Thermo King TS-200 - User Manual

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TS-200 &

TS-300

TK 50794-1-MM (Rev. 5, 04/03)

Printed in USA.

Main Page

Table of Contents5
List of Figures11
Safety Precautions13
General Practices13
Auto Start/Stop13
Refrigerant13
First Aid13
Refrigeration Oil14
First Aid14
Electrical Hazards14
Microprocessor Service14
Welding of Units or Truck Bodies15
High Voltage15
Low Voltage16
Unit Decals16
Figure 1: Refrigerant Decal Locations16
Figure 2: Refrigerant Decal16
Specifications17
Engine17
Belt Tension18
Refrigeration System18
Engine Clutch - Hilliard18
Electrical Control System19
Defrost Timer19
Thermostat19
Electrical Components19
Electric Standby (Model 50 Unit Only20
Standby Power Requirements20
Air Switch20
Maintenance Inspection Schedule21
Unit Description23
Thermoguard Μp-T Controller23
Data Acquisition System (Optional)23
Clutch23
Unit Features24
Unit Instruments25
Unit Protection Devices25
Unit Operation26
Pretrip Inspection (before Starting Unit)26
Thermoguard Μp-T Smart Reefer27
TM (SR) Microprocessor27
Displaying Operating Data27
Entering Setpoint Temperature27
Starting Unit (Full Unit Self Check)28
Selection of Operating Modes on CYCLE-SENTRY Equipped Units28
Selecting CYCLE-SENTRY or Continuous Run Mode (Diesel or Electric Operation)29
Initiating Manual Defrost29
Displaying and Clearing Alarm Codes30
Restarting the Unit30
After Start Inspection31
Loading Procedure31
Post Load Procedure31
Post Trip Checks31
Unit Photographs32
Figure 3: Front View32
Figure 4: Back View32
Figure 5: Left Side View33
Figure 6: Right Side View33
Figure 7: Components34
Figure 8: North American Power Receptacle Box35
Figure 9: Control Box36
Figure 10: Thermoguard Remote Control Panel37
Figure 11: Remote Light Display37
P-T System Description39
General Description39
P-T Control System39
Microprocessor Power Switch39
Optional Electric Standby (Model 50 Units Only)39
Figure 12: Microprocessor Power Switch39
Optional Model 50 Features40
Figure 13: High Voltage Tray with Phase Correction Standard Board40
Figure 14: High Voltage Tray with Phase Correction and Electric Heat40
Remote Control Panel Features41
Keypad Keys41
Figure 15: Remote Control Panel41
Understanding the Display42
Display Icons42
Reading a Typical Display42
Figure 16: Display Screen Features42
Figure 17: Typical Display42
The Standard Display43
Changing the Setpoint43
Figure 18: Standard Display43
Figure 19: Changing the Setpoint43
Selecting CYCLE-SENTRY or Continuous Mode44
Starting the Engine44
Figure 20: Selecting CYCLE-SENTRY or Continuous Mode44
Figure 21: Starting the Engine44
Initiating a Manual Defrost Cycle45
Checking the Software Revision45
Figure 22: Initiating a Manual Defrost Cycle45
Figure 23: Software Revision45
Viewing Prompt and Display Screens46
Figure 24: Viewing Prompt and Display Screens46
Viewing and Clearing Alarm Codes47
Figure 25: Alarm Code Display47
P-T Unit Self Check Test50
Electrical Maintenance51
Alternator (Prestolite) Charging System Diagnostic Procedures51
Figure 26: Prestolite Terminal Locations51
Excessive Voltage Output52
Battery53
Unit Wiring53
Electrical Contacts53
Charging System (12 VDC)53
Preheat Buzzer53
RPM Sensor53
Figure 27: Flywheel (RPM) Sensor53
Glow Plugs54
Figure 28: RPM+ and RPM- Wires54
Figure 29: Glow Plug Test54
Condenser/Evaporator Fan Rotation (Electric Standby Operation)55
Defrost Air Switch Checkout and Adjustment55
Figure 30: Testing Air Switch55
Figure 31: Air Switch55
High Capacity Thermax56
TM Heating System56
Cool Mode56
Heat/Condenser Evacuation Mode56
Defrost Mode57
Start up Mode57
Engine Maintenance59
Emi 200059
Engine Lubrication System59
Engine Oil Pressure Sensor59
Engine Oil Change59
Oil Filter Change60
Crankcase Breather60
Engine Air Cleaner (EMI 2000)60
Figure 32: Oil Filter Parts60
Figure 33: Dry Type Air Cleaner60
Engine Cooling System61
General Description61
Figure 34: Engine Cooling Components61
ELC (Extended Life Coolant)62
Figure 35: ELC Nameplate-Located on Expansion Tank62
Engine Thermostat64
Engine Fuel System64
Figure 36: Water Pump Assembly and Thermostat64
Bleeding the Fuel System65
Figure 37: Fuel and Oil System Components66
Draining Water from Fuel Tank68
Fuel Filter Replacement68
Electric Fuel Pump68
Figure 38: Electric Fuel Pump68
Injection Pump69
Figure 39: Timing Marks70
Figure 40: Individual Cylinder Timing and Firing Order71
Adjust Engine Valve Clearance72
Engine Maintenance (Continued)72
Fuel Limit Screw72
Engine Mounts73
Figure 41: Engine Mounting Components73
Restraining Mount Adjustment75
Figure 42: Chain/Restraining Mount75
Figure 43: Chain/Restraining Mount Bracket76
Integral Fuel Solenoid77
Fuel Solenoid Diagnostic and Replacement77
Figure 44: Integral Fuel Solenoid Components77
Engine Speed Adjustments78
Low Speed Adjustment78
High Speed Adjustment78
Belts79
Engine/Electric Motor Belt79
Figure 45: Front View Belt Arrangement79
Electric Motor/Compressor Belt80
Figure 46: Rear View Belt and Pulley Layout80
Alternator Adjustment81
Figure 47: Alternator Mounting and Belt Tension Adjustment81
Idler Pulley Bearing and Seal Installation82
Figure 48: Idler Pulley Assembly82
Assembly Instructions83
Refrigeration Maintenance85
Evacuation85
Figure 49: Evacuation Station86
Figure 50: Vacuum Gauge87
Set up and Test of Evacuation Equipment88
Unit Evacuation89
Unit Charging89
Remove Refrigerant Hoses90
Refrigerant Leaks90
Refrigerant Charge90
Testing the Refrigerant Charge with an Empty Box90
Testing the Refrigerant Charge with a Loaded Box91
Checking Compressor Oil91
Figure 51: Scroll Compressor91
High Pressure Cutout (HPCO)92
Low Side Pump down92
Figure 52: High Pressure Cutout Manifold92
Refrigeration System Checks93
Three-Way Valve Condenser Pressure Bypass Check Valve93
Figure 53: Gauge Manifold Installation93
Figure 54: Three-Way Valve Condenser Pressure Bypass Check Valve94
Discharge Pressure Regulator Valve95
Figure 55: Discharge Pressure Regulator Valve Assembly95
Refrigeration Service Operations97
Accumulator97
Removal97
Installation97
Compressor97
Figure 56: Compressor Components98
Shaft Seal Change Procedure99
Figure 57: Cross Section of Set Screw Type Bellows99
Figure 58: Set Screw Type Bellows Seal99
Figure 59: Bellows Installation with Tool100
Figure 60: Lip Seal and Hard Ring Installation100
Compressor Oil Filter Replacement101
Scroll Compressor Oil Change101
High Temperature Cutout Switch Change Procedure102
Liquid Injection Fitting Change Procedure102
Condenser/Radiator Coil103
Removal103
Installation103
Receiver Outlet Check Valve103
Liquid Injection Valve103
Installation104
Dehydrator (Filter-Drier)104
Removal104
Evaporator Coil104
Figure 61: Location of Injection Valve Bulb104
Figure 62: Completely Wrap Bulb with Tape104
Installation105
Refrigeration Service Operations (Continued)105
Expansion Valve Assembly105
Removal105
Figure 63: Location of Expansion Valve Bulb105
Figure 64: Completely Wrap Bulb with Tape105
Cleaning In-Line Screen106
Heat Exchanger106
Removal106
Installation106
Figure 65: Expansion Valve106
High Pressure Cutout Switch107
Removal107
Installation107
High Pressure Relief Valve107
Pilot Solenoid107
Receiver Tank107
Three-Way Valve Condenser Pressure Bypass Check Valve Repair108
Removal108
Installation108
Figure 66: Condenser Pressure Bypass Check Valve108
Three-Way Valve Repair109
Removal109
Figure 67: Three-Way Valve Assembly109
Installation110
Unit Identification110
Availability110
Leak Detection110
Figure 68: R404A Decal110
Compressor Oil111
Compressors Shipped with POE Oil111
Equipment Recommendations for Use with R-404A111
Gauge Manifold Sets111
Refrigerant Recovery112
Suction Pressure Regulator Valve112
Removal112
Installation112
Hilliard Clutch Maintenance113
Large Truck Unit Centrifugal Clutch Change113
Figure 69: Front View and Cross Section113
Figure 70: Hilliard Centrifugal Clutch114
Clutch Maintenance115
Tools Required115
Grease115
Disassembly Procedure115
Figure 71: Housing Removal115
Figure 72: Bearing Removal115
Assembly Procedure (Using New Bearings and Seal)116
Figure 73: Bushing Removal116
Figure 74: Bushing Insertion116
Figure 75: Clutch117
Structural Maintenance119
Unit and Engine Mounting Bolts119
Unit Inspection119
Condenser, Evaporator and Radiator Coils119
Fan Location119
Figure 76: Fan Blade Position in Orifice119
Defrost Damper120
Figure 77: Defrost Damper Adjustment120
Fanshaft Assembly121
Disassembly121
Figure 78: Fan Shaft Assembly121
Figure 79: Removing Bearing Retainer Bolts121
Figure 80: Removing Shaft121
Reassembly122
Figure 81: Removing Oil Seal122
Figure 82: Removing Roll Pin122
Figure 83: Installing Bearings122
Figure 84: Installing Splash Guard122
Figure 85: Installing Oil Seal123
Figure 86: Shims and O-Ring123
Figure 87: Torquing Retainer Plate Bolts123
Figure 88: Checking End Play123
Mechanical Diagnosis125
Electric Standby (Optional) Diagnosis129
Refrigeration Diagnosis131
Cycle Diagrams133
Cool Cycle133
Figure 89: Cool Cycle Diagram133
Condenser Evacuation Cycle134
Figure 90: Condenser Evacuation Cycle Diagram134
Heat/Defrost Cycle135
Figure 91: Heat/Defrost Cycle Diagram135
Index137
Wiring and Schematic Diagrams Index139

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Thermo King TS-200 Specifications

General

Power Supply	12/24 VDC
Display	LCD
Protection Rating	IP65
Application	Transport refrigeration
Operating Temperature Range	-40°C to +70°C
Inputs	Temperature sensors, door switches
Outputs	Relay outputs for controlling cooling and heating units

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