Thermo King SPECTRUM TS 30 SR NAD, Manual

Page 1: ...SPECTRUM TS TK 51448 1 MM Rev 1 03 06 Copyright 2002 Thermo King Corp Minneapolis MN USA Printed in USA ...

Page 2: ...unit models SPECTRUM TS 30 SR NAD System No 919120 SPECTRUM TS 50 SR 230 3 60 NAD System No 919121 SPECTRUM TS 50 SR 460 3 60 NAD System No 919122 SPECTRUM TS 30 SR EEC System No 919123 SPECTRUM TS 50 SR 220 3 50 EEC System No 919124 SPECTRUM TS 50 SR 230 3 60 EEC System No 919125 SPECTRUM TS 50 SR 380 3 50 EEC System No 919126 SPECTRUM TS 30 SR TK376 NAD System No 920255 SPECTRUM TS 50 SR 230 3 6...

Page 3: ...nformation on regulations and technician certification programs contact your local Thermo King dealer R 404A WARNING Use only Polyol Ester based refrigeration compressor oil in R 404A See Thermo King Parts Manual for part number Do not mix Polyol Ester and standard synthetic compressor oils Keep Polyol Ester compressor oil in tightly sealed containers If Polyol Ester oil becomes contaminated with ...

Page 4: ...4 ...

Page 5: ...50 Unit Only 24 Standby Power Requirements 24 Maintenance Inspection Schedule 25 Unit Description 27 Unit Overview 27 Design Features 27 Unit Options 27 Engine 28 Clutch 28 ELC Extended Life Coolant 28 EMI 2000 29 SPECTRUM Remote Evaporator 29 Compressor 29 SPECTRUM TS HMI Control Panel 29 Microprocessor Power Switch 30 CYCLE SENTRY Start Stop System 30 Defrost 30 DAS Data Acquisition System Optio...

Page 6: ...lay 62 Selecting a Zone Display 62 Turning a Zone On and Off 63 Changing the Setpoint 64 Starting the Diesel Engine 65 Initiating a Manual Defrost Cycle 65 Terminating a Defrost Cycle 66 Selecting High Speed Lockout if enabled 66 Using the Operators Menu 66 Operators Menu Choices 66 Selecting a Language 67 Selecting Cycle Sentry or Continuous Mode 68 Selecting Economy Mode 69 Selecting Sleep Mode ...

Page 7: ... 99 Draining Water from Fuel Tank 106 Fuel Filter Replacement 106 Electric Fuel Pump 106 Injection Pump 107 Injection Pump Timing TK 3 95 Engine 107 Timing Individual Cylinder Injection TK 3 95 Engine 109 Injection Pump Timing TK376 Engine 110 Injection Pump Removal and Installation TK376 Engine 111 Fuel Limit Screw 113 Adjust Engine Valve Clearance 113 Engine Mounts 114 TK 3 95 Engine 114 TK376 E...

Page 8: ...Radiator Coil 142 Removal 142 Installation 143 Liquid Injection Valve 143 Removal 143 Installation 143 Dehydrator Filter Drier 143 Removal 143 Installation 143 High Pressure Cutout Switch 143 Removal 143 Installation 143 High Pressure Relief Valve 144 Removal 144 Installation 144 Receiver Tank 144 Removal 144 Installation 144 R 404A 144 Unit Identification 144 Availability 144 Leak Detection 144 C...

Page 9: ...scription 171 Unit Operation 173 Defrost 173 Operating Modes 173 Unit Features 173 Unit Protection Devices 174 Serial Number Location 174 Remote Evaporator Electrical Maintenance 175 SPECTRUM Microprocessor Controlled Components 175 Unit Wiring 175 Remote Evaporator Refrigeration Service Operations 177 Expansion Valve Assembly 177 Removal 177 Installation 177 Evaporator Coil 177 Removal 177 Instal...

Page 10: ...Table of Contents 10 ...

Page 11: ...re 26 Complete SPECTRUM TS Control System with Multi Temp Option Board 56 Figure 27 Interface Board 56 Figure 28 Power Supply Board 57 Figure 29 Multi Temp Option Board 57 Figure 30 High Voltage Contactors with Shield Removed 58 Figure 31 Engine Serial Number Location 59 Figure 32 Compressor Serial Number Location 59 Figure 33 Label Locations 59 Figure 34 Laminated Unit Serial Number Plate 59 Figu...

Page 12: ...Figure 86 Program Wake Up Time 71 Figure 87 Select Day Screen 71 Figure 88 Select Time Screen 71 Figure 89 Run Pretrip On Wake Up 71 Figure 90 Sleep 71 Figure 91 Standard Display 72 Figure 92 Mode 72 Figure 93 Pretrip Display 72 Figure 94 Programming Test Pretrip Display 73 Figure 95 Selecting Menus 73 Figure 96 Zone 1 Cool Test 73 Figure 97 Pretrip Pass Display 73 Figure 98 Electric Standby Displ...

Page 13: ...ount Bracket 119 Figure 146 Integral Fuel Solenoid Components TK 3 95 Engine 120 Figure 147 High Speed Solenoid Components TK376 Engine 121 Figure 148 Front View Belt Arrangement 123 Figure 149 Alternator Mounting and Belt Tension Adjustment 124 Figure 150 Evacuation Station 126 Figure 151 Vacuum Gauge 127 Figure 152 Pressure Rise Graphs 128 Figure 153 Press Menu Key 129 Figure 154 Press and Hold ...

Page 14: ... 183 Fan Blade Position in Orifice for All Except Ten Blade Fan 157 Figure 184 Fan Blade Position in Orifice for Ten Blade Fan 157 Figure 185 SPECTRUMTM Evaporator 171 Figure 186 SPECTRUM TS Evaporator Front View 172 Figure 187 SPECTRUM TS Evaporator Back View 172 Figure 188 Serial Number Location 174 Figure 189 Check Valve with Cap Nut 179 ...

Page 15: ...letion resulting in suffocation and possible death DANGER Avoid engine operation in confined spaces and areas or circumstances where fumes from the engine could become trapped and cause serious injury or death WARNING Make sure your gauge manifold hoses are in good condition before using them Never let them come in contact with moving belts fans pulleys or hot surfaces Defective gauge equipment ca...

Page 16: ... Heat increases pressure inside storage containers which can cause them to burst DANGER Do not use oxygen O2 or compressed air for leak testing Oxygen mixed with refrigerant is combustible WARNING Wear butyl lined gloves when handling refrigerant to help prevent frostbite CAUTION Refrigerant in a liquid state evaporates rapidly when exposed to the atmosphere freezing anything it contacts Be carefu...

Page 17: ...mpt to stop the unit by disconnecting the power plug WARNING Make sure the unit power plug is clean and dry before connecting it to a power source WARNING Do not make rapid moves when working on high voltage circuits in refrigeration units Do not grab for falling tools because you might accidentally touch a high voltage source WARNING Use tools with well insulated handles Never hold uninsulated me...

Page 18: ...n it OFF before connecting or disconnecting the battery Disconnect power to the unit Disconnect all wire harnesses from the microprocessor If there are any electrical circuit breakers in the control box switch them OFF Close the control box Components that could be damaged by welding sparks should be removed from the unit Use normal welding procedures but keep the ground return electrode as close ...

Page 19: ...cuers should wear insulated gloves and safety glasses and avoid looking at wires being cut The ensuing flash can cause burns and blindness If the victim must be removed from a live circuit pull the victim away with a non conductive material Use wood rope a belt or coat to pull or push the victim away from the current DO NOT TOUCH the victim You will receive a shock from current flowing through the...

Page 20: ...Safety Precautions 20 ...

Page 21: ...y Multigrade Oil Ambient Temperature SAE 5W 30 22 to 32 F 30 to 0 C SAE 10W 30 13 to 86 F 25 to 30 C SAE 10W 40 13 to 104 F 25 to 40 C SAE 15W 40 5 to 122 F 15 to 50 C Engine RPM Low Speed Operation High Speed Operation 1800 25 RPM 2425 25 RPM Engine Oil Pressure TK 3 95 TK376 35 to 60 psig 241 to 414 kPa high speed 40 to 60 psig 276 to 414 kPa high speed Intake Valve Clearance 0 006 to 0 010 in 0...

Page 22: ...Extended Life Coolant the coolant must be changed after 2 years instead of 5 years Coolant System Capacity 4 0 qts 3 8 liters with overflow tank Radiator Cap Pressure 10 psig 69 kPa Engine Continued Belt Tension Belt Tension on TK Gauge See Tool Catalog New Belt Field Reset Engine Electric Motor Jackshaft Reading on bottom span between engine and electric motor 55 to 65 55 to 60 Electric Motor Jac...

Page 23: ...compressor is removed from the unit oil level should be noted or the oil removed from the compressor should be measured so that the same amount of oil can be added before placing the replacement compressor in the unit Engine Clutch Hilliard Engagement 600 100 RPM Dynamic Torque 66 ft lb 89 5 N m minimum 1600 RPM Electrical Control System Control System Voltage 12 5 Vdc Battery Fuse F1 2 Circuit 60...

Page 24: ...Solenoid 13 Watt 1 04 12 0 Hot Gas Bypass Solenoid 10 Watt 0 80 15 6 Hot Gas Solenoids 18 Watt 1 4 8 7 Liquid Line Solenoids 15 Watt 1 20 10 4 Suction Line Solenoids 18 Watt 1 4 8 7 NOTE Disconnect components from unit circuit to check resistance Electric Standby Model 50 Unit Only Voltage Phase Frequency Horsepower Kilowatts RPM Full Load Amps Locked Rotor Amps Overload Relay Setting Amps 220 3 5...

Page 25: ...ilter Inspect and clean electric fuel pump filter Drain water from fuel tank and check vent Check and adjust engine speeds high and low speed Check condition of engine mounts Maintain year round antifreeze protection at 30 F 34 C Change green engine coolant every 2 years Change ELC red engine coolant every 5 years or 12 000 hours Units equipped with ELC have an ELC nameplate on the expansion tank ...

Page 26: ...Defrost or Heat Check discharge and suction pressures Check compressor efficiency Replace dehydrator and compressor oil filter every two 2 years Structural Visually inspect unit for fluid leaks Visually inspect unit for damaged loose or broken parts includes air ducts and bulkheads Inspect clutch for shoe and anchor bushing wear with a mirror Check bearings Inspect idlers for leakage and bearing w...

Page 27: ...n diesel engine operation SPECTRUM TS 50 Cooling and heating on diesel engine operation or electric standby operation Design Features Air Cleaner Dry Type Alarm Code Display Alternator 90 amp Automatic Phase Correction Model 50 Battery Voltage Display Bypass Oil Filter Condenser Top Screen Continuous System Monitoring Coolant Expansion Tank Coolant Temperature Display Corrosion Resistant Protectio...

Page 28: ...n page 25 Figure 2 TK 3 95 Tier 1 Figure 3 TK376 Tier 2 Clutch The centrifugal clutch engages fully at 600 100 rpm on engine operation constantly turning the compressor and alternator at both high and low speed The clutch isolates the engine from the belt drive system during electric standby operation on Model 50 units ELC Extended Life Coolant ELC Extended Life Coolant is standard in these units ...

Page 29: ... whichever occurs first NOTE Units equipped with the EMI 2000 package do require regular inspection in accordance with Thermo King s maintenance recommendations SPECTRUM Remote Evaporator A SPECTRUM Remote Evaporator is located in each compartment and can provide separate temperature controlled areas Figure 4 SPECTRUM Remote Evaporator Compressor The unit features a high performance 6 hp TKO Scrol...

Page 30: ...onto the ground through the drain tubes Defrost can be initiated at any time the evaporator coil temperature is below 45 F 7 C Only one zone can be in defrost at a time There are three methods of defrost initiation 1 The microprocessor is programmed to initiate timed defrost cycles 2 The microprocessor is programmed to initiate forced defrost cycles The SPECTRUM TS uses temperature sensors to dete...

Page 31: ...contactors This allows correct motor rotation regardless of phase rotation on the incoming power High Voltage Tray The high voltage tray contains the contactors overload relay and phase select module used to operate the drive motor on units equipped with Electric Standby The contactors are controlled by 12 volt dc control signals from the Interface Board The high voltage tray is located inside the...

Page 32: ...e SPECTRUM TS Microprocessor The unit controls on this sensor under normal conditions This is a graded sensor and must be replaced with a graded sensor The SPECTRUM TS Microprocessor must be calibrated to the sensor grade of the sensor installed in the return air position in order to operate properly It is connected to the microprocessor via the RTP and RTN wires Discharge Air Sensor monitors the ...

Page 33: ... a set limit this valve is energized open to allow hot refrigerant gas to flow to the suction line until the suction pressure rises to an acceptable level This valve is normally closed This component is located in the hot gas bypass line next to the compressor This valve uses a similar technique for controlling compression ratios Discharge Pressure Regulator DPR This component is a mechanical cont...

Page 34: ... used by the diesel engine It is located on the radiator expansion tank If the coolant level falls below the sensor for a specified period of time a low coolant condition is assumed to exist It is connected to the microprocessor via the CLS wire Oil Pressure Switch The oil pressure switch monitors the oil pressure of the diesel engine It is located on the engine side of the unit frame It is connec...

Page 35: ...nt level and temperature engine RPM and suction and discharge pressure Sensors Display Menu The Sensors Display allows the operator to display the temperature of all unit temperature sensors and the temperature differential for each zone Service Test Mode Menu Since it is impossible to predict exact operating conditions a trouble shooting feature called Service Test Mode has been incorporated This...

Page 36: ...ion 36 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: ...s Solenoid 7 High Pressure Cutout Switch 24 Accumulator Tank 8 Condenser Inlet Solenoid 25 Suction Service Valve 9 Condenser Inlet Check Valve 26 Throttling Valve 10 Condenser Coil 27 Hot Gas Bypass Solenoid 11 High Pressure Relief Valve 28 Discharge Pressure Regulator Valve 12 Receiver Outlet Valve 29 Purge Valve 13 Receiver Sight Glass 30 Purge Check Valve 14 Dehydrator 31 Discharge Pressure Tra...

Page 38: ...to the Zone 2 evaporator There liquid refrigerant cools the Zone 2 evaporator as it evaporates into low pressure vapor The refrigerant returns to the compressor through the SLS2 the second suction line the SLCV2 and the accumulator Zone 1 Evaporator 1F Zone 1 Liquid Line Solenoid LLS1 Open 2F Zone 1 Liquid Return Check Valve LRCV1 Closed 3F Zone 1 Suction Line Check Valve SLCV1 Open 4F Zone 1 Suct...

Page 39: ...y during heat to drain the condenser coil Zone 1 Evaporator 1F Zone 1 Liquid Line Solenoid LLS1 Open 2F Zone 1 Liquid Return Check Valve LRCV1 Closed 3F Zone 1 Suction Line Check Valve SLCV1 Open 4F Zone 1 Suction Line Solenoid SLS1 Open 5F Zone 1 Hot Gas Solenoid HGS1 Open Zone 2 Evaporator 1R Zone 2 Liquid Line Solenoid LLS2 Open 2R Zone 2 Liquid Return Check Valve LRCV2 Closed 3R Zone 2 Suction...

Page 40: ...uction Line SLCV1 and the accumulator In the condensing unit the CIS valve closes and opens to regulate head pressure The purge valve is opened continuously during heat to drain the condenser coil Zone 1 Evaporator 1F Zone 1 Liquid Line Solenoid LLS1 Open 2F Zone 1 Liquid Return Check Valve LRCV1 Closed 3F Zone 1 Suction Line Check Valve SLCV1 Open 4F Zone 1 Suction Line Solenoid SLS1 Open 5F Zone...

Page 41: ...SLCV1 and the accumulator The LLS2 is closed which prevents refrigerant from reaching the Zone 2 evaporator Zone 1 Evaporator 1F Zone 1 Liquid Line Solenoid LLS1 Open 2F Zone 1 Liquid Return Check Valve LRCV1 Closed 3F Zone 1 Suction Line Check Valve SLCV1 Open 4F Zone 1 Suction Line Solenoid SLS1 Open 5F Zone 1 Hot Gas Solenoid HGS1 Closed Zone 2 Evaporator 1R Zone 2 Liquid Line Solenoid LLS2 Clo...

Page 42: ...ring heat to drain the condenser coil Zone 1 Evaporator 1F Zone 1 Liquid Line Solenoid LLS1 Open 2F Zone 1 Liquid Return Check Valve LRCV1 Closed 3F Zone 1 Suction Line Check Valve SLCV1 Open 4F Zone 1 Suction Line Solenoid SLS1 Open 5F Zone 1 Hot Gas Solenoid HGS1 Open Zone 2 Evaporator 1R Zone 2 Liquid Line Solenoid LLS2 Closed 2R Zone 2 Liquid Return Check Valve LRCV2 Closed 3R Zone 2 Suction L...

Page 43: ...1 evaporator In the condensing unit the CIS valve closes and opens to regulate head pressure The purge valve is opened continuously during defrost to drain the condenser coil Zone 1 Evaporator 1F Zone 1 Liquid Line Solenoid LLS1 Open 2F Zone 1 Liquid Return Check Valve LRCV1 Closed 3F Zone 1 Suction Line Check Valve SLCV1 Open 4F Zone 1 Suction Line Solenoid SLS1 Open 5F Zone 1 Hot Gas Solenoid HG...

Page 44: ... head pressure The purge valve is opened continuously during defrost to drain the condenser Zone 1 Evaporator 1F Zone 1 Liquid line Solenoid LLS1 Open 2F Zone 1 Liquid Return Check Valve LRCV1 Closed 3F Zone 1 Suction Line Check Valve SLVC1 Open 4F Zone 1 Suction Line Solenoid SLS1 Open 5F Zone 1 Hot Gas Solenoid HGS1 Open Zone 2 Evaporator 1R Zone 2 Liquid Line Solenoid LLS2 Open 2R Zone 2 Liquid...

Page 45: ...ressure The purge valve is opened continuously during defrost to drain the condenser Zone 1 Evaporator 1F Zone 1 Liquid Line Solenoid LLS Open 2F Zone 1 Liquid Return Check Valve LRCV Closed 3F Zone 1 Suction Line Check Valve SLCV Open 4F Zone 1 Suction Line SOlenoid SLS Open 5F Zone 1 Hot Gas Solenoid HGS Open Zone 2 Evaporator 1R Zone 2 Liquid Line Solenoid LLS2 Closed 2R Zone 2 Liquid Return Ch...

Page 46: ...Unit Description 46 Figure 17 Zone 1 Cool Zone 2 Heat and Zone 3 Heat 1F 2F 4F 3F 9 6 7 8 3C 5C 4C 2C 1C 5F 10 3R 5R 2R 1R 4R ...

Page 47: ...ses and opens to regulate head pressure The purge valve is opened continuously during heat to drain the condenser coil Zone 1 Evaporator 1F Zone 1 Liquid Line Solenoid LLS1 Open 2F Zone 1 Liquid Return Check Valve LRCV1 Closed 3F Zone 1 Suction Line Check Valve SLCV1 Open 4F Zone 1 Suction Line Solenoid SLS1 Open 5F Zone 1 Hot Gas Solenoid HGS1 Closed Zone 2 Evaporator 1C Zone 2 Liquid Line Soleno...

Page 48: ...Unit Description 48 Figure 18 Zone 1 Cool Zone 2 Heat and Zone 3 Defrost 1F 2F 4F 3F 9 6 7 8 3C 5C 4C 2C 1C 5F 10 3R 5R 2R 1R 4R ...

Page 49: ...rge valve is opened continuously during defrost to drain the condenser coil Zone 1 Evaporator 1F Zone 1 Liquid Line Solenoid LLS1 Open 2F Zone 1 Liquid Return Check Valve LRCV1 Closed 3F Zone 1 Suction Line Check Valve SLCV1 Open 4F Zone 1 Suction Line Solenoid SLS1 Open 5F Zone 1 Hot Gas Solenoid HGS1 Closed Zone 2 Evaporator 1C Zone 2 Liquid Line Solenoid LLS2 Open 2C Zone 2 Liquid Return Check ...

Page 50: ...ontrols the flow of refrigerant through the Purge Valve line The Purge Valve line runs from the liquid line upstream of the Condenser Check Valve to the accumulator inlet The Condenser Check Valve is located in the liquid line after the condenser outlet Defrost Mode The delayed switching of the Hot Gas Solenoid Condenser Inlet Solenoid and Suction Line Solenoid does not occur before the Defrost mo...

Page 51: ...Unit Description 51 Figure 19 Front View Figure 20 Back View AJA1350 AJA1500 ...

Page 52: ...Unit Description 52 1 On Off Switch Figure 21 Side View 1 ...

Page 53: ...le Valve 11 Suction Pressure Transducer 4 Discharge Service Port 12 Discharge Pressure Transducer 5 High Pressure Cutout Switch Location 13 Liquid Injection Valve 6 Condenser Inlet Solenoid 14 Hot Gas Bypass Solenoid 7 Receiver Tank Pressure Check Valve 15 Purge Valve 8 Condenser Inlet Check Valve 16 Purge Check Valve Figure 22 Condenser Compartment Components ...

Page 54: ... Interface Board 2 Multi Temp Option Board 8 SPECTRUM TS Microprocessor 3 Filter Drier 9 Receiver Tank Sight Glass 4 DAS Module Optional 10 Main On Off Switch 5 High Voltage Shield 11 Receiver Tank 6 Power Supply Board Figure 23 Control Box and Miscellaneous Components ...

Page 55: ...it Description 55 Figure 24 Power Receptacle Box Model 50 1 Display Screen 2 Defrost Key 3 High Speed Lockout Key 4 Soft Keys 5 Off Key 6 On Key Figure 25 HMI Control Panel AJA455 6 5 2 1 AJA116 4 3 4 4 4 ...

Page 56: ...P1 X2 X5 X7 CIS RTPS HGB PV P1 P2 LED1 FM3 2A FM2 K205 K206 K207 K202 K203 K204 K200 K201 15 15 1 P202 P201 J1 F202 F201 F200 SLS3 LLS3 HGS3 SLS2 LLS2 HGS2 FAN 2 FAN 3 AJA1201 1 2 5 3 Interface Board Fuse Size and Function Fuse Size Function F2 40A Starter Fuel Pull In F4 1A Remote Status Light Option F6 40A Preheat F7 15A 2A Power Zone 1 F8 2A Alternator Excitation F9 2A DAS 2A Power Option F10 2...

Page 57: ...lay is energized by the microprocessor and has transferred its contacts to the energized state The only user serviceable components on the multi temp option board are the fuses and jumpers Figure 29 Multi Temp Option Board Interface Board Relay Functions Relay Function K1 Alternator Excitation Relay K2 Zone 1 Fan Relay K3 Starter Relay K4 Fuel Solenoid Pull In Relay K5 Throttle Solenoid Relay K6 O...

Page 58: ...Unit Description 58 1 Phase Detect Module 2 Motor Contactor 3 Motor Contactor 4 Overload Relay Figure 30 High Voltage Contactors with Shield Removed 1 2 3 4 ...

Page 59: ...l Number and Refrigerant Label Locations Figure 34 Laminated Unit Serial Number Plate Nameplate on inside of top right side of unit frame See Figure 33 Figure 35 Refrigerant Type Label This label identifies the type of refrigerant in the unit See Figure 33 AJA1352 1 Refrigerant Type 2 Unit Serial Plate Figure 33 Label Locations 2 1 1 ...

Page 60: ...Unit Description 60 ...

Page 61: ... Zone 1 has a setpoint of 10 F and a box temperature of 9 4 F Zone 2 has a setpoint of 35 F and a box temperature of 35 8 F Microprocessor Power Switch The Microprocessor Power switch applies 12 Vdc power to the microprocessor The switch must be in the On position to operate the microprocessor It is located on the unit frame on the road side of the unit NOTE When the Microprocessor Power Switch is...

Page 62: ...abeled 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 Menu Display The unlabeled soft key is not used from the Standard Display Selecting a Zone Display To select a zone from the Standard Display press the soft key for the desired zone Zone 1 will be selected here Figure 43 Standard Display When a Zone soft key is press...

Page 63: ...e soft key label will then read ZONE 1 ON as shown below Pressing the key again will turn the zone back on Figure 47 Zone 1 Off When the zone is turned on or off the display will briefly indicate that the change is being made as shown below Figure 48 Programming Screen The display will show the new setting for several seconds as shown below Figure 49 Displays New Setting Figure 50 Zone 1 On Displa...

Page 64: ...r keys the change must confirmed or rejected by pressing the YES or NO soft key within 10 seconds of changing the setpoint Failure to confirm the new setpoint by pressing Yes or No within 10 seconds of changing the setpoint will result in Alarm Code 127 Setpoint not entered Figure 53 Programming New Setpoint Display After the YES soft key has been pressed the display will briefly show PROGRAMMING ...

Page 65: ...own below Figure 57 Diesel Engine Start Display Initiating a Manual Defrost Cycle Defrost cycles are usually initiated automatically based on time or demand Manual defrost is also available Manual defrost is available if the unit is running the zone is turned on and the zone coil temperature is less than 45 F 7 C Only one zone can be in defrost at a time Other features such as economy mode or door...

Page 66: ... LOCKOUT and then HIGH SPEED LOCKOUT ACTIVE or HIGH SPEED LOCKOUT INACTIVE as shown below Figure 62 Standard Display with High Speed Lockout Active Using the Operators Menu The Operators Menu contains several additional menus that allow the operator to view information and modify unit operation To access the Operators Menu press the MENU key Figure 63 Menu Key The first menu choice will appear Pre...

Page 67: ...enu After a new language is chosen all displays will appear in that language If the language feature is not enabled this menu does not appear Languages currently supported are English German Spanish French and Italian The default language is English Only languages that have been enabled will appear on this menu To select an alternate language press the MENU key Figure 65 Standard Display The Langu...

Page 68: ... will be indicated by the display In the display shown below the unit is operating in Cycle Sentry mode and the option exists to switch to Continuous mode In this example pressing the Select key will switch the mode from Cycle Sentry to Continuous Figure 72 Switching Modes Display Pressing the Select key will change the mode from Cycle Sentry to Continuous The display will confirm the change as sh...

Page 69: ...SELECT key Figure 77 Mode Display Press the Next key as required to display Economy Mode The current state of Economy mode either On or Off will be indicated by the display In the display shown below Economy Mode is turned off and the option exists to turn Economy mode on In this example pressing the Select key will turn Economy Mode on Pressing the Select key will turn Economy Mode on The display...

Page 70: ...programmed the operator can also program an automatic Pretrip Test when the unit restarts Sleep Mode is turned On and Off using the Mode Menu From the Standard Display press the MENU key Figure 81 Standard Display The Language Menu or Alarm Menu will appear Press the NEXT key as required to show the Mode Menu When the Mode Menu is shown press the SELECT key Figure 82 Mode Display Press the Next ke...

Page 71: ...p mode does not maintain zone temperatures Figure 90 Sleep The unit will restart at the programmed time in this example 4 30 am and perform a Pretrip Test if selected After the Pretrip Test is complete the test results will be displayed and the unit will resume normal operation and control to setpoint To exit Sleep Mode before the selected Wake up time press the EXIT key or turn the unit off and b...

Page 72: ... is checked Zone 2 Cool Check The ability of the unit to cool in low speed is checked Zone 2 Heat Check The ability of the unit to heat in low speed is checked Report Test Results The test results are reported as PASS CHECK or FAIL when the Pretrip Test is completed If test results are CHECK or FAIL alarm codes will exist to direct the technician to the source of the problem Performing a Pretrip T...

Page 73: ...ould be diagnosed and corrected before the unit is released for service 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 Figure 97 Pretrip Pass Display Selecting Diesel or Electric Operation The Diesel or Electric Display allows the operator to...

Page 74: ... to leave bulkheads up to ensure proper system operation In the example shown below a single temperature of 35 F 2 C has been set for both zones Figure 100 Single Temperature Operation Display Display Brightness The brightness of the HMI Control Panel display can be adjusted to allow for changing ambient light conditions The choices available to the operator are HIGH MEDIUM LOW and OFF OFF actuall...

Page 75: ...ghtness Please Wait Display Viewing Hourmeters Hourmeters are displayed using the Hourmeter Display From the Standard Display press the MENU key Figure 105 Standard Display The Language Menu or Alarm Menu will appear Press the NEXT key as required to show the Hourmeter Menu When the Hourmeter Menu is shown press the SELECT key The Hourmeter Display will appear Figure 106 Hourmeters Menu Display Pr...

Page 76: ...nning null time Total Maintenance Hours 1 User Programmable The number of hours before a Total Hours Maintenance Reminder 1 occurs Total Maintenance Hours 2 User Programmable The number of hours before a Total Hours Maintenance Reminder 2 occurs Total Controller Hours Total hours the controller and HMI control panel have been turned on Pretrip Reminder Hours User Programmable number of hours befor...

Page 77: ...n return to full performance If the unit is operating with reduced performance Alarm Code 85 Forced Unit Operation will also be present If the alarm condition reoccurs a set number of times the alarm is set as a shutdown alarm and no further restarts are possible If an alarm applies only to a specific zone that zone will be displayed with the alarm code Shutdown Alarms replace the Standard Display...

Page 78: ...IT IS SHUTDOWN REPAIR IMMEDIATELY OTHERWISE REPORT ALARM AT END OF THE DAY will be shown on the display After Start Inspection After the unit is running the following items can be quickly checked in the Gauges Menu to confirm that the unit is running properly Refer to TK 51652 the SPECTRUMTM TS Diagnostic Manual for detailed instructions Oil Pressure Check the engine oil pressure in high speed by ...

Page 79: ...hermo King units are designed to maintain loads at the temperature at which they were loaded Transport refrigeration units are not designed to pull hot loads down to temperature Post Load Procedure 1 Make sure all the doors are closed and locked 2 Start the unit if it was shut off to load 3 Make sure the setpoint is at the desired setting 4 One half hour after loading defrost the unit by momentari...

Page 80: ...SPECTRUM TS Operation 80 ...

Page 81: ...oose or corroded connections The alternator charging output will be low if the alternator belt or pulleys are defective or the belt is not properly adjusted Be sure the belt is not loose or cracked and the pulleys are the correct size and in good condition The excitation circuit EXC circuit must supply voltage to the EXC terminal of the alternator The sense circuit SENS circuit must supply voltage...

Page 82: ...p on ammeter to monitor output current both on initial startup and under full unit load conditions For example on multi temp units all remote evaporators should be turned on General Diagnostic and Warranty Evaluation Procedure Complete the following diagnostic procedures before replacing an alternator or the voltage regulator 1 When testing an alternator use accurate equipment such as a Thermo Kin...

Page 83: ...nt to the unit battery typically 5 10 amps A reading on the clamp on ammeter at or near 0 amps indicates the alternator is not charging Checking the unit ammeter will show a discharge condition The alternator is defective if there are no problems in the wiring Recheck the wiring before assuming the alternator is defective 15 Check the voltage at the B POS terminal The voltage should increase until...

Page 84: ...l the following solution may help solve the problem Remove the wire labeled SENSE and tape off Add a jumper wire from 2A to the SENSE terminal on the back of the alternator This should reduce the voltage to the battery by 0 2 to 0 3 of a volt Battery NOTE The Microprocessor Power switch must be placed in the Off position before connecting or disconnecting the battery terminals The Microprocessor P...

Page 85: ...M sensor may be checked as follows 1 Install the flywheel RPM sensor into the flywheel bracket of the start stop unit until it contacts the ring gear Back out the sensor 1 4 turn and tighten the locknut Figure 114 Flywheel RPM Sensor 2 Disconnect wires RPM and RPM from the sensor Figure 115 RPM and RPM Wires 3 Place the unit in Continuous Run Run the unit on low speed and high speed Check the AC v...

Page 86: ...ion Electric Standby Operation The condenser fan is belt driven On electric standby operation check for correct fan rotation by placing a small cloth or sheet of paper against the condenser fan grille on the front of the unit Correct rotation will hold the cloth or paper against the grille Improper rotation will blow the cloth or paper away from the grille To correct check motor and motor contacto...

Page 87: ... circuits If 12 24 volts DC is supplied then outputs 7EB and 7EC will be at 12 24 volts DC SP If this wire is connected to chassis ground the module will operate in single phase mode SP GR ND This is an internal ground for the module If SP GRND is jumpered to SP then the module will be set to operate on single phase Outputs Output Description 7EB If phase rotation is L1 L2 L3 then this wire will p...

Page 88: ...on Diagnostics Truck SPECTRUM TS Applications 1 Plug the standby power cord into a know good power supply and turn the unit on 2 Using a Fluke Meter test the L1 L2 and L3 circuits at the input to the terminals where the Brown Blue and Black wires are connected The voltage should be between 200 500 VAC between the circuits If not repair as necessary to supply the needed voltage to the unit 3 Check ...

Page 89: ...e following procedure to set up a new overload relay 1 Use a small screwdriver to set the opening amperage See Electric Standby Model 50 Unit Only on page 24 in the Specifications chapter for the correct overload relay setting 2 Use a small screwdriver to set the pointer on the selector to Aut automatic reset The new overload relay is now set up correctly Note which wires go to which terminals whe...

Page 90: ...Electrical Maintenance 90 ...

Page 91: ...ur Fuel Filter black with gold lettering New EMI 2000 Hour By Pass Oil Filter black with gold lettering API Rating CI 4 Mineral Oil ACEA Rating E3 or better for Europe Five Year or 12 000 Hour ELC Extended Life Coolant The EMI package allows standard maintenance intervals to be extended to 2 000 hours or 1 year whichever occurs first NOTE Units equipped with the EMI 2000 package do require regular...

Page 92: ...l will not run into the breather hose thus filling up an open cylinder Leaving the dipstick out while adding engine oil will vent the crankcase Add oil as necessary to reach the full mark See the Specifications chapter of this manual for correct type of oil 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 o...

Page 93: ...on of the air intake system affects horsepower fuel consumption and engine life 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 1 Output Connection 2 Intake Hose Connection 3 Dry Filter Element Figure 123 Dry Type Air Cleaner 1...

Page 94: ... automatically maintains coolant temperature within the specified temperature range All water cooled engines are shipped from the factory with a mixture of 50 percent permanent type antifreeze concentrate and 50 percent water in the engine cooling system This provides the following 1 Prevents freezing down to 30 F 34 C 2 Retards rust and mineral scale that can cause engine overheating 3 Retards co...

Page 95: ... 1 7 8 9 10 2 4 6 3 5 1 Engine 6 Water Level Sensors 2 Water Temperature Sensor 7 Radiator 3 Orifice 8 Drain Tubing 4 Bleed Line 9 Drain Cock Adaptor 5 Expansion Tank 10 Drain Cock Figure 125 TK376 Engine Cooling Components ...

Page 96: ...led water is recommended over tap water to insure the integrity of the cooling system is maintained ELC cannot be used in all older units The water pump seal bellows and o rings used on older units are not compatible with ELC To upgrade new production engines for ELC use all water pump seal bellows were changed from NBR to HNBR elastomer and the o rings upgraded from NBR to EPDM elastomer These ch...

Page 97: ... or Figure 125 on page 95 and completely drain coolant Observe coolant color If the coolant is dirty proceed with a b and c Otherwise go to step 3 a Run clear water into radiator and allow it to drain out of the drain cock until it is clear b Close the drain cock and install a commercially available radiator and block flushing agent and operate the unit in accordance with instructions of the flush...

Page 98: ...the nozzle at the correct time The increased fuel pressure will lift the spring loaded nozzle to admit fuel into the combustion chamber The fuel system is relatively trouble free and if properly maintained will usually not require major service repairs between engine overhauls The most common cause of fuel system problems is contamination It cannot be stressed enough that the fuel must be clean fu...

Page 99: ...el system or air gets into the system for any other reason NOTE MAKE SURE to keep the fuel tank vent open If the vent becomes clogged a partial vacuum develops in the tank and this increases the tendency for air to enter the system Proceed as follows 1 Loosen the bleeder screw on the inlet fuel fitting of the injection pump 2 Turn on the electric fuel pump The electric fuel pump is energized when ...

Page 100: ...Engine Maintenance 100 Figure 130 Early TK 3 95 Fuel and Oil System Components ...

Page 101: ... 33 Hose 14 Bracket fuel filter 34 Clamp fuel hose Screw 35 Clip oil drain hose Flatwasher 36 Tube fuel pickup Nut 37 Bracket connector 15 Plug pipe Screw bracket 16 Plug pipe Flatwasher 17 Filter oil bypass Nut Filter oil bypass EMI 2000 38 Bracket fuel filter pump Stud bypass filter Screw bracket 18 Filter oil full flow Flatwasher 19 Cap oil hose Nut 20 Hose oil drain 28 in 39 Tee after 2 97 Hos...

Page 102: ...Engine Maintenance 102 Figure 131 Late TK 3 95 Fuel and Oil System Components ...

Page 103: ... 33 Hose 14 Bracket fuel filter 34 Clamp fuel hose Screw 35 Clip oil drain hose Flatwasher 36 Tube fuel pickup Nut 37 Bracket connector 15 Plug pipe Screw bracket 16 Plug pipe Flatwasher 17 Filter oil bypass Nut Filter oil bypass EMI 2000 38 Bracket fuel filter pump Stud bypass filter Screw bracket 18 Filter oil full flow Flatwasher 19 Cap oil hose Nut 20 Hose oil drain 28 in 39 Tee after 2 97 Hos...

Page 104: ...Engine Maintenance 104 Figure 132 TK376 Fuel and Oil System Components ...

Page 105: ...24 Fitting restricted 8 Fitting 1 4 25 Pump fuel 12V 9 Hose 1 4 od x 35 ft lg Kit filter 10 Tee Gasket fuel pump 11 Tee 26 Bracket fuel filter pump 12 Plug Screw bracket 13 Filter fuel EMI 2000 Flatwasher 14 Adapter fuel pickup Nut 15 Bracket fuel filter 27 Valve Schrader Screw 28 Elbow oil drain Flatwasher 29 Hose oil drain 23 in Nut 30 Cap oil drain hose 16 Plug pipe 31 Clip oil drain hose 17 Pl...

Page 106: ...vals according to the Maintenance Inspection Schedule 1 Remove the filter and discard 2 Lubricate rubber ring of new filter with fuel 3 Install the filter and tighten until the filter is slightly loose rubber ring not making contact 4 Bleed the air from the filter by operating the electric pump until fuel bubbles appear at the top of filter 5 Tighten the filter until the rubber ring makes contact ...

Page 107: ... timing procedures used on the TK 3 95 engine One procedure involves checking to make sure the cylinders are timed correctly to each other and the other procedure times the injection pump correctly to the engine If the cylinders are not timed correctly to each other it is of no value to time the injection pump to the engine because one or two of the three cylinders would be out of time The individ...

Page 108: ...ng through the engine side door opening unless you use a mirror The timing mark on the starter mounting plate is a line stamped on the side of the plate facing the flywheel To locate the timing mark feel the back side of the plate 0 4 in 10 mm below the center of round notch in the edge of the plate To make it easier to align the timing marks file a V notch in the edge of the plate in line with th...

Page 109: ... lines bleed the air from the nozzles and test run the engine Timing Individual Cylinder Injection TK 3 95 Engine This procedure should be used when a poor running engine has had all possible problems checked but continues to run badly If the injection pump has been repaired or replaced the chance of individual cylinder timing problems has a greater possibility of occurring To check individual cyl...

Page 110: ...n stroke for the number one cylinder 4 Disconnect the 8S wire from the starter solenoid to prevent the engine from cranking when the unit is turned On 5 Activate the fuel solenoid and the fuel pump by energizing the run relay using the Interface Board Test mode Make sure the Diesel Electric switch is in the Diesel position See the SPECTRUM TS Microprocessor Diagnostic Manual for information about ...

Page 111: ...the number one cylinder the cylinder head cover tighten the other injection lines and reconnect the 8S wire to the starter solenoid when finished with the procedure Injection Pump Removal and Installation TK376 Engine Injection Pump Removal 1 Note the alignment of the index marks on the injection pump and the gear case If they are not marked mark them so the injection pump can be returned to the s...

Page 112: ... injection pump in the gear case Rotate the injection pump shaft to mate the key in the shaft with the keyway in the injection pump gear Take care to make sure the key mates with the keyway 3 Secure the injection pump to gear case with previously removed hardware Make sure to align the index marks on the injection pump and the gear case like they were in step 1 of Injection Pump Removal NOTE If a ...

Page 113: ... satisfactory engine operation Insufficient valve clearance will result in compression loss and misfiring of cylinders resulting in burned valves and seats Excessive valve clearance will result in noisy valve operation and abnormal wear of the valves and rocker arms The intake and exhaust valves are adjusted with the valve in the closed position 2 The intake valve and exhaust valve are adjusted to...

Page 114: ...the TK 3 95 engine contains three vibration mounts two snubber mounts and a chain restraining mount Figure 142 TK 3 95 Engine Mounting Components NOTE For details see Chain Restraining Mount on page 118 0 20 Air Gap Between Lower Snubber and Engine Bracket When Assembled Snubbers Only ...

Page 115: ...Blue Sealer 7 Engine Mount upper 21 Vibration Mount Screw socket head 10 x 1 5 25 mm lg 22 Bracket Screw socket head 10 x 1 25 20 mm lg 23 Stud Screw hex head 10 x 1 25 20 mm lg 24 3 Link Chain Belleville Washer 25 Eye Bolt 8 Engine Mount front 26 Mount Screw Mount Screw Flatwasher Flatwasher Nut Belleville Washer 27 Nut Nut 28 Flatwasher 9 Vibration Mount 29 Lockwasher 10 Engine Screw 30 Nut 11 E...

Page 116: ... TK376 Engine The engine mounting system for the TK376 engine contains three vibration mounts and a chain restraining mount Figure 143 TK376 Engine Mounting Components NOTE For details see Chain Restraining Mount on page 118 ...

Page 117: ...ront Mount Only 19 Screw Chain 5 Mount Vibration Front Set of Two 20 Chain 6 Washer Special 21 Stud Snubber 7 Washer Belleville 22 Bracket Snubber 8 Nut Screw Bracket 5 16 9 Bracket Engine Rear Flatwasher 5 16 Screw Bracket Socket Head Nut 5 16 Sealer Thread Screw Bracket 3 8 10 Mount Vibration Rear Set Of Two Flatwasher 3 8 11 Bracket Gauge Nut 3 8 12 Screw Mount Flatwasher Flatwasher TK376 Engin...

Page 118: ... balloon items for TK 3 95 Engine Mounting Components on page 114 and TK376 Engine Mounting Components on page 116 Install chain on Depressed side of eye bolt 1 Eye Bolt 11 Stud 2 Locknut 3 8 in 12 Locknut HH 3 Belleville Washer 3 8 in 13 Flatwasher 3 8 Galv 4 Vibration Mount 14 See Note 18 5 Screw 15 Locknut HH 6 Flatwasher 16 This End Through Existing Hole In Engine Flange 7 Nyloc Nut 17 Locknut...

Page 119: ...S Flatwasher 5 16 Nylock Nut 5 16 18 SS 4 Screw 3 8 16 SS Flatwasher 3 8 Nylock Nut 3 8 16 SS 2 Vibration Mount 5 3 Link Chain 3 Mount Frame Bracket 6 This End Through Existing Hole In Engine Flange Figure 145 Chain Restraining Mount Bracket ...

Page 120: ...lied to the coil creating an electro magnetic field which pulls the plunger in When in the pulled in position the plunger releases tension on the governor linkage The governor linkage then moves the fuel injector rack thus controlling the fuel flow and placing it in the Fuel On position Adjustments made to the throttle high speed solenoid change governor spring tension which in turn adjust speed s...

Page 121: ...m nut High Speed Adjustment 1 Start the unit and let it run until the engine is warmed up 2 Set the thermostat to make the engine run in high speed and check the engine speed The engine speed should be 2425 25 RPM 3 If the engine speed is not correct loosen the jam nut at the end of the ball joint attached to the throttle solenoid 4 Snap the ball joint off of the throttle lever and turn it to adju...

Page 122: ...ld reset 55 to 60 on TK gauge P N 204 427 Tighten the locknut on the idler pulley adjustment bolt and tighten the idler pulley mounting bolt Electric Motor Jackshaft Compressor Belt The electric motor jackshaft compressor belt is a polyvee belt that also drives the alternator Use the following procedure to adjust this belt 1 Loosen the alternator pivot bolt 2 Loosen the locknut below the mounting ...

Page 123: ... of idler 5 11 8 9 1 2 4 3 6 12 10 7 AJA1504 1 Clutch 7 Idler Pulley 5 5 Inch 2 Idler Pulley 7 Inch 8 Compressor Pulley 3 Engine Electric Motor Jackshaft 3V Belt 9 Electric Motor Jackshaft Pulley 4 Locate Belt Tension Gauge Here 10 Condenser fan 5 Electric Motor Jackshaft Compressor Polyvee Belt 11 Locate Belt Tension Gauge Here 6 Alternator Pulley 12 Water Pump Belt Figure 148 Front View Belt Arr...

Page 124: ...t is critical that the belt be correctly seated in pulley First and last edge of grooves are higher to improve seating of belts 1 2 3 4 5 6 7 8 AGA643 1 Mounting Bracket 5 Eye Bolt NOTE Use the hole on the alternator that allows proper belt tension and shortest length of eye bolt extended 2 Shims 6 Alternator 3 Adjusting Bracket 7 Pivot Bolt 4 Locknuts 8 Spacer Figure 149 Alternator Mounting and B...

Page 125: ...en the vacuum pump oil is contaminated c If the vacuum hoses and valves are leak free d If the unit is leak free e How long you should evacuate the unit f That the unit is still in a deep vacuum before any lines are disconnected or refrigerant is added NOTE The attached evacuation procedures have been written to be used with the Thermo King Evacuation System see P N 204 725 However the principles ...

Page 126: ...ce 126 2 4 5 3 1 6 8 9 10 AGA654 7 11 1 V 1 7 Iso Valve 2 V 2 8 To 110 Vac Power 3 V 3 9 Calibration Standard 4 V 4 10 Vacuum or Micron Gauge 5 Thermistor 11 Charging Port 6 Two Stage Vacuum Pump Figure 150 Evacuation Station ...

Page 127: ...0 Microns 3 1000 Microns 4 2500 Microns 5 5000 Microns 6 20 000 Microns 7 Atmospheric Pressure 8 Calibration Adjustment Screw 9 Example Meter needle shown at calibration position when Calibration Standard specifies 0 15 mm Hg Figure 151 Vacuum Gauge ...

Page 128: ...than 500 microns locate and correct the problem before continuing 6 With the vacuum pump still operating open valve V 4 The micron level will rise momentarily If the micron reading does not return to a level of less than 500 microns locate and correct the problem before continuing 7 Evacuate hoses to 100 microns or lowest achievable level below 500 microns 8 Once 100 microns is reached close valve...

Page 129: ...NU key Figure 153 Press Menu Key The Maintenance Menu is accessed from the first Operator Menu screen that appears either the Language Display or the Alarms Display The Alarms Display is shown here Press and hold both the unlabeled soft key and the Exit key for 5 seconds Figure 154 Press and Hold Exit and Unlabeled Key The Maintenance Hourmeter Menu will appear Press the NEXT key as required to sh...

Page 130: ...ire your recovery machine to pull the system s pressures lower than 0 psig 0 kPa 2 Put the unit into Evacuation Mode see Using The Evacuation Mode Menu on page 129 3 Install the evacuation station hoses on the receiver tank outlet valve suction service valve and discharge service port A low loss fitting must be used on the hose connected to the discharge service port 4 Mid seat the receiver tank o...

Page 131: ...n Mode by pressing the EXIT key and remove the battery charger 7 Set all zones to run in High Speed Cool through the HMI Service Test Mode Refer to the SPECTRUM TS Microprocessor Diagnostic Manual TK 51652 for information about the Service Test Mode 8 Observe the suction pressure and slowly open the low side gauge manifold valve to allow liquid refrigerant to flow into the compressor suction servi...

Page 132: ...s 2 Install a gauge manifold 3 Set all zones to run in High Speed Cool through the HMI Service Test Mode Refer to the SPECTRUM TS Microprocessor Diagnostic Manual TK 51652 for information about the Service Test Mode 4 Run the unit with all zones in high speed cool until the air in the box in each zone indicates 0 F 18 C By allowing a box to leak a small amount you will be able to maintain 0 F 18 C...

Page 133: ...e 32 F 0 C it will be necessary to force defrost To force defrost use the Service Test Mode If the box is empty you can run the unit on the Heat cycle instead of the Defrost cycle NOTE Use refrigeration compressor oil ONLY R 404A systems use a special Ester oil see Tool Catalog Required for Scroll compressors Oil can be added to the compressor through the Schrader valve on the throttling valve see...

Page 134: ... 7 Equalize low side pressure to 1 to 2 psig 7 to 14 kPa NOTE Repeat the pump down procedure if the pressures equalize above 20 psig 138 kPa If acceptable low pressures cannot be achieved after the third pump down the refrigerant must be recovered to perform service on the low side NOTE Valve stem MUST be back seated during normal unit operation 8 Plug in the hot gas bypass solenoid 9 Open the rec...

Page 135: ...e connected to the discharge service port 2 Run the unit with all zones in high speed cool until the system pressures stabilize 3 Note the head pressure on the high pressure gauge 4 Cover the condenser and check the head pressure The compressor should be able to increase the head pressure at least 100 psig 689 kPa The compressor is probably faulty if it cannot raise the head pressure 100 psig 689 ...

Page 136: ...Refrigeration Maintenance 136 ...

Page 137: ...Disconnect the thermister unsolder liquid injection line and the discharge line 5 Remove the compressor stabilization bracket and the compressor mounting bolts 6 Lift the compressor out of the unit Keep the compressor ports covered to prevent dust dirt etc from falling into the compressor 7 Unsolder the discharge line NOTE When the compressor is removed from the unit the oil level should be noted ...

Page 138: ... ft lb 24 to 30 N m 10 Screen 2 Pulley 11 Baffle 3 Shaft Seal Cover 12 Thermister 4 Shaft Seal Assembly 13 Oil Drain Plug 5 Oil Filter 14 Sight Glass 6 Oil Filter Spring 15 Screen Cover 7 Oil Filter Cover Plate 16 Screen 8 Schrader Valve 17 Spring 9 Throttling Valve 18 Oil Drain Cap Figure 162 Compressor Components ...

Page 139: ... 8 Loosen the set screws that secure the bellows to the shaft These set screws typically use an 1 8 inch Allen wrench which is provided with the new seal 9 Remove the old bellows from the shaft Use a small prybar or screwdriver on each side of the bellows but do not scratch the shaft when removing the bellows Be careful not to lose the spacer that is on the shaft 10 Ensure the spacer is properly l...

Page 140: ...ion tool is not available use the pad in the new seal packaging to protect the polished surface of the hard ring during assembly A substitute installation tool should have a diameter approximately the same size as the O D of the polished surface NOTE The following illustration shows the seal installation tool being used on a reciprocating compressor seal cover The same procedure applies to the scr...

Page 141: ...or oil 10 Install spring new gasket and cover plate using hex studs and torque head screws torquing to 290 to 310 in lb 34 to 36 N m Be certain to install hex studs in their original location Scroll Compressor Oil Change 1 Recover refrigerant Equalize pressure to slightly positive 2 Clean oil drain cap area bottom and bottom rear of compressor of excess dirt 3 Remove oil drain plug from bottom rea...

Page 142: ... fitting 3 Sweat tubing out of liquid injection fitting 4 Visually inspect screen in liquid injection fitting 5 If plugged carefully remove liquid injection fitting from compressor body 6 Install new o ring on new liquid injection fitting 7 Lubricate new o ring with MobilTM oil see Tool Catalog 8 Carefully thread new liquid injection fitting through compressor body into steel block on the inside M...

Page 143: ...frigerant and check the compressor oil 5 Test the unit to see that the valve is properly installed Dehydrator Filter Drier Removal 1 Pump down the low side and equalize the pressure to slightly positive 2 Disconnect the nuts at the end of the drier 3 Loosen the mounting hardware and remove the drier Installation 1 Install the new drier and tighten the mounting screws and nuts Install new o rings 2...

Page 144: ...e receiver tank mounting hardware securely 5 Pressurize the refrigeration system and check for leaks If no leaks are found evacuate the system 6 Recharge the unit with refrigerant R 404A The refrigeration industry has introduced a new refrigerant called R 404A This refrigeration is classified as a Hydro fluorocarbon HFC because it contains hydrogen fluorine and carbon It does not contain chlorine ...

Page 145: ...hermo King Evacuation Station is recommended This station is available from service parts see Tool Catalog See Truck and Trailer Service Bulletin T T 061 for additional details Use only recommended vacuum pump oils and change oil after every major evacuation Vacuum pump oils are highly refined and the use of contaminated oils will prevent the desired vacuum from being obtained Failure to follow th...

Page 146: ... your recovery equipment for details Throttling Valve Removal 1 Pump down the unit using the refrigerant recovery system 2 Front seat the suction service valve Release remaining pressure 3 Remove the suction valve and line 4 Unbolt and remove the throttling valve from the unit Disassembly 1 Remove the piston end cap 2 Remove the cotter pin from the castle nut and remove the nut 3 Remove the spring...

Page 147: ...stall the end cap 8 Throttling valve will have to be recalibrated on operating unit Refer to Specifications chapter for setting 9 Adjust by adding or removing shims under the spring Installation 1 Install the throttling valve using new o ring soaked in compressor oil same type of oil that is used in the system Bolt the throttling valve to the compressor 2 Connect the suction hose from the throttli...

Page 148: ...y vary 11 Gasket Piston Housing 3 Plate Bellows End 12 Piston 4 Gasket End Plate 13 Conformance Spring Piston 5 Shim Adjusting 14 Castle Nut Adjusting 6 Spring Bellows 15 Pin Cotter 7 Bellows and Shaft Assembly 16 Housing Piston 8 O ring 17 O Ring Valve to Compressor 9 Housing 18 Throttling Valve Cover Figure 172 Throttling Valve ...

Page 149: ...and must be replaced if it fails A heat sink must be used on the in line check valve when it is being soldered in place to prevent damage to the neoprene seal Removal 1 Recover the refrigerant charge 2 Place a heat sink on the check valve 3 Unsolder the lines and remove the check valve Installation NOTE A heat sink must be used on the in line check valve when it is being soldered in place to preve...

Page 150: ...harge the unit with proper refrigerant and check the compressor oil Condenser Inlet Check Valve Replacement Removal 1 Recover the refrigerant charge 2 Unsolder the lines and remove the check valve NOTE Disassemble the valve before unsoldering Installation 1 Clean the tubes for soldering 2 Place the disassembled check valve in position The arrow on the valve body indicates the direction of refriger...

Page 151: ... Hilliard Clutch Maintenance Large Truck Unit Centrifugal Clutch Change The centrifugal clutch has three belt grooves and its engagement speed is 600 100 RPM Figure 175 Front View and Cross Section AGA127 ...

Page 152: ...ooves 1 Screw 10 Grease Seal 2 Washer 11 Roller Bearing Inner Race 3 Snap Ring 12 Pulley Housing 4 Ball Bearing 13 Elastic Stop Nuts 6 5 Large Small Spacers 14 Connector Link 6 6 Rolling Bearing 15 Spring 6 7 Lockwasher 12 16 Shoe Assembly 3 8 Bushing 6 17 Screws 6 9 Hub Figure 176 Hilliard Centrifugal Clutch ...

Page 153: ...move retaining ring 2 Remove the 3 8 16 flat head cap screw and washer NOTE This screw was installed using LoctiteTM see Tool Catalog and will require the use of an impact tool for removal NOTE A small amount of heat propane or acetylene torch with small heating tip applied to the cap screw head may be required to help loosen the screw 3 Remove housing from hub by supporting hub in a minimum of th...

Page 154: ...4 in nut Thread nut onto screw approximately 3 4 to 1 in Insert threaded end of screw into bushing Lubricate bushing by dipping in clean water only Then press into place Figure 180 Bushing Insertion DO NOT USE SOAP OR OIL TO LUBRICATE BUSHING PRIOR TO ASSEMBLY 2 Remove the inner race from the roller bearing apply a small amount of LoctiteTM see Tool Catalog to race I D and press onto the housing s...

Page 155: ... 12 5 6 N m NOTE Shoes MUST be held tightly against hub while nuts are tightened 14 Place the hub and shoe assembly into the housing and place flatwasher over the bearing 15 Apply LoctiteTM see Tool Catalog to 3 8 16 x 1 in screw and install through washer into housing shaft The housing and hub will be drawn together to the proper relative position as the screw is tightened Tighten the screw to 30...

Page 156: ...Hilliard Clutch Maintenance 156 ...

Page 157: ...oils with compressed air or a pressure washer Be careful not to bend the fins when cleaning a coil If possible blow the air or water through the coil in the direction opposite the normal air flow Repair bent fins and any other noticeable damage Fan Location When mounting the fan and hub assembly on the fanshaft position the assembly in the orifice as follows for proper fan performance For all fans...

Page 158: ...Structural Maintenance 158 ...

Page 159: ...rt Misadjusted fuel solenoid linkage Adjust Fuel solenoid defective Replace solenoid No fuel or wrong fuel in tank Fill fuel tank After filling a completely empty tank first bleed fuel system Engine too cold Use winter preheat procedure Glow plugs defective Replace glow plugs Air in fuel system Bleed fuel system During this operation it can also be determined if the fuel lines are tight and filter...

Page 160: ...ilter blocked Install new filter Electric fuel pump filter dirty Clean and replace diesel filter Delivery of fuel pump insufficient Repair or replace pump Cylinder head gasket leaking Replace gasket Piston rings worn stuck or broken Replace rings Cylinder worn Replace or bore Leaking injection nozzle or irregular injection caused by fouling Clean and repair nozzle Insufficient compression pressure...

Page 161: ...epair or replace injection nozzle Dirty radiator Clean radiator Worn engine parts Overhaul engine Engine runs hot Engine coolant is low Add coolant slowly while engine is in operation Dirty or plugged radiator Clean radiator Cooling system heavily scaled Clean cooling system Water pump leaks Repair or replace water pump Worn or loose belt Replace belt or adjust Cylinder head gasket leaks bubbles a...

Page 162: ...epair as necessary White Smoke fuel is not burning Cold engine Allow engine to warm up Low compression Check and eliminate possible causes Repair as necessary Timing Readjust timing Air or water in fuel Bleed system Replace filters clean fuel system drain and clean tank and check supply tank for water Use known good fuel Insufficient preheat Check glow plugs Battery is not recharging Loose alterna...

Page 163: ...terface board must be set to electric position Check that X5 jumper is in electric left position Defective phase detect module Check 1 D E LED Electric On should be on 2 Motor Contactor MCA or MCB should be energized Replace phase detect module as needed Defective motor contactor Repair or replace motor contactor Overload relay tripping Check for shorted motor windings or wires Control circuit fus...

Page 164: ... voltage condition Check momentary voltage dip during starting Foreign matter prevents contacts from closing Clean contacts Rapid cycling Check for cause of short cycling such as thermostat Short circuit Correct fault Battery is not recharging Loose connections in electrical system Check all electrical connections and charging system Worn brushes in alternator Replace brushes Voltage regulator fau...

Page 165: ...t heating or defrosting Symptom Possible Causes Overcharge of refrigerant Shortage of refrigerant No refrigerant Air through condenser too hot ambient Air flow through condenser restricted Air through condenser too cold ambient Air in refrigerant system Condenser fan blades bent or broken Air short cycling around evaporator coil Air through evaporator restricted Evaporator needs defrosting Compres...

Page 166: ...oid Loose or broken electrical connections Thermostat or thermometer out of calibration Suction pressure gauge out of calibration Leaky receiver tank outlet valve DPR Valve Faulty Rapid cycling between Cool and Heat Unit cools in Heat and Defrost cycle Unit heats in Refrigeration cycle High head pressure Low head pressure No head pressure High suction pressure Low suction pressure No suction press...

Page 167: ...e 12 5 Vdc SPECTRUM TS Evaporator Fan Motor Horsepower 0 13 hp Fan Voltage 8 to 16 Vdc rpm 1900 Full Load Amps 8 7 amps per motor Fuse F1 1 F1 2 F2 1 F2 2 30 amp Remote Liquid Line Solenoid 15w Current Draw 1 2 amps Resistance 10 4 ohms Remote Hot Gas Solenoid 18w Current Draw 1 4 amps Resistance 8 7 ohms Remote Suction Line Solenoid 18w Current Draw 1 4 amps Resistance 8 7 ohms ...

Page 168: ...Remote Evaporator Specifications 168 ...

Page 169: ...ems Electrical Inspect wire harness for damaged wires or connections Inspect replace fan motor brushes Structural Visually inspect unit for fluid leaks Visually inspect unit for damaged loose or broken parts Clean entire unit including evaporator coils and defrost drains Check all unit mounting bolts brackets lines hoses etc ...

Page 170: ...Remote Evaporator Maintenance Inspection Schedule 170 ...

Page 171: ...emperature Sensor Ungraded 5 Discharge Return Air Sensor Graded 9 Terminal Board Bracket 2 Hot Gas Solenoid 6 Variable Blower 12 V 10 Terminal Board 3 Liquid Line Solenoid 7 Blower Housing 11 Terminal Board Markstrip 4 Hot Gas Solenoid 8 Blower Cover 12 Resistance Wire Drain Heater ...

Page 172: ...Remote Evaporator Unit Description 172 Figure 186 SPECTRUM TS Evaporator Front View Figure 187 SPECTRUM TS Evaporator Back View AJA984 AJA985 ...

Page 173: ... to provide cooling When the compartment temperature is near setpoint the SPECTRUM TS microprocessor de energizes the remote liquid line solenoid valve and switches the remote evaporator to null The SPECTRUM TS microprocessor energizes the remote hot gas solenoid when the remote compartment requires heat or defrost Defrost The Defrost mode can be initiated any time the evaporator coil temperature ...

Page 174: ...ion 174 Unit Protection Devices Fuses in Host Unit located on interface board Serial Number Location Unit Nameplate on the right end of the unit frame Figure 188 Serial Number Location 1 Nameplate on Right End of Unit Frame 1 AJA985 ...

Page 175: ...RUM 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 176 ...

Page 177: ... Install the access panels 7 Open the refrigeration valves and place the unit in operation 8 Test the unit to see that the expansion valve is properly installed Evaporator Coil Removal 1 Recover refrigerant by approved methods 2 Remove evaporator assembly 3 Remove the access panels 4 Disconnect the distributor from the expansion valve 5 Remove the insulating tape and feeler bulb from the suction l...

Page 178: ...sor oil Add as required IMPORTANT Truck Spectrum evaporators use Suction Line Solenoids with bleed port where Trailer evaporators do not Be careful not to intermix the two solenoids Check Valve Replacement Removal 1 Pump down the low side and equalize the pressure to slightly positive 2 Remove the access panels 3 Unsolder lines and remove the check valve NOTE Disassemble the valve before unsolderi...

Page 179: ... particles that might adhere to the seat and damage the new seat If the body is damaged replace the check valve 2 Install the new seat and spring Place a new gasket on the cap and tighten the cap 3 Pressurize the low side and test for leaks If no leaks are found evacuate the low side 4 Install the access panels 5 Open the refrigeration valves and place the unit in operation Check the refrigerant c...

Page 180: ...Remote Evaporator Refrigeration Service Operations 180 ...

Page 181: ... repair or replacement of parts Defrost Drains Clean the defrost drains during scheduled maintenance inspections to make sure the lines remain open Evaporator Coil Clean the evaporator coil during scheduled maintenance inspections by blowing compressed air from the top side of the coil down toward the bottom the direction opposite the normal air flow Inspect the coil and fins for damage and repair...

Page 182: ...Remote Evaporator Structural Maintenance 182 ...

Page 183: ...l Defrost or clean evaporator coil Expansion valve open too much Replace or adjust valve Poor fitting trailer door Repair or replace doors Liquid line solenoid partially closed or defective Repair or replace Evaporator fan not operating Check and correct evaporator fan Evaporator fan motor does not run Fuse blown Check for short circuit in unit wiring and replace fuse Open in FM circuit Locate ope...

Page 184: ...Remote Evaporator System Diagnosis 184 ...

Page 185: ...ical control system specifications 23 electrical maintenance 81 EMI 2000 29 91 engine 28 engine air cleaner 93 engine change 91 engine lubrication system 91 engine maintenance 91 engine mounts 114 engine oil dipstick 32 engine specifications 21 engine speed adjustments 121 high speed 121 low speed 121 engine valve clearance adjustment 113 evacuation 125 130 F fan location 157 first aid 18 electric...

Page 186: ...em diagnosis 183 unit description 171 restraining mount adjustment 118 RPM sensor 85 S safety precautions 15 auto start stop 16 battery removal 16 electrical hazards 17 general practices 15 microprocessor service precautions 17 refrigerant hazards 16 refrigerant oil hazards 16 welding precautions 18 schematic diagrams index 187 serial number and refrigerant label locations 59 serial number locatio...

Page 187: ...187 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 188 ...

Page 189: ...189 Wiring Diagram Page 1 of 4 ...

Page 190: ...190 Wiring Diagram Page 2 of 4 ...

Page 191: ...191 Wiring Diagram Page 3 of 4 ...

Page 192: ...192 Wiring Diagram Page 4 of 4 ...

Page 193: ...193 Schematic Diagram Page 1 of 3 ...

Page 194: ...194 Schematic Diagram Page 2 of 3 ...

Page 195: ...195 Schematic Diagram Page 3 of 3 ...

Page 196: ...196 ...