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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.
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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.
Safety Precautions Thermo King recommends that all service be DANGER: Avoid engine operation in performed by a Thermo King dealer. However, confined spaces and areas or you should be aware of several general safety circumstances where fumes from the practices: engine could become trapped and cause serious injury or death.
Safety Precautions NOTE: In the USA, EPA Section 608 WARNING: Wear butyl lined gloves when Certification is required to work on refrigeration handling refrigerant to help prevent systems. frostbite. Auto Start/Stop CAUTION: Refrigerant in a liquid state evaporates rapidly when exposed to the atmosphere, freezing anything it contacts.
Safety Precautions CAUTION: Wipe up spills immediately. WARNING: Safety glasses, rubber- Refrigerant oil can damage paints and insulated gloves and cable cutters should rubber materials. be near your work area, in the event of an electrical accident. Electrical Hazards WARNING: Use caution when working with electrical circuits that contain High Voltage capacitors.
Safety Precautions • Avoid wearing clothing that generates static • If there are any electrical circuit breakers in electricity (wool, nylon, polyester, etc.). the control box, switch them OFF. • Wear a wrist strap (P/N 204-622 or its • Close the control box. equivalent) with the lead end connected to the •...
Safety Precautions Do not induce vomiting. INGESTION: Immediately contact local poison control center or physician. First Aid, Electrical Shock Take IMMEDIATE action after a person has received an electrical shock. Get quick medical assistance, if possible. The source of the shock must be quickly stopped, by either shutting off the power or removing the victim.
Specifications Engine Model: Ending First Quarter 2006 TK 3.95 Starting First Quarter 2006 TK376 See “Engine” on page 28 to identify the engine in the unit. Fuel Type No. 2 Diesel fuel under normal conditions No. 1 Diesel fuel is acceptable cold weather fuel Oil Capacity: Crankcase &...
Specifications Engine (Continued) Engine Coolant Type ELC (Extended Life Coolant), which is red. Units equipped with ELC have an ELC nameplate on the expansion tank. Use a 50/50 concentration of any of the following equivalents: Cheveron Dex-Cool Texaco ELC Havoline Dex-Cool® Havoline XLC for Europe Shell Dexcool®) Shell Rotella...
Specifications System Controller Type SPECTRUM™ TS Microprocessor Controller Electrical Components Current Draw (Amps) Resistance at 12.5 Vdc (Ohms) Glow Plug TK 3.95 1.5 ± 0.15 TK376 2.3 ± 0.2 Fuel Solenoid: Pull In 35 to 45 0.2 to 0.3 Hold In 24 to 29 Starter Motor 90 to 105 (cranking)
Maintenance Inspection Schedule Pretrip 1,200 2,000 Annual/ Inspect/Service These Items Hours Hours 3,000 Hours Microprocessor • Run pretrip test (see “Pretrip Test” in the Operating Manual). Engine • Check fuel supply. • • Check engine oil level. • • Check engine coolant (check gauges screen on HMI) CAUTION: Do not remove radiator cap while coolant is hot (should display “ok”).
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Maintenance Inspection Schedule Pretrip 1,200 2,000 Annual/ Inspect/Service These Items Hours Hours 3,000 Hours Electrical • Check controller for alarms. • Run pretrip test • Check battery voltage screen. • Inspect battery terminals and electrolyte level. • Inspect electrical contacts for pitting or corrosion. •...
Unit Description • Continuous System Monitoring • Coolant Expansion Tank • Coolant Temperature Display • Corrosion Resistant Protection • CYCLE-SENTRY Start/Stop Controls AJA1350 • Diesel/Electric Autoswitching ™ Figure 1: SPECTRUM TS Front View • Total Run Hourmeter Unit Overview • Electric Hourmeter The SPECTRUM TS is a diesel-powered,...
Unit Description Engine Engine power for the SPECTRUM ™ TS is provided by a three cylinder, special clean and silent diesel engine. A belt drive system transfers energy to the compressor, unit fans and alternator. In the first quarter of 2006 the engines in these units changed from a TK 3.95 to a TK376 to meet EPA Tier 2 requirements.
Thermo King's maintenance the diesel engine. All information is shown in recommendations. English, with the ability to display in several other languages.
Unit Description Microprocessor Power Switch Defrost is accomplished by passing hot refrigerant gas through the affected evaporator coil, thus The Microprocessor Power switch applies 12 Vdc melting the frost (or ice). Melted frost drains out control power to the microprocessor and must be of the unit onto the ground through the drain On to operate the unit.
• Automatic Diesel/Electric Selection – The unit will automatically switch to electric Brown operation when a power cord is connected and THERMO KING 9131C98G06 the standby power is switched “on”. The unit Blue can also be programmed to automatically 0202...
Unit Description Unit Instruments coil temperature and ambient temperature since these temperatures are not as critical as Return • Coolant Expansion Tank-The coolant level and Discharge air temperatures. and temperature are monitored by the • Return Air Sensor - monitors the SPECTRUM TS Microprocessor controller.
Unit Description Refrigeration System located in the hot gas bypass line next to the compressor. This valve uses a similar Components technique for controlling compression ratios. The refrigeration system controls are used to • Discharge Pressure Regulator (DPR) (This control the operation of the refrigeration system as component is a mechanical control device) - required by the microprocessor.
Unit Description information is used by the microprocessor and coolant condition is assumed to exist. It is software to determine the unit operating connected to the microprocessor via the CLS conditions. wire. The following valves are required for each zone. •...
Relays and outputs can all be energized Technician Features momentarily. In addition, all functions except the Preheat relay and starter can be locked on. If a The Thermo King SPECTRUM ™ TS control system function is locked on that function will remain features many special technician functions.
Unit Description Refrigeration System Diagrams The following pages show the refrigeration system and examples of the refrigerant flow through two and three zone systems. The operation of two and three zone systems are similar.
Unit Description Scroll Compressor Evaporator Coil Thermister Liquid Line Solenoid Compressor Oil Sight Glass Liquid Return Check Valve Liquid Injection Solenoid Suction Line Check Valve Liquid Injection Check Valve Suction Line Solenoid Discharge Service Port Hot Gas Solenoid High Pressure Cutout Switch Accumulator Tank Condenser Inlet Solenoid Suction Service Valve...
Unit Description Figure 9: Zone 1 Cool and Zone 2 Cool Zone 1 Cool and Zone 2 Cool 4F. Zone 1 Suction Line Solenoid (SLS1)-Open High pressure refrigerant vapor leaves the 5F. Zone 1 Hot Gas Solenoid (HGS1)-Closed compressor and flows through the open CIS to the Zone 2 Evaporator condenser where the refrigerant condenses into high pressure liquid.
Unit Description Figure 10: Zone 1 Heat and Zone 2 Heat Zone 1 Heat and Zone 2 Heat Zone 2 Evaporator The CIS is closed so high pressure refrigerant 1R. Zone 2 Liquid Line Solenoid (LLS2)-Open vapor leaves the compressor and flows through 2R.
Unit Description Figure 11: Zone 1 Cool and Zone 2 Heat Zone 1 Cool and Zone 2 Heat 3F. Zone 1 Suction Line Check Valve (SLCV1)-Open The CIS is closed so high pressure refrigerant vapor leaves the compressor and flows through 4F.
Unit Description Figure 12: Zone 1 Cool and Zone 2 Null Zone 1 Cool and Zone 2 Null Zone 2 Evaporator High pressure refrigerant vapor leaves the 1R. Zone 2 Liquid Line Solenoid (LLS2)-Closed compressor and flows through the open CIS to the 2R.
Unit Description Figure 13: Zone 1 Heat and Zone 2 Null Zone 1 Heat and Zone 2 Null 2R. Zone 2 Liquid Return Check Valve (LRCV2)-Closed The CIS is closed so high pressure refrigerant vapor leaves the compressor and flows through 3R.
Unit Description Figure 14: Zone 1 Cool and Zone 2 Defrost Zone 1 Cool and Zone 2 Defrost 4F. Zone 1 Suction Line Solenoid (SLS1)-Open The CIS is closed so high pressure refrigerant 5F. Zone 1 Hot Gas Solenoid (HGS1)-Closed vapor leaves the compressor and flows through Zone 2 Evaporator the DPR to the Zone 2 hot gas line and the open...
Unit Description Figure 15: Zone 1 Heat and Zone 2 Defrost Zone 1 Heat and Zone 2 Defrost Zone 2 Evaporator The CIS is closed so high pressure refrigerant 1R. Zone 2 Liquid Line Solenoid (LLS2)-Open vapor leaves the compressor and flows through 2R.
Unit Description Figure 16: Zone 1 Defrost and Zone 2 Null Zone 1 Defrost and Zone 2 Null Zone 2 Evaporator The CIS is closed so high pressure refrigerant 1R. Zone 2 Liquid Line Solenoid (LLS2)-Closed vapor leaves the compressor and flows through 2R.
Unit Description Zone 1 Cool, Zone 2 Heat, and Zone Zone 3 Evaporator 3 Heat 1R. Zone 3 Liquid Line Solenoid (LLS3)-Open The CIS is closed so high pressure refrigerant 2R. Zone 3 Liquid Return Check Valve vapor leaves the compressor and flows through (LRCV3)-Open the DPR to the Zone 2 and Zone 3 hot gas lines and the open HGS2 and HGS3 into the Zone 2...
Unit Description Zone 1 Cool, Zone 2 Heat and Zone Zone 3 Evaporator 3 Defrost 1R. Zone 2 Liquid Line Solenoid (LLS3)-Open The CIS is closed so high pressure refrigerant 2R. Zone 2 Liquid Return Check Valve vapor leaves the compressor and flows through (LRCV3)-Closed the DPR to the Zone 3 hot gas line and the open HGS3 into the Zone 3 evaporator.
Unit Description Inverted Heat Mode Defrost Mode When the unit switches from cooling in all The delayed switching of the Hot Gas Solenoid, running zones to reverse heat, there is a Condenser Inlet Solenoid, and Suction Line one-minute period where the purge valve is Solenoid does not occur before the Defrost mode.
Unit Description AJA1172 Control Box Interface Board Multi-Temp Option Board ™ SPECTRUM TS Microprocessor Filter Drier Receiver Tank Sight Glass DAS Module (Optional) Main On/Off Switch High Voltage Shield Receiver Tank Power Supply Board Figure 23: Control Box and Miscellaneous Components...
Unit Description AJA455 Figure 24: Power Receptacle Box—Model 50 AJA116 Display Screen Defrost Key High Speed Lockout Key Soft Keys Off Key On Key Figure 25: HMI Control Panel...
Unit Description Control Box, Fuses and Relays The control box is located on the compressor side of the unit (see Figure 23 on page 54). It contains the SPECTRUM TS Microprocessor, Interface ™ board, Multi-Temp Option board, power supply board, the high voltage tray, and miscellaneous F23 F16 fuses and relays located on these boards.
Unit Description Multi-Temp Option Board Interface Board Relay Functions The Multi-temp Option Board adds the control Relay Function functions for Zone 2 and Zone 3. The Alternator Excitation Relay microprocessor controls the operation of the Zone 1 Fan Relay additional zones through the control relays on the Starter Relay multi-temp option board.
Unit Description Serial Number Locations Serial Number and Refrigerant Label Locations AJA1352 Figure 31: Engine Serial Number Location Refrigerant Type Unit Serial Plate Figure 33: Label Locations Figure 34: Laminated Unit Serial Number Plate Figure 32: Compressor Serial Number Location Nameplate on inside of top right side of unit frame.
SPECTRUM™ TS Operation HMI Controller Overview The Standard Display of box temperature and setpoint for 2 zones is shown here. In the display The HMI (Human Machine Interface) Control shown here, Zone 1 has a setpoint of -10 F and a Panel is connected to the microprocessor and is box temperature of -9.4 F.
SPECTRUM™ TS Operation AJA1111 AJA1108 Figure 39: Startup Screen Zone 1 Soft Keys When the unit is ready to run the Standard Zone 2 Soft Key Display will appear. See Figure 40 on page 62. Menu Soft Key Figure 42: One Zone Off The soft key labeled Zone 1 is used to select the Zone 1 Display, the Zone 2 soft key selects Zone 2 Display and the Menu soft key selects the Main...
SPECTRUM™ TS Operation AJA1113 AJA1116 Figure 47: Zone 1 Off “-” Soft Key When the zone is turned on or off, the display will “+” Soft Key briefly indicate that the change is being made as Zone “X” Soft Key shown below.
SPECTRUM™ TS Operation Changing the Setpoint Failure to confirm the new setpoint by pressing Yes or No within 10 seconds of changing the At the Standard Display, press the soft key to setpoint will result in Alarm Code 127 (Setpoint show the Zone Display for the desired zone.
SPECTRUM™ TS Operation • If the NO key is pressed the setpoint change Initiating a Manual Defrost made with the “+” or “-” keys will not be Cycle accepted, the setpoint will not be changed and Defrost cycles are usually initiated automatically the display will return to the Setpoint Display.
SPECTRUM™ TS Operation Terminating a Defrost Cycle Using the Operators Menu The defrost cycle will terminate automatically The Operators Menu contains several additional when the coil temperature is greater than 52 F (11 menus that allow the operator to view information C) or the defrost timer expires.
SPECTRUM™ TS Operation Allows the operator to change Cycle Sentry Mode: The Language menu will appear as shown below. the unit to cycle sentry mode. See “Selecting Press the + or - keys to select the desired Cycle Sentry or Continuous Mode” on page 68. language.
SPECTRUM™ TS Operation Selecting Cycle Sentry or Pressing the Select key will change the mode Continuous Mode from Cycle Sentry to Continuous. The display will confirm the change as shown below. When Cycle Sentry mode is selected the unit will start and stop automatically to maintain setpoint in all compartments, keep the engine warm and the battery charged.
SPECTRUM™ TS Operation Selecting Economy Mode Pressing the Select key will turn Economy Mode on. The display will confirm the change as shown Economy Mode is used on selected loads that do below. not require critical temperature control. The temperature control points are relaxed and other features are optimized for maximum fuel economy.
SPECTRUM™ TS Operation Selecting Sleep Mode CAUTION: The engine may start automatically any time the unit is turned Normal Cycle Sentry mode starts and stops the AJA1133 unit as required to maintain the desired Figure 82: Mode Display temperature in all zones, maintain the unit battery in a charged condition and keep the unit engine Press the Next key as required to display the Sleep warm in cold ambient conditions.
SPECTRUM™ TS Operation To enter a Wake-up Time verify that the unit clock is set properly. Then press the YES key at the Sleep Mode menu. AJA1265 Figure 89: Run Pretrip On Wake-Up The display will show SLEEP and the unit will AJA1260 start and stop as required to keep the engine warm Figure 86: Program Wake-Up Time...
SPECTRUM™ TS Operation Performing a Pretrip Test • The unit will autoswitch from Diesel Mode to Electric Mode or from Electric Mode to Diesel CAUTION: The engine may start Mode during a Pretrip Test if these features automatically any time the unit is turned are enabled.
SPECTRUM™ TS Operation To stop a Pretrip Test at any time turn the unit off. This will generate Alarm Code 28 Pretrip Abort. Other alarm codes may also be generated. This is normal when the Pretrip test is halted before completion.
SPECTRUM™ TS Operation Display Brightness IMPORTANT: If the unit was switched on or to electric and electric standby power is not The brightness of the HMI Control Panel display available. the operator will receive a prompt to can be adjusted to allow for changing ambient return to Diesel Mode operation.
SPECTRUM™ TS Operation Viewing Hourmeters The Display Brightness menu will appear as shown below. Press the + or - keys to select the Hourmeters are displayed using the Hourmeter desired display brightness. When the desired Display. From the Standard Display, press the brightness is shown press the YES key to confirm MENU key.
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SPECTRUM™ TS Operation Hourmeter names and definitions are shown below in the order they appear. To return to the Standard Display, press the EXIT key. Hourmeter Names And Definitions Hourmeter Name Definition Total Hours Total number of hours the unit has been turned on (protection hours). Total Run Hours Total number of hours the unit has run in both diesel and electric mode.
SPECTRUM™ TS Operation replace the Standard Display Viewing and Clearing Alarm Shutdown Alarms: with a flashing Alarm Display and the statement Codes [UNIT NOT RUNNING – SERVICE Alarms may be one of four types as shown. If an REQUIRED]. alarm applies only to a specific zone, that zone The flashing display shows the alarm that caused will be displayed with the alarm code.
SPECTRUM™ TS Operation The Language Menu or Alarm Menu will appear. If the Language Menu appears press the NEXT key to show the Alarm Menu. When the Alarm Menu is shown press the SELECT key. The Alarm Display will appear. AJA1138 Figure 112: Serious Alarm Display A help message will appear.
1. Wash the unit. 4. Products should be pre-cooled before loading. 2. Check for leaks. Thermo King units are designed to maintain loads at the temperature at which they were 3. Check for loose or missing hardware. loaded. Transport refrigeration units are not 4.
Electrical Maintenance Alternator (Prestolite) Charging • The alternator charging output will be low if the alternator belt or pulleys are defective or System Diagnostic Procedures the belt is not properly adjusted. Be sure the belt is not loose or cracked and the pulleys are General Information the correct size and in good condition.
Removing the resistor bypass fuse places the 300 ohm resistor in the excitation Complete the following diagnostic procedures circuit as required for Bosch and Thermo King before replacing an alternator or the voltage Powder Coated alternators. Installing the resistor regulator.
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On unit startup, the current flow the resistor bypass fuse installed will should momentarily increase to allow for damage Bosch and Thermo King Powder battery current used during preheat and Coated alternators. Be sure the resistor cranking. Within a short time the current...
Excessive Voltage Output 12 Volt Alternators With Internal Regular Setting: Charging System (12 Vdc) When a Thermo King unit is installed on a truck, Immediately after start-up, the voltmeter may it is often connected to a truck battery. When both...
Electrical Maintenance NOTE: On installations where the unit is connected to the truck battery and both units are running—it is normal for the unit to indicate a discharge condition while the truck engine is running because of the truck’s higher voltage charge rate.
8.3 amps for the TK 3.95 monitor both single and 3 phase voltages from engine, or 4.3 amps for the TK376 engine. 160 volts AC thru 510 volts AC. Brown THERMO KING 9131C98G06 Blue 0202 Black AJA1501...
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Electrical Maintenance 160 volts AC or a phase is lost, the ER output is Outputs turned off after the condition exists for 8 to 10 Output Description seconds. The module continues to monitor the power and the module ER wire will again output If phase rotation is L1, L2, L3 then this wire will provide either a chassis ground 12-24 volts DC within 2 to 4 seconds after the...
Electrical Maintenance Removal and Replacement Diagnostics - Truck SPECTRUM ™ Applications Procedure 1. Plug the standby power cord into a know good 1. Turn unit off. power supply and turn the unit on. 2. Disconnect the unit battery. 2. Using a Fluke Meter, test the L1, L2, and L3 circuits at the input to the terminals where the 3.
Electrical Maintenance Overload Relay The overload relay protects the standby electric motor. It is located on the high voltage tray (see Figure 30 on page 58). The overload relay opens the circuit to the electric motor if the current exceeds the overload relay setting. The overload relay resets automatically.
2,000 hours, or 1 year, whichever occurs first. NOTE: Units equipped with the EMI 2000 package do require regular inspection in accordance with Thermo King's maintenance recommendations. Figure 119: TK 3.95 (Tier 1) Engine Lubrication System The engine has a pressure lubrication system.
Engine Maintenance Oil Filter Change The oil filters should be changed along with the engine oil. Spin-on Filters: 1. Remove the filter. 2. Apply oil to rubber ring of new filter and install filter. 3. Tighten the filter until the rubber ring makes contact, then tighten 1/2 turn more.
Inspect the element at every oil change. Replace the EMI 2000 air cleaner element 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. Output Connection Intake Hose Connection Dry Filter Element...
Engine Maintenance Engine Cooling System All water-cooled engines are shipped from the factory with a mixture of 50 percent permanent type antifreeze concentrate and 50 percent water General Description in the engine cooling system. The engine employs a closed, circulating type, This provides the following: pressurized cooling system.
(water) is clear. The system can then be filled with extended life coolant (ELC). The following are the Extended Life Coolants currently approved by Thermo King for use in Units with engine serial numbers before K19855 ELC units for five years or 12,000 hours: must have the water pump replaced to change over to ELC coolant.
Engine Maintenance Antifreeze Maintenance Procedures 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.
Engine Maintenance Engine Thermostat Engine Fuel System For the best engine operation, use a 180 F (82 C) The fuel system used on these diesel engines is a thermostat year round. high pressure system used in conjunction with a prechamber. The components of the fuel system are: •...
Engine Maintenance Thermo King recommends that any major injection pump or nozzle repairs be done by a quality diesel injection service specialty shop. The investment in equipment and facilities to service these components is quite high. Therefore, this equipment is not found in most repair shops.
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.
Engine Maintenance Reassembly Injection Pump Timing TK 3.95 Engine Place the cover gasket on the bottom cover and install the filter and cover assembly. Replace the There are two different types of timing procedures three screws. used on the TK 3.95 engine. One procedure involves checking to make sure the cylinders are If pump does not operate, check for: timed correctly to each other, and the other...
Engine Maintenance TDC Mark File V-Notch Here Injection Timing Mark Timing Mark Round Notch Figure 134: 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.
Engine Maintenance Timing Individual Cylinder Injection CAUTION: The 8S wire on the starter TK 3.95 Engine motor should be disconnected. This procedure should be used when a poor running engine has had all possible problems CAUTION: Loosen the injection lines on checked but continues to run badly.
Engine Maintenance Injection Pump Timing 2. Remove the cylinder head cover (valve TK376 Engine cover/intake manifold assembly). This is the only timing procedure for the TK376 3. Place the engine at top dead center of the engine. It is not necessary to check the individual compression stroke for the number one cylinder timing.
Engine Maintenance 9. Check position of the timing marks. The injection timing mark on the flywheel should be aligned with the timing mark on the starter mounting plate. Repeat steps 6 through 9 to recheck the timing. Injection Timing Mark Timing Mark on Starter Mounting Plate Figure 137: Correct Injection Timing Mark Alignment...
Engine Maintenance NOTE: The injection pump gear assembly is 2. Place the injection pump in the gear case. made of two pieces, the flange and the gear. Rotate the injection pump shaft to mate the Do not loosen or remove the four bolts that key in the shaft with the keyway in the fasten the gear to the flange because that injection pump gear.
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. a. Turn the engine so number 1 cylinder is on compression with piston to TDC. Both push rods should turn freely.
Engine Maintenance Engine Mounts TK 3.95 Engine The engine mounting system for the TK 3.95 engine contains three vibration mounts, two snubber mounts, and a chain restraining mount. 0.20 Air Gap Between Lower Snubber and Engine Bracket When Assembled (Snubbers Only) NOTE: For details see “Chain/Restraining Mount”...
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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.
Engine Maintenance TK376 Engine The engine mounting system for the TK376 engine contains three vibration mounts and a chain restraining mount. NOTE: For details see “Chain/Restraining Mount” on page 118. Figure 143: TK376 Engine Mounting Components...
Engine Maintenance Restraining Mount Adjustment retighten belts using TK Gauge (P/N 204-427). Set belt tension to a reading of 55 to 60. Recheck Use this procedure for both the TK 3.95 and restraining mount alignment using a straight edge. TK376 engines. Install belts and remove slack. This is a blowup of balloon items for “TK 3.95 After belt tension has been set (no slack).
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.
Engine Maintenance High Speed (Throttle) Solenoid Ball Joint Low Speed Adjustment Screw Throttle Lever Fuel Solenoid Figure 147: High Speed Solenoid Components TK376 Engine Engine Speed Adjustments High Speed Adjustment 1. Start the unit and let it run until the engine is Low Speed Adjustment warmed up.
Engine Maintenance Belts Electric Motor (Jackshaft)/Compressor Belt The unit uses only two belts to transfer power The electric motor (jackshaft)/compressor belt is a from the engine and the electric motor (or polyvee belt that also drives the alternator. Use the jackshaft) to the alternator and compressor.
Engine Maintenance Idler pulleys are crowned to help pull belt to center 5/11 of idler. NOTE: Pulley and belt alignment is very critical for poly-v belts. Feel pulleys with hand to see that belt is fully seated in pulley. AJA1504 Clutch Idler Pulley (5.5 Inch) Idler Pulley (7-Inch)
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 60 on TK gauge. AGA643 NOTE: It is critical that the belt be correctly seated in pulley.
See the diagram of the Thermo King Evacuation be overcharged with refrigerant when charged Station (Figure 150 on page 126) and note the using the sight glass method.
Refrigeration Maintenance AGA654 Iso-Valve To 110 Vac Power Calibration Standard 10. Vacuum or Micron Gauge Thermistor Charging Port Two Stage Vacuum Pump Figure 150: Evacuation Station...
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.
Refrigeration Maintenance 9. Observe the micron gauge reading. The The Maintenance Menu is accessed from the first vacuum rise should not exceed 2000 microns Operator Menu screen that appears; either the in 5 minutes. Language Display or the Alarms Display. The Alarms Display is shown here.
Leak Check System valve, and discharge service port. A low loss fitting must be used on the hose connected to NOTE: Refer to Diagnosing Thermo King the discharge service port. Refrigeration Systems (TK-5984-10) for leak detection procedures.
Refrigeration Maintenance 8. When the desired micron level has been 7. Set all zones to run in High Speed Cool achieved (500 to 1000 microns), close valve through the HMI Service Test Mode. Refer to V-1 at the pump. Turn the pump off. the SPECTRUM TS Microprocessor Diagnostic Manual (TK 51652) for 9.
Refrigeration Maintenance 3. Open both service manifold hand valves. 3. Set all zones to run in High Speed Cool through the HMI Service Test Mode. Refer to 4. Set all zones to run in Low Speed Cool the SPECTRUM TS Microprocessor through the HMI Service Test Mode.
Refrigeration Maintenance Checking Compressor Oil If the box is empty, you can run the unit on the Heat cycle instead of the Defrost cycle. The compressor oil should be checked when there NOTE: Use refrigeration compressor oil ONLY. is evidence of oil loss (oil leaks) or when R-404A systems use a special Ester oil (see Tool components in the refrigeration system have been Catalog).
Refrigeration Maintenance 2. Set the sepoints in all zones well below the NOTE: Repeat the pump down procedure if zone temperatures so that all zones will be in the pressures equalize above 20 psig High Speed Cool. (138 kPa). If acceptable low pressures cannot be achieved after the third pump 3.
Refrigeration Maintenance The discharge pressure regulator valve is not repairable and must be replaced as an assembly. Refrigeration System Checks NOTE: The Scroll compressor can not be pumped down. Check the compressor efficiency using the following procedure. 1. Install a gauge manifold set. Attach the compound (low pressure) gauge to the service port on the suction service valve.
Refrigeration Service Operations NOTE: It is generally good practice to replace 7. Unsolder the discharge line. the filter drier whenever the high side is opened NOTE: When the compressor is removed or when the low side is opened for an extended from the unit, the oil level should be noted, period of time.
Refrigeration Service Operations 13. Use seal installation tool (P/N 204-995) 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.
When the oil filter 5. Scrape gasket from oil drain cap and body. is changed, Thermo King also recommends changing the oil. 6. Remove spring, screen and screen cover from body.
Procedure 7. Lubricate new o-ring with Mobil oil (see Tool Catalog). NOTE: Thermo King recommends changing the temperature thermister whenever the insulation 8. Carefully thread new liquid injection fitting on the leads has been broken or there is other through compressor body into steel block on reason to suspect a defective thermister.
Refrigeration Service Operations Dehydrator (Filter-Drier) 5. Unbolt and remove the condenser/radiator cap. Removal Installation 1. Pump down the low side and equalize the 1. Clean the tubes for soldering. pressure to slightly positive. 2. Place the coil in the unit and install the 2.
Refrigeration Service Operations High Pressure Relief Valve R-404A The refrigeration industry has introduced a new Removal refrigerant called R-404A. This refrigeration is 1. Recover the refrigerant charge. classified as a Hydro-fluorocarbon (HFC) because it contains hydrogen fluorine and carbon. It does 2.
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.
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.
Refrigeration Service Operations 6. Insert the cotter pin. Inspect for Damage Tighten Castle Nut to Bottom—Then Figure 170: Throttle Valve Housing Back Off 1 Turn Only. Insert Cotter Pin. Figure 171: Throttle Valve Piston Assembly 9. Clean the parts to be reused. 7.
Refrigeration Service Operations Solenoid Valves NOTE: Valves that have nylon seats must be disassembled before soldering. Removal 1. Recover the refrigerant charge. 2. Remove the coil, and disassemble the valve if necessary. 3. Unsolder the refrigeration lines from the valve, and remove the valve from the unit. Valve Neoprene Seal CAUTION: Use a heat sink to prevent...
Refrigeration Service Operations Condenser Inlet Check Valve Condenser Inlet Check Valve Repair Replacement Removal Removal 1. Recover the refrigerant charge. 1. Recover the refrigerant charge. 2. Remove the cap nut from the check valve and 2. Unsolder the lines and remove the check remove the spring and seat.
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 175: Front View and Cross Section...
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.
Hilliard Clutch Maintenance 7. Press bushings out of hub. Figure 179: Bushing Removal 8. Remove inner race of roller bearing from the housing shaft. Figure 180: 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.
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.
Structural Maintenance Unit and Engine Mounting Bolts Fan Location Periodically check and tighten all unit and engine When mounting the fan and hub assembly on the mounting bolts. Torque the unit mounting fanshaft, position the assembly in the orifice as bolts to 60 ft-lb (81.3 N•m).
Mechanical Diagnosis Condition Possible Cause Remedy Unit switch On—nothing happens Dead battery Recharge or replace battery Remote switch Off (optional) Turn On Fuse open Replace Corroded battery connections Clean and tighten Main harness fuse blown Check for shorted main harness and replace fuse Unit switch On—indicator lights Battery low...
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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...
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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.
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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.
Electric Standby (Optional) Diagnosis Condition Possible Cause Remedy Unit switch On—Microprocessor Battery discharged Charge or replace battery display does not come on Electric motor reset switch tripping Check for short circuit in unit wiring (high voltage) Fuse blown Replace fuse Dirty battery terminals Clean and retighten terminals Unit switch On—Microprocessor...
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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.
Refrigeration Diagnosis Possible Causes • • • • Overcharge of refrigerant • • • • • • Shortage of refrigerant • • • • • No refrigerant • Air through condenser too hot (ambient) • Air flow through condenser restricted •...
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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 •...
Remote Evaporator Specifications Refrigeration System Evaporator Coil Type Direct Expansion Refrigerant Type R404a Heat/Defrost Method Hot Gas Electrical Control System Voltage 12.5 Vdc ™ 0.13 hp SPECTRUM TS Evaporator Fan Motor: Horsepower Fan Voltage 8 to 16 Vdc 1900 Full Load Amps 8.7 amps per motor Fuse F1-1, F1-2, F2-1, F2-2 30 amp...
Remote Evaporator Unit Description Defrost The SPECTRUM™ multi-temperature refrigeration system provides heavy duty The Defrost mode can be initiated any time the temperature control for multiple compartment evaporator coil temperature is below 45 F (7 C). trucks. The system provides direct expansion Defrost is initiated automatically by the controller cooling in all cargo compartments.
Remote Evaporator Unit Description Unit Protection Devices • Fuses in Host Unit (located on interface board) Serial Number Location Nameplate on the right end of the unit frame. Unit: AJA985 1. Nameplate on Right End of Unit Frame Figure 188: Serial Number Location...
Remote Evaporator Electrical Maintenance ™ SPECTRUM Microprocessor Controlled Components ™ Refer to the appropriate SPECTRUM Microprocessor Controller Diagnostic Manual (TK 51652) for information about maintenance of the microprocessor controlled components. Unit Wiring Inspect the unit wiring and wire harnesses during scheduled maintenance inspections for loose, chaffed or broken wires to protect against unit malfunction due to opens or shorts.
Remote Evaporator Refrigeration Service Operations NOTE: It is generally good practice to replace 8. Test the unit to see that the expansion valve is the filter drier whenever the high side is opened properly installed. or when the low side is opened for an extended period of time.
Remote Evaporator Refrigeration Service Operations Solenoid Valves Check Valve Replacement NOTE: Valves that have nylon seats must be Removal disassembled before soldering. 1. Pump down the low side and equalize the Removal pressure to slightly positive. 1. Pump down the low side and equalize the 2.
Remote Evaporator Refrigeration Service Operations Check Valve Repair Removal 1. Pump down the low side and equalize the pressure to slightly positive. 2. Remove the access panels. 3. Remove the cap nut from the check valve and remove the spring and seat. AGA173 Gasket Spring...
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Remote Evaporator Refrigeration Service Operations...
Remote Evaporator Structural Maintenance Unit Inspection Inspect the unit during the unit pre-trip inspection and scheduled maintenance inspections for loose or broken wires or hardware, compressor oil leaks, or other physical damage which might affect unit performance and require repair or replacement of parts.
Remote Evaporator System Diagnosis Condition Possible Cause Remedy Load temperature too high Refrigerant shortage Repair leak and recharge Setpoint too high Adjust setpoint Expansion valve plugged Clean or replace Partial obstruction in low side of Locate obstruction and repair refrigeration system Iced or dirty evaporator coil Defrost or clean evaporator coil Expansion valve open too much...
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