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SPECTRUM TS Series
Thermo King SPECTRUM TS Series User Manual
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Engine M
aintenanc
e
104
Figure 1
32:
TK3
76 F
uel and
Oil Sy
stem Compo
nent
s
103
105
Table of Contents
Table of Contents
5
List of Figures
11
Safety Precautions
15
General Practices
15
Auto Start/Stop
16
Battery Removal
16
Refrigerant Hazards
16
Refrigerant Oil Hazards
16
Electrical Hazards
17
High Voltage
17
Low Voltage
17
Microprocessor Service Precautions
17
Welding Precautions
18
First Aid
18
First Aid, Refrigerant
18
First Aid, Refrigerant Oil
18
First Aid, Engine Coolant
18
First Aid, Electrical Shock
19
Specifications
21
Engine
21
Belt Tension
22
Refrigeration System
23
Engine Clutch - Hilliard
23
Electrical Control System
23
Defrost Timer
23
System Controller
24
Electrical Components
24
Electric Standby (Model 50 Unit Only)
24
Standby Power Requirements
24
Maintenance Inspection Schedule
25
Unit Description
27
Unit Overview
27
Design Features
27
Unit Options
27
Figure 1: SPECTRUM TS Front View
27
Engine
28
Clutch
28
ELC (Extended Life Coolant)
28
Figure 2: TK 3.95 (Tier 1)
28
Figure 3: TK376 (Tier 2)
28
Emi 2000
29
SPECTRUM Remote Evaporator
29
Compressor
29
SPECTRUM TS HMI Control Panel
29
Figure 4: SPECTRUM Remote Evaporator
29
Figure 5: HMI Control Panel
29
Microprocessor Power Switch
30
CYCLE-SENTRY Start/Stop System
30
Defrost
30
DAS - Data Acquisition System (Optional)
30
Figure 6: Microprocessor Power Switch
30
Electric Standby (Model 50 Units Only)
31
Standard Model 50 Features
31
High Voltage Tray
31
Phase Detect Module for Truck Unit Model 50 Applications
31
Figure 7: Phase Detect Module
31
Unit Instruments
32
Unit Sensors
32
Graded and Ungraded Sensors
32
Refrigeration System Components
33
Engine Controls
34
Refrigeration Cycles
35
All Zones Cooling
35
One or Two Zones Cooling and Other Zones Heating
35
All Zones Heating
35
Any Zone Defrosting
35
Technician Features
35
Refrigeration System Diagrams
36
Figure 8: Refrigeration System Components
37
Zone 1 Cool and Zone 2 Cool
38
Figure 9: Zone 1 Cool and Zone 2 Cool
38
Zone 1 Heat and Zone 2 Heat
39
Figure 10: Zone 1 Heat and Zone 2 Heat
39
Zone 1 Cool and Zone 2 Heat
40
Figure 11: Zone 1 Cool and Zone 2 Heat
40
Zone 1 Cool and Zone 2 Null
41
Figure 12: Zone 1 Cool and Zone 2 Null
41
Zone 1 Heat and Zone 2 Null
42
Figure 13: Zone 1 Heat and Zone 2 Null
42
Zone 1 Cool and Zone 2 Defrost
43
Figure 14: Zone 1 Cool and Zone 2 Defrost
43
Zone 1 Heat and Zone 2 Defrost
44
Figure 15: Zone 1 Heat and Zone 2 Defrost
44
Zone 1 Defrost and Zone 2 Null
45
Figure 16: Zone 1 Defrost and Zone 2 Null
45
Figure 17: Zone 1 Cool, Zone 2 Heat, and Zone 3 Heat
46
Zone 1 Cool, Zone 2 Heat, and Zone 3 Heat
47
Zone 2 Evaporator
47
Figure 18: Zone 1 Cool, Zone 2 Heat, and Zone 3 Defrost
48
Zone 1 Cool, Zone 2 Heat and Zone 3 Defrost
49
Inverted Heat Mode
50
Defrost Mode
50
Start up and Sweeping Unit Evaporator Coils
50
Figure 19: Front View
51
Figure 20: Back View
51
Figure 21: Side View
52
Figure 22: Condenser Compartment Components
53
Figure 23: Control Box and Miscellaneous Components
54
Figure 24: Power Receptacle Box-Model 50
55
Figure 25: HMI Control Panel
55
Control Box, Fuses and Relays
56
Figure 26: Complete SPECTRUM
56
Figure 27: Interface Board
56
Power Supply Board
57
Multi-Temp Option Board
57
Figure 28: Power Supply Board
57
Figure 29: Multi-Temp Option Board
57
Figure 30: High Voltage Contactors with Shield Removed
58
Serial Number Locations
59
Serial Number and Refrigerant Label Locations
59
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
Figure 35: Refrigerant Type Label
59
SPECTRUM™ TS Operation
61
HMI Controller Overview
61
Display
61
Microprocessor Power Switch
61
Turning the Unit on and off
61
Figure 36: Dedicated and Soft Keys
61
Figure 37: Microprocessor Power Switch
61
Figure 38: On/Off Key
61
The Standard Display
62
Selecting a Zone Display
62
Figure 39: Startup Screen
62
Figure 40: Standard Display
62
Figure 41: Standard Display
62
Figure 42: One Zone off
62
Figure 43: Standard Display
62
Turning a Zone on and off
63
Figure 44: Selecting a Zone
63
Figure 45: Standard Display
63
Figure 46: Zone 1 on
63
Figure 47: Zone 1 off
63
Figure 48: Programming Screen
63
Figure 49: Displays New Setting
63
Figure 50: Zone 1 on Display
63
Changing the Setpoint
64
Figure 51: Zone 2 Display
64
Figure 52: New Setpoint Display
64
Figure 53: Programming New Setpoint Display
64
Figure 54: New Setpoint
64
Figure 55: Standard Display with New Setpoint Displayed
64
Starting the Diesel Engine
65
Initiating a Manual Defrost Cycle
65
Figure 56: Setpoint Not Changed Display
65
Figure 57: Diesel Engine Start Display
65
Figure 58: Standard Display
65
Figure 59: Select Zone to Defrost Display
65
Figure 60: Zone 1 in Defrost
65
Terminating a Defrost Cycle
66
Selecting High Speed Lockout (if Enabled)
66
Using the Operators Menu
66
Operators Menu Choices
66
Figure 61: Programming Display
66
Figure 62: Standard Display with High Speed Lockout Active
66
Figure 63: Menu Key
66
Figure 64: Mode Display
66
Selecting a Language
67
Figure 65: Standard Display
67
Figure 66: New Language
67
Figure 67: New Language
67
Figure 68: Programming Please Wait
67
Figure 69: Language Menu
67
Selecting Cycle Sentry or Continuous Mode
68
Figure 70: Standard Display
68
Figure 71: Mode Display
68
Figure 72: Switching Modes Display
68
Figure 73: Programming Modes Display
68
Figure 74: Continuous Mode Display
68
Figure 75: Cycle Sentry Mode Display
68
Selecting Economy Mode
69
Figure 76: Standard Display
69
Figure 77: Mode Display
69
Figure 78: Programming Economy Mode Display
69
Figure 79: Programming Economy Mode Display
69
Figure 80: Economy Mode Display
69
Selecting Sleep Mode
70
Figure 81: Standard Display
70
Figure 82: Mode Display
70
Figure 83: Start Sleep Mode
70
Figure 84: Program Wake-Up Time
70
Figure 85: Sleep
70
Pretrip Tests
71
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
Performing a Pretrip Test
72
Figure 91: Standard Display
72
Figure 92: Mode
72
Figure 93: Pretrip Display
72
Selecting Diesel or Electric Operation
73
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 Display
73
Single Temperature Operation
74
Display Brightness
74
Figure 99: Switch to Diesel Display
74
Figure 100: Single Temperature Operation Display
74
Figure 101: Standard Display
74
Figure 102: Adjust Brightness Display
74
Viewing Hourmeters
75
Figure 103: Medium Display
75
Figure 104: Adjusting Brightness Please Wait Display
75
Figure 105: Standard Display
75
Figure 106: Hourmeters Menu Display
75
Figure 107: Hourmeter Display
75
Viewing and Clearing Alarm Codes
77
Displaying and Clearing Alarm Codes
77
Figure 108: Standard Display
77
After Start Inspection
78
Figure 109: Alarms
78
Figure 110: no Alarms Display
78
Figure 111: Alarms Present Display
78
Figure 112: Serious Alarm Display
78
Loading Procedure
79
Post Load Procedure
79
Post Trip Checks
79
Electrical Maintenance
81
Alternator (Prestolite) Charging System Diagnostic Procedures
81
General Information
81
Figure 113: Prestolite Terminal Locations
81
Interface Board Fuse F8
82
Test Equipment for Checking Voltage and Current
82
Alternator Load Test
82
General Diagnostic and Warranty Evaluation Procedure
82
Excessive Voltage Output
84
Battery
84
Unit Wiring
84
Electrical Contacts
84
Charging System (12 VDC)
84
Preheat Buzzer
85
RPM Sensor
85
Figure 114: Flywheel (RPM) Sensor
85
Figure 115: RPM+ and RPM- Wires
85
Glow Plugs
86
Condenser Fan Rotation (Electric Standby Operation)
86
Phase Detect Module for Truck Unit Model 50 Applications
86
Operation
86
Figure 116: Glow Plug Test
86
Removal and Replacement
88
Overload Relay
89
Overload Relay Replacement
89
Figure 117: Overload Relay
89
Figure 118: Setting Overload Relay
89
Engine Maintenance
91
Engine Change
91
Emi 2000
91
Engine Lubrication System
91
Figure 119: TK 3.95 (Tier 1)
91
Figure 120: TK376 (Tier 2)
91
Engine Oil Pressure Switch
92
Engine Oil Change
92
Oil Filter Change
92
Crankcase Breather
92
Figure 121: Engine Oil Pressure Switch
92
Figure 122: Oil Filter Parts
92
Engine Air Cleaner (EMI 2000)
93
Figure 123: Dry Type Air Cleaner
93
Engine Cooling System
94
General Description
94
Figure 124: TK 3.95 Engine Cooling Components
94
Figure 125: TK376 Engine Cooling Components
95
ELC (Extended Life Coolant)
96
Figure 126: ELC Nameplate Located on Expansion Tank
96
Antifreeze Maintenance Procedures
97
Engine Thermostat
98
Engine Fuel System
98
Figure 127: Water Pump Assembly and Thermostat
98
Bleeding the Fuel System
99
Figure 128: TK 3.95 Injection Pump
99
Figure 129: TK376 Injection Pump
99
Figure 130: Early TK 3.95 Fuel and Oil System Components
100
Figure 131: Late TK 3.95 Fuel and Oil System Components
102
Figure 132: TK376 Fuel and Oil System Components
104
Draining Water from Fuel Tank
106
Fuel Filter Replacement
106
Electric Fuel Pump
106
Figure 133: Electric Fuel Pump
106
Injection Pump
107
Injection Pump Timing TK 3.95 Engine
107
Figure 134: Timing Marks
108
Timing Individual Cylinder Injection TK 3.95 Engine
109
Figure 135: Individual Cylinder Timing and Firing Order
109
Injection Pump Timing TK376 Engine
110
Figure 136: Component Location
110
Injection Pump Removal and Installation TK376 Engine
111
Figure 137: Correct Injection Timing Mark Alignment
111
Figure 138: Index Mark Location
111
Figure 139: Index Mark Alignment
111
Figure 140: TK376 Injection Pump Removal and Installation
112
Fuel Limit Screw
113
Adjust Engine Valve Clearance
113
Figure 141: Emission Control Label
113
Engine Mounts
114
TK 3.95 Engine
114
Figure 142: TK 3.95 Engine Mounting Components
114
TK376 Engine
116
Figure 143: TK376 Engine Mounting Components
116
Restraining Mount Adjustment
118
Figure 144: Chain/Restraining Mount
118
Figure 145: Chain/Restraining Mount Bracket
119
Integral Fuel Solenoid
120
Fuel Solenoid Diagnostic and Replacement
120
Figure 146: Integral Fuel Solenoid Components TK 3.95 Engine
120
Engine Speed Adjustments
121
Low Speed Adjustment
121
High Speed Adjustment
121
Figure 147: High Speed Solenoid Components TK376 Engine
121
Belts
122
Engine/Electric Motor (Jackshaft) Belt
122
Electric Motor (Jackshaft)/Compressor Belt
122
Figure 148: Front View Belt Arrangement
123
Alternator Adjustment
124
Figure 149: Alternator Mounting and Belt Tension Adjustment
124
Refrigeration Maintenance
125
Evacuation
125
Figure 150: Evacuation Station
126
Figure 151: Vacuum Gauge
127
Set up and Test of Evacuation Equipment
128
Figure 152: Pressure Rise Graphs
128
Using the Evacuation Mode Menu
129
Figure 153: Press Menu Key
129
Figure 154: Press and Hold Exit and Unlabeled Key
129
Figure 155: Evacuation Mode Menu
129
Figure 156: Programming
129
Figure 157: Connect Battery
129
Leak Check System
130
Unit Evacuation
130
Figure 158: Battery Voltage
130
Unit Charging
131
Remove Refrigerant Hoses
131
Refrigerant Leaks
132
Refrigerant Charge
132
Testing the Refrigerant Charge with an Empty Box
132
Testing the Refrigerant Charge with a Loaded Box
132
Checking Compressor Oil
133
High Pressure Cutout Switch (HPCO)
133
Figure 159: Scroll Compressor
133
Figure 160: High Pressure Cutout Manifold
133
Low Side Pump down
134
Discharge Pressure Regulator Valve
134
Figure 161: Discharge Pressure Regulator
134
Refrigeration System Checks
135
Refrigeration Service Operations
137
Accumulator
137
Removal
137
Installation
137
Compressor
137
Figure 162: Compressor Components
138
Shaft Seal Change Procedure
139
Figure 163: Cross Section of Set Screw Type Bellows
139
Figure 164: Set Screw Type Bellows Seal
139
Figure 165: Bellows Installation with Tool
140
Figure 166: Lip Seal and Hard Ring Installation
140
Compressor Oil Filter Replacement
141
Scroll Compressor Oil Change
141
Temperature Thermister Change Procedure
142
Liquid Injection Fitting Change Procedure
142
Condenser/Radiator Coil
142
Removal
142
Installation
143
Liquid Injection Valve
143
Removal
143
Dehydrator (Filter-Drier)
143
High Pressure Cutout Switch
143
High Pressure Relief Valve
144
Removal
144
Installation
144
Receiver Tank
144
Unit Identification
144
Availability
144
Leak Detection
144
Figure 167: R404A Decal
144
Compressor Oil
145
Compressors Shipped with POE Oil
145
Equipment Recommendations for Use with R-404A
145
Gauge Manifold Sets
145
System Clean-Up
146
Refrigerant Recovery
146
Throttling Valve
146
Removal
146
Disassembly
146
Figure 168: Throttle Valve, Cap and Spring
146
Figure 169: Throttle Valve Piston
146
Reassembly
147
Installation
147
Figure 170: Throttle Valve Housing
147
Figure 171: Throttle Valve Piston Assembly
147
Figure 172: Throttling Valve
148
Solenoid Valves
149
In-Line Check Valves
149
Figure 173: Cross Section of In-Line Check Valve
149
Condenser Inlet Check Valve Repair
150
Condenser Inlet Check Valve Replacement
150
Figure 174: Check Valve with Cap Nut
150
Hilliard Clutch Maintenance
151
Large Truck Unit Centrifugal Clutch Change
151
Figure 175: Front View and Cross Section
151
Figure 176: Hilliard Centrifugal Clutch
152
Clutch Maintenance
153
Tools Required
153
Grease
153
Disassembly Procedure
153
Figure 177: Housing Removal
153
Figure 178: Bearing Removal
153
Assembly Procedure (Using New Bearings and Seal)
154
Figure 179: Bushing Removal
154
Figure 180: Bushing Insertion
154
Figure 181: Clutch
155
Structural Maintenance
157
Unit and Engine Mounting Bolts
157
Unit Inspection
157
Condenser and Radiator Coils
157
Fan Location
157
Figure 182: Mounting Bolts
157
Figure 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
Mechanical Diagnosis
159
Electric Standby (Optional) Diagnosis
163
Refrigeration Diagnosis
165
Remote Evaporator Specifications
167
Refrigeration System
167
Electrical
167
Figure 185: SPECTRUM
167
Remote Evaporator Maintenance Inspection Schedule
169
Remote Evaporator Unit Description
171
Figure 186: SPECTRUM™ TS Evaporator-Front View
172
Figure 187: SPECTRUM™ TS Evaporator-Back View
172
Unit Operation
173
Defrost
173
Operating Modes
173
Unit Features
173
Unit Protection Devices
174
Serial Number Location
174
Figure 188: 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
Solenoid Valves
178
Removal
178
Installation
178
Check Valve Replacement
178
Check Valve Repair
179
Figure 189: Check Valve with Cap Nut
179
Remote Evaporator Structural Maintenance
181
Unit Inspection
181
Defrost Drains
181
Evaporator Coil
181
Remote Evaporator System Diagnosis
183
Index
185
Wiring and Schematic Diagrams Index
187
5
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Thermo King SPECTRUM TS Series Specifications
General
Brand
Thermo King
Model
SPECTRUM TS Series
Category
Industrial Equipment
Language
English
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