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Refrigerator
TS-500 NAD
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Thermo King TS-500 NAD Manual
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Contents
Table of Contents
Bookmarks
Table of Contents
Table of Contents
List of Figures
Safety Precautions
General Practices
Auto Start/Stop
Refrigerant
First Aid
Refrigeration Oil
First Aid
Electrical Hazards
Microprocessor Service
Welding of Units or Truck Bodies
High Voltage
Low Voltage
Unit Decals
Figure 1: Refrigerant Decal Locations
Figure 2: Refrigerant Decal
Specifications
Engine
Belt Tension
Refrigeration System
Engine Clutch - Hilliard
Electrical Control System
Defrost Timer
Thermostat
Electrical Components
Electric Standby (Model 50 Unit Only)
Standby Power Requirements
Air Switch
Maintenance Inspection Schedule
Unit Description
Thermoguard Μp-T Controller
Data Acquisition System (Optional)
Clutch
Unit Features
Unit Instruments
Unit Protection Devices
Unit Operation
Pretrip Inspection (before Starting Unit)
Thermoguard Μp-T Smart Reefer
TM (SR) Microprocessor
Displaying Operating Data
Entering Setpoint Temperature
Starting Unit (Full Unit Self Check)
Selection of Operating Modes on CYCLE-SENTRY Equipped Units
Products Requiring Continuous Run Operation for Air Flow
Products Acceptable for CYCLE-SENTRY Operation
Selecting CYCLE-SENTRY or Continuous Run Mode (Diesel or Electric Operation)
Initiating Manual Defrost
Displaying and Clearing Alarm Codes
Restarting the Unit
After Start Inspection
Loading Procedure
Post Load Procedure
Post Trip Checks
Unit Photographs
Figure 3: Front View
Figure 4: Back View
Figure 5: Side View
Figure 6: Components
Figure 7: Control Box with High Voltage Shield in Place
Figure 8: Power Receptacle Box-Model 50
Figure 9: Thermoguard Remote Control Panel
Figure 10: Remote Light Display Kit
P-T System Description
General Description
P-T Control System
Microprocessor Power Switch
Optional Electric Standby (Model 50 Units Only)
Figure 11: Microprocessor Power Switch
Standard Model 50 Features
Optional Model 50 Features
Figure 12: High Voltage Contactors with Shield Removed
Remote Control Panel Features
Keypad Keys
Figure 13: Remote Control Panel
Understanding the Display
Display Icons
Reading a Typical Display
Figure 14: Display Screen Features
Figure 15: Typical Display
The Standard Display
Changing the Setpoint
Figure 16: Standard Display
Figure 17: Changing the Setpoint
Selecting CYCLE-SENTRY or Continuous Mode
Starting the Engine
Figure 18: Selecting CYCLE-SENTRY or Continuous Mode
Figure 19: Starting the Engine
Initiating a Manual Defrost Cycle
Checking the Software Revision
Figure 20: Initiating a Manual Defrost Cycle
Figure 21: Software Revision
Viewing Prompt and Display Screens
Figure 22: Viewing Prompt and Display Screens
Viewing and Clearing Alarm Codes
Figure 23: Alarm Code Display
P-T Unit Self Check Test
Electrical Maintenance
Alternator (Prestolite) Charging System Diagnostic Procedures
Figure 24: Prestolite Terminal Locations
Excessive Voltage Output
Battery
Unit Wiring
Electrical Contacts
Charging System (12 VDC)
Preheat Buzzer
RPM Sensor
Figure 25: Flywheel (RPM) Sensor
Glow Plugs
Figure 26: RPM+ and RPM- Wires
Figure 27: Glow Plug Test
Condenser/Evaporator Fan Rotation (Electric Standby Operation)
Defrost Air Switch Checkout and Adjustment
Figure 28: Testing Air Switch
Figure 29: Air Switch
High Capacity Thermax
TM Heating System
Cool Mode
Heat/Condenser Evacuation Mode
Defrost Mode
Start up Mode
Engine Maintenance
Emi 2000
Engine Lubrication System
Engine Oil Pressure Sensor
Engine Oil Change
Oil Filter Change
Crankcase Breather
Engine Air Cleaner (EMI 2000)
Figure 30: Oil Filter Parts
Figure 31: Dry Type Air Cleaner
Engine Cooling System
General Description
Figure 32: Engine Cooling Components
ELC (Extended Life Coolant)
Figure 33: ELC Nameplate-Located on Expansion Tank
Engine Thermostat
Engine Fuel System
Figure 34: Water Pump Assembly and Thermostat
Bleeding the Fuel System
Figure 35: Fuel and Oil System Components
Draining Water from Fuel Tank
Fuel Filter Replacement
Electric Fuel Pump
Figure 36: Electric Fuel Pump
Injection Pump
Engine Maintenance (Continued)
Figure 37: Timing Marks
Figure 38: Individual Cylinder Timing and Firing Order
Adjust Engine Valve Clearance
Fuel Limit Screw
Engine Mounts
Figure 39: Engine Mounting Components
Restraining Mount Adjustment
Figure 40: Chain/Restraining Mount
Figure 41: Chain/Restraining Mount Bracket
Integral Fuel Solenoid
Fuel Solenoid Diagnostic and Replacement
Figure 42: Integral Fuel Solenoid Components
Engine Speed Adjustments
Low Speed Adjustment
High Speed Adjustment
Belts
Engine/Electric Motor Belt
Figure 43: Front View Belt Arrangement
Electric Motor/Compressor Belt
Alternator Adjustment
Figure 44: Alternator Mounting and Belt Tension Adjustment
Idler Pulley Bearing and Seal Installation
Figure 45: Idler Pulley Assembly
Assembly Instructions
Refrigeration Maintenance
Evacuation
Figure 46: Evacuation Station
Figure 47: Vacuum Gauge
Set up and Test of Evacuation Equipment
Unit Evacuation
Unit Charging
Remove Refrigerant Hoses
Refrigerant Leaks
Refrigerant Charge
Testing the Refrigerant Charge with an Empty Box
Testing the Refrigerant Charge with a Loaded Box
Checking Compressor Oil
Figure 48: Scroll Compressor
High Pressure Cutout (HPCO)
Low Side Pump down
Figure 49: High Pressure Cutout Manifold
Refrigeration System Checks
Three-Way Valve Condenser Pressure Bypass Check Valve
Figure 50: Gauge Manifold Installation
Figure 51: Three-Way Valve Condenser Pressure Bypass Check Valve
Discharge Pressure Regulator Valve
Figure 52: Discharge Pressure Regulator Valve Assembly
Refrigeration Service Operations
Accumulator
Removal
Installation
Compressor
Figure 53: Compressor Components
Shaft Seal Change Procedure
Figure 54: Cross Section of Set Screw Type Bellows
Figure 55: Set Screw Type Bellows Seal
Figure 56: Bellows Installation with Tool
Figure 57: Lip Seal and Hard Ring Installation
Compressor Oil Filter Replacement
Scroll Compressor Oil Change
High Temperature Cutout Switch Change Procedure
Liquid Injection Fitting Change Procedure
Condenser/Radiator Coil
Removal
Installation
Receiver Outlet Check Valve
Liquid Injection Valve
Installation
Dehydrator (Filter-Drier)
Removal
Refrigeration Service Operations (Continued)
Evaporator Coil
Figure 58: Location of Injection Valve Bulb
Figure 59: Completely Wrap Bulb with Tape
Installation
Expansion Valve Assembly
Removal
Figure 60: Location of Expansion Valve Bulb
Figure 61: Completely Wrap Bulb with Tape
Cleaning In-Line Screen
Heat Exchanger
Removal
Installation
Figure 62: Expansion Valve
High Pressure Cutout Switch
Removal
Installation
High Pressure Relief Valve
Pilot Solenoid
Receiver Tank
Three-Way Valve Condenser Pressure Bypass Check Valve Repair
Removal
Installation
Figure 63: Condenser Pressure Bypass Check Valve
Three-Way Valve Repair
Removal
Figure 64: Three-Way Valve Assembly
Installation
Unit Identification
Availability
Leak Detection
Figure 65: R404A Decal
Compressor Oil
Compressors Shipped with POE Oil
Equipment Recommendations for Use with R-404A
Gauge Manifold Sets
Refrigerant Recovery
Throttling Valve
Removal
Disassembly
Figure 66: Throttle Valve, Cap and Spring
Figure 67: Throttle Valve Piston
Reassembly
Installation
Figure 68: Throttle Valve Housing
Figure 69: Throttle Valve Piston Assembly
Figure 70: Throttling Valve
Hilliard Clutch Maintenance
Large Truck Unit Centrifugal Clutch Change
Figure 71: Front View and Cross Section
Figure 72: Hilliard Centrifugal Clutch
Clutch Maintenance
Tools Required
Grease
Disassembly Procedure
Figure 73: Housing Removal
Figure 74: Bearing Removal
Assembly Procedure (Using New Bearings and Seal)
Figure 75: Bushing Removal
Figure 76: Bushing Insertion
Figure 77: Clutch
Structural Maintenance
Unit and Engine Mounting Bolts
Unit Inspection
Condenser, Evaporator and Radiator Coils
Fan Location
Figure 78: Fan Blade Position in Orifice
Defrost Damper
Figure 79: Defrost Damper Adjustment
Fanshaft Assembly
Disassembly
Figure 80: Fan Shaft Assembly
Figure 81: Removing Bearing Retainer Bolts
Figure 82: Removing Shaft
Reassembly
Figure 83: Removing Oil Seal
Figure 84: Removing Roll Pin
Figure 85: Installing Bearings
Figure 86: Installing Splash Guard
Figure 87: Installing Oil Seal
Figure 88: Shims and O-Ring
Figure 89: Torquing Retainer Plate Bolts
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TS-500 NAD
TK 50799-1-MM (Rev. 5, 04/03)
Copyright© 1999 Thermo King Corp., Minneapolis, MN, USA.
Printed in USA.
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This manual is also suitable for:
Ts-500 30 sr
Ts-500 50 sr 230v
Ts-500 50 sr 460v
919200
919201
919202
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