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TS-200 30 SR
Thermo King TS-200 30 SR User Manual
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TS-200 &
TS-300
TK 50794
-1-MM (Re
v
. 5, 04/0
3)
Copyright©
2000 Thermo King C
orp., Minneapo
lis, MN, U
SA.
Printe
d in
USA.
2
Table of Contents
Table of Contents
5
List of Figures
11
Safety Precautions
13
General Practices
13
Auto Start/Stop
13
Refrigerant
13
First Aid
13
Refrigeration Oil
14
First Aid
14
Electrical Hazards
14
Microprocessor Service
14
Welding of Units or Truck Bodies
15
High Voltage
15
Low Voltage
16
Unit Decals
16
Figure 1: Refrigerant Decal Locations
16
Figure 2: Refrigerant Decal
16
Specifications
17
Engine
17
Belt Tension
18
Refrigeration System
18
Engine Clutch - Hilliard
18
Electrical Control System
19
Defrost Timer
19
Thermostat
19
Electrical Components
19
Electric Standby (Model 50 Unit Only
20
Standby Power Requirements
20
Air Switch
20
Maintenance Inspection Schedule
21
Unit Description
23
Thermoguard Μp-T Controller
23
Data Acquisition System (Optional)
23
Clutch
23
Unit Features
24
Unit Instruments
25
Unit Protection Devices
25
Unit Operation
26
Pretrip Inspection (before Starting Unit)
26
Thermoguard Μp-T Smart Reefer
27
TM (SR) Microprocessor
27
Displaying Operating Data
27
Entering Setpoint Temperature
27
Starting Unit (Full Unit Self Check)
28
Selection of Operating Modes on CYCLE-SENTRY Equipped Units
28
Selecting CYCLE-SENTRY or Continuous Run Mode (Diesel or Electric Operation)
29
Initiating Manual Defrost
29
Displaying and Clearing Alarm Codes
30
Restarting the Unit
30
After Start Inspection
31
Loading Procedure
31
Post Load Procedure
31
Post Trip Checks
31
Unit Photographs
32
Figure 3: Front View
32
Figure 4: Back View
32
Figure 5: Left Side View
33
Figure 6: Right Side View
33
Figure 7: Components
34
Figure 8: North American Power Receptacle Box
35
Figure 9: Control Box
36
Figure 10: Thermoguard Remote Control Panel
37
Figure 11: Remote Light Display
37
P-T System Description
39
General Description
39
P-T Control System
39
Microprocessor Power Switch
39
Optional Electric Standby (Model 50 Units Only)
39
Figure 12: Microprocessor Power Switch
39
Optional Model 50 Features
40
Figure 13: High Voltage Tray with Phase Correction Standard Board
40
Figure 14: High Voltage Tray with Phase Correction and Electric Heat
40
Remote Control Panel Features
41
Keypad Keys
41
Figure 15: Remote Control Panel
41
Understanding the Display
42
Display Icons
42
Reading a Typical Display
42
Figure 16: Display Screen Features
42
Figure 17: Typical Display
42
The Standard Display
43
Changing the Setpoint
43
Figure 18: Standard Display
43
Figure 19: Changing the Setpoint
43
Selecting CYCLE-SENTRY or Continuous Mode
44
Starting the Engine
44
Figure 20: Selecting CYCLE-SENTRY or Continuous Mode
44
Figure 21: Starting the Engine
44
Initiating a Manual Defrost Cycle
45
Checking the Software Revision
45
Figure 22: Initiating a Manual Defrost Cycle
45
Figure 23: Software Revision
45
Viewing Prompt and Display Screens
46
Figure 24: Viewing Prompt and Display Screens
46
Viewing and Clearing Alarm Codes
47
Figure 25: Alarm Code Display
47
P-T Unit Self Check Test
50
Electrical Maintenance
51
Alternator (Prestolite) Charging System Diagnostic Procedures
51
Figure 26: Prestolite Terminal Locations
51
Excessive Voltage Output
52
Battery
53
Unit Wiring
53
Electrical Contacts
53
Charging System (12 VDC)
53
Preheat Buzzer
53
RPM Sensor
53
Figure 27: Flywheel (RPM) Sensor
53
Glow Plugs
54
Figure 28: RPM+ and RPM- Wires
54
Figure 29: Glow Plug Test
54
Condenser/Evaporator Fan Rotation (Electric Standby Operation)
55
Defrost Air Switch Checkout and Adjustment
55
Figure 30: Testing Air Switch
55
Figure 31: Air Switch
55
High Capacity Thermax
56
TM Heating System
56
Cool Mode
56
Heat/Condenser Evacuation Mode
56
Defrost Mode
57
Start up Mode
57
Engine Maintenance
59
Emi 2000
59
Engine Lubrication System
59
Engine Oil Pressure Sensor
59
Engine Oil Change
59
Oil Filter Change
60
Crankcase Breather
60
Engine Air Cleaner (EMI 2000)
60
Figure 32: Oil Filter Parts
60
Figure 33: Dry Type Air Cleaner
60
Engine Cooling System
61
General Description
61
Figure 34: Engine Cooling Components
61
ELC (Extended Life Coolant)
62
Figure 35: ELC Nameplate-Located on Expansion Tank
62
Engine Thermostat
64
Engine Fuel System
64
Figure 36: Water Pump Assembly and Thermostat
64
Bleeding the Fuel System
65
Figure 37: Fuel and Oil System Components
66
Draining Water from Fuel Tank
68
Fuel Filter Replacement
68
Electric Fuel Pump
68
Figure 38: Electric Fuel Pump
68
Injection Pump
69
Figure 39: Timing Marks
70
Figure 40: Individual Cylinder Timing and Firing Order
71
Adjust Engine Valve Clearance
72
Engine Maintenance (Continued)
72
Fuel Limit Screw
72
Engine Mounts
73
Figure 41: Engine Mounting Components
73
Restraining Mount Adjustment
75
Figure 42: Chain/Restraining Mount
75
Figure 43: Chain/Restraining Mount Bracket
76
Integral Fuel Solenoid
77
Fuel Solenoid Diagnostic and Replacement
77
Figure 44: Integral Fuel Solenoid Components
77
Engine Speed Adjustments
78
Low Speed Adjustment
78
High Speed Adjustment
78
Belts
79
Engine/Electric Motor Belt
79
Figure 45: Front View Belt Arrangement
79
Electric Motor/Compressor Belt
80
Figure 46: Rear View Belt and Pulley Layout
80
Alternator Adjustment
81
Figure 47: Alternator Mounting and Belt Tension Adjustment
81
Idler Pulley Bearing and Seal Installation
82
Figure 48: Idler Pulley Assembly
82
Assembly Instructions
83
Refrigeration Maintenance
85
Evacuation
85
Figure 49: Evacuation Station
86
Figure 50: Vacuum Gauge
87
Set up and Test of Evacuation Equipment
88
Unit Evacuation
89
Unit Charging
89
Remove Refrigerant Hoses
90
Refrigerant Leaks
90
Refrigerant Charge
90
Testing the Refrigerant Charge with an Empty Box
90
Testing the Refrigerant Charge with a Loaded Box
91
Checking Compressor Oil
91
Figure 51: Scroll Compressor
91
High Pressure Cutout (HPCO)
92
Low Side Pump down
92
Figure 52: High Pressure Cutout Manifold
92
Refrigeration System Checks
93
Three-Way Valve Condenser Pressure Bypass Check Valve
93
Figure 53: Gauge Manifold Installation
93
Figure 54: Three-Way Valve Condenser Pressure Bypass Check Valve
94
Discharge Pressure Regulator Valve
95
Figure 55: Discharge Pressure Regulator Valve Assembly
95
Refrigeration Service Operations
97
Accumulator
97
Removal
97
Installation
97
Compressor
97
Figure 56: Compressor Components
98
Shaft Seal Change Procedure
99
Figure 57: Cross Section of Set Screw Type Bellows
99
Figure 58: Set Screw Type Bellows Seal
99
Figure 59: Bellows Installation with Tool
100
Figure 60: Lip Seal and Hard Ring Installation
100
Compressor Oil Filter Replacement
101
Scroll Compressor Oil Change
101
High Temperature Cutout Switch Change Procedure
102
Liquid Injection Fitting Change Procedure
102
Condenser/Radiator Coil
103
Removal
103
Installation
103
Receiver Outlet Check Valve
103
Liquid Injection Valve
103
Installation
104
Dehydrator (Filter-Drier)
104
Removal
104
Evaporator Coil
104
Figure 61: Location of Injection Valve Bulb
104
Figure 62: Completely Wrap Bulb with Tape
104
Installation
105
Refrigeration Service Operations (Continued)
105
Expansion Valve Assembly
105
Removal
105
Figure 63: Location of Expansion Valve Bulb
105
Figure 64: Completely Wrap Bulb with Tape
105
Cleaning In-Line Screen
106
Heat Exchanger
106
Removal
106
Installation
106
Figure 65: Expansion Valve
106
High Pressure Cutout Switch
107
Removal
107
Installation
107
High Pressure Relief Valve
107
Pilot Solenoid
107
Receiver Tank
107
Three-Way Valve Condenser Pressure Bypass Check Valve Repair
108
Removal
108
Installation
108
Figure 66: Condenser Pressure Bypass Check Valve
108
Three-Way Valve Repair
109
Removal
109
Figure 67: Three-Way Valve Assembly
109
Installation
110
Unit Identification
110
Availability
110
Leak Detection
110
Figure 68: R404A Decal
110
Compressor Oil
111
Compressors Shipped with POE Oil
111
Equipment Recommendations for Use with R-404A
111
Gauge Manifold Sets
111
Refrigerant Recovery
112
Suction Pressure Regulator Valve
112
Removal
112
Installation
112
Hilliard Clutch Maintenance
113
Large Truck Unit Centrifugal Clutch Change
113
Figure 69: Front View and Cross Section
113
Figure 70: Hilliard Centrifugal Clutch
114
Clutch Maintenance
115
Tools Required
115
Grease
115
Disassembly Procedure
115
Figure 71: Housing Removal
115
Figure 72: Bearing Removal
115
Assembly Procedure (Using New Bearings and Seal)
116
Figure 73: Bushing Removal
116
Figure 74: Bushing Insertion
116
Figure 75: Clutch
117
Structural Maintenance
119
Unit and Engine Mounting Bolts
119
Unit Inspection
119
Condenser, Evaporator and Radiator Coils
119
Fan Location
119
Figure 76: Fan Blade Position in Orifice
119
Defrost Damper
120
Figure 77: Defrost Damper Adjustment
120
Fanshaft Assembly
121
Disassembly
121
Figure 78: Fan Shaft Assembly
121
Figure 79: Removing Bearing Retainer Bolts
121
Figure 80: Removing Shaft
121
Reassembly
122
Figure 81: Removing Oil Seal
122
Figure 82: Removing Roll Pin
122
Figure 83: Installing Bearings
122
Figure 84: Installing Splash Guard
122
Figure 85: Installing Oil Seal
123
Figure 86: Shims and O-Ring
123
Figure 87: Torquing Retainer Plate Bolts
123
Figure 88: Checking End Play
123
Mechanical Diagnosis
125
Electric Standby (Optional) Diagnosis
129
Refrigeration Diagnosis
131
Cycle Diagrams
133
Cool Cycle
133
Figure 89: Cool Cycle Diagram
133
Condenser Evacuation Cycle
134
Figure 90: Condenser Evacuation Cycle Diagram
134
Heat/Defrost Cycle
135
Figure 91: Heat/Defrost Cycle Diagram
135
Index
137
Wiring and Schematic Diagrams Index
139
4
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Thermo King TS-200 30 SR Specifications
General
Brand
Thermo King
Model
TS-200 30 SR
Category
Control Systems
Language
English
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