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
Table of Contents List of Figures ................11 Safety Precautions .
Page 6 Table of Contents Technician Features ..............35 Refrigeration System Diagrams .
Page 7 Table of Contents Battery ................. 84 Unit Wiring .
Page 8 Table of Contents Refrigerant Leaks ............... 132 Refrigerant Charge .
Page 9 Table of Contents Clutch Maintenance ..............153 Tools Required .
Page 10 Table of Contents...
Page 11: List Of Figures
List of Figures Figure 1: SPECTRUM TS Front View ............27 ™...
Page 12 List of Figures Figure 59: Select Zone To Defrost Display ........... . . 65 Figure 60: Zone 1 in Defrost .
Page 13 List of Figures Figure 119: TK 3.95 (Tier 1) ..............91 Figure 120: TK376 (Tier 2) .
Page 14 List of Figures Figure 179: Bushing Removal ............. . 154 Figure 180: Bushing Insertion .
Page 15: Safety Precautions
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.
Page 16: Auto Start/Stop
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.
Page 17: Electrical Hazards
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.
Page 18: Welding Precautions
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 •...
Page 19: First Aid, Electrical Shock
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.
Page 20 Safety Precautions...
Page 21: Specifications
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 &...
Page 22: Belt Tension
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...
Page 23: Refrigeration System
Specifications Refrigeration System Compressor Model TKO Scroll Refrigerant Charge Approximately 13.44 lb (6kg) *Compressor Oil Charge 1.6 qt (1.5 liters) Compressor Oil Type: R-404A (EAL 22) Ester base required for Scroll compressor (See Tool Catalog) P/N 203-516 Throttling Valve Setting 28 ±...
Page 24: System Controller
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)
Page 25: Maintenance Inspection Schedule
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”).
Page 26 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. •...
Page 27: Unit Description
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,...
Page 28: Engine
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.
Page 29: Emi 2000
Thermo King's maintenance the diesel engine. All information is shown in recommendations. English, with the ability to display in several other languages.
Page 30: Microprocessor Power Switch
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.
Page 31: Electric Standby (Model 50 Units Only)
• 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...
Page 32: Unit Instruments
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.
Page 33: Refrigeration System Components
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.
Page 34: Engine Controls
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. •...
Page 35: Refrigeration Cycles
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.
Page 36: Refrigeration System Diagrams
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.
Page 37: Figure 8: Refrigeration System Components
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...
Page 38: Zone 1 Cool And Zone 2 Cool
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.
Page 39: Zone 1 Heat And Zone 2 Heat
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.
Page 40: Zone 1 Cool And Zone 2 Heat
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.
Page 41: Zone 1 Cool And Zone 2 Null
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.
Page 42: Zone 1 Heat And Zone 2 Null
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.
Page 43: Zone 1 Cool And Zone 2 Defrost
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...
Page 44: Zone 1 Heat And Zone 2 Defrost
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.
Page 45: Zone 1 Defrost And Zone 2 Null
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.
Page 46: Figure 17: Zone 1 Cool, Zone 2 Heat, And Zone 3 Heat
Unit Description Figure 17: Zone 1 Cool, Zone 2 Heat, and Zone 3 Heat...
Page 47: Zone 1 Cool, Zone 2 Heat, And Zone 3 Heat
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...
Page 48: Figure 18: Zone 1 Cool, Zone 2 Heat, And Zone 3 Defrost
Unit Description Figure 18: Zone 1 Cool, Zone 2 Heat, and Zone 3 Defrost...
Page 49: Zone 1 Cool, Zone 2 Heat And Zone 3 Defrost
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.
Page 50: Inverted Heat Mode
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.
Page 51: Figure 19: Front View
Unit Description AJA1350 Figure 19: Front View AJA1500 Figure 20: Back View...
Page 52: Figure 21: Side View
Unit Description On/Off Switch Figure 21: Side View...
Page 53: Figure 22: Condenser Compartment Components
Unit Description AJA1176 Electric Motor Discharge Pressure Regulator Alternator Suction Service Valve Throttle Valve Suction Pressure Transducer Discharge Service Port Discharge Pressure Transducer High Pressure Cutout Switch Location Liquid Injection Valve Condenser Inlet Solenoid Hot Gas Bypass Solenoid Receiver Tank Pressure Check Valve Purge Valve Condenser Inlet Check Valve Purge Check Valve...
Page 54: Figure 23: Control Box And Miscellaneous Components
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...
Page 55: Figure 24: Power Receptacle Box-Model 50
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...
Page 56: Control Box, Fuses And Relays
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.
Page 57: Power Supply Board
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.
Page 58: Figure 30: High Voltage Contactors With Shield Removed
Unit Description Phase Detect Module Motor Contactor Motor Contactor Overload Relay Figure 30: High Voltage Contactors with Shield Removed...
Page 59: Serial Number Locations
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.
Page 60 Unit Description...
Page 61: Spectrum™ Ts Operation
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.
Page 62: The Standard Display
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...
Page 63: Turning A Zone On And Off
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.
Page 64: Changing The Setpoint
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.
Page 65: Starting The Diesel Engine
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.
Page 66: Terminating A Defrost Cycle
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.
Page 67: Selecting A Language
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.
Page 68: Selecting Cycle Sentry Or Continuous Mode
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.
Page 69: Selecting Economy Mode
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.
Page 70: Selecting Sleep Mode
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.
Page 71: Pretrip Tests
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...
Page 72: Performing A Pretrip Test
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.
Page 73: Selecting Diesel Or Electric Operation
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.
Page 74: Single Temperature Operation
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.
Page 75: Viewing Hourmeters
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.
Page 76 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.
Page 77: Viewing And Clearing Alarm Codes
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.
Page 78: After Start Inspection
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.
Page 79: Loading Procedure
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.
Page 80 SPECTRUM™ TS Operation...
Page 81: Electrical Maintenance
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.
Page 82: Interface Board Fuse F8
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.
Page 83 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...
Page 84: Excessive Voltage Output
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...
Page 85: Preheat Buzzer
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.
Page 86: Glow Plugs
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...
Page 87 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...
Page 88: Removal And Replacement
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.
Page 89: Overload Relay
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.
Page 90 Electrical Maintenance...
Page 91: Engine Maintenance
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.
Page 92: Engine Oil Pressure Switch
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.
Page 93: Engine Air Cleaner (Emi 2000)
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...
Page 94: Engine Cooling System
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.
Page 95: Figure 125: Tk376 Engine Cooling Components
Engine Maintenance Engine Water Level Sensors Water Temperature Sensor Radiator Orifice Drain Tubing Bleed Line Drain Cock Adaptor Expansion Tank 10. Drain Cock Figure 125: TK376 Engine Cooling Components...
Page 96: Elc (Extended Life Coolant)
(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.
Page 97: Antifreeze Maintenance Procedures
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.
Page 98: Engine Thermostat
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: •...
Page 99: Bleeding The Fuel System
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.
Page 100: Figure 130: Early Tk 3.95 Fuel And Oil System Components
Engine Maintenance Figure 130: Early TK 3.95 Fuel and Oil System Components...
Page 101 Engine Maintenance Elbow—hose fitting (3/8) 26. Lockwasher Kit—sleeve & eyelet (3/8) 27. Flatwasher Nut (3/8) Washer (nylon) Hose (3/8 od x 35 ft lg) 28. Sensor—oil pressure Not Used Nut—sensor Kit—sleeve & eyelet (1/4) Lockwasher Nut (1/4) Flatwasher Elbow 29. Fitting—engine (3.0 in. lg) Hose 30.
Page 102: Figure 131: Late Tk 3.95 Fuel And Oil System Components
Engine Maintenance Figure 131: Late TK 3.95 Fuel and Oil System Components...
Page 103 Engine Maintenance Elbow—hose fitting (3/8) 26. Lockwasher Kit—sleeve & eyelet (3/8) 27. Flatwasher Nut (3/8) Washer (nylon) Hose (3/8 od x 35 ft lg) 28. Sensor—oil pressure Not Used Nut—sensor Kit—sleeve & eyelet (1/4) Lockwasher Nut (1/4) Flatwasher Elbow 29. Fitting—engine (3.0 in. lg) Hose 30.
Page 104: Figure 132: Tk376 Fuel And Oil System Components
Engine Maintenance Figure 132: TK376 Fuel and Oil System Components...
Page 105 Engine Maintenance Elbow—hose fitting (3/8) 18. Filter—oil bypass (EMI 2000) Kit—sleeve & eyelet (3/8) 19. Stud—bypass filter Nut (3/8) 20. Filter—oil (full flow) Hose (3/8 od x 35 ft lg) 21. Tee Adapter—oil line 22. Switch—oil pressure Kit—sleeve & eyelet (1/4) 23.
Page 106: 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 107: Injection Pump
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...
Page 108: Figure 134: Timing Marks
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.
Page 109: Timing Individual Cylinder Injection Tk 3.95 Engine
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.
Page 110: Injection Pump Timing Tk376 Engine
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.
Page 111: Injection Pump Removal And Installation Tk376 Engine
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...
Page 112: Figure 140: Tk376 Injection Pump Removal And Installation
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.
Page 113: Fuel Limit Screw
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.
Page 114: Engine Mounts
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”...
Page 115 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 116: Tk376 Engine
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...
Page 117 Engine Maintenance Bracket - Snubber 13. Mount - Vibration Plate - Front Bracket 14. Nut Screw - Plate & Bracket (Socket Head) 15. Washer - Belleville Washer - Belleville 16. Flatwasher Sealer - Thread 17. Nut Screw - Mount 18. Bolt - Eye Flatwasher (Front Mount Only) 19.
Page 118: Restraining Mount Adjustment
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).
Page 119: Figure 145: Chain/Restraining Mount Bracket
Engine Maintenance 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 3-Link Chain Mount Frame Bracket This End Through Existing Hole In Engine Flange Figure 145: Chain/Restraining Mount Bracket...
Page 120: 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 121: Engine Speed Adjustments
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.
Page 122: Belts
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.
Page 123: Figure 148: Front View Belt Arrangement
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)
Page 124: 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 60 on TK gauge. AGA643 NOTE: It is critical that the belt be correctly seated in pulley.
Page 125: Refrigeration Maintenance
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.
Page 126: Figure 150: Evacuation Station
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...
Page 127: Figure 151: 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 151: Vacuum Gauge...
Page 128: 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 129: Using The Evacuation Mode Menu
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.
Page 130: Leak Check System
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.
Page 131: Unit Charging
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.
Page 132: Refrigerant Leaks
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.
Page 133: Checking Compressor Oil
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).
Page 134: Low Side Pump Down
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.
Page 135: Refrigeration System Checks
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.
Page 136 Refrigeration Maintenance...
Page 137: Refrigeration Service Operations
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.
Page 138: Figure 162: Compressor Components
Refrigeration Service Operations Pulley Bolt (Torque to 18 to 22 ft-lb (24 to 30 N•m) 10. Screen Pulley Baffle Shaft Seal Cover 12. Thermister Shaft Seal Assembly 13. Oil Drain Plug Oil Filter 14. Sight Glass Oil Filter Spring 15. Screen Cover Oil Filter Cover Plate 16.
Page 139: 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 140: Figure 165: Bellows Installation With Tool
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.
Page 141: Compressor Oil Filter Replacement
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.
Page 142: Temperature Thermister Change Procedure
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.
Page 143: Installation
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.
Page 144: High Pressure Relief Valve
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.
Page 145: 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 146: System Clean-Up
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 147: Reassembly
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.
Page 148: Figure 172: Throttling Valve
Refrigeration Service Operations Screw—Plate and Flatwasher 10. Test Port—Schrader Valve Schrader Valve and Cap (location may vary) Gasket—Piston Housing Plate—Bellows End 12. Piston Gasket—End Plate 13. Conformance Spring—Piston Shim—Adjusting 14. Castle Nut—Adjusting Spring—Bellows 15. Pin—Cotter Bellows and Shaft—Assembly 16. Housing—Piston O-ring 17.
Page 149: Solenoid Valves
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...
Page 150: Condenser Inlet Check Valve Repair
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.
Page 151: 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 175: Front View and Cross Section...
Page 152: Figure 176: 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 176: Hilliard Centrifugal Clutch...
Page 153: 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 154: Assembly Procedure (Using New Bearings And Seal)
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.
Page 155: Figure 181: 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 156 Hilliard Clutch Maintenance...
Page 157: Structural Maintenance
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).
Page 158 Structural Maintenance...
Page 159: 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 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...
Page 160 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 161 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 162 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 163: Electric Standby (Optional) Diagnosis
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...
Page 164 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 165: 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 166 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 167: Remote Evaporator Specifications
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...
Page 168 Remote Evaporator Specifications...
Page 169: Remote Evaporator Maintenance Inspection Schedule
Remote Evaporator Maintenance Inspection Schedule Every Annual / Pre-Trip 1,500 4,500 Inspect/Service These Items Hours Hours Electrical • • Inspect wire harness for damaged wires or connections. • • Inspect/replace fan motor brushes. Structural • • • Visually inspect unit for fluid leaks. •...
Page 170 Remote Evaporator Maintenance Inspection Schedule...
Page 171: Remote Evaporator Unit Description
Remote Evaporator Unit Description Discharge & Return Air 1. Coil Temperature Sensor, Ungraded) Terminal Board Bracket Sensor (Graded) 2. Hot Gas Solenoid 6. Variable Blower (12 V) 10. Terminal Board 3. Liquid Line Solenoid 7. Blower Housing 11. Terminal Board Markstrip Resistance Wire 4.
Page 172: Figure 186: Spectrum™ Ts Evaporator-Front View
Remote Evaporator Unit Description AJA984 Figure 186: SPECTRUM™ TS Evaporator-Front View AJA985 Figure 187: SPECTRUM™ TS Evaporator-Back View...
Page 173: Unit Operation
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.
Page 174: Unit Protection Devices
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...
Page 175: Remote Evaporator Electrical Maintenance
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.
Page 176 Remote Evaporator Electrical Maintenance...
Page 177: Remote Evaporator Refrigeration Service Operations
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.
Page 178: Solenoid Valves
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.
Page 179: Check Valve Repair
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...
Page 180 Remote Evaporator Refrigeration Service Operations...
Page 181: Remote Evaporator Structural Maintenance
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.
Page 182 Remote Evaporator Structural Maintenance...
Page 183: Remote Evaporator System Diagnosis
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...
Page 184 Remote Evaporator System Diagnosis...
Page 185: Index
Index engine mounts 114 engine oil dipstick 32 accumulator 137 engine specifications 21 alternator 81 engine speed adjustments 121 alternator adjustment 124 high speed 121 antifreeze low speed 121 changing 97 engine valve clearance adjustment 113 checking 97 evacuation 125, 130 maintenance procedure 97 fan location 157 battery 84...
Page 186 Index preheat buzzer 85 unit operation, remote evaporator 173 unit options 27 unit protection devices, remote evaporator 174 R-404A 3, 144 radiator coil 142, 157 receiver tank 144 wiring 84 receiver tank sight glass 32 wiring diagrams index 187 recover refrigerant 3 refrigerant charge 132 refrigerant leaks 132 refrigeration diagnosis 165...
Page 187: Wiring And Schematic Diagrams Index
Wiring and Schematic Diagrams Index Dwg No. Drawing Title Page 5D55036 Wiring Diagram 189-191 5D55037 Schematic Diagram 192-195...
Page 188 Wiring and Schematic Diagrams Index...
Page 189 Wiring Diagram — Page 1 of 4...
Page 190 Wiring Diagram — Page 2 of 4...
Page 191 Wiring Diagram — Page 3 of 4...
Page 192 Wiring Diagram — Page 4 of 4...
Page 193 Schematic Diagram — Page 1 of 3...
Page 194 Schematic Diagram — Page 2 of 3...
Page 195 Schematic Diagram — Page 3 of 3...

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