Related Manuals for Thermo King TS-500 30 SR
Summarization of Contents
Safety Precautions
General Practices
General safety guidelines for operating and maintaining equipment.
Auto Start/Stop
Information on automatic unit starting and stopping procedures.
Refrigerant
Precautions regarding refrigerant exposure and handling.
First Aid
First aid measures for refrigerant exposure and frostbite.
Refrigeration Oil
Safety precautions when working with or around refrigeration oil.
Electrical Hazards
Warnings and precautions related to electrical hazards.
Microprocessor Service
Precautions for servicing microprocessor controllers and related components.
Welding of Units or Truck Bodies
Procedures to avoid damage to electronic circuits during welding.
High Voltage
Extreme caution procedures for working with high voltage circuits.
Low Voltage
Precautions for working with low voltage control circuits.
Unit Decals
Identifies and explains the purpose of various decals on the unit.
Specifications
Engine
Details the engine model, fuel type, oil capacity, viscosity, and RPM specifications.
Belt Tension
Specifications for belt tension on various drive systems.
Refrigeration System
Provides specifications for the refrigerant charge, oil type, and valve settings.
Engine Clutch - Hilliard
Specifications for the Hilliard engine clutch engagement and torque.
Electrical Control System
Outlines control system voltage, charging system, and component specifications.
Defrost Timer
Specifies defrost timer settings for SR models with µP-T.
Thermostat
Identifies the thermostat type used in the system.
Electrical Components
Lists electrical components with their current draw and resistance.
Electric Standby (Model 50 Unit Only)
Specifications for electric standby operation on Model 50 units.
Standby Power Requirements
Details power supply and extension cord requirements for electric standby.
Air Switch
Specifies the setting for the air switch.
Maintenance Inspection Schedule
Microprocessor
Inspection and service items for the microprocessor system.
Engine
Lists engine inspection and service items for various operating hours.
Electrical
Details electrical system checks required during scheduled maintenance.
Refrigeration
Outlines refrigeration system checks, including refrigerant and compressor oil levels.
Structural
Covers structural inspections for leaks, damage, and mounting bolts.
Unit Description
ThermoGuard µP-T Controller
Describes the microprocessor controller and its role in unit operation.
Unit Instruments
Explains the functions and display of unit instruments and indicators.
Unit Protection Devices
Details the unit's protection devices, including fuses and high pressure cutout.
Unit Operation
Covers procedures for operating the unit, including pretrip inspections.
Pretrip Inspection (Before Starting Unit)
Provides a checklist for essential inspections before starting the unit.
Structural
Describes structural inspection points for leaks and damage.
Displaying Operating Data
Explains how to view operating information on the unit's display screen.
Entering Setpoint Temperature
Provides step-by-step instructions for adjusting the unit's setpoint temperature.
Starting Unit (Full Unit Self Check)
Details the procedure for performing a full unit self-check.
Selection of Operating Modes on CYCLE-SENTRY Equipped Units
Guidance on selecting operating modes for commodity protection.
Initiating Manual Defrost
Instructions on how to manually initiate a defrost cycle.
Displaying and Clearing Alarm Codes
Explains how to view, understand, and clear alarm codes.
Restarting the Unit
Procedures for restarting units after a shutdown.
µP-T System Description
General Description
Provides an overview of the µP-T microprocessor control units for transport refrigeration.
µP-T Control System
Details the main components of the µP-T microprocessor control system.
Microprocessor Power Switch
Details the location and function of the microprocessor power switch.
Standard Model 50 Features
Lists standard features for Model 50 units equipped with electric standby.
Optional Model 50 Features
Describes optional features available for Model 50 units with electric standby.
Remote Control Panel Features
Keypad Keys
Describes the functions of the nine touch-sensitive keys on the remote control panel.
Display
Explains the standard display and possible segments shown.
Understanding the Display
Explains how to interpret the display screen and icons for unit status.
Display Icons
Explains the meaning of various icons displayed on the unit.
Reading a Typical Display
Provides an example of a typical display reading and its interpretation.
The Standard Display
Describes the default display screen showing box temperature and setpoint.
Changing The Setpoint
Provides step-by-step instructions for adjusting the unit's setpoint temperature.
Selecting CYCLE-SENTRY or Continuous Mode
Guides on selecting between CYCLE-SENTRY and Continuous modes.
Starting The Engine
Explains how to start the unit's engine, including preheating sequence.
Initiating a Manual Defrost Cycle
Instructions on how to manually initiate a defrost cycle.
Checking The Software Revision
Describes how to check the unit's software revision number.
Viewing Prompt And Display Screens
Explains how to navigate and view different prompt and display screens.
µP-T Alarms
Details the µP-T alarm system, including types and codes.
Types of Alarms
Categorizes and explains the three types of alarms: Stored, Check, and Shutdown.
µP-T Unit Self Check Test
Provides a functional test of the unit's operating capability.
Electrical Maintenance
Alternator (Prestolite) Charging System Diagnostic Procedures
Outlines diagnostic procedures for the alternator charging system.
Excessive Voltage Output
Discusses troubleshooting excessive voltage output from 12-volt alternators.
Battery
Covers battery inspection, cleaning, and electrolyte level checks.
Charging System (12 Vdc)
Details low voltage conditions after start-up and checks for charging circuits.
RPM Sensor
Explains the function and testing procedure for the engine RPM sensor.
Glow Plugs
Describes the function and testing of glow plugs for starting assistance.
Condenser/Evaporator Fan Rotation (Electric Standby Operation)
Procedure to check correct fan rotation during electric standby operation.
Defrost Air Switch Checkout and Adjustment
Covers testing and adjusting the defrost air switch settings.
High Capacity TherMaxTM Heating System
Explains the high capacity heating system and its components.
Start Up Mode
Describes the unit's start-up mode for diesel and electric operation.
Engine Maintenance
EMI 2000
Explains the EMI 2000 extended maintenance interval package.
Engine Lubrication System
Describes the engine's pressure lubrication system and oil pressure factors.
Engine Oil Change
Provides instructions and recommendations for changing engine oil and filter.
Oil Filter Change
Details the procedure for changing the spin-on oil filters.
Engine Air Cleaner (EMI 2000)
Explains the function and replacement of the EMI 2000 dry element air cleaner.
Engine Cooling System
Describes the engine's closed, circulating, pressurized cooling system.
ELC (Extended Life Coolant)
Details the use and specifications of Extended Life Coolant (ELC).
Antifreeze Maintenance Procedure
Outlines procedures for maintaining antifreeze, including checks and changes.
Engine Fuel System
Details the components and operation of the engine's fuel system.
Bleeding the Fuel System
Provides steps for bleeding air from the fuel system.
Injection Pump
Covers the injection pump, its adjustments, and timing procedures.
Adjust Engine Valve Clearance
Provides instructions for adjusting engine valve clearance.
Engine Mounts
Describes the engine mounting system including vibration and snubber mounts.
Integral Fuel Solenoid
Explains the function and operation of the integral fuel solenoid.
Engine Speed Adjustments
Details procedures for adjusting low and high engine speeds.
Belts
Covers belt arrangement and adjustment procedures for drive systems.
Alternator Adjustment
Explains how to adjust alternator mounting and belt tension.
Idler Pulley Bearing and Seal Installation
Provides procedures for changing idler pulley bearings and seals.
Refrigeration Maintenance
Evacuation
Explains the importance and principles of system evacuation to remove moisture and non-condensables.
Set Up and Test of Evacuation Equipment
Provides steps for setting up and testing evacuation equipment.
Unit Evacuation
Provides detailed steps for evacuating the unit using specific equipment.
Unit Charging
Details the procedure for charging the refrigeration system with refrigerant.
Remove Refrigerant Hoses
Instructions for safely removing refrigerant hoses from the unit.
Refrigerant Leaks
Methods for detecting refrigerant leaks in the system.
Refrigerant Charge
Procedures for testing and verifying the refrigerant charge.
Testing the Refrigerant Charge with an Empty Box
Tests to determine refrigerant charge with an empty box.
Testing the Refrigerant Charge with a Loaded Box
Tests to determine refrigerant charge with a loaded box.
Checking Compressor Oil
Explains how to check and maintain the compressor oil level.
High Pressure Cutout (HPCO)
Details the function and testing of the high pressure cutout switch.
Low Side Pump Down
Procedure for pumping down the low side of the system.
Refrigeration System Checks
Covers checks for system pressures and refrigerant flow.
Three-way Valve Condenser Pressure Bypass Check Valve
Explains the operation and checking procedure for the three-way valve bypass check valve.
Discharge Pressure Regulator Valve
Describes the function and replacement of the discharge pressure regulator valve.
Refrigeration Service Operations
Accumulator
Covers the removal and installation procedures for the accumulator.
Compressor
Covers the removal and installation procedures for the compressor.
Shaft Seal Change Procedure
Outlines the steps for changing the compressor shaft seal.
Compressor Oil Filter Replacement
Provides instructions for replacing the compressor oil filter and oil.
Scroll Compressor Oil Change
Details the procedure for changing the oil in a scroll compressor.
High Temperature Cutout Switch Change Procedure
Explains how to change the high temperature cutout switch.
Liquid Injection Fitting Change Procedure
Details the procedure for changing the liquid injection fitting.
Condenser/Radiator Coil
Details the removal and installation procedures for the condenser/radiator coil.
Receiver Outlet Check Valve
Covers the removal and installation of the receiver outlet check valve.
Liquid Injection Valve
Explains the removal and installation of the liquid injection valve.
Dehydrator (Filter-Drier)
Provides procedures for removing and installing the dehydrator (filter-drier).
Evaporator Coil
Details the removal and installation procedures for the evaporator coil.
Expansion Valve Assembly
Explains the removal and installation of the expansion valve assembly.
Cleaning In-line Screen
Instructions for cleaning the in-line screen in the expansion valve.
Heat Exchanger
Covers the removal and installation procedures for the heat exchanger.
High Pressure Cutout Switch
Details the removal and installation of the high pressure cutout switch.
High Pressure Relief Valve
Covers the removal and installation of the high pressure relief valve.
Pilot Solenoid
Explains the removal and installation procedures for the pilot solenoid.
Receiver Tank
Details the removal and installation procedures for the receiver tank.
Three-way Valve Condenser Pressure Bypass Check Valve Repair
Provides instructions for repairing the three-way valve bypass check valve.
Three-way Valve Repair
Details the procedure for repairing the three-way valve.
R-404A
Information about the R-404A refrigerant, its properties, and capacities.
Unit Identification
Methods for identifying units charged with R-404A refrigerant.
Leak Detection
Describes methods and tools for detecting refrigerant leaks.
Compressor Oil
Information on Thermo King's chosen compressor oil, Polyol Ester (POE).
Vacuum Pumps
Recommendations for vacuum pumps and oils used with R-404A systems.
Gauge Manifold Sets
Guidance on selecting and using gauge manifold sets for proper readings.
System Clean-up
Procedures for cleaning up devices to prevent R-404A system contamination.
Refrigerant Recovery
Information on adapting systems for R-404A refrigerant recovery.
Throttling Valve
Covers the removal, disassembly, and installation of the throttling valve.
Disassembly (Throttling Valve)
Detailed steps for disassembling the throttling valve.
Reassembly (Throttling Valve)
Provides instructions for reassembling the throttling valve.
Installation (Throttling Valve)
Details the process for installing the throttling valve.
Hilliard Clutch Maintenance
Large Truck Unit Centrifugal Clutch Change
Describes the procedure for changing the centrifugal clutch on large truck units.
Clutch Maintenance
Guidelines for inspecting and maintaining the clutch based on operation hours.
Tools Required
Lists the necessary tools for clutch maintenance procedures.
Disassembly Procedure
Provides steps for disassembling the Hilliard clutch.
Assembly Procedure (Using New Bearings and Seal)
Details the process for reassembling the clutch with new components.
Structural Maintenance
Unit And Engine Mounting Bolts
Instructions for checking and tightening unit and engine mounting bolts.
Unit Inspection
Guidance on inspecting the unit for loose parts, leaks, or damage.
Condenser, Evaporator and Radiator Coils
Procedures for cleaning coils to ensure proper airflow and performance.
Fan Location
Instructions for positioning the fan and hub assembly for optimal performance.
Defrost Damper
Covers checking damper operation, shaft wear, and sealing against airflow.
Fanshaft Assembly
Details the disassembly and reassembly of the fanshaft assembly.
Disassembly (Fanshaft)
Step-by-step instructions for disassembling the fanshaft assembly.
Reassembly (Fanshaft)
Provides instructions for reassembling the fanshaft assembly.
Mechanical Diagnosis
Unit switch On—nothing happens
Troubleshooting steps when the unit switch is on but nothing happens.
Unit switch On—indicator lights come on but engine does not crank
Diagnoses issues where unit lights are on but the engine doesn't crank.
Engine cranks but fails to start
Lists possible causes and remedies when the engine cranks but does not start.
Engine stops after starting
Explains common causes and solutions for the engine stopping after starting.
Engine does not reach full power
Addresses potential causes for the engine not reaching full power.
Engine is sooting heavily, emits thick black clouds of smoke (excessive fuel to air ratio)
Diagnoses issues related to excessive fuel and air ratio causing black smoke.
Engine knocks
Troubleshooting causes and remedies for engine knocking.
Engine runs hot
Addresses potential causes and remedies for the engine overheating.
Oil pressure too low or drops suddenly
Diagnoses sudden drops in oil pressure and low oil pressure issues.
High oil consumption
Identifies causes and solutions for excessive engine oil consumption.
Battery is not recharging
Troubleshoots issues related to the battery not recharging.
Electric Standby (Optional) Diagnosis
Unit switch On— µP-T lights do not come on
Troubleshoots issues where the unit powers on but no lights activate.
Unit switch On— µP-T lights come on but electric motor does not run
Troubleshoots issues where the unit powers on but the electric motor fails to run.
Electric motor hums but does not run
Diagnoses why the electric motor hums but does not operate.
Contact chatter
Discusses causes and remedies for contact chatter in electrical components.
Battery is not recharging
Troubleshoots issues related to the battery not recharging.
Refrigeration Diagnosis
Rapid cycling between Cool and Heat
Diagnoses rapid cycling issues between cooling and heating modes.
Unit not refrigerating
Identifies symptoms and possible causes for the unit failing to refrigerate.
Unit not heating or defrosting
Lists symptoms and potential causes for the unit failing to heat or defrost.
Cycle Diagrams
Cool Cycle
Illustrates the refrigerant flow and component operation during the cool cycle.
Condenser Evacuation Cycle
Depicts the refrigerant flow and component operation during condenser evacuation.
Heat/Defrost Cycle
Shows the refrigerant flow and component operation during heat and defrost cycles.
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