Related Manuals for Thermo King TS-300 30 SR
Summarization of Contents
Refrigerant Handling and Safety
Recover Refrigerant
Guidelines for refrigerant recovery to protect the environment and minimize loss.
R-404A Refrigerant Precautions
Specific warnings and information regarding the handling of R-404A refrigerant.
Safety Precautions Overview
General Practices
General safety guidelines for operating and maintaining the unit.
Auto Start/Stop Safety
Important safety notice regarding automatic unit startup and shutdown procedures.
Refrigerant Exposure Safety
Safety information regarding refrigerant exposure and handling.
First Aid for Exposure
Essential first aid procedures for refrigerant and oil exposure.
Electrical and Mechanical Safety
Refrigeration Oil Safety
Precautions when working with or around refrigeration oil.
Electrical Hazards
Warnings and procedures related to electrical hazards and static discharge.
Microprocessor Service Safety
Precautions for servicing microprocessor components and preventing ESD.
Operational and High Voltage Safety
Welding Safety Procedures
Procedures to prevent damage to electronic circuits during welding operations.
High Voltage Safety Precautions
Critical safety precautions when working with high voltage circuits.
First Aid for Electrical Shock
Immediate actions and medical assistance for electrical shock incidents.
Low Voltage and Unit Decals
Low Voltage Safety
Safety considerations for low voltage circuits and potential hazards.
Unit Decals Information
Importance of serial, refrigerant, and warning decals for proper service.
Unit Specifications
Engine Specifications
Technical specifications for the TK 3.74 diesel engine.
Engine Coolant Types
Information on conventional and ELC coolants, and their compatibility.
Component Specifications
Belt Tension Specifications
Specifications and procedures for checking and setting belt tension.
Refrigeration System Specifications
Specifications for refrigeration system components and settings.
Hilliard Engine Clutch Specifications
Specifications for the Hilliard engine clutch, including engagement.
Electrical and System Specifications
Electrical Control System Specs
Specifications for voltage, charging system, and regulator settings.
Defrost Timer Specifications
Defrost timer settings for SR models with µP-T controller.
Thermostat Type
Details on the type of thermostat used in the system.
Electrical Components Specs
Specifications for electrical components including current draw and resistance.
Standby and Air Switch Specifications
Electric Standby Specifications
Specifications for electric standby operation of Model 50 units.
Standby Power Requirements
Requirements for supply circuit breakers and extension cords.
Air Switch Setting
Setting specifications for the unit's air switch.
Maintenance Inspection Schedule
Microprocessor Maintenance
Pretrip test procedure for the microprocessor.
Engine Maintenance Schedule
Engine maintenance tasks at various intervals (hours/years).
Engine Oil Change Intervals
Recommended intervals for changing engine oil and filter.
Maintenance Checks by System
Electrical System Maintenance Checks
Electrical system checks performed during maintenance inspections.
Refrigeration System Maintenance Checks
Refrigeration system checks performed during maintenance inspections.
Structural System Maintenance Checks
Structural component checks performed during maintenance inspections.
Unit Description and Controller
TS-200/TS-300 Unit Overview
General overview of the TS-200/TS-300 units, their design, and features.
ThermoGuard µP-T Controller
Detailed description of the µP-T microprocessor controller's functions.
Optional Data Acquisition System
Description of the optional data acquisition system for monitoring.
Clutch Operation
Explanation of the unit's clutch operation and engagement.
Unit Features and Instruments
Unit Features Table
Table outlining standard and optional features for TS-200/TS-300 models.
Microprocessor LCD Display
Description of the microprocessor LCD display and its icons.
Unit Protection Devices
Information on fuses and the high pressure cutout switch.
Component Functions and Operation
High Pressure Relief Valve
Function and operation of the high pressure relief valve.
Low Oil Level Switch
Description of the low oil level switch function.
Compressor High Temp Cutout
Operation of the compressor high temperature cutout switch.
Pretrip Inspection Guide
Essential pretrip inspection steps before starting the unit.
Unit Status and Control
Structural Inspection
Visual inspection of the unit's structural integrity.
ThermoGuard µP-T Smart Reefer
Explanation of the µP-T microprocessor's role in unit control.
Displaying Operational Data
How to view operational data on the unit's display screen.
Entering Setpoint Temperature
Step-by-step instructions for adjusting the unit's setpoint temperature.
Unit Startup and Mode Selection
Starting Unit Self Check
Procedure for performing a full unit self-check before loading cargo.
Operating Modes for CYCLE-SENTRY
Guidance on selecting operating modes for CYCLE-SENTRY equipped units.
Products for Continuous Run
List of products requiring continuous fan operation for air flow.
Mode Selection and Defrost
Products for CYCLE-SENTRY
List of products suitable for CYCLE-SENTRY mode operation.
Selecting CYCLE-SENTRY or Continuous Mode
Steps to select between CYCLE-SENTRY and continuous run modes.
Initiating Manual Defrost Cycle
Procedure to manually start a defrost cycle on the unit.
Alarm Codes and Unit Restart
Displaying and Clearing Alarm Codes
How to view, interpret, and clear alarm codes from the unit.
Restarting the Unit
Procedures for restarting the unit after a shutdown.
Automatic Unit Start
Steps to initiate an automatic unit startup sequence.
Post-Operation Procedures
After Start Inspection
Quick checks to confirm proper unit operation after startup.
Loading Procedure
Steps for loading product into the refrigerated unit correctly.
Post Load Procedure
Actions to take after loading product and closing unit doors.
Post Trip Checks
Checks to perform on the unit after completing a trip.
Unit Photographs
Front View Photograph
Visual representation of the unit's front view.
Back View Photograph
Visual representation of the unit's back view.
Left Side View Photograph
Visual representation of the unit's left side view.
Right Side View Photograph
Visual representation of the unit's right side view.
Unit Components Identification
Labeled Unit Components Diagram
Labeled diagram identifying key unit components.
Power Receptacle Box
Image and label for the North American power receptacle box.
Control Box Diagram
Labeled diagram of components within the unit's control box.
Remote Control Panel
Image and labels for the remote control panel keypad and display.
µP-T System Description
General Description of µP-T Units
General information about the µP-T controlled temperature control units.
µP-T Control System Components
List and description of the µP-T microprocessor control system components.
Microprocessor Power Switch
Description and location of the microprocessor power switch.
Optional Electric Standby
Details on the electric standby option for Model 50 units.
Model 50 Features and System Diagrams
Standard Model 50 Features
Standard features on Model 50 units equipped with electric standby.
Optional Model 50 Features
Optional features available for Model 50 units.
High Voltage Tray Diagrams
Schematic diagrams of the high voltage tray with phase correction.
Remote Control Panel Features
Remote Control Panel Overview
Features and operation of the remote control panel.
Keypad Key Descriptions
Description of each key on the remote control panel keypad.
Understanding the Unit Display
Display Screen Interpretation
How to interpret the unit's display screen and icons.
Display Icons Explained
Explanation of various icons displayed on the unit screen.
Typical Display Example
Example of a typical display screen and its interpretation.
Setpoint Adjustment and Standard Display
The Standard Display
Description of the default display screen when the unit is on.
Changing the Setpoint Temperature
Step-by-step instructions for adjusting the unit's setpoint temperature.
Mode Selection and Engine Start
Selecting CYCLE-SENTRY or Continuous Mode
Steps to select between CYCLE-SENTRY and continuous run modes.
Starting the Unit Engine
How to start the unit's engine.
Defrost and Software Revision
Initiating a Manual Defrost Cycle
Procedure to manually start a defrost cycle on the unit.
Checking Software Revision
Procedure to view the unit's software revision number.
Display Navigation and Locking
Viewing Prompt and Display Screens
How to navigate and view different prompt and display screens.
Locking Display Screens
Method to keep a specific display screen active.
Alarm Code Management
Viewing and Clearing Alarm Codes
How to view, interpret, and clear alarm codes from the unit.
µP-T Alarm Types
Explanation of stored, check, and shutdown alarms.
µP-T Alarm Codes List
µP-T Alarm Codes Table
List of µP-T alarm codes, their types, and descriptions.
µP-T Unit Self Check Test
Initiating the Unit Self Check
Steps to initiate the µP-T unit self-check procedure.
Unit Self Check Test Procedures
Description of the tests performed during the µP-T unit self-check.
Electrical Maintenance Procedures
Alternator Charging System Diagnostics
Diagnostic steps for the Prestolite alternator charging system.
Alternator Terminal Locations
Diagram showing the terminal locations on the Prestolite alternator.
Alternator Voltage and Battery Checks
Alternator Voltage Checks
Procedure for checking alternator voltage at various terminals.
Excessive Voltage Output Troubleshooting
Troubleshooting steps for excessive voltage output from the charging system.
Battery and Charging System Maintenance
Battery Inspection and Maintenance
Battery inspection, cleaning, and maintenance procedures.
Unit Wiring Inspection
Inspection of unit wiring and harnesses for damage.
Electrical Contacts Inspection
Inspection of electrical relay contacts for pitting or corrosion.
12 Vdc Charging System Checks
Checks for the 12 Vdc charging system after startup.
Engine Sensors and Components
Preheat Buzzer Function
Explanation of the function of the preheat buzzer.
RPM Sensor Description and Testing
Description and testing procedures for the RPM sensor.
Glow Plugs and Air Switch
Glow Plugs Function and Testing
Function, testing, and troubleshooting of glow plugs.
Fan Rotation and Air Switch Adjustment
Fan Rotation Check (Electric Standby)
Checking fan rotation during electric standby operation.
Defrost Air Switch Checkout and Adjustment
Procedures for checking and adjusting the defrost air switch.
Heating System and Operational Modes
High Capacity TherMax Heating System
Explanation of TherMax heating system components and operation.
Cool Mode Operation
Description of the unit's Cool mode operation.
Heat/Condenser Evacuation Mode
Operation of the Heat/Condenser Evacuation mode.
Defrost and Start Up Modes
Defrost Mode Operation
Description of the unit's operation during Defrost mode.
Start Up Mode Operation
Description of the unit's Start Up mode.
Engine Maintenance Overview
EMI 2000 Maintenance Package
Description of the EMI 2000 extended maintenance interval package.
Engine Lubrication System
Explanation of the TK 3.74 diesel engine's lubrication system.
Engine Oil Pressure Sensor
Function of the engine oil pressure sensor.
Engine Oil Change Procedure
Procedure and intervals for changing engine oil.
Engine Filter and Breather Maintenance
Oil Filter Change Procedure
Procedure for changing spin-on oil filters.
Crankcase Breather Inspection
Function and inspection of the crankcase breather system.
EMI 2000 Engine Air Cleaner
Maintenance of the EMI 2000 dry element air cleaner.
Engine Cooling System
Engine Cooling System Description
General description and function of the engine cooling system.
Extended Life Coolant (ELC) Information
ELC Coolant Details
Information on Extended Life Coolant, its types, and compatibility.
Antifreeze Maintenance Procedures
Antifreeze Maintenance Procedure
Procedures for maintaining and changing antifreeze.
Checking Antifreeze Concentration
Methods for checking antifreeze concentration.
Changing Antifreeze
Step-by-step instructions for changing the antifreeze.
Bleeding the Cooling System
Procedure for bleeding air from the cooling system.
Engine Thermostat and Fuel System
Engine Thermostat Recommendation
Recommended thermostat for optimal engine operation.
Engine Fuel System Description
Description of the TK 3.74 diesel engine's fuel system components.
Fuel System Maintenance
Bleeding the Fuel System
Procedure for bleeding air from the fuel system.
Fuel and Oil System Components
Fuel and Oil System Diagram
Diagram identifying components of the fuel and oil systems.
Fuel and Oil System Component List
Detailed list of components shown in the fuel and oil system diagram.
Fuel Tank and Filter Maintenance
Draining Water from Fuel Tank
Procedure for draining water from the fuel tank.
Fuel Filter Replacement Procedure
Steps for replacing the fuel filter.
Electric Fuel Pump Operation and Maintenance
Operation and maintenance of the electric fuel pump.
Injection Pump Timing
Timing the Injection Pump to the Engine
Procedure for timing the injection pump to the engine.
Engine Timing Marks
Engine Timing Marks Diagram
Diagram and explanation of engine timing marks.
Individual Cylinder Injection Timing
Timing Individual Cylinder Injection
Procedure for checking individual cylinder injection timing.
Engine Valve Clearance Adjustment
Adjust Engine Valve Clearance
Steps to adjust engine valve clearance.
Fuel Limit Screw Information
Information on the non-adjustable fuel limit screw.
Engine Mounts Description
Engine Mounts System
Description of the engine mounting system components.
Engine Mounting Components
Engine Mounting Components List
Detailed list of components for engine mounting.
Restraining Mount Adjustment
Restraining Mount Adjustment Procedure
Procedure for adjusting the restraining mount.
Chain/Restraining Mount Bracket
Chain/Restraining Mount Bracket Diagram
Diagram of the chain/restraining mount bracket.
Integral Fuel Solenoid
Integral Fuel Solenoid Operation
Description and operation of the integral fuel solenoid.
Fuel Solenoid Diagnostics
Reference to diagnostic procedures for the fuel solenoid.
Engine Speed Adjustments
Low Speed Engine Adjustment
Steps to adjust the engine's low speed.
High Speed Engine Adjustment
Steps to adjust the engine's high speed.
Belt Maintenance
Unit Drive Belts Overview
Information on the unit's drive belts.
Engine/Electric Motor Belt Adjustment
Procedure to adjust the engine/electric motor belt.
Electric Motor/Compressor Belt Adjustment
Electric Motor/Compressor Belt Adjustment
Procedure to adjust the electric motor/compressor belt.
Alternator Mounting and Adjustment
Alternator Mounting and Belt Tension
Procedure for alternator mounting and belt tension adjustment.
Idler Pulley Bearing and Seal Service
Idler Pulley Bearing and Seal Installation
Procedure for changing idler pulley bearings and seals.
Fanshaft Assembly Instructions
Fanshaft Assembly Instructions
Instructions for assembling the fanshaft assembly.
Refrigeration Maintenance Procedures
System Evacuation Importance
Importance and principles of system evacuation.
Evacuation Station Diagram
Diagram of the evacuation station and its valves.
Vacuum Gauge Description
Description and scale of the vacuum gauge.
Evacuation Equipment Setup and Testing
Evacuation Equipment Setup and Test
Steps to set up and test evacuation equipment for leaks and moisture.
Unit Evacuation and Charging
Unit Evacuation Procedure
Procedure for evacuating the unit to a low micron level.
Unit Charging Procedure
Procedure for charging the refrigeration system with refrigerant.
Refrigerant System Checks
Remove Refrigerant Hoses
Steps for safely removing refrigerant hoses.
Refrigerant Leak Detection
Methods for detecting refrigerant leaks.
Testing Refrigerant Charge (Empty Box)
How to test the refrigerant charge in the system.
Compressor Oil and Refrigerant Charge
Checking Compressor Oil Level
How to check and add compressor oil.
Testing Refrigerant Charge (Loaded Box)
Procedure to test refrigerant charge with a loaded box.
Pressure Switch and Pump Down
High Pressure Cutout (HPCO) Test
Testing the high pressure cutout switch.
Low Side Pump Down Procedure
Procedure for performing a low side pump down.
Refrigeration System Checks
Refrigeration System Pressure Checks
System checks for proper operation and pressures.
Three-Way Valve Bypass Check Valve
Explanation of the three-way valve bypass check valve.
Three-Way Valve Bypass Check Valve Repair
Three-Way Valve Bypass Check Valve Repair
Repair procedure for the three-way valve bypass check valve.
Discharge Pressure Regulator Valve
Discharge Pressure Regulator Valve Function
Function and operation of the discharge pressure regulator valve.
Refrigeration Service Operations
Accumulator Removal and Installation
Procedures for removing and installing the accumulator.
Compressor Removal and Installation
Procedures for removing and installing the compressor.
Compressor Components and Shaft Seal
Compressor Components Diagram
Diagram identifying compressor components.
Shaft Seal Change Procedure
Steps to change the compressor shaft seal.
Shaft Seal Installation Details
Shaft Seal Installation Steps
Detailed steps for installing new seals and bellows.
Compressor Oil and Filter Service
Compressor Oil Filter Replacement
Procedure for replacing the compressor oil filter and oil.
Scroll Compressor Oil Change
Procedure for changing the oil in a scroll compressor.
Component Replacement Procedures
High Temperature Cutout Switch Change
Steps to change the high temperature cutout switch.
Liquid Injection Fitting Change
Procedure to change the liquid injection fitting.
Coil and Valve Service
Condenser/Radiator Coil Removal and Installation
Procedures for removing and installing the condenser/radiator coil.
Receiver Outlet Check Valve Service
Removal and installation of the receiver outlet check valve.
Liquid Injection Valve Service
Removal and installation of the liquid injection valve.
Drier and Evaporator Coil Service
Dehydrator (Filter-Drier) Service
Removal and installation of the dehydrator (filter-drier).
Evaporator Coil Removal and Installation
Removal and installation of the evaporator coil.
Expansion Valve Assembly Service
Evaporator Coil Installation
Installation of the evaporator coil.
Expansion Valve Assembly Service
Removal and installation of the expansion valve assembly.
In-line Screen and Heat Exchanger Service
Cleaning In-line Screen
Procedure for cleaning the in-line screen.
Heat Exchanger Service
Removal and installation of the heat exchanger.
Pressure Switch and Valve Service
High Pressure Cutout Switch Service
Removal and installation of the high pressure cutout switch.
High Pressure Relief Valve Service
Removal and installation of the high pressure relief valve.
Pilot Solenoid Service
Removal and installation of the pilot solenoid.
Receiver Tank Service
Removal and installation of the receiver tank.
Three-Way Valve Bypass Valve Repair
Three-Way Valve Bypass Check Valve Repair
Repair procedure for the three-way valve bypass check valve.
Three-Way Valve Repair Procedure
Three-Way Valve Repair
Detailed procedure for repairing the three-way valve.
R-404A Refrigerant Information
R-404A Refrigerant Overview
Information on R-404A refrigerant, its classification, and capacities.
Unit Identification for R-404A
Methods for identifying units charged with R-404A.
R-404A Availability
Information on the availability of R-404A refrigerant.
Refrigerant Leak Detection
Methods for detecting refrigerant leaks.
Compressor Oil and Equipment Recommendations
Compressor Oil Information
Information on Polyol Ester (POE) oil compatibility and use.
Compressors Shipped with POE Oil
Details on POE oil used in Thermo King scroll compressors.
R-404A Equipment Recommendations
Recommended equipment for use with R-404A refrigerant.
Dedicated Equipment for R-404A
Specific equipment requirements for R-404A systems.
Vacuum Pumps and Gauge Sets
Vacuum Pump Recommendations
Recommendations for vacuum pumps used with R-404A systems.
Gauge Manifold Set Recommendations
Recommendations for gauge manifold sets.
System Clean-up and Refrigerant Recovery
System Clean-up Procedures
Procedures for cleaning the system and devices.
Refrigerant Recovery for R-404A
Adapting systems for R-404A refrigerant recovery.
Suction Pressure Regulator Valve Service
Removal and installation of the suction pressure regulator valve.
Hilliard Clutch Maintenance
Centrifugal Clutch Change Procedure
Steps for changing the centrifugal clutch on large truck units.
Hilliard Clutch Components
Hilliard Centrifugal Clutch Diagram
Diagram identifying components of the Hilliard centrifugal clutch.
Clutch Maintenance and Disassembly
Clutch Inspection and Maintenance
Inspection and maintenance of the clutch.
Tools Required for Clutch Service
List of tools needed for clutch maintenance.
Clutch Disassembly Procedure
Step-by-step instructions for disassembling the clutch.
Clutch Assembly Procedures
Bushing Removal from Hub
Procedure for pressing bushings out of the hub.
Assembly with New Bearings and Seal
Instructions for assembling the clutch with new bearings and seals.
Clutch Assembly Tightening
Clutch Assembly Continued
Continued steps for clutch assembly, including greasing and tightening.
Structural Maintenance Procedures
Unit and Engine Mounting Bolt Tightening
Periodic checks and tightening of unit and engine mounting bolts.
Unit Inspection for Damage
General inspection of the unit for damage or loose parts.
Condenser, Evaporator, Radiator Coil Cleaning
Cleaning procedures for the unit's coils.
Fan Location for Proper Performance
Proper positioning of the fan and hub assembly.
Defrost Damper Adjustment
Defrost Damper Check and Adjustment
Checking and adjusting the defrost damper for proper sealing.
Fanshaft Assembly Service
Fanshaft Assembly Description
Description of the fanshaft assembly and its maintenance requirements.
Fanshaft Assembly Disassembly
Step-by-step instructions for disassembling the fanshaft assembly.
Fanshaft Assembly Disassembly and Reassembly
Removing Oil Seal
How to remove the oil seal from the evaporator end.
Removing Roll Pin
Procedure for removing the roll pin from the shaft.
Fanshaft Assembly Reassembly
Instructions for reassembling the fanshaft assembly with new parts.
Installing Splash Guard
Reinstalling the splash guard after bearing replacement.
Fanshaft Assembly Installation Details
Installing Oil Seal
How to install a new oil seal.
Shims and O-ring Installation
Information on shims and O-rings for seal installation.
Torquing Retainer Plate Bolts
Torque specifications for retainer plate bolts.
Checking and Adjusting End Play
Procedure for measuring and adjusting end play using a dial indicator.
Mechanical Diagnosis Guide
Unit Switch On - Nothing Happens Troubleshooting
Troubleshooting steps when the unit switch is on but nothing occurs.
Engine Not Cranking Troubleshooting
Troubleshooting steps when unit powers on but engine won't crank.
Engine Cranks but Fails to Start Troubleshooting
Troubleshooting steps when the engine cranks but fails to start.
Engine Performance Diagnosis
Engine Stops After Starting Troubleshooting
Troubleshooting steps when the engine stops after starting.
Engine Not Reaching Full Power Troubleshooting
Troubleshooting steps when the engine does not reach full power.
Engine Smoke and Running Conditions
Engine Sooting and Black Smoke Diagnosis
Troubleshooting causes for excessive black smoke from the engine.
Engine Knocking Diagnosis
Troubleshooting causes for engine knocking.
Engine Overheating Diagnosis
Troubleshooting steps when the engine runs hot.
Low or Dropping Oil Pressure Diagnosis
Troubleshooting causes for low or suddenly dropping oil pressure.
Engine Oil Consumption and Battery
High Engine Oil Consumption Diagnosis
Troubleshooting causes for high engine oil consumption.
Blue Smoke (Oil Consumption) Diagnosis
Troubleshooting causes for blue smoke indicating oil consumption.
White Smoke (Fuel Not Burning) Diagnosis
Troubleshooting causes for white smoke indicating unburnt fuel.
Battery Not Recharging Troubleshooting
Troubleshooting steps when the battery is not recharging.
Electric Standby Diagnosis
Unit Lights On, Motor Not Running
Troubleshooting steps when unit powers on but electric motor doesn't run.
Electric Motor Hums But Does Not Run
Troubleshooting steps when the electric motor hums but doesn't run.
Electric Standby Electrical Issues
Contact Chatter Troubleshooting
Troubleshooting causes for contact chatter in electrical circuits.
Contact Welding or Freezing Troubleshooting
Troubleshooting causes for contact welding or freezing.
Electric Heaters Not Heating Troubleshooting
Troubleshooting when electric heaters are on but not producing heat.
Refrigeration Diagnosis Guide
Refrigeration Symptoms and Causes
Guide to diagnosing refrigeration problems based on symptoms.
Refrigeration System Diagnosis (Continued)
More Refrigeration Symptoms and Causes
Continues listing potential causes for refrigeration system symptoms.
Refrigeration Cycle Diagrams
Cool Cycle Diagram
Diagram illustrating the Cool cycle of the refrigeration system.
Condenser Evacuation Cycle Diagram
Diagram illustrating the condenser evacuation cycle.
Heat/Defrost Cycle Diagram
Diagram illustrating the Heat/Defrost cycle of the refrigeration system.
Need help?
Do you have a question about the TS-300 30 SR and is the answer not in the manual?
Questions and answers