filter oil drained from compressor. is changed, Thermo King also recommends changing the oil. 4. Remove two screws and oil drain cap from compressor.
Page 102: High Temperature Cutout Switch Change Procedure
Change Procedure 2. Clean compressor body in area of liquid injection fitting. NOTE: Thermo King recommends changing the high temperature cutout switch whenever the 3. Sweat tubing out of liquid injection fitting. insulation on the leads has been broken or there 4.
Page 103: Condenser/Radiator Coil
Refrigeration Service Operations Condenser/Radiator Coil Installation Removal CAUTION: A heat sink must be used on the in-line check valve when it is being 1. Remove the refrigerant charge. soldered in place to prevent damage to the 2. Remove the grille assembly. neoprene seal.
Page 104: Installation
Refrigeration Service Operations Installation Dehydrator (Filter-Drier) 1. Install and bolt the liquid injection valve Removal assembly in the unit. 1. Pump down the refrigeration system and 2. Solder (95-5 Solder) the inlet liquid line and equalize the pressure to slightly positive. the outlet line to the injection valve.
Page 105: Installation
Refrigeration Service Operations Installation 3. Solder (95-5 Solder) the equalizer line to the expansion valve. 1. Place the evaporator coil in the housing. 4. Clean the suction line to a bright polished 2. Install the mounting bolts and tighten. condition. Install the feeler bulb clamps and 3.
Page 106: Cleaning In-Line Screen
Refrigeration Service Operations Cleaning In-line Screen 8. Unsolder the remaining outlet suction line and inlet liquid line connections from the 1. Perform a low side pump down; bleed condenser side of the bulkhead. Remove putty pressure back to 1 psig (7 kPa). from around the lines before unsoldering the 2.
Page 107: High Pressure Cutout Switch
Refrigeration Service Operations High Pressure Cutout Switch Pilot Solenoid Removal Removal 1. Front seat the three-way valve bypass check 1. Recover refrigerant from the unit. valve 2. Disconnect the lines to the solenoid and 2. Start the unit and pump down the low side. immediately cap to prevent moisture and air from entering the system.
Page 108: Three-Way Valve Condenser Pressure Bypass Check Valve Repair
Refrigeration Service Operations 3. Solder the filter drier line to the receiver tank 5. Remove the spring and Teflon valve. outlet valve. 6. Inspect the check valve seat in the three-way 4. Tighten the receiver tank mounting hardware valve. securely. 7.
Page 109: Three-Way Valve Repair
Refrigeration Service Operations Three-way Valve Repair NOTE: The three-way valve can be repaired in the unit if leakage or damage to the Teflon seals should occur. Removal 1. Remove the refrigerant charge. 2. Clean the exterior surface of the valve. 3.
Page 110: Installation
Refrigeration Service Operations Installation R-404A NOTE: Three-way valve kit is used to repair The refrigeration industry has introduced a new three-way valves (see Tool Catalog). refrigerant called R-404A. This refrigeration is classified as a Hydro-fluorocarbon (HFC) because After cleaning and inspecting all parts, reassemble it contains hydrogen fluorine and carbon.
Page 111: Compressor Oil
Refrigeration Service Operations Compressor Oil Vacuum Pumps As of January 1, 1993, Thermo King Corporation When evacuating, a two stage three or five CFM has chosen to use a compressor oil called Polyol pump is recommended. It is also recommended Ester (POE)—also called ester based oil.
Page 112: Refrigerant Recovery
R-404A systems. NOTE: For additional information on parts and supplies, consult your local Thermo King dealer and the Thermo King Tool Catalog. Refrigerant Recovery Present systems can be adapted to the recovery of R-404A but should be dedicated to the recovery of these refrigerants.
Page 113: Hilliard Clutch Maintenance
Hilliard Clutch Maintenance Large Truck Unit Centrifugal Clutch Change The centrifugal clutch has three belt grooves and its engagement speed is 600 ± 100 RPM. AGA127 Figure 69: Front View and Cross Section...
Page 114: Figure 70: Hilliard Centrifugal Clutch
Hilliard Clutch Maintenance aea558 (3 belt grooves) Screw Grease Seal Washer Roller Bearing Inner Race Snap-Ring Pulley Housing Ball Bearing Elastic Stop Nuts (6) Large & Small Spacers Connector Link (6) Rolling Bearing Spring (6) Lockwasher (12) Shoe Assembly (3) Bushing (6) Screws (6) Figure 70: Hilliard Centrifugal Clutch...
Page 115: Clutch Maintenance
Hilliard Clutch Maintenance Clutch Maintenance 3. Remove housing from hub by supporting hub (in a minimum of three places) in spoke area, Using an inspection mirror, inspect the clutch and pressing on the housing shaft. The inner every 1000 hours of operation or yearly, race of the roller bearing will remain on the whichever occurs first.
Page 116: Assembly Procedure (Using New Bearings And Seal)
Hilliard Clutch Maintenance 7. Press bushings out of hub. Figure 73: Bushing Removal 8. Remove inner race of roller bearing from the housing shaft. Figure 74: Bushing Insertion NOTE: This race had Loctite applied and was pressed in place. A puller will be *DO NOT USE SOAP OR OIL TO required to remove it.
Page 117: Figure 75: Clutch
Hilliard Clutch Maintenance 6. Apply Mobil (see Tool Catalog) grease to roller bearing and fill cavity between large and small spacers. A small amount of grease should also be applied to the seal lip and space between the seal and roller bearing. 7.
Page 118 Hilliard Clutch Maintenance...
Page 119: Structural Maintenance
Structural Maintenance Unit And Engine Mounting Fan Location Bolts When mounting the fan and hub assembly on the fanshaft, position the assembly in the orifice with Periodically check and tighten all unit and engine 30 to 35 percent of the blade width to the air mounting bolts.
Page 120: Defrost Damper
Structural Maintenance Defrost Damper 2. If the damper blade does not seal evenly along full width of blade: Check the damper during scheduled maintenance a. Loosen the damper bearing blocks. inspections for shaft wear, end play and sealing against air flow. b.
Page 121: Fanshaft Assembly
Structural Maintenance Fanshaft Assembly Disassembly 1. Remove the fanshaft assembly from the unit. The unit is equipped with a one-piece fanshaft Remove both oil plugs and drain the oil from assembly that contains tapered roller bearings in a the housing. sealed oil reservoir.
Page 122: Reassembly
Structural Maintenance Reassembly 4. Using a punch, remove the oil seal from the evaporator end of the assembly. With the seal 1. Install the new bearings on the shaft with a removed, clean the housing in solvent. pipe in the same way they were removed. Figure 81: Removing Oil Seal 5.
Page 123: Figure 85: Installing Oil Seal
Structural Maintenance 3. Install a new oil seal after replacing the 6. Torque the bolts in a criss-cross pattern in bearing race and splash guard. equal steps to 80 in.-lbs (9.04 N•m). NOTE: Tape shaft holes or keyway to prevent seal damage.
Page 124 Structural Maintenance 8. After the correct end play is obtained, add grease for the bearings. NOTE: Use ONLY Thermo King special fanshaft grease (see Tool Catalog) in this assembly. Lock the assembly in a vise with the vent facing up. Pour grease through the top plug until it runs out of the side hole.
Page 125: Mechanical Diagnosis
Mechanical Diagnosis Condition Possible Cause Remedy Unit switch On—nothing happens Dead battery Recharge or replace battery Remote switch Off (optional) Turn On Circuit breaker open Replace or reset Corroded battery connections Clean and tighten Fusible link blown Check for shorted main harness and replace fusible link Unit switch On—indicator lights Battery low...
Page 126 Mechanical Diagnosis Condition Possible Cause Remedy Engine stops after starting Air in injection pump Bleed fuel system Fuel filter obstructed Replace filter element High water temperature coolant Add coolant. Check for leaks Low oil pressure Add oil. Check for leaks Vent of fuel tank obstructed Remove obstruction Electric fuel pump not operating...
Page 127 Mechanical Diagnosis Condition Possible Cause Remedy Engine is sooting heavily, emits Wrong fuel Drain and refill with correct fuel thick black clouds of smoke Clogged air intake system Clean air cleaner (excessive fuel to air ratio) Restricted exhaust system Clean or replace Opening pressure of nozzle is Repair nozzle.
Page 128 Mechanical Diagnosis Condition Possible Cause Remedy High oil consumption Oil leakage Check and eliminate possible causes Clogged air cleaner Clean air cleaner Damaged valve seals Replace seals on valve stem Worn valve stem or valve guides Replace valves and valve guides Broken piston rings or cylinder bore Have engine repaired.
Page 129: Electric Standby (Optional) Diagnosis
Electric Standby (Optional) Diagnosis Condition Possible Cause Remedy Unit switch On— µ P-T lights do Battery discharged Charge or replace battery not come on Electric motor reset switch tripping Check for short circuit in unit wiring (high voltage) Fuse link blown Replace fuse link Dirty battery terminals Clean and retighten terminals...
Page 130 Electric Standby (Optional) Diagnosis Condition Possible Cause Remedy Contact chatter Low battery voltage Check voltage condition. Check momentary voltage dip during starting—low voltage prevents magnet sealing Defective or incorrect coil Replace coil Poor contact in control circuit Check auxiliary switch contacts and overload relay contacts.
Page 131: Refrigeration Diagnosis
Refrigeration Diagnosis Possible Causes • • • • Overcharge of refrigerant • • • • • • Shortage of refrigerant • • • • • No refrigerant • Air through condenser too hot (ambient) • Air flow through condenser restricted •...
Page 132 Refrigeration Diagnosis Possible Causes • • • Expansion valve feeler bulb making poor contact • • Expansion valve open too much • • Expansion valve closed too much • • Expansion valve needle eroded or leaking • • • Expansion valve partially closed by ice, dirt or wax •...
Page 133: Cycle Diagrams
Cycle Diagrams Cool Cycle Scroll Compressor Expansion Valve Compressor Temperature Sensor Expansion Valve Feeler Bulb Compressor Oil Sight Glass Equalizer Line Discharge Check Valve Distributor Discharge Service Port Drain Pan Heater High Pressure Relief Valve Evaporator Coil Three-way Valve Accumulator Tank Condenser Pressure By-pass Check Valve Suction Pressure Regulator Condenser Coil...
Page 134: Condenser Evacuation Cycle
Cycle Diagrams Condenser Evacuation Cycle Scroll Compressor Expansion Valve Compressor Temperature Sensor Expansion Valve Feeler Bulb Compressor Oil Sight Glass Equalizer Line Discharge Check Valve Distributor Discharge Service Port Drain Pan Heater High Pressure Relief Valve Evaporator Coil Three-way Valve Accumulator Tank Condenser Pressure By-pass Check Valve Suction Pressure Regulator...
Page 135: Heat/Defrost Cycle
Cycle Diagrams Heat/Defrost Cycle Scroll Compressor Expansion Valve Compressor Temperature Sensor Expansion Valve Feeler Bulb Compressor Oil Sight Glass Equalizer Line Discharge Check Valve Distributor Discharge Service Port Drain Pan Heater High Pressure Relief Valve Evaporator Coil Three-way Valve Accumulator Tank Condenser Pressure By-pass Check Valve Suction Pressure Regulator Condenser Coil...
Page 136 Cycle Diagrams...
Page 137: Index
Index Evaporator Fan Rotation 55 Expansion Valve 105 Accumulator 97 Air Switch Specifications 20 Alarm Codes 47 Alternator 51 Fan Location 119 Alternator Adjustment 81 Fanshaft Assembly 121 Fuel Limit Screw 72 Fuel Solenoid 77 Battery 53 Belt Tension Specifications 18 Belts 79 Glow Plugs 54 Charging System 53...
Page 138 Index Remote Control Panel 41 Restraining Mount 75 RPM Sensor 53 Safety Precautions 13 Safety, Auto Start/Stop 13 Safety, Electrical Hazards 14 Safety, High Voltage 15 Safety, Low Voltage 16 Safety, Refrigerant 13 Safety, Refrigeration Oil 14 Safety, Welding 15 Schematic Diagrams Index 139 Smart Reefer (SR) 27 Specifications 17...
Page 139: Wiring And Schematic Diagrams Index
Wiring and Schematic Diagrams Index Dwg No. Drawing Title Page 5D49383 Truck “S” Model SR 30 Schematic Diagram 141-142 Truck “S” Model 30 Units with µ P-T Wiring Diagram 5D49384 143-144 5D48563 Truck “S” Model 50 Schematic Diagram 145-146 Truck “S” Model 50 Units with µ P-T Wiring Diagram 5D48747 147-148...
Page 140 Wiring and Schematic Diagrams Index...
Page 141 Truck “S” Model SR 30 Schematic Diagram—Page 1 of 2...
Page 142 Truck “S” Model SR 30 Schematic Diagram—Page 2 of 2...
Page 143 Truck “S” Model 30 Units with µP-T Wiring Diagram—Page 1 of 2...
Page 144 Truck “S” Model 30 Units with µP-T Wiring Diagram—Page 2 of 2...
Page 145 Truck “S” Model 50 Schematic Diagram—Page 1 of 2...
Page 146 Truck “S” Model 50 Schematic Diagram—Page 2 of 2...
Page 147 Truck “S” Model 50 Units with µP-T Wiring Diagram—Page 1 of 2...
Page 148 Truck “S” Model 50 Units with µP-T Wiring Diagram—Page 2 of 2...

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Thermo King TS-200 Manual

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