Related Manuals for Thermo King TS-300 50 SR 230V
Summarization of Contents
Safety Precautions
General Safety and Warnings
General safety rules and warnings for unit operation and startup procedures.
Refrigerant and First Aid
Precautions for handling refrigerants and essential first aid measures for exposure.
Refrigeration Oil Safety
Precautions for handling refrigeration oil and first aid for exposure.
Electrical Hazards and Microprocessor Safety
Precautions to prevent electrostatic discharge when servicing electronic components.
Welding and High Voltage Safety
Safety procedures for welding and working with high voltage circuits.
Low Voltage Safety
Precautions for working with low voltage circuits, noting potential for severe burns.
Unit Decals
Information about serial number, refrigerant type, and warning decals on Thermo King equipment.
Specifications
Engine Specifications
Detailed specifications for the TK 3.74 diesel engine, including oil, fuel, and coolant.
Belt Tension and Refrigeration System Specs
Specifications for belt tension, refrigeration system components, and pressure cutouts.
Engine Clutch and Electrical System Specs
Specifications for the Hilliard engine clutch and electrical control system.
Defrost Timer, Thermostat, and Electrical Components
Specifications for defrost timer, thermostat, and electrical components' current draw.
Electric Standby and Air Switch Specifications
Specifications for electric standby operation, power requirements, and air switch setting.
Maintenance Inspection Schedule
Pretrip and Engine Maintenance
Pretrip inspection tasks and engine maintenance schedule for various intervals.
Electrical, Refrigeration, and Structural Maintenance
Maintenance checks for electrical, refrigeration, and structural systems.
Unit Description
General Unit Overview
Overview of the TS-200/TS-300 units, power, and operational modes.
ThermoGuard µP-T Controller and DAS
Description of the µP-T controller and optional Data Acquisition System.
Clutch and Unit Features
Explanation of the clutch engagement and a table of unit features.
Unit Instruments and Protection Devices
Description of unit instruments, fuses, and high pressure cutout switch.
Key System Components
Description of high pressure relief valve, cutout switch, and engine/system sensors.
Unit Operation
Pretrip Inspection
Pretrip inspection checklist for fuel, engine oil, coolant, battery, belts, and electrical connections.
Structural Inspection and Microprocessor
Visual inspection of unit structure and description of the µP-T microprocessor.
Displaying Data and Setting Temperature
How to view data on the display and change the setpoint temperature.
Starting Unit and Operating Modes
Procedure for unit startup, self-check, and selecting operating modes.
Manual Defrost and Software Revision
Procedure to initiate manual defrost and check software revision.
Viewing Screens and Clearing Alarms
How to view prompt/display screens, clear alarms, and restart the unit.
Post-Start Checks, Loading, and Post-Trip
Procedures for after-start checks, loading, post-load, and post-trip inspections.
Unit Photographs
Front and Back Views
Photographic view of the front and back of the TS-200 unit.
Side Views and Components Diagram
Photographic views of the left and right sides, and a diagram of unit components.
Power Receptacle and Control Box
Illustration of the power receptacle box and diagram of the control box components.
Remote Control Panel and Light Display
Images of the ThermoGuard remote control panel and the remote light display.
µP-T System Description
General and Control System Overview
Overview of the µP-T system, its control system components, and power switch.
Optional Electric Standby and Standard Features
Information on optional electric standby for Model 50 units and standard Model 50 features.
Optional Model 50 Features
Optional features available for Model 50 units with Electric Standby.
Remote Control Panel Features
Keypad Keys and Display Overview
Explanation of keypad keys and how to understand the display screen.
Display Icons and Typical Display Reading
Definitions of display icons and how to read a typical display screen.
Standard Display and Changing Setpoint
Description of the standard display and procedures for changing the unit setpoint.
Selecting Modes and Starting Engine
How to select CYCLE-SENTRY/Continuous mode and start the engine.
Manual Defrost and Software Revision
Procedure to initiate manual defrost and check the software revision.
Viewing Screens and Locking Display
How to view prompt/display screens and lock a screen for continuous viewing.
Viewing and Clearing Alarm Codes
µP-T Alarms and Code Interpretation
Explanation of µP-T alarms, codes, and their significance for service technicians.
Types of Alarms and Code Listing
Classification of alarms and a comprehensive listing of µP-T alarm codes.
µP-T Unit Self Check Test
Starting the Self Check and Test Reports
Steps to start the self-check test and interpret the results ([PASS], [CHEC], [FAIL]).
Self Check Component Tests
Specific tests performed during self-check: Defrost, RPM, Cooling, and Heating checks.
Electrical Maintenance
Alternator Charging System Diagnostics
Diagnostic procedures for the alternator charging system, including pre-checkout steps.
Excessive Voltage Output Troubleshooting
Troubleshooting and solutions for excessive voltage output from 12 Volt alternators.
Battery, Wiring, Contacts, and Charging System
Maintenance for battery, wiring, electrical contacts, and the 12 Vdc charging system.
RPM Sensor and Glow Plugs
Description of RPM sensor function and troubleshooting for glow plugs.
Fan Rotation and Defrost Air Switch
Checking fan rotation and adjusting the defrost air switch for proper operation.
TherMax Heating System Modes
Description of Cool, Heat/Condenser Evacuation, and Defrost modes in the TherMax system.
Start Up Mode
Description of the Start Up mode for diesel and electric operation.
Engine Maintenance
EMI 2000 Package and Lubrication System
Description of the EMI 2000 package and the engine's lubrication system.
Oil Pressure Sensor and Oil Change
Function of the oil pressure sensor and procedure for changing engine oil.
Oil Filter, Crankcase Breather, and Air Cleaner
Procedures for oil filter change, crankcase breather inspection, and air cleaner service.
Engine Cooling System and ELC Coolant
Description of the cooling system and information on Extended Life Coolant (ELC).
Antifreeze Maintenance and Bleeding System
Procedures for antifreeze maintenance, checking, changing, and bleeding the cooling system.
Engine Thermostat and Fuel System
Information on the engine thermostat and a description of the fuel system.
Bleeding the Fuel System
Procedure for bleeding air from the fuel system after fuel running out or repairs.
Fuel and Oil System Components Diagram
Diagram identifying the components of the engine's fuel and oil systems.
Draining Fuel Tank and Filter Replacement
Procedures for draining water from the fuel tank and replacing the fuel filter.
Electric Fuel Pump Operation and Maintenance
Operation and maintenance details for the electric fuel pump.
Injection Pump Timing Procedures
Procedures for timing the injection pump to the engine for optimal performance.
Engine Valve Clearance and Fuel Limit Screw
Procedure for adjusting engine valve clearance and information on the fuel limit screw.
Engine Mounts and Restraining Mount Adjustment
Description of engine mounts and procedure for restraining mount adjustment.
Integral Fuel Solenoid and Speed Adjustments
Description of the fuel solenoid and procedures for adjusting engine speed.
Belt Adjustments and Alternator Mounting
Procedures for adjusting engine/electric motor and motor/compressor belts, and alternator mounting.
Idler Pulley Bearing and Seal Installation
Procedure for performing a bearing and seal change on the idler pulley assembly.
Fanshaft Assembly Disassembly and Reassembly
Procedures for disassembling and reassembling the fanshaft assembly.
Refrigeration Maintenance
Evacuation Procedures and Equipment Setup
Importance of evacuation and setup/testing of evacuation equipment.
Unit Evacuation and Charging
Steps for unit evacuation to a low micron level and charging with refrigerant.
Refrigerant Leaks and Charge Testing
Methods for detecting leaks and testing refrigerant charge levels.
Compressor Oil Checks and HPCO
Checking compressor oil level and testing the High Pressure Cutout (HPCO).
Low Side Pump Down and System Checks
Procedure for low side pump down and refrigeration system pressure checks.
Three-way Valve Bypass Check Valve and DPR Valve
Checking bypass check valve operation and information on the Discharge Pressure Regulator Valve.
Refrigeration Service Operations
Accumulator and Compressor Service
Procedures for removing and installing the accumulator and compressor.
Shaft Seal and Compressor Oil Filter Replacement
Procedure for changing compressor shaft seal, oil filter, and scroll compressor oil.
High Temperature Cutout Switch and Liquid Injection Fitting
Procedures for changing the high temperature cutout switch and liquid injection fitting.
Condenser/Radiator Coil, Check Valve, and Injection Valve
Procedures for servicing coils, receiver outlet check valve, and liquid injection valve.
Evaporator Coil and Expansion Valve Assembly
Procedures for removing and installing evaporator coil and expansion valve assembly.
Heat Exchanger and High Pressure Cutout Switch
Procedures for servicing heat exchanger and high pressure cutout switch.
High Pressure Relief Valve, Pilot Solenoid, and Receiver Tank
Procedures for servicing relief valve, pilot solenoid, and receiver tank.
Three-Way Valve Bypass Check Valve Repair
Procedure for repairing the three-way valve's bypass check valve.
Three-way Valve Repair and R-404A Information
Procedure for repairing the three-way valve and information on R-404A refrigerant.
Compressor Oil and Equipment Recommendations
Information on compressor oil, vacuum pumps, and gauge sets for R-404A systems.
System Clean-up and Suction Pressure Regulator Valve
Procedures for system clean-up and servicing the suction pressure regulator valve.
Hilliard Clutch Maintenance
Centrifugal Clutch Change and Components
Information on the centrifugal clutch and a diagram of its components.
Clutch Maintenance and Disassembly
Clutch inspection, tools required, grease, and disassembly procedures.
Bushing Removal and Assembly Procedure
Procedures for removing and assembling clutch bushings, bearings, and seals.
Clutch Final Assembly and Torque
Final steps for clutch assembly, including applying grease and tightening screws.
Structural Maintenance
Mounting Bolts, Unit Inspection, and Coil Cleaning
Checking mounting bolts, unit inspection, and cleaning coils for proper air flow.
Fan Location and Defrost Damper Adjustment
Guidelines for fan positioning and procedure for defrost damper adjustment.
Fanshaft Assembly Disassembly and Reassembly
Procedures for disassembling and reassembling the fanshaft assembly.
Bearing and Seal Installation
Steps for installing new bearings, seals, and splash guards in the fanshaft assembly.
End Play Check and Final Assembly Steps
Procedure for checking and adjusting end play, and final assembly steps.
Mechanical Diagnosis
Unit Switch On Issues
Troubleshooting steps for unit switch issues: nothing happens or engine does not crank.
Engine Starting and Power Issues
Troubleshooting steps when the engine cranks but fails to start, or does not reach full power.
Engine Running Issues
Troubleshooting for engine stopping after starting, lack of power, sooting, knocking, and overheating.
Oil Pressure and Battery Recharging Issues
Troubleshooting for low oil pressure, high oil consumption, and battery not recharging.
Electric Standby (Optional) Diagnosis
Unit On - No Lights or Motor Operation
Troubleshooting for unit lights not coming on or electric motor not running.
Motor Hums But Does Not Run
Troubleshooting for electric motor humming but failing to run.
Contact Chatter and Welding Issues
Troubleshooting for contact chatter, welding, freezing, and rapid cycling.
Heater and Battery Recharging Problems
Troubleshooting for electric heaters not heating and battery not recharging.
Refrigeration Diagnosis
Cycle and Pressure Related Symptoms
Troubleshooting symptoms related to rapid cycling, unit cooling/heating in wrong cycles, and pressure issues.
Vacuum, Frosting, and Compressor Issues
Troubleshooting symptoms related to vacuum, suction line frosting, noisy compressor, and lack of refrigeration.
Expansion Valve and System Restrictions
Troubleshooting symptoms related to expansion valve, restricted lines, and drier.
Electrical and Calibration Related Issues
Troubleshooting symptoms related to electrical connections, calibration, and faulty valves.
Cycle Diagrams
Cool Cycle Diagram
Diagram illustrating the refrigerant flow and component operation during the Cool cycle.
Condenser Evacuation Cycle Diagram
Diagram illustrating the refrigerant flow during the Condenser Evacuation cycle.
Heat/Defrost Cycle Diagram
Diagram illustrating the refrigerant flow and component operation during the Heat/Defrost cycle.
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