Thermo King SPECTRUM TS Series - Figure 131: Late TK 3.95 Fuel and Oil System Components

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Engine Maintenance

102

Figure 131: Late TK 3.95 Fuel and Oil System Components

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Table of Contents5
List of Figures11
Safety Precautions15
General Practices15
Auto Start/Stop16
Battery Removal16
Refrigerant Hazards16
Refrigerant Oil Hazards16
Electrical Hazards17
High Voltage17
Low Voltage17
Microprocessor Service Precautions17
Welding Precautions18
First Aid18
First Aid, Refrigerant18
First Aid, Refrigerant Oil18
First Aid, Engine Coolant18
First Aid, Electrical Shock19
Specifications21
Engine21
Belt Tension22
Refrigeration System23
Engine Clutch - Hilliard23
Electrical Control System23
Defrost Timer23
System Controller24
Electrical Components24
Electric Standby (Model 50 Unit Only)24
Standby Power Requirements24
Maintenance Inspection Schedule25
Unit Description27
Unit Overview27
Design Features27
Unit Options27
Figure 1: SPECTRUM TS Front View27
Engine28
Clutch28
ELC (Extended Life Coolant)28
Figure 2: TK 3.95 (Tier 1)28
Figure 3: TK376 (Tier 2)28
Emi 200029
SPECTRUM Remote Evaporator29
Compressor29
SPECTRUM TS HMI Control Panel29
Figure 4: SPECTRUM Remote Evaporator29
Figure 5: HMI Control Panel29
Microprocessor Power Switch30
CYCLE-SENTRY Start/Stop System30
Defrost30
DAS - Data Acquisition System (Optional)30
Figure 6: Microprocessor Power Switch30
Electric Standby (Model 50 Units Only)31
Standard Model 50 Features31
High Voltage Tray31
Phase Detect Module for Truck Unit Model 50 Applications31
Figure 7: Phase Detect Module31
Unit Instruments32
Unit Sensors32
Graded and Ungraded Sensors32
Refrigeration System Components33
Engine Controls34
Refrigeration Cycles35
All Zones Cooling35
One or Two Zones Cooling and Other Zones Heating35
All Zones Heating35
Any Zone Defrosting35
Technician Features35
Refrigeration System Diagrams36
Figure 8: Refrigeration System Components37
Zone 1 Cool and Zone 2 Cool38
Figure 9: Zone 1 Cool and Zone 2 Cool38
Zone 1 Heat and Zone 2 Heat39
Figure 10: Zone 1 Heat and Zone 2 Heat39
Zone 1 Cool and Zone 2 Heat40
Figure 11: Zone 1 Cool and Zone 2 Heat40
Zone 1 Cool and Zone 2 Null41
Figure 12: Zone 1 Cool and Zone 2 Null41
Zone 1 Heat and Zone 2 Null42
Figure 13: Zone 1 Heat and Zone 2 Null42
Zone 1 Cool and Zone 2 Defrost43
Figure 14: Zone 1 Cool and Zone 2 Defrost43
Zone 1 Heat and Zone 2 Defrost44
Figure 15: Zone 1 Heat and Zone 2 Defrost44
Zone 1 Defrost and Zone 2 Null45
Figure 16: Zone 1 Defrost and Zone 2 Null45
Figure 17: Zone 1 Cool, Zone 2 Heat, and Zone 3 Heat46
Zone 1 Cool, Zone 2 Heat, and Zone 3 Heat47
Zone 2 Evaporator47
Figure 18: Zone 1 Cool, Zone 2 Heat, and Zone 3 Defrost48
Zone 1 Cool, Zone 2 Heat and Zone 3 Defrost49
Inverted Heat Mode50
Defrost Mode50
Start up and Sweeping Unit Evaporator Coils50
Figure 19: Front View51
Figure 20: Back View51
Figure 21: Side View52
Figure 22: Condenser Compartment Components53
Figure 23: Control Box and Miscellaneous Components54
Figure 24: Power Receptacle Box-Model 5055
Figure 25: HMI Control Panel55
Control Box, Fuses and Relays56
Figure 26: Complete SPECTRUM56
Figure 27: Interface Board56
Power Supply Board57
Multi-Temp Option Board57
Figure 28: Power Supply Board57
Figure 29: Multi-Temp Option Board57
Figure 30: High Voltage Contactors with Shield Removed58
Serial Number Locations59
Serial Number and Refrigerant Label Locations59
Figure 31: Engine Serial Number Location59
Figure 32: Compressor Serial Number Location59
Figure 33: Label Locations59
Figure 34: Laminated Unit Serial Number Plate59
Figure 35: Refrigerant Type Label59
SPECTRUM™ TS Operation61
HMI Controller Overview61
Display61
Microprocessor Power Switch61
Turning the Unit on and off61
Figure 36: Dedicated and Soft Keys61
Figure 37: Microprocessor Power Switch61
Figure 38: On/Off Key61
The Standard Display62
Selecting a Zone Display62
Figure 39: Startup Screen62
Figure 40: Standard Display62
Figure 41: Standard Display62
Figure 42: One Zone off62
Figure 43: Standard Display62
Turning a Zone on and off63
Figure 44: Selecting a Zone63
Figure 45: Standard Display63
Figure 46: Zone 1 on63
Figure 47: Zone 1 off63
Figure 48: Programming Screen63
Figure 49: Displays New Setting63
Figure 50: Zone 1 on Display63
Changing the Setpoint64
Figure 51: Zone 2 Display64
Figure 52: New Setpoint Display64
Figure 53: Programming New Setpoint Display64
Figure 54: New Setpoint64
Figure 55: Standard Display with New Setpoint Displayed64
Starting the Diesel Engine65
Initiating a Manual Defrost Cycle65
Figure 56: Setpoint Not Changed Display65
Figure 57: Diesel Engine Start Display65
Figure 58: Standard Display65
Figure 59: Select Zone to Defrost Display65
Figure 60: Zone 1 in Defrost65
Terminating a Defrost Cycle66
Selecting High Speed Lockout (if Enabled)66
Using the Operators Menu66
Operators Menu Choices66
Figure 61: Programming Display66
Figure 62: Standard Display with High Speed Lockout Active66
Figure 63: Menu Key66
Figure 64: Mode Display66
Selecting a Language67
Figure 65: Standard Display67
Figure 66: New Language67
Figure 67: New Language67
Figure 68: Programming Please Wait67
Figure 69: Language Menu67
Selecting Cycle Sentry or Continuous Mode68
Figure 70: Standard Display68
Figure 71: Mode Display68
Figure 72: Switching Modes Display68
Figure 73: Programming Modes Display68
Figure 74: Continuous Mode Display68
Figure 75: Cycle Sentry Mode Display68
Selecting Economy Mode69
Figure 76: Standard Display69
Figure 77: Mode Display69
Figure 78: Programming Economy Mode Display69
Figure 79: Programming Economy Mode Display69
Figure 80: Economy Mode Display69
Selecting Sleep Mode70
Figure 81: Standard Display70
Figure 82: Mode Display70
Figure 83: Start Sleep Mode70
Figure 84: Program Wake-Up Time70
Figure 85: Sleep70
Pretrip Tests71
Figure 86: Program Wake-Up Time71
Figure 87: Select Day Screen71
Figure 88: Select Time Screen71
Figure 89: Run Pretrip on Wake-Up71
Figure 90: Sleep71
Performing a Pretrip Test72
Figure 91: Standard Display72
Figure 92: Mode72
Figure 93: Pretrip Display72
Selecting Diesel or Electric Operation73
Figure 94: Programming Test Pretrip Display73
Figure 95: Selecting Menus73
Figure 96: Zone 1 Cool Test73
Figure 97: Pretrip Pass Display73
Figure 98: Electric Standby Display73
Single Temperature Operation74
Display Brightness74
Figure 99: Switch to Diesel Display74
Figure 100: Single Temperature Operation Display74
Figure 101: Standard Display74
Figure 102: Adjust Brightness Display74
Viewing Hourmeters75
Figure 103: Medium Display75
Figure 104: Adjusting Brightness Please Wait Display75
Figure 105: Standard Display75
Figure 106: Hourmeters Menu Display75
Figure 107: Hourmeter Display75
Viewing and Clearing Alarm Codes77
Displaying and Clearing Alarm Codes77
Figure 108: Standard Display77
After Start Inspection78
Figure 109: Alarms78
Figure 110: no Alarms Display78
Figure 111: Alarms Present Display78
Figure 112: Serious Alarm Display78
Loading Procedure79
Post Load Procedure79
Post Trip Checks79
Electrical Maintenance81
Alternator (Prestolite) Charging System Diagnostic Procedures81
General Information81
Figure 113: Prestolite Terminal Locations81
Interface Board Fuse F882
Test Equipment for Checking Voltage and Current82
Alternator Load Test82
General Diagnostic and Warranty Evaluation Procedure82
Excessive Voltage Output84
Battery84
Unit Wiring84
Electrical Contacts84
Charging System (12 VDC)84
Preheat Buzzer85
RPM Sensor85
Figure 114: Flywheel (RPM) Sensor85
Figure 115: RPM+ and RPM- Wires85
Glow Plugs86
Condenser Fan Rotation (Electric Standby Operation)86
Phase Detect Module for Truck Unit Model 50 Applications86
Operation86
Figure 116: Glow Plug Test86
Removal and Replacement88
Overload Relay89
Overload Relay Replacement89
Figure 117: Overload Relay89
Figure 118: Setting Overload Relay89
Engine Maintenance91
Engine Change91
Emi 200091
Engine Lubrication System91
Figure 119: TK 3.95 (Tier 1)91
Figure 120: TK376 (Tier 2)91
Engine Oil Pressure Switch92
Engine Oil Change92
Oil Filter Change92
Crankcase Breather92
Figure 121: Engine Oil Pressure Switch92
Figure 122: Oil Filter Parts92
Engine Air Cleaner (EMI 2000)93
Figure 123: Dry Type Air Cleaner93
Engine Cooling System94
General Description94
Figure 124: TK 3.95 Engine Cooling Components94
Figure 125: TK376 Engine Cooling Components95
ELC (Extended Life Coolant)96
Figure 126: ELC Nameplate Located on Expansion Tank96
Antifreeze Maintenance Procedures97
Engine Thermostat98
Engine Fuel System98
Figure 127: Water Pump Assembly and Thermostat98
Bleeding the Fuel System99
Figure 128: TK 3.95 Injection Pump99
Figure 129: TK376 Injection Pump99
Figure 130: Early TK 3.95 Fuel and Oil System Components100
Figure 131: Late TK 3.95 Fuel and Oil System Components102
Figure 132: TK376 Fuel and Oil System Components104
Draining Water from Fuel Tank106
Fuel Filter Replacement106
Electric Fuel Pump106
Figure 133: Electric Fuel Pump106
Injection Pump107
Injection Pump Timing TK 3.95 Engine107
Figure 134: Timing Marks108
Timing Individual Cylinder Injection TK 3.95 Engine109
Figure 135: Individual Cylinder Timing and Firing Order109
Injection Pump Timing TK376 Engine110
Figure 136: Component Location110
Injection Pump Removal and Installation TK376 Engine111
Figure 137: Correct Injection Timing Mark Alignment111
Figure 138: Index Mark Location111
Figure 139: Index Mark Alignment111
Figure 140: TK376 Injection Pump Removal and Installation112
Fuel Limit Screw113
Adjust Engine Valve Clearance113
Figure 141: Emission Control Label113
Engine Mounts114
TK 3.95 Engine114
Figure 142: TK 3.95 Engine Mounting Components114
TK376 Engine116
Figure 143: TK376 Engine Mounting Components116
Restraining Mount Adjustment118
Figure 144: Chain/Restraining Mount118
Figure 145: Chain/Restraining Mount Bracket119
Integral Fuel Solenoid120
Fuel Solenoid Diagnostic and Replacement120
Figure 146: Integral Fuel Solenoid Components TK 3.95 Engine120
Engine Speed Adjustments121
Low Speed Adjustment121
High Speed Adjustment121
Figure 147: High Speed Solenoid Components TK376 Engine121
Belts122
Engine/Electric Motor (Jackshaft) Belt122
Electric Motor (Jackshaft)/Compressor Belt122
Figure 148: Front View Belt Arrangement123
Alternator Adjustment124
Figure 149: Alternator Mounting and Belt Tension Adjustment124
Refrigeration Maintenance125
Evacuation125
Figure 150: Evacuation Station126
Figure 151: Vacuum Gauge127
Set up and Test of Evacuation Equipment128
Figure 152: Pressure Rise Graphs128
Using the Evacuation Mode Menu129
Figure 153: Press Menu Key129
Figure 154: Press and Hold Exit and Unlabeled Key129
Figure 155: Evacuation Mode Menu129
Figure 156: Programming129
Figure 157: Connect Battery129
Leak Check System130
Unit Evacuation130
Figure 158: Battery Voltage130
Unit Charging131
Remove Refrigerant Hoses131
Refrigerant Leaks132
Refrigerant Charge132
Testing the Refrigerant Charge with an Empty Box132
Testing the Refrigerant Charge with a Loaded Box132
Checking Compressor Oil133
High Pressure Cutout Switch (HPCO)133
Figure 159: Scroll Compressor133
Figure 160: High Pressure Cutout Manifold133
Low Side Pump down134
Discharge Pressure Regulator Valve134
Figure 161: Discharge Pressure Regulator134
Refrigeration System Checks135
Refrigeration Service Operations137
Accumulator137
Removal137
Installation137
Compressor137
Figure 162: Compressor Components138
Shaft Seal Change Procedure139
Figure 163: Cross Section of Set Screw Type Bellows139
Figure 164: Set Screw Type Bellows Seal139
Figure 165: Bellows Installation with Tool140
Figure 166: Lip Seal and Hard Ring Installation140
Compressor Oil Filter Replacement141
Scroll Compressor Oil Change141
Temperature Thermister Change Procedure142
Liquid Injection Fitting Change Procedure142
Condenser/Radiator Coil142
Removal142
Installation143
Liquid Injection Valve143
Removal143
Dehydrator (Filter-Drier)143
High Pressure Cutout Switch143
High Pressure Relief Valve144
Removal144
Installation144
Receiver Tank144
Unit Identification144
Availability144
Leak Detection144
Figure 167: R404A Decal144
Compressor Oil145
Compressors Shipped with POE Oil145
Equipment Recommendations for Use with R-404A145
Gauge Manifold Sets145
System Clean-Up146
Refrigerant Recovery146
Throttling Valve146
Removal146
Disassembly146
Figure 168: Throttle Valve, Cap and Spring146
Figure 169: Throttle Valve Piston146
Reassembly147
Installation147
Figure 170: Throttle Valve Housing147
Figure 171: Throttle Valve Piston Assembly147
Figure 172: Throttling Valve148
Solenoid Valves149
In-Line Check Valves149
Figure 173: Cross Section of In-Line Check Valve149
Condenser Inlet Check Valve Repair150
Condenser Inlet Check Valve Replacement150
Figure 174: Check Valve with Cap Nut150
Hilliard Clutch Maintenance151
Large Truck Unit Centrifugal Clutch Change151
Figure 175: Front View and Cross Section151
Figure 176: Hilliard Centrifugal Clutch152
Clutch Maintenance153
Tools Required153
Grease153
Disassembly Procedure153
Figure 177: Housing Removal153
Figure 178: Bearing Removal153
Assembly Procedure (Using New Bearings and Seal)154
Figure 179: Bushing Removal154
Figure 180: Bushing Insertion154
Figure 181: Clutch155
Structural Maintenance157
Unit and Engine Mounting Bolts157
Unit Inspection157
Condenser and Radiator Coils157
Fan Location157
Figure 182: Mounting Bolts157
Figure 183: Fan Blade Position in Orifice for All Except Ten-Blade Fan157
Figure 184: Fan Blade Position in Orifice for Ten-Blade Fan157
Mechanical Diagnosis159
Electric Standby (Optional) Diagnosis163
Refrigeration Diagnosis165
Remote Evaporator Specifications167
Refrigeration System167
Electrical167
Figure 185: SPECTRUM167
Remote Evaporator Maintenance Inspection Schedule169
Remote Evaporator Unit Description171
Figure 186: SPECTRUM™ TS Evaporator-Front View172
Figure 187: SPECTRUM™ TS Evaporator-Back View172
Unit Operation173
Defrost173
Operating Modes173
Unit Features173
Unit Protection Devices174
Serial Number Location174
Figure 188: Serial Number Location174
Remote Evaporator Electrical Maintenance175
SPECTRUM ™ Microprocessor Controlled Components175
Unit Wiring175
Remote Evaporator Refrigeration Service Operations177
Expansion Valve Assembly177
Removal177
Installation177
Evaporator Coil177
Solenoid Valves178
Removal178
Installation178
Check Valve Replacement178
Check Valve Repair179
Figure 189: Check Valve with Cap Nut179
Remote Evaporator Structural Maintenance181
Unit Inspection181
Defrost Drains181
Evaporator Coil181
Remote Evaporator System Diagnosis183
Index185
Wiring and Schematic Diagrams Index187

Thermo King SPECTRUM TS Series - Figure 131: Late TK 3.95 Fuel and Oil System Components

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