Spectrum Ts Series

SPECTRUM™ TS
TK 51448-1-MM (Rev. 1, 03/06)
Copyright© 2002 Thermo King Corp., Minneapolis, MN, USA.

Printed in USA.
The maintenance information in this manual covers 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 30 SR TK376 NAD (System No. 920255)
SPECTRUM™ TS 50 SR 230/3/60 TK376 NAD (System No. 920256)
SPECTRUM™ TS 50 SR 460/3/60 TK376 NAD (System No. 920257)
SPECTRUM™ TS 30 SR TK376 EEC (System No. 920258)
SPECTRUM™ TS 50 SR 220/3/50 TK376 EEC (System No. 920259)
For further information, refer to:
ThermoGuard SPECTRUM TS Multi-Temp Microprocessor Control System TK 51652
Diagnostic Manual
SPECTRUM™ TS Operator’s Manual TK 51449
SPECTRUM™ TS-500 Parts Manual TK 51447
SPECTRUM™ TS-500 Tier 2 Engine Parts Manual TK 53276
Diagnosing Thermo King Refrigeration System TK 5984
Truck Open Drive Scroll Compressor Diagnostic Manual TK 51205
Tool Catalog TK 5955
2.44, 2.49, 3.66, 3.74, 3.88, 3.95 Engine Overhaul Manual TK 8312
TK270, TK370, and TK376 Engine Overhaul Manual TK 53163
Evacuation Station Operation and Field Application TK 40612
Electrostatic Discharge Training Guide TK 40282
The information in this manual is provided to assist owners, operators and service people in the proper upkeep
and maintenance of Thermo King® units.
This manual is published for informational purposes only and the information so provided should
not be considered as all-inclusive or covering all contingencies. If further information is required,
Thermo King Corporation should be consulted.
Sale of product shown in this manual is subject to Thermo King’s terms and conditions
including, but not limited to, the Thermo King Limited Express Warranty. Such terms and
conditions are available upon request. Thermo King’s warranty will not apply to any
equipment which has been “so repaired or altered outside the manufacturer’s plants as,
in the manufacturer’s judgment, to effect its stability.”
No warranties, express or implied, including warranties of fitness for a particular

purpose or merchantability, or warranties arising from course of dealing or usage of
trade, are made regarding the information, recommendations, and descriptions
contained herein. Manufacturer is not responsible and will not be held liable in contract
or in tort (including negligence) for any special, indirect or consequential damages,
including injury or damage caused to vehicles, contents or persons, by reason of the
installation of any Thermo King product or its mechanical failure.
2
Recover Refrigerant
At Thermo King, we recognize the need to preserve the environment
and limit the potential harm to the ozone layer that can result from
allowing refrigerant to escape into the atmosphere.
We strictly adhere to a policy that promotes the recovery and limits

the loss of refrigerant into the atmosphere.
In addition, service personnel must be aware of Federal regulations

concerning the use of refrigerants and the certification of technicians.
For additional information 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 moisture or standard oils, dispose of properly–DO NOT USE.
When servicing Thermo King R-404A unit, use only those service tools certified
for and dedicated to R-404A refrigerant and Polyol Ester compressor oils.
Residual non-HFC refrigerants or oils will contaminate R-404A systems.
3
4
Table of Contents
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
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 (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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
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
5
Table of Contents
Technician Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Refrigeration System Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Zone 1 Cool and Zone 2 Cool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Zone 1 Heat and Zone 2 Heat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Zone 1 Cool and Zone 2 Heat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Zone 1 Cool and Zone 2 Null . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Zone 1 Heat and Zone 2 Null . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Zone 1 Cool and Zone 2 Defrost . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Zone 1 Heat and Zone 2 Defrost . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Zone 1 Defrost and Zone 2 Null . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Zone 1 Cool, Zone 2 Heat, and Zone 3 Heat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Zone 2 Evaporator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
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
Control Box, Fuses and Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Power Supply Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Multi-Temp Option Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Serial Number Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Serial Number and Refrigerant Label Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
SPECTRUM™ TS Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
HMI Controller Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Microprocessor Power Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Turning the Unit On and Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
The Standard Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Pretrip Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Performing a Pretrip Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Selecting Diesel or Electric Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Single Temperature Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Display Brightness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Viewing Hourmeters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Viewing and Clearing Alarm Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Displaying and Clearing Alarm Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
After Start Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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
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
6
Table of Contents
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Unit Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Electrical Contacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Charging System (12 Vdc) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Preheat Buzzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
RPM Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Glow Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Condenser Fan Rotation (Electric Standby Operation) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Phase Detect Module for Truck Unit Model 50 Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Removal and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Overload Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Overload Relay Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Engine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Engine Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
EMI 2000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Engine Lubrication System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Engine Oil Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Engine Oil Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Oil Filter Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Crankcase Breather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Engine Air Cleaner (EMI 2000) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Engine Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
ELC (Extended Life Coolant) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Antifreeze Maintenance Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Engine Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Engine Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Bleeding the Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
Restraining Mount Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
Integral Fuel Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
Fuel Solenoid Diagnostic and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
Engine Speed Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Low Speed Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
High Speed Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Engine/Electric Motor (Jackshaft) Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Electric Motor (Jackshaft)/Compressor Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Alternator Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
Refrigeration Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
Evacuation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
Set Up and Test of Evacuation Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
Using The Evacuation Mode Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
Leak Check System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
Unit Evacuation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
Unit Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
Remove Refrigerant Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
7
Table of Contents
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
Low Side Pump Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
Discharge Pressure Regulator Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
Refrigeration System Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
Refrigeration Service Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
Accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
Shaft Seal Change Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
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
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
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
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
Solenoid Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
In-Line Check Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
Condenser Inlet Check Valve Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
Condenser Inlet Check Valve Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
Hilliard Clutch Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
Large Truck Unit Centrifugal Clutch Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
8
Table of Contents
Clutch Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153

Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
Grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
Disassembly Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
Assembly Procedure (Using New Bearings and Seal) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
Structural Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
Unit and Engine Mounting Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
Unit Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
Condenser and Radiator Coils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
Fan Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
Mechanical Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
Electric Standby (Optional) Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
Refrigeration Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
Remote Evaporator Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
Refrigeration System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
Remote Evaporator Maintenance Inspection Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
Remote Evaporator Unit Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
Solenoid Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
Check Valve Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
Check Valve Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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
9
Table of Contents
10
List of Figures
Figure 1: SPECTRUM™ TS Front View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Figure 2: TK 3.95 (Tier 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Figure 3: TK376 (Tier 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Figure 4: SPECTRUM™ Remote Evaporator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Figure 5: HMI Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Figure 6: Microprocessor Power Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Figure 7: Phase Detect Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Figure 8: Refrigeration System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Figure 9: Zone 1 Cool and Zone 2 Cool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Figure 10: Zone 1 Heat and Zone 2 Heat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Figure 11: Zone 1 Cool and Zone 2 Heat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Figure 12: Zone 1 Cool and Zone 2 Null . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Figure 13: Zone 1 Heat and Zone 2 Null . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Figure 14: Zone 1 Cool and Zone 2 Defrost . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Figure 15: Zone 1 Heat and Zone 2 Defrost . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Figure 16: Zone 1 Defrost and Zone 2 Null . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Figure 17: Zone 1 Cool, Zone 2 Heat, and Zone 3 Heat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Figure 18: Zone 1 Cool, Zone 2 Heat, and Zone 3 Defrost . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
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
Figure 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
Figure 35: Refrigerant Type Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Figure 36: Dedicated and soft keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Figure 37: Microprocessor Power Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Figure 38: On/Off Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Figure 39: Startup Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Figure 40: Standard Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Figure 42: One Zone Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Figure 44: Selecting A Zone . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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
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
Figure 56: Setpoint Not Changed Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Figure 57: Diesel Engine Start Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
11
List of Figures
Figure 59: Select Zone To Defrost Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

Figure 60: Zone 1 in Defrost . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
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
Figure 66: New Language . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Figure 67: New Language . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Figure 68: Programming Please Wait . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Figure 69: Language Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
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
Figure 78: Programming Economy Mode Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Figure 79: Programming Economy Mode Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Figure 80: Economy Mode Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Figure 83: Start Sleep Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Figure 84: Program Wake-Up Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Figure 85: Sleep . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
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 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 Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
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
Figure 103: Medium Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Figure 104: Adjusting Brightness Please Wait Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Figure 106: Hourmeters Menu Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Figure 107: Hourmeter Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Figure 109: Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Figure 110: No Alarms Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Figure 111: Alarms Present Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Figure 112: Serious Alarm Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Figure 113: Prestolite Terminal Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Figure 114: Flywheel (RPM) Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Figure 115: RPM+ and RPM- Wires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Figure 116: Glow Plug Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Figure 117: Overload Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Figure 118: Setting Overload Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
12
List of Figures
Figure 119: TK 3.95 (Tier 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

Figure 120: TK376 (Tier 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Figure 121: Engine Oil Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Figure 122: Oil Filter Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Figure 123: Dry Type Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Figure 124: TK 3.95 Engine Cooling Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Figure 125: TK376 Engine Cooling Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Figure 126: ELC Nameplate Located On Expansion Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Figure 127: Water Pump Assembly and Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
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
Figure 133: Electric Fuel Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Figure 134: Timing Marks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Figure 135: Individual Cylinder Timing and Firing Order . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Figure 136: Component Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
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
Figure 141: Emission Control Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Figure 142: TK 3.95 Engine Mounting Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Figure 143: TK376 Engine Mounting Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
Figure 144: Chain/Restraining Mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
Figure 145: Chain/Restraining Mount 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 Exit and Unlabeled Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
Figure 155: Evacuation Mode Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
Figure 156: Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
Figure 157: Connect Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
Figure 158: Battery voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
Figure 159: Scroll Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
Figure 160: High Pressure Cutout Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
Figure 161: Discharge Pressure Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
Figure 162: Compressor Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
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
Figure 167: R404A Decal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
Figure 168: Throttle Valve, Cap and Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
Figure 169: Throttle Valve Piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
Figure 170: Throttle Valve Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
Figure 171: Throttle Valve Piston Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
Figure 172: Throttling Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
Figure 173: Cross Section of In-line Check Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
Figure 174: Check Valve with Cap Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
Figure 175: Front View and Cross Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
Figure 176: Hilliard Centrifugal Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
Figure 177: Housing Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
Figure 178: Bearing Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
13
List of Figures
Figure 179: Bushing Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154

Figure 180: Bushing Insertion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
Figure 181: Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
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
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
14
Safety Precautions
Thermo King recommends that all service be
DANGER: Avoid engine operation in
performed by a Thermo King dealer. However,
confined spaces and areas or
you should be aware of several general safety
circumstances where fumes from the
practices:
engine could become trapped and cause
serious injury or death.
The symbol appears next to a point that is
particularly important WARNING: Make sure your gauge
manifold hoses are in good condition
DANGER: Denotes the possibility of before using them. Never let them come in
serious injury or death. contact with moving belts, fans, pulleys or
hot surfaces. Defective gauge equipment
WARNING: Denotes the possibility of can damage components or cause serious
serious equipment damage or serious injury.
personal injury.
WARNING: Always wear goggles or safety
CAUTION: Denotes the possibility of glasses when working on a unit.
minor to severe equipment damage or Refrigerant liquid, oil and battery acid can
personal injury. permanently damage your eyes. See “First
Aid” on page 18.
General Practices
WARNING: Use extreme caution when
DANGER: Do not operate the compressor drilling holes in a unit. Holes might
with the discharge service valve closed. weaken structural components. Holes
This condition increases internal pressure, drilled into electrical wiring can cause a
which can cause an explosion. fire or explosion.
DANGER: Never apply heat to a sealed WARNING: Exposed coil fins can cause
refrigeration system or container. Heat lacerations. Service work on the
increases internal pressure, which might evaporator or condenser coils is best left to
cause an explosion. a certified Thermo King technician.
DANGER: Refrigerant in the presence of WARNING: Do not apply heat to a closed

an open flame, spark or electrical short cooling system. Before applying heat to a
produces toxic gases that are severe cooling system, drain it. Then flush it with
respiratory irritants. water and drain the water. Antifreeze
contains water and ethylene glycol. The
DANGER: Keep your hands, clothing and ethylene glycol is flammable and can
tools clear of fans when working on a unit ignite if the antifreeze is heated enough to
that is running. Loose clothing might boil off the water.
entangle moving pulleys or belts, causing
serious injury or possible death. WARNING: Be careful when using
ladders or scaffolding to install or service
DANGER: Do not inhale refrigerant. Use a unit. Observe the manufacture’s safety
caution when working with refrigerant or labels and warnings.
a refrigeration system in any confined
area with a limited air supply, such as a CAUTION: Make sure all mounting bolts
cargo area or garage. Refrigerant are tight and are the correct length for
displaces air and can cause oxygen their applications. Improper torque and
depletion, resulting in suffocation and incorrect bolt lengths can damage
possible death. equipment.
15
Safety Precautions
NOTE: In the USA, EPA Section 608

WARNING: Wear butyl lined gloves when
Certification is required to work on refrigeration
handling refrigerant to help prevent
systems.
frostbite.
Auto Start/Stop CAUTION: Refrigerant in a liquid state

evaporates rapidly when exposed to the
CAUTION: The unit may start atmosphere, freezing anything it contacts.
automatically and at any time when the Be careful when handling refrigerant to
unit On/Off switch is in the On position. protect your skin from frostbite.
Units with the CYCLE-SENTRYTM option
start automatically in both CAUTION: When being transferred,
CYCLE-SENTRY mode and Continuous refrigerant must be in liquid state to avoid
mode. Be sure to turn the On/Off switch possible equipment damage.
Off before opening doors or inspecting or
working on any part of the unit. CAUTION: When transferring
refrigerant, use a process that prevents or
greatly restricts refrigerant from escaping
Battery Removal into the atmosphere. Refrigerant damages
DANGER: Disconnect the negative the earth’s upper ozone layer.
battery terminal (-) first when removing a
battery. Connect the positive terminal (+) Refrigerant Oil Hazards
first when installing a battery.
WARNING: Protect your eyes from
This order is important because the frame is contact with refrigerant oil. The oil can
grounded to the negative battery terminal. If the cause serious eye injuries. Avoid
negative terminal is still connected, a complete prolonged or repeated contact with
circuit exists from the positive terminal of the refrigerant oil. To prevent irritation, wash
battery to the frame. Metal objects contacting the your hands and clothing thoroughly after
positive side and the frame simultaneously will handling the oil.
cause sparks or arcing. If there are sufficient
hydrogen gases emitted from the battery, an CAUTION: Use the correct oil in Thermo
explosion might occur, causing equipment King systems to avoid damaging
damage, serious injury, even death. equipment and invalidating its warranty.
Refrigerant Hazards CAUTION: Do not mix refrigerant oils

because that can cause system damage.
DANGER: Do not use a Halide torch.
When a flame comes in contact with CAUTION: Use dedicated equipment to
refrigerant, toxic gases are produced. prevent contaminating systems with the
These gases can cause suffocation, even wrong type of oil.
death.
CAUTION: Store refrigerant oil in an
DANGER: Store refrigerant in proper approved sealed container to avoid
containers, out of direct sunlight and away moisture contamination.
from intense heat. Heat increases pressure
inside storage containers, which can cause CAUTION: Do not expose the refrigerant
them to burst. oil to the air any longer than necessary.
The oil will absorb moisture, which results
DANGER: Do not use oxygen (O2 ) or in much longer evacuation times and
compressed air for leak testing. Oxygen possible system contamination.
mixed with refrigerant is combustible.
16
Safety Precautions
CAUTION: Wipe up spills immediately. WARNING: Safety glasses, rubber-

Refrigerant oil can damage paints and insulated gloves and cable cutters should
rubber materials. be near your work area, in the event of an
electrical accident.
Electrical Hazards WARNING: Use caution when working
with electrical circuits that contain
High Voltage
capacitors. Some capacitors hold a
DANGER: When servicing or repairing a significant charge that might cause burns
temperature control unit, the possibility of or shocks if accidentally discharged. Make
serious or even fatal injury from electrical sure capacitors are discharged before
shock exists. Extreme care must be used working on electrical circuits.
when working with a refrigeration unit
that is connected to a source of operating Low Voltage
power, even if the unit is not operating.
Lethal voltage potentials can exist at the WARNING: Control circuits used in
unit power cord, inside the control box, at refrigeration units are low voltage (12 to
the motors and within the wiring 24 volts dc). This voltage is not dangerous,
harnesses. but the large amount of amperage
available from the alternator can cause
WARNING: Make sure the unit On/Off severe burns if accidentally shorted to
switch is turned Off before connecting or ground with metal objects, such as tools.
disconnecting the standby power plug.
Never attempt to stop the unit by WARNING: Do not wear jewelry, watches
disconnecting the power plug. or rings because they increase the risk of
shorting out electrical circuits and
WARNING: Make sure the unit power damaging equipment or causing severe
plug is clean and dry before connecting it burns.
to a power source.
Microprocessor Service
WARNING: Do not make rapid moves Precautions
when working on high voltage circuits in Take precautions to prevent electrostatic
refrigeration units. Do not grab for falling discharge when servicing the microprocessor and
tools because you might accidentally touch its related components. Even tiny amounts of
a high voltage source. current can severely damage or destroy electronic
components.
WARNING: Use tools with well insulated
handles. Never hold uninsulated metal Observe the following precautions when servicing
tools near exposed, energized conductors. a microprocessor control system to avoid
damaging electronic components. Refer to the
WARNING: Treat all wires and ThermoGuard SPECTRUM TS Multi-Temp
connections as if they were high voltage Microprocessor Control System Diagnostic
until a meter and wiring diagram indicate Manual (TK 51652) and the Electrostatic
otherwise. Discharge Training Guide (TK 40282) for more
information.
WARNING: Never work alone on high
• If the microprocessor has a power switch, turn
voltage circuits in the refrigeration unit.
it OFF before connecting or disconnecting the
Another person should be nearby to shut
battery.
off the unit and provide aid in the event of
an accident. • Disconnect power to the unit.
17
Safety Precautions
• Avoid wearing clothing that generates static • If there are any electrical circuit breakers in
electricity (wool, nylon, polyester, etc.). the control box, switch them OFF.
• Wear a wrist strap (P/N 204-622 or its • Close the control box.
equivalent) with the lead end connected to the
• Components that could be damaged by
microprocessor’s ground terminal. These
welding sparks should be removed from the
straps are available from most electronic
unit.
equipment distributors. DO NOT wear these
straps with power applied to the unit. • Use normal welding procedures, but keep the
ground return electrode as close to the area
• Avoid unnecessary contact with the electronic
being welded as practical. This will reduce the
components.
likelihood of stray welding currents passing
• Store and ship electronic components in through any electronic circuits.
antistatic bags and protective packaging.
• Leave electronic components in their antistatic First Aid
packing materials until you’re ready to use
them. First Aid, Refrigerant
• After servicing any electronic components, In the event of frostbite, protect the frozen area
check the wiring for possible errors before from further injury, warm the area rapidly and
restoring power to the unit. maintain respiration.
EYES : For contact with liquid, immediately flush
• Never use a battery and a light bulb to test
circuits on any microprocessor-based eyes with large amounts of water. CALL A
equipment. PHYSICIAN.
SKIN: Flush area with large amounts of warm
NOTE: The following T.I.P. Procedures may be
water. Do not apply heat. Remove contaminated
found in the ThermoGuard SPECTRUM TS
clothing and shoes. Wrap burns with dry, sterile,
Multi-Temp Microprocessor Control System
bulky dressing to protect from infection. CALL A
Diagnostic Manual
PHYSICIAN. Wash contaminated clothing before
• Calibrating the sensors. reuse.
• Replacing the microprocessor. INHALATION: Move victim to fresh air and use
CPR (cardio pulmonary resuscitation) or
• Welding on the unit or truck. mouth-to-mouth resuscitation to restore breathing,
if necessary. Stay with victim until emergency
Welding Precautions personnel arrive.
Take precautions before electrically welding any
portion of the unit or the vehicle to which it is First Aid, Refrigerant Oil
attached. Ensure that welding currents are not EYES : Immediately flush with water for at least
allowed to flow through the unit’s electronic 15 minutes. CALL A PHYSICIAN. Wash skin
circuits. with soap and water.
Observe the following precautions when welding INGESTION: Do not induce vomiting.
to avoid damaging electronic components. Immediately contact local poison control center or
physician.
• If the microprocessor has a power switch, turn
it OFF before connecting or disconnecting the
battery.
First Aid, Engine Coolant
EYES : Immediately flush with water for at least
• Disconnect power to the unit. 15 minutes. CALL A PHYSICIAN. Wash skin
• Disconnect all wire harnesses from the with soap and water.
microprocessor.
18
Safety Precautions
INGESTION: Do not induce vomiting.

Immediately contact local poison control center or
physician.
First Aid, Electrical Shock

Take IMMEDIATE action after a person has
received an electrical shock. Get quick medical
assistance, if possible.
The source of the shock must be quickly stopped,
by either shutting off the power or removing the
victim. If the power cannot be shut off, the wire
should be cut with an non-conductive tool, such as
a wood-handle axe or thickly insulated cable
cutters. Rescuers 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 victim’s body. After
separating the victim from power source,
immediately check for signs of a pulse and
respiration. If no pulse is present, start CPR
(cardio pulmonary resuscitation). If a pulse is
present, respiration might be restored by using
mouth-to-mouth resuscitation. Call for emergency
medical assistance.
19
Safety Precautions
20
Specifications
Engine
Model: Ending First Quarter 2006 TK 3.95
Starting First Quarter 2006 TK376
See “Engine” on page 28 to identify the engine in the
unit.
Fuel Type No. 2 Diesel fuel under normal conditions
No. 1 Diesel fuel is acceptable cold weather fuel
Oil Capacity: Crankcase & Oil Filter 12 quarts (11.2 liters)
w/Bypass Oil Filter 13 quarts (12.3 liters) Fill to full mark on dipstick
Oil Type API Classification CI-4 or better recommended
(ACEA Rating E3 or better for Europe)
API Synthetic Classification CI-4 (ACEA Rating E3 for
Europe) or better after first 500 hours (optional)
Oil Viscosity 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 1800 ± 25 RPM
High Speed Operation 2425 ± 25 RPM
Engine Oil Pressure: TK 3.95 35 to 60 psig (241 to 414 kPa)—high speed
TK376 40 to 60 psig (276 to 414 kPa)—high speed
Intake Valve Clearance 0.006 to 0.010 in. (0.15 to 0.25 mm)
Exhaust Valve Clearance 0.006 to 0.010 in. (0.15 to 0.25 mm)
Valve Setting Temperature Room temperature
Timing Injection Pump 16 degrees BTDC
Injection Nozzle Pressure: TK 3.95 1700 psig (11721 kPa)
TK376 1711 to 1856 psig (11800 to 12800 kPa)
Low Oil Pressure Switch 10 ± 2 psig (69 ± 14 kPa)—shutdown
High Coolant Temperature Sensor 220 ± 5 F (104 ± 3 C)—shutdown
Engine Thermostat 180 F (82 C)
21
Specifications
Engine (Continued)
Engine Coolant Type ELC (Extended Life Coolant), which is red. Units
equipped with ELC have an ELC nameplate on the
expansion tank. Use a 50/50 concentration of any of
the following equivalents:
Cheveron Dex-Cool
Texaco ELC
Havoline Dex-Cool®
Havoline XLC for Europe
Shell Dexcool®)
Shell Rotella
Saturn/General Motors Dex-Cool®
Caterpillar ELC
Detroit Diesel POWERCOOL® Plus
CAUTION: Do not mix conventional (green or
blue-green) coolant and ELC except in an
emergency. If conventional coolant is added to
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)
Belt Tension
Belt Tension on TK Gauge (See Tool Catalog)
New Belt Field Reset
Engine/Electric Motor (Jackshaft) Reading on bottom 55 to 65 55 to 60
span between engine and electric motor
Electric Motor (Jackshaft)/Compressor Reading 55 to 60 55 to 60
between electric motor and alternator (or 1/4 in.
deflection with 10 lb pressure)
Water Pump 40 40
NOTE: Use belt tension gauge (P/N 204-427) whenever possible to check belt tension.
New belts should be tensioned cold and tensioned cold again after 10 hours of unit operation.
22
Specifications
Refrigeration System
Compressor Model TKO Scroll
Refrigerant Charge Approximately 13.44 lb (6kg)
*Compressor Oil Charge 1.6 qt (1.5 liters)
Compressor Oil Type: R-404A (EAL 22) Ester base required for Scroll compressor (See Tool
Catalog) P/N 203-516
Throttling Valve Setting 28 ± 1 psig (193 ± 7 kPa)
High Pressure Cutout Switch: Open 470 ± 7 psig (3241 ± 48 kPa)
Close 375 ± 38 psig (2586 ± 262 kPa)
Liquid Injection Valve: Closed Below 250 F (121 C)
Open 285 F (141 C)
Compressor High Temperature: Shutdown 300 F (149 C) for 3 seconds
Restart <250 F (121 C) plus a 15 min timer
Discharge Pressure Regulator Valve Setting: 340 to 400 psig (2344 to 2758 kPa) with one zone in
heat or defrost regardless of ambient temperature
* When the 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 amps
Fan Motor Fuses 30 amps each
Starter Fuse F2 (2 Circuit) 40 amps
Battery Charging System 12 volt 90 amp alternator
Voltage Regulator Setting 14.1 ± 0.2 volts @ 70 F (21 C)
Alternator/Regulator Capacitor 4.7 µfd 50 Vdc
Alternator/Output Capacitor 0.5 µfd 100 Vdc
Interface Board Fuses See Description Section
NOTE: Disconnect components from unit circuit to check resistance.
Defrost Timer
SPECTRUM™ TS with HMI Controller 2, 4, 6, 8 or 12 hours (adjustable through
SPECTRUM™ TS Microprocessor controller) (default
setting =6)
23
Specifications
System Controller
Type SPECTRUM™ TS Microprocessor Controller
Electrical Components
Current Draw (Amps) Resistance
at 12.5 Vdc (Ohms)
Glow Plug TK 3.95 8.3 1.5 ± 0.15
TK376 4.3 2.3 ± 0.2
Fuel Solenoid: Pull In 35 to 45 0.2 to 0.3
Hold In 0.5 24 to 29
Starter Motor 90 to 105 (cranking)
High Speed Solenoid 2.9 4.3
High Speed (Throttle) Solenoid: TK 3.95 2.9 4.3
TK376 3.3 3.8
Condenser Inlet Solenoid 22 Watt 1.76 7.1
Purge Valve 15 Watt 1.20 10.4
Liquid Injection 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 Locked Rotor Overload
Amps Amps Relay Setting
Amps
220/3/50 10 7.5 1455 25.1 116 32
230/3/60 12 8.9 1750 28.8 123 32
380/3/50 10 7.5 1455 14.5 58 16
460/3/60 12 8.9 1750 14.4 62 16
Standby Power Requirements

Supply Circuit Breaker: 50 amp/220-230 volts
20 amp/380-460 volts
Extension Cord Size: Up to 50 ft—10 gauge
75 ft—8 gauge
24
Maintenance Inspection Schedule
Pretrip 1,200 2,000 Annual/ Inspect/Service These Items

Hours Hours 3,000
Hours
Microprocessor
• Run pretrip test (see “Pretrip Test” in the Operating Manual).
Engine
• Check fuel supply.
• • Check engine oil level.
• • Check engine coolant (check gauges screen on HMI)
CAUTION: Do not remove radiator cap while coolant is hot
(should display “ok”).
• • Inspect belts for condition and proper tension.
• • Check engine oil pressure hot, on high speed (should display “OK”).
• • • • Listen for unusual noises, vibrations, etc.
• Dry air cleaner. Replace air cleaner element at 2,000 hours or 1 year
(whichever occurs first)
• Check air cleaner hose for damage.
• Clean and service crankcase breather (TK 3.95 engine only).
• Change EMI 2000 (black) fuel filter.
• 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.
Engine Oil Change Intervals (see below)
NOTE: Change engine oil and filter (hot).
NOTE: The 1,200 hour maintenance interval may be
extended to 2,000 hours or 1 year (whichever occurs first)
when equipped with EMI fuel filter and EMI bypass oil filter.
• Oil change interval with API classification CI-4 (or better) mineral oil
or synthetic oil (ACEA Rating E3 or better for Europe).
• Oil change interval with API classification CI-4 (or better) mineral oil
or synthetic oil, and EMI 2000 bypass oil filter (ACEA Rating E3 or
better for Europe).
25
Maintenance Inspection Schedule
Pretrip 1,200 2,000 Annual/ Inspect/Service These Items

Hours Hours 3,000
Hours
Electrical
• Check controller for alarms.
• Run pretrip test
• Check battery voltage screen.
• Inspect battery terminals and electrolyte level.
• Inspect electrical contacts for pitting or corrosion.
• Inspect wire harness for damaged wires or connections.
• Check calibration of return and discharge air sensors in 32 F (0 C)
ice water.
• Inspect alternator bearings and brushes*.
• Inspect electric motor bearings* (Model 50).
*With Belt removed, spin bearings by hand. Listen for noise (bearings roll freely).
Refrigeration
• • Check refrigerant level.
• Check compressor oil level.
• Check throttling valve setting on 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 wear.*
• Clean entire unit including condenser coils, evaporator coils, and
defrost drains.
• • • Check all unit, fuel tank, engine, and electric motor mounting bolts,
brackets, lines, hoses, etc.
*With belt removed, spin bearings by hand. Listen for noise (bearings roll freely). Up to 1/8” axial play (wobble) in either
direction is normal for composite idlers.
26
Unit Description
• Continuous System Monitoring
• Coolant Expansion Tank
• Coolant Temperature Display
• Corrosion Resistant Protection
• CYCLE-SENTRY Start/Stop Controls
AJA1350
Figure 1: SPECTRUM™ TS Front View • Diesel/Electric Autoswitching

• Total Run Hourmeter
Unit Overview
• Electric Hourmeter
The SPECTRUM™ TS is a diesel-powered,
multi-temperature cooling/heating system • Engine Hourmeter
designed to control temperature in up to three • Fahrenheit and Celsius Scales
separate truck cargo compartments. Each
compartment contains a SPECTRUM™ remote • Fuel Filter, Spin On
evaporator. The condensing unit is mounted on • SPECTRUM™ TS HMI Control Panel
the outside front of the truck box, contains the
diesel engine, compressor and condenser and is • SPECTRUM™ TS Microprocessor Controller
connected to the remote evaporator(s) located • Oil Filter, Full Flow
inside the truck box.
• Oil Pressure Display
The SPECTRUM™ TS operates under the control
of a SPECTRUM™ TS Microprocessor Controller. • R-404A
The SPECTRUM™ TS Microprocessor Controller • Scroll Compressor
has an in-cab HMI (Human Machine Interface)
control panel that provides safe, convenient • Smart Defrost
operation and monitoring of cargo compartment • Stainless Steel Condenser Hardware
temperatures. The temperature of each of the
compartments can be controlled separately. • Stainless Steel Evaporator Hardware
There are two SPECTRUM™ TS models: • TK 3.95 Engine (Ending First Quarter 2006)
• SPECTRUM™ TS 30: Cooling and heating on • TK376 Engine (Starting First Quarter 2006)
diesel engine operation. • Silicone Hoses
• SPECTRUM™ TS 50: Cooling and heating on
diesel engine operation or electric standby Unit Options
operation.
• DAS (Data Acquisition System)
Design Features • Door Switch
• Air Cleaner, Dry Type • Electric Standby
• Alarm Code Display • Engine Block Heater
• Alternator, 90 amp • Remote Status Light
• Automatic Phase Correction (Model 50) • Synthetic Engine Oil
• Battery Voltage Display • Hose Management Kit
• Bypass Oil Filter • Three Cargo Compartment Temperature

Control
• Condenser Top Screen
27
Unit Description
Engine
Engine power for the SPECTRUM™ TS is
provided by a three cylinder, special clean and
silent diesel engine. A belt drive system transfers
energy to the compressor, unit fans and alternator.
In the first quarter of 2006 the engines in these
units changed from a TK 3.95 to a TK376 to meet
EPA Tier 2 requirements.
The TK 3.95 is an EPA Tier 1 engine. It is a
three-cylinder diesel engine rated at 17.0
continuous horsepower (12.7 kW) at 2400 rpm.
The TK376 is an EPA Tier 2 engine. It is a
three-cylinder diesel engine rated at 19.6
maximum horsepower (14.6 kW) at 2425 rpm.
The most noticeable difference is that the valve Figure 3: TK376 (Tier 2)
cover and intake manifold are separate on the
TK 3.95, but are an assembly on the TK376 (see Clutch
the following illustrations). There are other
differences, but the periodic maintenance is The centrifugal clutch engages fully at 600 ± 100
basically the same. See “Maintenance Inspection rpm on engine operation, constantly turning the
Schedule” on page 25. 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. The maintenance interval for ELC is five
years or 12,000 hours. A nameplate on the coolant
expansion tank identifies units with ELC. See
“ELC (Extended Life Coolant)” on page 96. The
new engine coolant, Texaco Extended Life
Coolant, is RED instead of the previous GREEN
or BLUE-GREEN conventional coolants.
ELC cannot be used in older units. The water
Figure 2: TK 3.95 (Tier 1) pump seal bellows and O-rings used in older units
are not compatible with ELC.
CAUTION: Do not add Green or
Blue-Green, conventional coolant to
cooling systems using Red, Extended Life
Coolant, except in an emergency. If
conventional coolant is added to Extended
Life Coolant, the coolant must be changed
after 2 years instead of 5 years.
28
Unit Description
NOTE: The use of 50/50 percent pre-mixed ELC

is recommended to ensure that deionized water is
being used. If 100 percent full strength
concentrate is used, deionized or distilled water
is recommended instead of tap water to ensure
the integrity of the cooling system is maintained.
NOTE: Units equipped with ELC are not
necessarily equipped with EMI 2000, but units
equipped with EMI 2000 are equipped with ELC.
EMI 2000
EMI 2000 is an extended maintenance interval
package. It is standard equipment on this unit. The Figure 4: SPECTRUM™ Remote Evaporator
EMI 2000 package consists of the following key
components:
Compressor
• New EMI 2000-Hour Cyclonic Air Cleaner
The unit features a high performance 6 hp TKO
Assembly and Air Cleaner Element (standard
Scroll compressor.
equipment on all TS Units)
• New EMI 2000-Hour Fuel Filter (black with SPECTRUM™ TS HMI Control
gold lettering)
Panel
• New EMI 2000-Hour By-Pass Oil Filter
The HMI (Human Machine Interface) Control
(black with gold lettering)
Panel consists of a display and eight touch
• API Rating CI-4 (ACEA Rating E3) Mineral sensitive keys. The four keys on each side of the
Oil display screen are used to turn the unit on and off,
initiate a manual defrost cycle, and select the high
• Five Year or 12,000 Hour ELC (Extended Life
speed lockout mode operation. The function of the
Coolant)
four keys located under the display screen
The EMI package allows standard maintenance (referred to as “soft keys”) change as required by
intervals to be extended to 2,000 hours, or 1 year, the current menu shown on the display screen.
whichever occurs first.
The display screen is used by the microprocessor
NOTE: Units equipped with the EMI 2000 to provide visual prompt and display information
package do require regular inspection in to the operator, such as operating mode, setpoints,
accordance with Thermo King's maintenance hourmeter readings and operating conditions of
recommendations. the diesel engine. All information is shown in
English, with the ability to display in several other
SPECTRUM™ Remote languages.
Evaporator
A SPECTRUM™ Remote Evaporator is located in
each compartment and can provide separate
temperature controlled areas.
AJA1169
Figure 5: HMI Control Panel
29
Unit Description
Microprocessor Power Switch Defrost is accomplished by passing hot refrigerant

gas through the affected evaporator coil, thus
The Microprocessor Power switch applies 12 Vdc melting the frost (or ice). Melted frost drains out
control power to the microprocessor and must be of the unit onto the ground through the drain
On to operate the unit. It is located on the roadside tubes.
of unit, lower left corner.
Defrost can be initiated at any time the evaporator
NOTE: When the Microprocessor Power Switch coil temperature is below 45 F (7 C).
is turned to the Off position, power is still applied
to the Interface Board and control circuits. To Only one zone can be in defrost at a time.
completely remove power from the control There are three methods of defrost initiation:
system, disconnect the unit battery.
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 determine if
forced defrost is required.
Figure 6: Microprocessor Power Switch
3. Manual Defrost allows the operator to initiate
a defrost cycle by pressing the DEFROST key.
CYCLE-SENTRY Start/Stop See “Initiating a Manual Defrost Cycle” on
System page 65.
A CYCLE-SENTRY Start-Stop fuel saving
system provides optimum operating economy. DAS - Data Acquisition System
WARNING: Turn the unit off by pressing (Optional)
the OFF key before opening doors or The DAS (Data Acquisition System) works with
inspecting any part of the unit. The unit the SPECTRUM™ TS Microprocessor to monitor
can start at any time without warning if it and record the temperatures of (up to) six
has been turned on by pressing the ON key. additional sensors. The sensors are independent
from the microprocessor and are normally located
The CYCLE-SENTRY system automatically in the truck box to monitor load temperatures.
starts the unit on microprocessor demand and Data from the DAS sensors and the
shuts down the unit when all demands are SPECTRUM™ TS Microprocessor can be
satisfied. downloaded through a serial port to an IBM® PC
compatible computer. WinTrac™ 4.2 (or higher)
The system monitors and maintains the software is used to view and analyze the data.
compartment temperature, the engine block Brief reports can be printed on a microprinter
temperature, and battery charge levels at a point connected to the serial port. WinTrac™ 4.4 (or
where quick, easy starts are possible. higher) is required for three temperature
operation.
Defrost
Frost will gradually build up on the remote
evaporator coils as a result of normal operation.
Periodically this frost must be melted to prevent a
loss of cooling and airflow.
30
Unit Description
Electric Standby (Model 50 High Voltage Tray

Units Only) The high voltage tray contains the contactors,
The Electric Standby option allows the unit to be overload relay and phase select module used to
operated on either the diesel engine or external operate the drive motor on units equipped with
electric power. The units are supplied to operate Electric Standby. The contactors are controlled by
on three phase power. +12 volt dc control signals from the Interface
Board. The high voltage tray is located inside the
control box just to the right of the
CAUTION: High voltage AC power is
Microprocessor/Interface Board Assembly.
present whenever the unit is operating in
Electric mode and whenever the unit is
connected to external standby power. Phase Detect Module for Truck Unit
Voltages of this magnitude can be lethal. Model 50 Applications
Exercise extreme caution when working The new phase detect module is designed to
on the unit. monitor both single and 3 phase voltages from
160 volts AC thru 510 volts AC.
Standard Model 50 Features The Phase Detection Module will detect missing
The following features are standard equipment on phases, phase rotation and low voltage on three
units equipped with Electric Standby. phase power.
• Automatic Diesel/Electric Selection – The
unit will automatically switch to electric
Brown
operation when a power cord is connected and THERMO KING
9131C98G06
the standby power is switched “on”. The unit Blue L1
L2
can also be programmed to automatically L3
0202
Black
switch back to diesel power if the standby
power is switched off or fails.
AJA1501
• Automatic Overload Reset - The overload
relay resets automatically after the motor Figure 7: Phase Detect Module
cools. See “Overload Relay” on page 89 for
more information.
• Hot Gas Heat - Hot gas heat is utilized on
standard model 50 units.
• Automatic Phase Correction - The control
system features two motor contactors. This
allows correct motor rotation regardless of
phase rotation on the incoming power.
31
Unit Description
Unit Instruments coil temperature and ambient temperature since

these temperatures are not as critical as Return
• Coolant Expansion Tank-The coolant level and Discharge air temperatures.
and temperature are monitored by the
SPECTRUM™ TS Microprocessor controller. • Return Air Sensor - monitors the
If the coolant temperature becomes too high or temperature of the air returning to the remote
the level becomes too low, an alarm will occur evaporator coil. The sensor is located in the
and the engine will shut down. return air flow and is connected directly to the
SPECTRUM™ TS Microprocessor. The unit
The engine must have antifreeze protection to controls on this sensor under normal
–30 F (–34 C). Check and add coolant in the conditions. This is a graded sensor and must
expansion tank as needed. be replaced with a graded sensor. The
CAUTION: Do not add Green or SPECTRUM™ TS Microprocessor must be
Blue-Green, conventional coolant to calibrated to the sensor grade of the sensor
cooling systems using Red, Extended Life installed in the return air position in order to
Coolant, except in an emergency. If operate properly. It is connected to the
conventional coolant is added to Extended microprocessor via the RTP and RTN wires.
Life Coolant, the coolant must be changed • Discharge Air Sensor - monitors the
after 2 years instead of 5 years. temperature of the air leaving the evaporator
coil. The sensor is located in the remote
CAUTION: Do not remove expansion evaporator discharge air path and is connected
tank cap while the coolant is hot. directly to the SPECTRUM™ TS
Microprocessor. The unit will control on this
• Compressor Oil Sight Glass-The compressor sensor if the return air sensor fails or if
oil sight glass is used to check the relative discharge air sensor control is selected. This is
level of compressor oil in the compressor a graded sensor and must be replaced with a
sump. graded sensor. The microprocessor must be
• Engine Oil Dipstick-Use the engine oil calibrated to the sensor grade of the sensor
dipstick to check the engine oil level. installed in the discharge air position in order
to operate properly. It is connected to the
• Receiver Tank Sight Glass-The receiver tank microprocessor via the DTP and DTN wires.
sight glass is used to check the amount of
refrigerant in the system, and the moisture • Coil Temperature Sensor - monitors the
content of the refrigerant. temperature of the evaporator coil. The sensor
is located on the remote evaporator coil header
plate and is connected directly to the
Unit Sensors micro-processor. This is not a graded sensor.
The sensors monitor temperatures and pressures at It is connected to the microprocessor via the
various points in the system as well as oil CTP and CTN wires.
pressure, oil and coolant levels and engine speed. • Ambient Temperature Sensor - monitors the
ambient air temperature. The sensor is located
Graded and Ungraded Sensors in the main unit and is connected directly to
The Return Air and Discharge Air sensors are the microprocessor. This is not a graded
graded sensors. This feature allows accuracy sensor. It is connected to the microprocessor
without the need for ice water calibration. The via the ATP and ATN wires.
sensor grade (from 1L thru 9H) is stamped on the
sensor and must be entered into the
microprocessor when a sensor is changed in order
to properly calibrate temperature readings. An
ungraded sensor is used to measure the evaporator
32
Unit Description
Refrigeration System located in the hot gas bypass line next to the
Components compressor. This valve uses a similar
technique for controlling compression ratios.
The refrigeration system controls are used to
control the operation of the refrigeration system as • Discharge Pressure Regulator (DPR) (This
required by the microprocessor. The component is a mechanical control device) -
microprocessor determines these requirements by This valve is used to increase the discharge
considering the setpoint, the software, the setting pressure during heat and defrost. The valve
of programmable features and the information controls discharge pressure mechanically
supplied by the sensors. Refer to TK 51652, the based on temperature and the actual system
SPECTRUM™ TS Microprocessor Diagnostic pressure.
Manual for additional information. This valve is normally closed and opens when
These three valves are located in the condenser the set pressure is reached. This component is
section of the unit. They are common to all zones. located in the hot gas line in the condenser
section of the unit
• Condenser Inlet Solenoid - This valve
controls the flow of refrigerant to the The following components are also located in the
condenser. This solenoid is energized (closed) main unit.
when any compartment is operating in heat or • High Pressure Cutout - The high pressure
defrost mode. This is a normally open valve. cutout is located on the discharge line of scroll
• Receiver Tank Pressure Check Valve- This compressors. This switch monitors the
check valve is used to equalize pressure in the discharge pressure at the compressor. The
receiver tank in the off cycle. switch is closed with normal pressures and
open with excessive pressures. The switch
• Purge Valve - The purge valve operates in the will open and close at pressures determined by
heat or defrost mode to make sure adequate the refrigerant used in the unit. It opens on
refrigeration is available. high discharge pressure to shut the unit down
The following components are located in the to prevent damage.
condensing section of the unit and serve the scroll • Discharge Pressure Transducer - This
compressor. They are controlled by compressor transducer supplies the discharge pressure at
temperature, suction pressure and discharge the compressor to the microprocessor. This
pressure. information is used by the microprocessor and
• Liquid Injection Valve (LIV) - This valve software to determine the unit operating
helps control the temperature of the scroll conditions.
compressor. It is energized or pulsed (open) • Suction Pressure Transducer - This
when the scroll compressor temperature transducer supplies the suction pressure at the
exceeds a set value to inject liquid refrigerant compressor to the microprocessor. This
directly into the compressor. The liquid information is used by the microprocessor and
refrigerant flashes to a gas to effectively cool software to determine the unit operating
the compressor. This valve is normally closed. conditions. It should be noted that the suction
This component is located between the liquid pressure transducer is located downstream of
line and the compressor in the condenser the throttle valve. As a result, the suction
section of the unit. pressure displayed is compressor suction
• Hot Gas Bypass Valve (HGB) - This valve pressure.
helps control suction pressure. If the suction • Compressor Temperature Sensor - This
pressure falls below a set limit this valve is transducer supplies the compressor
energized (open) to allow hot refrigerant gas temperature to the microprocessor. This
to flow to the suction line until the suction
pressure rises to an acceptable level. This
valve is normally closed. This component is
33
Unit Description
information is used by the microprocessor and coolant condition is assumed to exist. It is

software to determine the unit operating connected to the microprocessor via the CLS
conditions. wire.
The following valves are required for each zone. • Oil Pressure Switch - The oil pressure switch
They are located in the remote evaporator(s) for monitors the oil pressure of the diesel engine.
each zone. It is located on the engine side of the unit
frame. It is connected to the microprocessor
• Liquid Line Solenoid - This valve is
via the 20B and CHO- wires.
energized (open) any time cooling, heating or
defrosting is required in its zone. The valve is • Oil Level Sensor - The oil level sensor
de-energized when the zone is in null to stop monitors the oil level in the diesel engine. It is
refrigerant flow in that zone. This is a located above the oil pan on the door side of
normally closed valve. the engine. It supplies information on the oil
level to the microprocessor via the OLS wire.
• Hot Gas Solenoid - This valve is energized
The switch is closed with low oil level.
(open) any time heating or defrosting is
required in the zone. This is a normally closed • Flywheel Sensor - This sensor monitors the
valve. RPM of the diesel engine. The flywheel
sensor is located just under the door side
• Suction Line Solenoid - If a zone is capable
engine mount. It supplies engine speed
of reverse cycle operation it is said to be
information to the microprocessor via the
invertible. Reverse cycle means that the
RPMP and RPMN wires.
evaporator coil in that zone is used as the
condenser coil during heat operation as long • Glow Plugs - The glow plugs are energized by
as at least one other zone is operating in cool the microprocessor via the H wire to preheat
mode. the engine.
The suction line solenoid is energized (closed) • Starter - The starter is located on the
when its compartment is operating in heat compressor side of the engine. It is energized
mode as long as at least one other zone is by the microprocessor via the 8S wire to crank
operating in cool mode. This is a normally the engine.
open valve.
• Fuel Solenoid -The fuel solenoid is located at
the rear of the injector pump and is used to
Engine Controls start and stop the flow of fuel to the diesel
The engine controls are used to control the engine. It is energized to start fuel flow by the
operation of the diesel engine (or electric motor) microprocessor via the 8D wire. The fuel
as required by the microprocessor. The solenoid features two coils, a pull-in coil and a
microprocessor determines these requirements by hold coil. The pull-in coil draws
considering the setpoint, the software, the setting approximately 40 amperes and the hold coil
of programmable features and the information draws approximately 1 ampere. The pull-in
supplied by the sensors. coil is momentarily energized by the fuel
solenoid timer for a few seconds to shift the
• Coolant Temperature Sensor - This sensor fuel linkage.
monitors the temperature of the coolant in the
diesel engine. It is located on the diesel engine • Throttle Solenoid - The high speed (throttle)
thermostat housing and is connected to the solenoid is located just below the fuel
microprocessor via the WTP and WTN wires. injection pump. It is energized by the
microprocessor via the 7D wire to initiate high
• Coolant Level Sensor - This sensor monitors speed operation.
the level of coolant in the radiator 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
34
Unit Description
Refrigeration Cycles Gauges Display Menu: The Gauges Display allows

the operator to display the unit operating gauges
All Zones Cooling such as coolant level and temperature, engine RPM
and suction and discharge pressure.
When all zones are cooling the unit condenser is
Sensors Display Menu: The Sensors Display allows
used to eliminate the heat from all zones. This is a
Conventional Cooling cycle. the operator to display the temperature of all unit
temperature sensors and the temperature differential
for each zone.
One or Two Zones Cooling and
Other Zones Heating Service Test Mode Menu: Since it is impossible to
predict exact operating conditions, a
When at least one zone is cooling and another zone trouble-shooting feature called Service Test Mode
is heating, the evaporator in the heating zone is used has been incorporated. This feature allows the unit
as a condenser to remove the heat from the zone that to be “forced” to a known set of operating
is cooling. The unit condenser is not used. This is conditions in Diesel mode, regardless of setpoint or
Reverse Cycle. temperature sensor inputs. Service personnel can
• Invertible System - If a zone is capable of now troubleshoot the system under defined
reverse cycle operation it is said to be invertable. conditions. Service Test Mode can be used with the
Reverse cycle means that the evaporator coil in unit running or shut down.
that zone is used as the condenser coil during When a Service Test Mode function is selected, the
heat operation as long as at least one other zone unit will operate in that mode for 15 minutes. If no
is operating in cool mode. All invertable other Service Test Mode function is selected during
systems are capable maintaining any this time the unit will shut down and generate Alarm
temperature in any zone and can also heat or Code 54. All protection circuits operate normally in
cool in any zone at any time Service Test Mode. The Service Test Mode display
also shows return air temperature, discharge air
All Zones Heating temperature, evaporator coil temperature and the
When all zones are heating the unit condenser is not calculated value for temperature differential. The
used. This is Hot Gas Heat operation. Gauge Menu is also available.
Interface Board Test Mode Menu: Interface Board
Any Zone Defrosting Test Mode allows individual relays or outputs to
When any zone enters defrost, zones that are cooling be energized. This permits service personnel to
or heating are placed in Delayed Cool/Heat mode. troubleshoot the system under defined conditions.
The unit condenser is not used. Defrost is Interface Board Test mode is use with the unit
accomplished by means of Hot Gas Heat. shut down.
Relays and outputs can all be energized
Technician Features momentarily. In addition, all functions except the
The Thermo King SPECTRUM™ TS control system Preheat relay and starter can be locked on. If a
features many special technician functions. These function is locked on that function will remain
functions are available from the Maintenance energized for 15 minutes if no other Interface
Menus. A brief explanation of each menu is Board Test Mode function is selected.
included here. For additional details refer to the At the end of 15 minutes, if no other function is
SPECTRUM™ TS Microprocessor Diagnostic selected the unit will shut down and record Alarm
Manual. Code 54. All protection circuits operate normally in
Hours Display Menu: The Hours Menu allows the Service Test Mode.
operator to check the readings of all unit
The Interface Board Test Mode display also shows
hour-meters that have been enabled. In addition, a
suction pressure, discharge pressure, amps and
reset button is provided for each user programmable
battery volts.
hour-meter.
35
Unit Description
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.
36
Unit Description
18 19 15
30 28
8 9
20
16
6 10
22 27
21 7
29
26
32
17 24 31
25 2
23 1 5
12 33
3
4
11
14
13 34
1. Scroll Compressor 18. Evaporator Coil

2. Thermister 19. Liquid Line Solenoid
3. Compressor Oil Sight Glass 20. Liquid Return Check Valve
4. Liquid Injection Solenoid 21. Suction Line Check Valve
5. Liquid Injection Check Valve 22. Suction Line Solenoid
6. Discharge Service Port 23. Hot Gas 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 Transducer
15. Heat Exchanger 32. Suction Pressure Transducer
16. Expansion Valve 33. Receiver Tank Pressure Check Valve
17. Distributor 34. Condenser Check Valve
Figure 8: Refrigeration System Components
37
Unit Description
1F 6 7
2F 10
9
4F
3F
5F
1R
2R
4R 3R
5R
Figure 9: Zone 1 Cool and Zone 2 Cool
Zone 1 Cool and Zone 2 Cool 4F. Zone 1 Suction Line Solenoid (SLS1)-Open
High pressure refrigerant vapor leaves the 5F. Zone 1 Hot Gas Solenoid (HGS1)-Closed
compressor and flows through the open CIS to the
condenser where the refrigerant condenses into Zone 2 Evaporator
high pressure liquid. The liquid refrigerant flows
1R. Zone 2 Liquid Line Solenoid (LLS2)-Open
through the receiver tank into the liquid lines.
2R. Zone 2 Liquid Return Check Valve
The LLS1 is open so some of the refrigerant flows
(LRCV2)-Closed
through the Zone 1 expansion valve into the Zone
1 evaporator. There, liquid refrigerant cools the 3R. Zone 2 Suction Line Check Valve
Zone 1 evaporator as it evaporates into low (SLCV2)-Open
pressure vapor. The refrigerant returns to the
4R. Zone 2 Suction Line Solenoid (SLS2)-Open
compressor through the SLS1, the suction line,
SLCV1 and the accumulator. 5R. Zone 2 Hot Gas Solenoid (HGS2)-Closed
The LLS2 is also open so some of the refrigerant
Condensing Unit
flows through the Zone 2 expansion valve into the
Zone 2 evaporator. There, liquid refrigerant cools 6. Condenser Inlet Solenoid (CIS)-Open
the Zone 2 evaporator as it evaporates into low
7. Condenser Inlet Check Valve (CICV)-Open
compressor through the SLS2, the second suction 8. Condenser Check Valve (CCV)-Open
line, the SLCV2 and the accumulator.
9. Purge Valve (PV)-Closed
Zone 1 Evaporator 10. Purge Check Valve (PCV)-Closed
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
38
Unit Description
1F 6 7
2F 10
9
4F
3F
5F
1R
2R
4R 3R
5R
Figure 10: Zone 1 Heat and Zone 2 Heat
Zone 1 Heat and Zone 2 Heat Zone 2 Evaporator

The CIS is closed so high pressure refrigerant 1R. Zone 2 Liquid Line Solenoid (LLS2)-Open
vapor leaves the compressor and flows through
the DPR to Zone 1 and Zone 2 hot gas lines and
(LRCV2)-Closed
through HGS1 and HGS2 into both evaporators.
There, the refrigerant heats both evaporators and 3R. Zone 2 Suction Line Check Valve
condenses into high pressure liquid. The (SLCV2)-Open
refrigerant flows through the open suction line
solenoids and back to accumulator.
5R. Zone 2 Hot Gas Solenoid (HGS2)-Open
In the condensing unit, the CIS valve closes and
opens to regulate head pressure. The purge valve
Condensing Unit
is opened continuously during heat to drain the
condenser coil. 6. Condenser Inlet Solenoid (CIS)-Closed/Open
(Pressure Dependent)
Zone 1 Evaporator
7. Condenser Inlet Check Valve
1F. Zone 1 Liquid Line Solenoid (LLS1)-Open (CICV)-Closed/Open
2F. Zone 1 Liquid Return Check Valve 8. Condenser Check Valve (CCV)-Closed
(LRCV1)-Closed
9. Purge Valve (PV)-Open
10. Purge Check Valve (PCV)-Open
(SLCV1)-Open
4F. Zone 1 Suction Line Solenoid (SLS1)-Open
5F. Zone 1 Hot Gas Solenoid (HGS1)-Open
39
Unit Description
1F 6 7
2F 10
9
4F
3F
5F
1R
2R
4R 3R
5R
Figure 11: Zone 1 Cool and Zone 2 Heat
Zone 1 Cool and Zone 2 Heat 3F. Zone 1 Suction Line Check Valve
(SLCV1)-Open
The CIS is closed so high pressure refrigerant
vapor leaves the compressor and flows through 4F. Zone 1 Suction Line Solenoid (SLS1)-Open
the DPR to the Zone 2 hot gas line and the open
5F. Zone 1 Hot Gas Solenoid (HGS1)-Closed
HGS2 into the Zone 2 evaporator. There, the
refrigerant heats the Zone 2 evaporator and
Zone 2 Evaporator
condenses into high pressure liquid. Because the
SLS2 is closed, the liquid refrigerant flows 1R. Zone 2 Liquid Line Solenoid (LLS2)-Open
through the LRCV2 and the liquid line to the
LLS1.
(LRCV2)-Open
The LLS1 is open so the refrigerant flows through
3R. Zone 2 Suction Line Check Valve
the Zone 1 expansion valve into the Zone 1
(SLCV2)-Closed
evaporator. There, the liquid refrigerant cools the
Zone 1 evaporator as it evaporates into low 4R. Zone 2 Suction Line Solenoid (SLS2)-Closed
5R. Zone 2 Hot Gas Solenoid (HGS2)-Open
compressor through the SLS1, Suction Line,
SLCV1 and the accumulator.
Condensing Unit
6. Condenser Inlet Solenoid (CIS)-Closed/Open
(Pressure Dependent)
condenser coil. 7. Condenser Inlet Check Valve
(CICV)-Closed/Open
Zone 1 Evaporator
8. Condenser Check Valve (CCV)-Closed
(LRCV1)-Closed
40
Unit Description
1F 6 7
2F 10
9
4F
3F
5F
1R
2R
4R 3R
5R
Figure 12: Zone 1 Cool and Zone 2 Null
Zone 1 Cool and Zone 2 Null Zone 2 Evaporator

High pressure refrigerant vapor leaves the 1R. Zone 2 Liquid Line Solenoid (LLS2)-Closed
compressor and flows through the open CIS to the
condenser, where refrigerant condenses into high
(LRCV2)-Closed
pressure liquid. The liquid refrigerant flows
through the receiver tank into the Zone 1 liquid 3R. Zone 2 Suction Line Check Valve
line. (SLCV2)-Open
The LLS1 is open so the refrigerant flows through 4R. Zone 2 Suction Line Solenoid (SLS2)-Open
the Zone 1 expansion valve into the Zone 1
5R. Zone 2 Hot Gas Solenoid (HGS2)-Closed
Zone 1 evaporator as it evaporates into low
Condensing Unit
compressor through the SLS1, suction line, 6. Condenser Inlet Solenoid (CIS)-Open
7. Condenser Inlet Check Valve (CICV)-Open
The LLS2 is closed, which prevents refrigerant
8. Condenser Check Valve (CCV)-Open
from reaching the Zone 2 evaporator.
9. Purge Valve (PV)-Closed
Zone 1 Evaporator
10. Purge Check Valve (PCV)-Closed
(LRCV1)-Closed
(SLCV1)-Open
41
Unit Description
1F 6 7
2F 10
9
4F
3F
5F
1R
2R
4R 3R
5R
Figure 13: Zone 1 Heat and Zone 2 Null
Zone 1 Heat and Zone 2 Null 2R. Zone 2 Liquid Return Check Valve
(LRCV2)-Closed
vapor leaves the compressor and flows through 3R. Zone 2 Suction Line Check Valve
the DPR to the Zone 1 hot gas line and though (SLCV2)-Open
refrigerant heats the evaporator and condenses
into high pressure liquid. The refrigerant returns 5R. Zone 2 Hot Gas Solenoid (HGS2)-Closed
to the compressor through the SLS1, Suction
Line, SLCI, and the accumulator. Condensing Unit
In the condensing unit, the CIS valve closes and 6. Condenser Inlet Solenoid (CIS)-Closed/Open
opens to regulate head pressure. The purge valve (Pressure Dependent)
condenser coil.
(CICV)-Closed/Open
Zone 1 Evaporator 8. Condenser Check Valve (CCV)-Closed
1F. Zone 1 Liquid Line Solenoid (LLS1)-Open 9. Purge Valve (PV)-Open
2F. Zone 1 Liquid Return Check Valve 10. Purge Check Valve (PCV)-Open
(LRCV1)-Closed
(SLCV1)-Open
Zone 2 Evaporator
1R. Zone 2 Liquid Line Solenoid (LLS2)-Closed
42
Unit Description
1F 6 7
2F 10
9
4F
3F
5F
1R
2R
4R 3R
5R
Figure 14: Zone 1 Cool and Zone 2 Defrost
Zone 1 Cool and Zone 2 Defrost 4F. Zone 1 Suction Line Solenoid (SLS1)-Open
The CIS is closed so high pressure refrigerant 5F. Zone 1 Hot Gas Solenoid (HGS1)-Closed
the DPR to the Zone 2 hot gas line and the open Zone 2 Evaporator
1R. Zone 2 Liquid Line Solenoid (LLS2)-Open
refrigerant heats the Zone 2 evaporator and
condenses into high pressure liquid. Because the 2R. Zone 2 Liquid Return Check Valve
SLS2 is open, the liquid refrigerant returns to the (LRCV2)-Open
compressor through the SLS2, the second suction
3R. Zone 2 Suction Line Check Valve
line, SLCV2 and the accumulator. The fans stay
(SLCV2)-Open
off in the Zone 2 evaporator, allowing the coil to
defrost without warming the load. 4R. Zone 2 Suction Line Solenoid (SLS2)-Open
Due to the low pressure in the second suction line, 5R. Zone 2 Hot Gas Solenoid (HGS2)-Open
little or no refrigerant goes through the Zone 1
evaporator. Condensing Unit
In the condensing unit, the CIS valve closes and 6. Condenser Inlet Solenoid (CIS)-Closed/Open
opens to regulate head pressure. The purge valve (Pressure Dependent)
is opened continuously during defrost to drain the
condenser coil.
(CICV)-Closed/Open
Zone 1 Evaporator 8.Condenser Check Valve (CCV)-Closed
1F. Zone 1 Liquid Line Solenoid (LLS1)-Open 9. Purge Valve (PV)-Open
2F. Zone 1 Liquid Return Check Valve 10. Purge Check Valve (PCV)-Open
(LRCV1)-Closed
(SLCV1)-Open
43
Unit Description
1F 6 7
2F 10
9
4F
3F
5F
1R
2R
4R
3R
5R
Figure 15: Zone 1 Heat and Zone 2 Defrost
Zone 1 Heat and Zone 2 Defrost Zone 2 Evaporator

The CIS is closed so high pressure refrigerant 1R. Zone 2 Liquid Line Solenoid (LLS2)-Open
the DPR to Zone 1 and Zone 2 hot gas lines and
(LRCV2)-Closed
through HGS1 and HGS2 into both evaporators.
There, the refrigerant heats both evaporators and 3R. Zone 2 Suction Line Check Valve
condenses into high pressure liquid. The (SLCV2)Open
refrigerant flows through the open suction line
solenoids and back to accumulator. The fans stay
off in the Zone 2 evaporator, allowing the coil to 5R. Zone 2 Hot Gas Solenoid (HGS2)-Open
defrost without warming the load.
Condensing Unit
opens to regulate head pressure. The purge valve 6. Condenser Inlet Solenoid 9CIS)-Closed/Open
is opened continuously during defrost to drain the (Pressure Dependent)
condenser
(CICV)-Closed/Open
Zone 1 Evaporator
1F. Zone 1 Liquid line Solenoid (LLS1)-Open
(LRCV1)-Closed 10. Purge Check Valve (PCV)-Open
(SLVC1)-Open
44
Unit Description
1F 6 7
2F 10
9
4F
3F
5F
1R
2R
4R
3R
5R
Figure 16: Zone 1 Defrost and Zone 2 Null
Zone 1 Defrost and Zone 2 Null Zone 2 Evaporator

The CIS is closed so high pressure refrigerant 1R. Zone 2 Liquid Line Solenoid (LLS2)-Closed
the DPR to the Zone 1 hot gas line and through
(LRCV2)-Closed
refrigerant heats the evaporator and condenses 3R. Zone 2 Suction Line Check Valve
into high pressure liquid. The refrigerant flows (SLCV2)-Open
through the open suction line solenoid and back to
accumulator. The fans stay off in the Zone 1
evaporator, allowing the coil to defrost without 5R. Zone 2 Hot Gas Solenoid (HGS2)-Closed
warming the load.
Condensing Unit
opens to regulate head pressure. The purge valve 6. Condenser Inlet Solenoid (CIS)-Closed/Open
is opened continuously during defrost to drain the (Pressure Dependent)
condenser
(CICV)-Closed/Open
Zone 1 Evaporator
1F. Zone 1 Liquid Line Solenoid (LLS)-Open
(LRCV)-Closed 10. Purge Check Valve (PCV)-Open
(SLCV)-Open
4F. Zone 1 Suction Line SOlenoid (SLS)-Open
5F. Zone 1 Hot Gas Solenoid (HGS)-Open
45
Unit Description
1F 6 7
2F 10
9
4F
3F
5F
1C
2C
4C
3C
5C
1R
2R
4R
3R
5R
Figure 17: Zone 1 Cool, Zone 2 Heat, and Zone 3 Heat
46
Unit Description
Zone 1 Cool, Zone 2 Heat, and Zone Zone 3 Evaporator

3 Heat 1R. Zone 3 Liquid Line Solenoid (LLS3)-Open
(LRCV3)-Open
the DPR to the Zone 2 and Zone 3 hot gas lines
and the open HGS2 and HGS3 into the Zone 2 3R. Zone 3 Suction Line Check Valve
and Zone 3 evaporators. There, the refrigerant (SLCV3)-Closed
heats the Zone 2 and Zone 3 evaporators and
4R. Zone 3 Suction Line Solenoid (SLS3)-Closed
condenses into high pressure liquid. Because
SLS2 and SLS3 are closed, the liquid refrigerant 5R. Zone 3 Hot Gas Solenoid (HGS3)-Open
flows through LRCV2 and LRCV3, and through
the liquid line to the LLS1. Condensing Unit
The LLS1 is open so the refrigerant flows through 6. Condenser Inlet Solenoid (CIS)-Closed/Open
the Zone 1 expansion valve into the Zone 1 (Pressure Dependent)
Zone 1 evaporator as it evaporates into low
(CICV)-Closed/Open
compressor through the SLS1, Suction Line, 8. Condenser Check Valve (CCV)-Closed
condenser coil.
Zone 1 Evaporator
(LRCV1)-Closed
(SLCV1)-Open
Zone 2 Evaporator
1C. Zone 2 Liquid Line Solenoid (LLS2)-Open
2C. Zone 2 Liquid Return Check Valve
(LRCV2)-Open
3C. Zone 2 Suction Line Check Valve
(SLCV2)-Closed
4C. Zone 2 Suction Line Solenoid (SLS2)-Closed
5C. Zone 2 Hot Gas Solenoid (HGS2)-Open
47
Unit Description
1F 6 7
2F 10
9
4F
3F
5F
1C
2C
4C
3C
5C
1R
2R
4R
3R
5R
Figure 18: Zone 1 Cool, Zone 2 Heat, and Zone 3 Defrost
48
Unit Description
Zone 1 Cool, Zone 2 Heat and Zone Zone 3 Evaporator

3 Defrost 1R. Zone 2 Liquid Line Solenoid (LLS3)-Open
(LRCV3)-Closed
the DPR to the Zone 3 hot gas line and the open
HGS3 into the Zone 3 evaporator. There, the 3R. Zone 2 Suction Line Check Valve (SLCV3)
refrigerant heats the Zone 3 evaporator and -Open
condenses into high pressure liquid. The liquid
4R. ZOne 2 Suction Line Solenoid (SLS3)-Open
refrigerant flows through the open SLS2, the
second suction line, SLCV2 and the 5R. Zone 2 Hot Gas Solenoid (HGS3)-Open
accumulator.The fans stay off in the Zone
3evaporator, allowing the coil to defrost without Condensing Unit
warming the load.
6. Condenser Inlet Solenoid (CIS)-Closed/Open
Little or no refrigerant flows through the Zone 1 (Pressure Dependent)
and Zone 2 evaporators because there is a higher
resistance to flow through those evaporators than
(CICV)-Closed/Open
through the Zone 3 evaporator.
8.Condenser Check Valve (CCV)-Closed
opens to regulate head pressure. The purge valve 9. Purge Valve (PV)-Open
is opened continuously during defrost to drain the
condenser coil.
Zone 1 Evaporator
(LRCV1)-Closed
(SLCV1)-Open
Zone 2 Evaporator
1C. Zone 2 Liquid Line Solenoid (LLS2)-Open
2C. Zone 2 Liquid Return Check Valve
(LRCV2)-Open
3C. Zone 2 Suction Line Check Valve
(SLCV2)-Closed
4C. Zone 2 Suction Line Solenoid (SLS2)-Closed
5C. Zone 2 Hot Gas Solenoid (HGS2)-Open
49
Unit Description
Inverted Heat Mode Defrost Mode

When the unit switches from cooling in all The delayed switching of the Hot Gas Solenoid,
running zones to reverse heat, there is a Condenser Inlet Solenoid, and Suction Line
one-minute period where the purge valve is Solenoid does not occur before the Defrost mode.
energized, while all running zones remain in cool. The Purge Valve, Hot Gas Solenoid and
This is followed by a two-minute period where Condenser Inlet Solenoid are all energized at he
the hot gas solenoid in the zone calling for heat is same time. The Purge Valve remains open while
energized along with the condenser inlet solenoid. the unit is in the Defrost Mode.
Finally, the suction line solenoid in the zone
calling for heat is energized. This process Start Up and Sweeping Unit
pre-conditions the evaporator in the zone calling Evaporator Coils
for heat.
For the first 30 seconds following unit start up, the
The heating system increases the capacity of the Hot Gas Solenoids in all zones are energized as
Heat mode by making more refrigerant available well as the Liquid Line Solenoid in Zone 1. This
for use in the Heat mode. This is accomplished by sweeps refrigerant from the coils and returns it to
the Purge Valve, which opens during the the compressor along with oil trapped in the
beginning of the Heat mode to move liquid evaporators. High speed diesel operation is
refrigerant from the condenser to the accumulator delayed for 2 minutes after startup and the
where it can be used in the Heat mode. The Purge alternator excitation output is delayed for 30
Valve controls the flow of refrigerant through the seconds after startup to reduce the load on the
Purge Valve line. The Purge Valve line runs from engine.
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.
50
Unit Description
AJA1350
Figure 19: Front View
AJA1500
Figure 20: Back View
51
Unit Description
1. On/Off Switch
Figure 21: Side View
52
Unit Description
1 2 3
16
8
15
9
AJA1176
14 13 12 11 10
1. Electric Motor 9. Discharge Pressure Regulator

2. Alternator 10. Suction Service Valve
3. Throttle 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
53
Unit Description
1 2 3 4
11
10
8
7
6 5
AJA1172
1. Control Box 7. 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
54
Unit Description
AJA455
Figure 24: Power Receptacle Box—Model 50
6 2
5 AJA116
3
4 4 4 4
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
55
Unit Description
Control Box, Fuses and Relays

The control box is located on the compressor side SP1
F8 F18 F7
of the unit (see Figure 23 on page 54). It contains F6 F27
15
15
2
the SPECTRUM™ TS Microprocessor, Interface
25
2
board, Multi-Temp Option board, power supply K1 K5 K8 K13 K14 K10 K7 K9 K6
board, the high voltage tray, and miscellaneous F4 F5 F23 F16
fuses and relays located on these boards.
7.5
1
2
EXC HI SPD HG1 LLS1 SLS1 D/E RUN PREHEAT
P23 METV P19

F31
2
2 F15
CH
P201 J1 P202
K207
2 F9 REMOTE
FAN 2 FAN 3 LIQI EGOV
P3 ZONE 2 / ZONE 3 P24 HMI LIGHT
1
K204
SLS2 F8 F18 F7
SP1
SLS3 F28 2 F10
F6 F27
K206 F22 2 5
15
15
LLS2 K200 K201

2
LLS3
25
1
2
K203
1
FM1
P22 DAS
2
HGS2 F201 HGS3 F29
K1 K5 K8 K13 K14 K10 K7 K9 K6 K205
FM2 2A FM3 P18 ZONE 1
15
15
K202 FAN1/DEF
F4 F5 F23 F16 F21 F20 F17 F19
F200 F202 7.5 P15 REMOTE
1
RUN PREHEAT F14 F11

EXC HI SPD HG1 LLS1 SLS1 D/E
J1
P23 METV P19
2
F31
K2
2
CH K3 K4
7.5
2 F15
2
2 F9 REMOTE
P16 ELECTRIC
HGS3 HGS3
P3 ZONE 2 / ZONE 3 P24 HMI LIGHT
F28 2 F10
F22 2 5
P20 F2 X2
2A
FM1
1 P22 DAS
2
F29 X5 X7
P18 ZONE 1
40
FAN1/DEF
F21 F20 F17 F19
P15 REMOTE
F14 F11 CIS RTPS HGB PV
P17 COMMS
K2 K3 K4
7.5
2
P16 ELECTRIC
P20 F2
2A
X2
X5 X7 P1
40
CIS
J2RTPS HGB PV
P17 COMMS
3
2
LED1
P2 AJA1202 1
2
1
P14
P14
5
AJA1201
Figure 27: Interface Board

1. Multi-Temp Option Board
2. Interface Board
Interface Board Fuse Size and Function
3. Power Supply Board Fuse Size Function
4. SPECTRUM™ TS Microprocessor F2 40A Starter, Fuel Pull-In
Figure 26: Complete SPECTRUM™ TS Control F4 1A Remote Status Light (Option)
System with Multi-Temp Option Board
F6 40A Preheat
F7 15A 2A Power Zone 1
F8 2A Alternator Excitation
F9 2A DAS 2A Power (Option)
F10 2A Remote Display 2A Power (Option)
F11 7.5A Run Relay
F15 2A HMI 2A Power
F16 7.5A 8 Power to HMI, DAS
F17 2A Purge Valve
F18 15A High Speed Solenoid
F20 2A Hot Gas Bypass
F21 2A Condenser Inlet Solenoid
F22 2A Liquid Injection Valve
F23 2A Power Supply
F29 1A Zone 1 Door Switch 2A Power
56
Unit Description
Interface Board Relay Functions Multi-Temp Option Board

Relay Function The Multi-temp Option Board adds the control
K1 Alternator Excitation Relay functions for Zone 2 and Zone 3. The
microprocessor controls the operation of the
K2 Zone 1 Fan Relay
additional zones through the control relays on the
K3 Starter Relay multi-temp option board. An LED is illuminated
K4 Fuel Solenoid Pull In Relay when a relay is energized by the microprocessor
and has transferred its contacts to the energized
K5 Throttle Solenoid Relay
state.
K6 On/Off Relay
The only user serviceable components on the
K7 Run Relay
“multi-temp option board” are the fuses and
K8 Zone 1 Hot Gas Solenoid Relay jumpers.
K9 Preheat Relay
K10 Diesel/Electric Relay P201 J1 P202
K207
FAN 2 FAN 3
K204
K13 Zone 1 Liquid Line Solenoid Relay SLS2 SLS3
K206
K14 Zone 1 Suction Line Solenoid Relay LLS2 K200 K201 LLS3
1
K203
F201
HGS2 HGS3
K205
FM2 2A FM3
Power Supply Board
15
15
K202
F200 F202
The power supply board provides regulated DC

Figure 29: Multi-Temp Option Board
power to the microprocessor and interface board.
It is separate from the other boards due to
manufacturing considerations and to allow the Multi-Temp Option Board Fuse Size and Function
capability to be increased as required for future Fuse Size Function
applications. F200 15A 2A Power Zone 2
If the LED on the power supply board is F201 1A Zone 2, 3 Door Switch 2A Power
illuminated the power supply board is functioning F202 15A 2A Power Zone 3
normally.
P1
LED1
P2
Figure 28: Power Supply Board
57
Unit Description
1. Phase Detect Module

2. Motor Contactor
3. Motor Contactor
4. Overload Relay
Figure 30: High Voltage Contactors with Shield Removed
58
Unit Description
Serial Number Locations Serial Number and Refrigerant

Label Locations
2
1
1
AJA1352
Figure 31: Engine Serial Number Location

.
1. Refrigerant Type
2. Unit Serial Plate
Figure 33: Label Locations
Figure 34: Laminated Unit Serial Number Plate
Figure 32: Compressor Serial Number Location 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.
59
Unit Description
60
SPECTRUM™ TS Operation
HMI Controller Overview The Standard Display of box temperature and

setpoint for 2 zones is shown here. In the display
The HMI (Human Machine Interface) Control shown here, Zone 1 has a setpoint of -10 F and a
Panel is connected to the microprocessor and is box temperature of -9.4 F. Zone 2 has a setpoint
used to operate the unit. It is located in the truck of 35 F and a box temperature of 35.8 F
cab mounted in or under the dashboard.
The HMI control panel consists of a display and 8 Microprocessor Power Switch
touch sensitive keys. The display is capable of
showing both text and graphics. The four keys on The Microprocessor Power switch applies 12 Vdc
the left and right sides of the display are dedicated power to the microprocessor. The switch must be
keys and the functions are described in detail later in the “On” position to operate the
in this chapter. The four keys under the display microprocessor. It is located on the unit frame on
are “soft” keys. The function of “soft” keys the road side of the unit.
change depending on the operation being NOTE: When the Microprocessor Power Switch
performed. If a soft key is active, the current key is turned to the Off position, power is still applied
function will be shown in the display directly to the Interface Board and the HMI. To
above the key. completely remove power from the control
system, disconnect the unit battery.
1 3 8 7
2 4
AJA1167
AJA1112
6 6 6 6 Figure 37: Microprocessor Power Switch
1. On Key (Dedicated Key)
2. Off Key (Dedicated Key) Turning the Unit On and Off
3. Display The unit is turned on by pressing the ON key and
off by pressing the OFF key. When the On key is
4. Defrost Key (Dedicated Key)
pressed the display will briefly show THERMO
5. High Speed Lockout Key (Dedicated Key) KING as the display initializes.
6. Soft Keys
7. Arrow Up- Zone is Heating
1
8. Arrow Down - Zone is Cooling
No Arrow - Zone is in Null
2
Figure 36: Dedicated and soft keys AJA1107
1. On Key
Display
2. Off Key
The display is used to supply unit information to
the operator. This information includes setpoint Figure 38: On/Off Key
and temperature for all installed zones, zone Then the startup screen shown below appears
operating information, unit gauge readings, while communications are established and the unit
system temperatures and other information as prepares for operation. See Figure 39 on page 62.
selected by the operator.
61
AJA1108 AJA1111
1 2 3
Figure 39: Startup Screen
1. Zone 1 Soft Keys
When the unit is ready to run the Standard 2. Zone 2 Soft Key
Display will appear. See Figure 40 on page 62.
3. Menu Soft Key
Figure 42: One Zone Off
The soft key labeled 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
AJA1109 Menu Display. The unlabeled soft key is not used
Figure 40: Standard Display from the Standard Display.
Pressing the OFF key stops unit operation. The
unit will shutdown and the display will briefly Selecting a Zone Display
show OFF and then the display will go blank. To select a zone from the Standard Display, press
the soft key for the desired zone. Zone 1 will be
The Standard Display selected here.
The Standard Display is the default display that
appears if no other display function is selected.
The Standard Display shows the box temperature
and setpoint or OFF for all installed zones. The
box temperature is that measured by the
controlling sensor, usually the return air sensor. A AJA1112
two zone application is shown here. The Figure 43: Standard Display
temperature in Zone 1 is –9.4 F with a –10 F
setpoint. The temperature in Zone 2 is 35.8 F with When a Zone soft key is pressed the Zone Display
a 35 F setpoint. The top of the display shows that shown will appear. The zone display allows the
the unit is operating in CYCLE SENTRY mode. operator to change the zone setpoint and turn the
The two arrows indicate that both zones are zone on and off. To return to the Standard Display
cooling. press the soft key labeled EXIT. If no key is
pressed the display will return to the Standard
Display after 30 seconds.
The soft keys labeled “–” and “+” are used to
change the setpoint. The Zone On/Off soft key
identifies the zone being displayed and indicates if
the zone is on or off. If the zone being shown by
AJA1110
Figure 41: Standard Display
the Zone Display is currently turned on the third
soft key will be labeled “TURN ZONE X OFF”.
If OFF appears below the box temperature as If the zone is currently turned off the third soft
shown below for Zone 2, then the zone has been key will be labeled “TURN ZONE X ON”. Zone
turned off. If the setpoint appears the zone is 1 is turned on in the illustration shown on the next
turned on, as shown below for Zone 1. page. Pressing the EXIT soft key returns the
display to the Standard Display.
62
AJA1113
2 AJA1116
1 3 4
Figure 47: Zone 1 Off
1. “-” Soft Key
When the zone is turned on or off, the display will
2. “+” Soft Key briefly indicate that the change is being made as
3. Zone “X” Soft Key shown below.
4. EXIT Soft Key
Figure 44: Selecting A Zone
Turning a Zone On and Off

At the Standard Display, press the soft key to
show the Zone Display for the desired zone. AJA1117
Figure 48: Programming Screen
The display will show the new setting for several

seconds as shown below.
AJA1114
If the zone shown by the Zone Display is AJA1118

currently turned on the third soft key will be Figure 49: Displays New Setting
labeled “TURN ZONE X OFF”, where X is the
zone number. If the zone is currently turned off
the third soft key will be labeled “TURN ZONE X
ON”. Zone 1 is shown on the display below, with
the zone turned on.
AJA1119
Figure 50: Zone 1 On Display
The display then returns to the Zone Display.

Pressing the ZONE 1 ON key will turn the zone
AJA1115 back on.
Figure 46: Zone 1 On
If no keys are pressed the display will return to the
Pressing the “TURN ZONE 1 OFF” key will turn Standard Display after 30 seconds.
Zone 1 Off, and the soft key label will then read
ZONE 1 ON as shown below. Pressing the key
again will turn the zone back on.
63
Changing the Setpoint Failure to confirm the new setpoint by pressing

Yes or No within 10 seconds of changing the
At the Standard Display, press the soft key to setpoint will result in Alarm Code 127 (Setpoint
show the Zone Display for the desired zone. The not entered).
display below shows the Zone 2 display with a
setpoint of 35 F. The Zone is turned on as shown
previously.
AJA1123
Figure 53: Programming New Setpoint Display
AJA1120 After the YES soft key has been pressed the
Figure 51: Zone 2 Display display will briefly show PROGRAMMING
NEW SETPOINT as shown above.
Pressing the “-” and/or “+” soft keys changes the
display to the Setpoint Display for the selected The display then confirms the new setpoint for
zone. The display title changes and the YES and several seconds as shown below.
NO soft keys appear as shown below. The “+” and
“-” soft keys are used to increase or decrease the
setpoint. Here the setpoint has been changed to 40
F using the “+” key.
NOTE: The allowable range for the setpoint is
limited if Setpoint Limits have been AJA1251
programmed. Refer to the ThermoGuard Figure 54: New Setpoint
SPECTRUM TS Multi-Temp Microprocessor
Control System Diagnostic Manual (TK 51652) The display then returns to the Standard Display
for more information. showing the new setpoint.Notice that the Zone 2
arrow now points up to indicate the zone is
heating.
AJA1121
1 2 3 4
AJA1124
1. “-” Soft Key
Figure 55: Standard Display With New Setpoint
2. “+” Soft Key Displayed
3. Yes Soft Key
IMPORTANT: If the setpoint is changed using
4. No Soft Key the “+” or “-” keys, the change must be
Figure 52: New Setpoint Display confirmed or rejected by pressing the YES or NO
soft key within 10 seconds of changing the
The YES and NO soft keys confirm the setpoint setpoint.
change. When the desired setpoint has been
• If the YES key is pressed, the setpoint change
selected using the “+” and/or “-” keys, press the
made with the “+” or “-”keys will be accepted,
YES soft key to confirm and load the new
the setpoint will be changed and the display
setpoint. If the setpoint is changed using the “+”
will return to the Standard Display.
or “-” keys, the change must confirmed or rejected
by pressing the YES or NO soft key within 10
seconds of changing the setpoint.
64
• If the NO key is pressed the setpoint change Initiating a Manual Defrost

made with the “+” or “-” keys will not be Cycle
accepted, the setpoint will not be changed and
the display will return to the Setpoint Display. Defrost cycles are usually initiated automatically
based on time or demand. Manual defrost is also
• If the YES or NO key is not pressed within 10 available. Manual defrost is available if the unit is
seconds of making a change with the “+” or running, the zone is turned on and the zone coil
“-” keys, the setpoint will not be changed and temperature is less than 45 F (7 C). Only one zone
the display will return to the Setpoint Display. can be in defrost at a time. Other features such as
The display will briefly show [SETPOINT economy mode or door switch settings may not
NOT CHANGED] and Alarm Code 127 allow manual defrost in some instances.
Setpoint Not Entered will be set to indicate
that the setpoint change was started but not
completed.
AJA1127
To initiate a manual defrost cycle, press the

AJA1125
Defrost Key from the standard display. The
Figure 56: Setpoint Not Changed Display
display will prompt for the desired zone.
Starting the Diesel Engine Press the soft key to select the zone to defrost as
shown below. Pressing the indicated soft key will
Diesel engine preheats and starts are automatic in initiate a defrost cycle in Zone 1.
both Continuous Mode and Cycle Sentry Mode.
The engine will preheat and start if necessary
when the unit is turned on. The engine preheat and
start will be delayed in Cycle Sentry mode if there
is no current need for the engine to run. If any
keys are being pressed on the HMI, the engine
will preheat and start 10 seconds after the last key AJA1128
is pressed. Figure 59: Select Zone To Defrost Display
When the engine is preparing to start the HMI will The display will briefly show [PROGRAMMING
display the engine start screen as shown below. DEFROST] and then briefly show [ZONE “X”
DEFROST STARTED], where “X” is the number
of the selected zone.
The display will then return to the Standard
Display as shown below. The zone in defrost will
show “DEF” instead of setpoint and a status bar to
AJA1126
indicate time to complete defrost as shown below.
Figure 57: Diesel Engine Start Display
CAUTION: The engine may start

automatically any time the unit is turned on.
WARNING: Never use starting fluid. AJA1129

Figure 60: Zone 1 in Defrost
65
Terminating a Defrost Cycle Using the Operators Menu

The defrost cycle will terminate automatically The Operators Menu contains several additional
when the coil temperature is greater than 52 F (11 menus that allow the operator to view information
C) or the defrost timer expires. Defrost can also be and modify unit operation. To access the
terminated by turning the unit off and back on. Operators Menu press the MENU key.
Selecting High Speed Lockout

(if enabled)
If enabled, high speed operation can be locked out
if required in noise sensitive areas.
AJA1132
NOTE: High Speed Lockout Enable must be
programmed [YES] or this feature will not be Figure 63: Menu Key
available. If High Speed Inhibit Timeout has The first menu choice will appear. Press the
been programmed, the unit will return to high NEXT and PREVIOUS keys to scroll thru the
speed operation if the set time is exceeded and menu choices. When the desired choice is shown
conditions allow. on the display, press the SELECT key to access it.
The High Speed Lockout key is a toggle. If high The MODE Menu is shown here.
speed is enabled, then pressing the key will
disable high speed operation. Pressing the key
again will enable high speed operation.
AJA1133
1 2 3 4
1. Exit Key
AJA1131 2. Select Key
Figure 61: Programming Display 3. Previous Key
4. Next Key
The display will then return to the Standard
Display. Figure 64: Mode Display
If High Speed Lockout is turned on, the message The Operators Menu choices are shown below
HIGH SPEED LOCKOUT ACTIVE will replace and on the next page. For detailed information see
the CYCLE SENTRY/CONTINUOUS indication the individual explanations of each menu item
at the top of the display. Pressing the High Speed later in this section of the manual. To return to the
Lockout key again will turn this feature off. Standard Display press the EXIT key.
The display will briefly show [PROGRAMMING Operators Menu Choices
HIGH SPEED LOCKOUT] and then [HIGH
SPEED LOCKOUT ACTIVE] or [HIGH SPEED Language Menu: If enabled, allows the operator to
select a language from a list of 5 languages. All
LOCKOUT INACTIVE] as shown below.
other subsequent displays are shown in the
selected language. English is the default language.
See “Selecting a Language” on page 67.
Alarm Menu: Shows any active alarms, and allows
alarms to be cleared. See “Displaying and
Clearing Alarm Codes” on page 77.
AJA1252
Mode Menu: Allows the operator to change the
Figure 62: Standard Display with High Speed
Lockout Active unit operating modes.
66
Cycle Sentry Mode: Allows the operator to change The Language menu will appear as shown below.
the unit to cycle sentry mode. See “Selecting Press the + or - keys to select the desired
Cycle Sentry or Continuous Mode” on page 68. language.
Continuous Mode: Allows the operator to change
the unit to continuous mode. See “Selecting Cycle
Sentry or Continuous Mode” on page 68.
Economy Mode: Allows the operator to change the
unit to economy mode. See “Selecting Economy
Mode” on page 69.
AJA1255
Sleep Mode: Allows the operator to change the Figure 66: New Language
unit to the sleep mode. See “Selecting Sleep
Mode” on page 70. When the desired language is shown press the
YES key to confirm the choice.
Pretrip Menu: Allows the operator to select a Full
Pretrip Test or Running Pretrip Test. See
“Performing a Pretrip Test” on page 72.
Display Intensity: Allows the operator to adjust
the display intensity as required by conditions.
Selecting a Language AJA1256

Figure 67: New Language
If the Language feature is enabled an alternate
language can be selected from the Operators The display will briefly show PROGRAMMING
Menu. After a new language is chosen all displays LANGUAGE-PLEASE WAIT
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.
AJA1258
To select an alternate language, press the MENU Figure 68: Programming Please Wait
key.
AJA1257
AJA1257
Figure 69: Language Menu
The Language Menu is the first menu item to The display will then return to the language menu.
appear as shown below. Press the SELECT key to To select a different Main Menu item press the
choose the Language menu. NEXT key. To return to the Standard Display
press the EXIT key.
67
Selecting Cycle Sentry or Pressing the Select key will change the mode
Continuous Mode from Cycle Sentry to Continuous. The display
will confirm the change as shown below.
When Cycle Sentry mode is selected the unit will
start and stop automatically to maintain setpoint
in all compartments, keep the engine warm and
the battery charged. When Continuous Mode is
selected, the unit will start automatically and run
continuously to maintain setpoint and provide
constant airflow.
AJA1145
Cycle Sentry and Continuous Mode are selected Figure 73: Programming Modes Display
using the Mode Menu. From the Standard
Display, press the MENU key. The new mode is then confirmed for 10 seconds.
AJA1142 AJA1146
Figure 70: Standard Display Figure 74: Continuous Mode Display
The Language Menu or Alarm Menu will appear. The display then returns to the Mode Menu. In the
Press the NEXT key as required to show the example here the unit is running in Continuous
Mode Menu. When the Mode Menu is shown mode. Pressing the Select key again allows the
press the SELECT key. operator to change back to Cycle Sentry mode
operation.
AJA1143
Figure 71: Mode Display AJA1147
The current mode, either Cycle Sentry or Figure 75: Cycle Sentry Mode Display
Continuous, will be indicated by the display. In
the display shown below, the unit is operating in CAUTION: If the unit is in Cycle Sentry
Cycle Sentry mode and the option exists to switch null and the mode is switched to
to Continuous mode. In this example, pressing the Continuous Mode, the unit will start
Select key will switch the mode from Cycle automatically
Sentry to Continuous.
AJA1144
Figure 72: Switching Modes Display
68
Selecting Economy Mode Pressing the Select key will turn Economy Mode
on. The display will confirm the change as shown
Economy Mode is used on selected loads that do
below.
not require critical temperature control. The
temperature control points are relaxed and other
features are optimized for maximum fuel
economy. This mode should be used as directed
by individual company policy. Economy Mode
can be turned on or off as required.
AJA1151
Economy Mode is turned On and Off using the
Mode Menu. From the Standard Display, press the Figure 78: Programming Economy Mode Display
MENU key. The new mode is then confirmed for 10 seconds.
AJA1148 AJA1152
Figure 76: Standard Display Figure 79: Programming Economy Mode Display
The Language Menu, then Alarm Menu appears. The display then returns to the Mode Menu. In the
Press the NEXT key as required to show the example here Economy Mode is turned on.
Mode Menu. When the Mode Menu is shown Pressing the Select key again allows the operator
press the SELECT key. to turn Economy Mode off.
AJA1149 AJA1153
Figure 77: Mode Display Figure 80: Economy 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.
AJA1150
69
Selecting Sleep Mode

automatically any time the unit is turned
on.
Normal Cycle Sentry mode starts and stops the
AJA1133
unit as required to maintain the desired
Figure 82: Mode Display
temperature in all zones, maintain the unit battery
in a charged condition and keep the unit engine Press the Next key as required to display the Sleep
warm in cold ambient conditions. Sleep mode Mode prompt.
does not maintain zone temperatures – it only
keeps the engine warm and the unit battery
charged. This is useful in extremely cold weather
or when the unit is to be out of service for an
extended time.
Sleep mode operates in both Diesel mode and
Electric mode. In Diesel mode the unit will start AJA1259
and stop as required to maintain engine Figure 83: Start Sleep Mode
temperature and battery charge. In Electric mode
the unit starts and stops as necessary to maintain Press the Select key to choose the Sleep Mode
battery charge only. menu.
When Sleep mode is entered, the operator can
program an automatic Wake-up Time up to a
week away. Using this feature, the unit will
automatically restart and run normally at the
determined time. If a Wake-up Time is
programmed the operator can also program an
AJA1260
automatic Pretrip Test when the unit restarts.
Figure 84: Program Wake-Up Time
Sleep Mode is turned On and Off using the Mode
Menu. From the Standard Display, press the The operator can now choose a Sleep Mode
MENU key. Wake-up Time or simply enter Sleep Mode
immediately. If NO is pressed the unit will
immediately enter Sleep Mode
The display will show SLEEP and the unit will
start and stop as required to keep engine warm
and/or the battery charged. Sleep mode does not
maintain zone temperatures. To exit Sleep Mode
AJA1154 press the EXIT key or turn the unit off and back
Figure 81: Standard Display on. The unit will resume normal operation and
control to setpoint.
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.
AJA1261
Figure 85: Sleep
70
To enter a Wake-up Time verify that the unit

clock is set properly. Then press the YES key at
the Sleep Mode menu.
AJA1265
Figure 89: Run Pretrip On Wake-Up
The display will show SLEEP and the unit will

AJA1260
start and stop as required to keep the engine warm
Figure 86: Program Wake-Up Time
and/or the battery charged. Sleep mode does not
The display will prompt the operator for the DAY maintain zone temperatures.
the unit is to restart in normal operation. In this
example Monday has been chosen. Press the YES
key to confirm the DAY.
AJA1261
Figure 90: Sleep
The unit will restart at the programmed time (in

AJA1262 this example 4:30 am) and perform a Pretrip Test
Figure 87: Select Day Screen (if selected). After the Pretrip Test is complete the
test results will be displayed and the unit will
The display will now prompt the operator for the resume normal operation and control to setpoint.
Hour the unit is to restart in normal operation. In
this example 4:00 am has been chosen. Press the To exit Sleep Mode before the selected Wake-up
YES key to confirm the HOUR. Note that 24 hour time press the EXIT key or turn the unit off and
“military time” is used. back on. The unit will resume normal operation
and control to setpoint.
Pretrip Tests
automatically any time the unit is turned
AJA1263 on.
The display will now prompt the operator for the A Pretrip Test verifies unit operation. This display
MINUTE the unit is to restart in normal operation. allows a Pretrip Test to be selected and initiated
In this example 4:30 am has been chosen. Press by the operator. If the Pretrip Test is entered with
the YES key to confirm the MINUTE. the unit shut down a Full Pretrip Test with device
amp checks will be performed. If the Pretrip Test
is entered with the unit running in either diesel or
electric mode a Partial Pretrip Test is performed.
Test results are reported as PASS, CHECK or
FAIL when the Pretrip Test is completed.
AJA1264 Pretrip Test Conditions:
Figure 88: Select Time Screen
• All zones are forced on.
• Pretrip Test can be run in either Diesel or
Electric Mode.
71
• The unit will autoswitch from Diesel Mode to Performing a Pretrip Test
Electric Mode or from Electric Mode to Diesel
Mode during a Pretrip Test if these features CAUTION: The engine may start
are enabled. automatically any time the unit is turned
on.
Pretrip Tests are not allowed if:
If a Pretrip Test is initiated with the engine shut
• Any alarms are present. down a Full Pretrip Test will be performed. If a
• The unit is in Sleep Mode. Pretrip Test is initiated with the engine or motor
running a Partial Pretrip Test is performed.
• Unit is in Service Test Mode, Interface Board
Test Mode or Evacuation Mode. Before initiating a Pretrip Test, clear all alarm
codes.
Pretrip Test Sequence:
Pretrip Tests are initiated using the Pretrip Menu.
Pretrip tests proceed in the order shown below. A From the Standard Display, press the MENU key.
Full Pretrip Test includes all tests. A Partial
Pretrip Test is started with the engine or motor
running and does not include the Amp Checks or
Engine Start Check.
• Amp Checks – Each electrical control
component is energized and the current drawn
is confirmed as within specification. AJA1154
• Engine Start – The Engine will start
automatically. The Language Menu or Alarm Menu will appear.
• Zone 1 Defrost – If the Zone 1 coil Pretrip Menu. When the Pretrip Menu is shown
temperature is below 45 F (7 C), a defrost is press the SELECT key to start a Pretrip Test.
cycle is initiated.
• Zone 1 Cool Check – The ability of the unit to
cool in low speed is checked.
• RPM Check – The engine RPM in high and
low speed is checked during the Zone 1 Cool
Check. AJA1155
• Zone 1 Heat Check - The ability of the unit to Figure 92: Mode
heat in low speed 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 AJA1156
Figure 93: Pretrip Display
reported as PASS, CHECK or FAIL when the
Pretrip Test is completed. If test results are If the unit is not running a Full Pretrip Test will be
CHECK or FAIL alarm codes will exist to initiated. If the unit is running in either diesel or
direct the technician to the source of the electric mode a Running Pretrip will be
problem. performed.
72
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.
AJA1157
Figure 94: Programming Test Pretrip Display
The Pretrip Test display appears. The top line of

the display indicates the unit is performing the
non-running Pretrip Test. Test progress is
measured by the number of tests completed out of AJA1159
a total of 26. In the example below the unit is Figure 97: Pretrip Pass Display
performing Test 1 of 26, Sensor Check. The soft
keys may be used during the Pretrip Test to select Selecting Diesel or Electric
the Hourmeter, Gauge or Sensor menus. Operation
The Diesel or Electric Display allows the operator
to manually select diesel mode operation. The unit
can also be programmed to automatically select
electric mode operation when standby power is
available and diesel mode operation if standby
AJA1266 power fails or is removed. If the unit is
Figure 95: Selecting Menus programmed to switch automatically from diesel
When all tests are complete, the results are to electric and electric to diesel these screens do
reported as PASS, CHECK or FAIL. If the results not appear.
are CHECK or FAIL, the accompanying alarm Factory units are programmed to
codes will direct the technician to the cause of the automatically switch to electric mode when
problem. standby power becomes available. The unit
When the non-running test are complete the unit must be switched to diesel power manually as
will start automatically and continue with the programmed from factory.
Running Pretrip Test. In the example shown If the unit has standby power available and is
below the unit is in the Running Pretrip and is turned on, the electric standby run screen will
performing Test 21 of 26, Zone 1 Cool test. appear after the standard screen. The new mode is
then confirmed for 10 seconds.
.
AJA1267
Figure 96: Zone 1 Cool Test AJA1164

Figure 98: Electric Standby Display
If the Pretrip Test results are CHECK or FAIL the
problem should be diagnosed and corrected before
the unit is released for service.
73
IMPORTANT: If the unit was switched on or to Display Brightness

electric and electric standby power is not
available. the operator will receive a prompt to The brightness of the HMI Control Panel display
return to Diesel Mode operation. The prompt can be adjusted to allow for changing ambient
will appear as show below. light conditions. The choices available to the
operator are HIGH, MEDIUM, LOW and OFF.
To switch back to Diesel mode press the YES key. OFF actually results in a very dim screen suitable
Pressing the NO key will allow the unit to remain for low light conditions.
in Electric Standby mode even though standby
power is not available. Display brightness is adjusted using the Adjust
Brightness Menu. From the Standard Display,
press the MENU key.
AJA1166
Figure 99: Switch To Diesel Display AJA1130

Single Temperature Operation
If a single temperature is desired in all zones, turn Press the NEXT key as required to show the
all zones on and set the same setpoint in all zones. Adjust Brightness Menu. When the Adjust
The compartment bulkheads may be installed or Brightness Menu is shown press the SELECT key.
removed.
NOTE: It is recommended 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.
AJA1268
Figure 102: Adjust Brightness Display
AJA1179
Figure 100: Single Temperature Operation Display
74
The Display Brightness menu will appear as Viewing Hourmeters

shown below. Press the + or - keys to select the
Hourmeters are displayed using the Hourmeter
desired display brightness. When the desired
Display. From the Standard Display, press the
brightness is shown press the YES key to confirm
MENU key.
the choice.
AJA1139
AJA1269
Figure 103: Medium Display
The display will briefly show ADJUSTING The Language Menu or Alarm Menu will appear.
BRIGHTNESS-PLEASE WAIT. 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.
AJA1270
Figure 104: Adjusting Brightness Please Wait

Display
AJA1140
Figure 106: Hourmeters Menu Display
Press the NEXT or PREVIOUS key to scroll

through the hourmeters.
AJA1141
Figure 107: Hourmeter Display
75
Hourmeter names and definitions are shown below in the order they appear. To return to the Standard Display,
press the EXIT key.
Hourmeter Names And Definitions Hourmeter Name Definition
Total Hours Total number of hours the unit has been turned on (protection hours).
Total Run Hours Total number of hours the unit has run in both diesel and electric mode.
Engine Hours Total number of hours the unit has run in diesel mode.
Electric House Total number of hours the unit has run in electric mode.
Zone 1 Run Hours Total number of hours that Zone 1 has run in both diesel and electric mode.
Includes running null time.
Zone 2 Run Hours Total number of hours that Zone 2 has run in both diesel and electric mode.
Zone 3Run Hours Total number of hours that Zone 3 has run in both diesel and electric mode.
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
Total Controller Hours Total hours the controller and HMI control panel have been turned on.
Pretrip Reminder Hours User Programmable - number of hours before a Pretrip Reminder occurs.
Engine Maintenance Hours 1 User Programmable - The number of hours before an Engine Hours
Engine Maintenance Hours 2 User Programmable - The number of hours before an Engine Hours
Electric Maintenance Hours 1 User Programmable - The number of hours before an Electric Hours
Electric Maintenance Hours 2 User Programmable - The number of hours before an Electric Hours
IMPORTANT: If a programmable hourmeter is not enabled and/or the view for that hourmeter is not turned on, it will not
appear in the display sequence.
76
Viewing and Clearing Alarm Shutdown Alarms: replace the Standard Display
with a flashing Alarm Display and the statement
Codes
[UNIT NOT RUNNING – SERVICE
Alarms may be one of four types as shown. If an REQUIRED].
alarm applies only to a specific zone, that zone
will be displayed with the alarm code. The flashing display shows the alarm that caused
the shutdown. Shutdown alarms will force the unit
Log Alarms: are indicated at the top of the into shutdown. The unit will remain in shutdown
Standard Display for 30 seconds each time the until the shutdown alarm is cleared. Exceptions
unit is turned on. The alarm indication will go off are some engine and electric shutdown alarms that
after 30 seconds. The Alarm Display must be used become log alarms when switched to the alternate
to view the existing alarms. This level of alarm operating mode (diesel to electric or electric to
serves as a notice to take corrective action before diesel).Special Considerations
a problem becomes severe. Maintenance items
Pretrip Alarm Codes: If an alarm occurs during a
such as maintenance hourmeter time-outs are log
alarms. Pretrip Test the alarm code will be displayed as
Pretrip Alarm XX, where XX is the alarm code.
Check Alarms: are indicated at the top of the
Alarm Codes and switching modes from diesel to
Standard Display with the statement [SERVICE
electric or electric to diesel:
REQUIRED WITHIN 24 HOURS]. The Alarm
Display must be used to view the existing alarms. If a shutdown alarm occurs that affects only diesel
This level of alarm serves as a notice to take mode operation and the unit is switched to
corrective action before a problem becomes electric, the diesel mode shutdown alarm becomes
severe. The unit will run with check alarms but an electric mode log alarm. This allows the unit to
some features and functions may be inhibited. If run in electric mode without clearing the
an alarm applies only to a specific zone, that zone shutdown alarm that is preventing diesel mode
will be displayed with the alarm code. On a operation. If the unit is switched back to diesel
multi-temp application if a zone specific problem mode, the alarm again become a diesel mode
is severe the zone will shut down but the alarm is shutdown alarm and prevents unit operation. In
set as a check alarm to allow the other zones to the same manner, if a shutdown alarm occurs that
continue to run. If severe problems occur in all affects only electric mode operation and the unit is
zones the unit will shut down. switched to diesel, the electric mode shutdown
Prevent Alarms: are indicated at the top of the
alarm becomes a diesel mode log alarm to allow
Standard Display with the statement [UNIT IN diesel mode operation. If the unit is switched back
PREVENT MODE]. The Alarm Display must be to electric mode, the alarm reverts to an electric
used to view the existing alarms. The unit may mode shutdown alarm and prevents unit
wait a timed restart interval or until conditions operation.
allow and then restart. If the unit is in a restart
interval Alarm Code 84 Restart Null will be Displaying and Clearing Alarm
present along with the Prevent Alarm. In other Codes
cases the unit may restart or run with reduced Alarms are displayed and cleared using the Alarm
performance to determine if continued operation Menu. From the Standard Display, press the
is possible. If the alarm does not reoccur with MENU key.
reduced performance the unit will then 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 AJA1134
zone, that zone will be displayed with the alarm
code. Figure 108: Standard Display
77

If the Language Menu appears press the NEXT
key to show the Alarm Menu. When the Alarm
Menu is shown press the SELECT key. The
Alarm Display will appear.
AJA1138
Figure 112: Serious Alarm Display
A help message will appear. For the alarm shown

above, the message “CHECK OIL LEVEL. IF
AJA1135 UNIT IS SHUTDOWN, REPAIR
Figure 109: Alarms IMMEDIATELY. OTHERWISE, REPORT
ALARM AT END OF THE DAY” will be shown
If no alarms are present Alarm 00 is 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
AJA1136 TK 51652, the SPECTRUMTM TS Diagnostic
Manual for detailed instructions.
Figure 110: No Alarms Display
Oil Pressure: Check the engine oil pressure in
If alarms are present, the quantity of alarms (if high speed by pressing the SELECT key to
more than one) and the most recent alarm code [OIL PRESS]. The oil pressure should be ok or
number will be shown. If the alarm pertains to a low.
specific zone, that zone will be identified. In the
example below, there are two alarms present. The When first starting a cold engine, the oil pressure
most recent is Alarm Code 3 in Zone 2. It may be higher.
indicates a possible problem with the return air Compressor Oil: The compressor oil level should
sensor. be visible in the sight glass.
Refrigerant: Checkthe refrigerant charge. See
“Refrigerant Charge” on page 132.
Pre-Cooling: Make sure that the setpoint is at the
desired temperature and allow the unit to run for a
minimum of 1/2 hour (longer if possible) before
loading the trailer.
AJA1137
Figure 111: Alarms Present Display This provides a good test of the refrigeration
system while removing residual heat and the
If a serious alarm occurs, the unit will be shut moisture from the trailer interior to prepare it for a
down to prevent damage to the unit or the load. If refrigerated load.
this occurs, the display will show that the unit is
Defrost: When the unit has finished pre-cooling
shut down and display the alarm code that caused
the trailer interior, manually initiate a Defrost
the shutdown. In the example below, the unit is
cycle. This will remove the frost that builds up
shut down due to low oil level. For additional
while running the unit to pre-cool the trailer.
information regarding the alarm shown on the
display press the HELP key. To manually initiate a Defrost cycle, press the
MANUAL DEFROST key. See “Initiating a Manual
Defrost Cycle” on page 65.
78
The Defrost cycle should end automatically. Post Load Procedure

NOTE: The unit will not defrost unless the 1. Make sure all the doors are closed and locked.
evaporator coil temperature is below 45 F (7 C).
2. Start the unit if it was shut off to load.
Loading Procedure 3. Make sure the setpoint is at the desired setting.
1. Make sure the unit is Off before opening the 4. One-half hour after loading, defrost the unit
doors to minimize frost accumulation on the by momentarily pressing the Manual Defrost
evaporator coil and heat gain in the truck. switch. If the evaporator coil sensor
(Unit may be running when loading the truck). temperature is below 45 F (7 C), the unit will
defrost. The microprocessor will terminate
2. Spot check and record load temperature while defrost automatically when the evaporator coil
loading. Especially note any off-temperature temperature reaches 52 F (11 C) or the unit
product. has been in the Defrost mode for 30 to 45
3. Load the product so that there is adequate minutes (depending on setting).
space for air circulation completely around the
load. Do not block the evaporator inlet or Post Trip Checks
outlet.
1. Wash the unit.
4. Products should be pre-cooled before loading.
Thermo King units are designed to maintain 2. Check for leaks.
loads at the temperature at which they were 3. Check for loose or missing hardware.
loaded. Transport refrigeration units are not
designed to pull hot loads down to 4. Check for physical damage to the unit.
temperature.
79
80
Electrical Maintenance
Alternator (Prestolite) Charging • The alternator charging output will be low if

System Diagnostic Procedures the alternator belt or pulleys are defective or
the belt is not properly adjusted. Be sure the
General Information belt is not loose or cracked and the pulleys are
the correct size and in good condition.
Poor charging performance may not be caused by
a bad alternator. The following conditions can • The excitation circuit (EXC circuit) must
cause improper battery charging, even with a supply voltage to the EXC terminal of the
good alternator. (See Service Bulletin T&T 388 alternator.
for more information.) • The sense circuit (SENS circuit) must supply
• A problem may exist in the 2A output circuit voltage to the sense terminal of the alternator.
from the alternator to the battery. Check for an • The alternator must be properly grounded.
open 2A circuit, loose connections, defective
battery cables or dirty battery terminals. • The unit control circuits or installed
accessories may be drawing excessive current.
• The battery must be in good condition and
capable of accepting a charge. Check for a • An overcharged battery is usually caused by a
damaged battery, correct electrolyte level, and defective voltage regulator.
loose or corroded connections.
1 3
6 5
AGA219
1. EXC Terminal 5. NEG—B- Terminal

2. F2 Terminal 6. POS—B+ Terminal
3. VOLT SENSE Terminal 7. REG—D+ Terminal
4. AC TAP Terminal
Figure 113: Prestolite Terminal Locations
81
Interface Board Fuse F8 under full unit load conditions. For example, on
multi-temp units, all remote evaporators should be
The Interface Board has a 300 ohm resistor and a
turned on.
resistor bypass fuse (F8) in the alternator
excitation circuit. The fuse and resistor are
connected in parallel and are located on the General Diagnostic and Warranty
interface board Removing the resistor bypass fuse Evaluation Procedure
places the 300 ohm resistor in the excitation Complete the following diagnostic procedures
circuit as required for Bosch and Thermo King before replacing an alternator or the voltage
Powder Coated alternators. Installing the resistor regulator.
bypass fuse removes the 300 ohm resistor from
1. When testing an alternator, use accurate
the excitation circuit as required for Prestolite
equipment such as a Thermo King P/N
alternators. See the specific unit wiring diagram
204-1079 digital multimeter and a Thermo
for exact details.
King P/N 204-947 amp clamp or an
NOTE: The F8 fuse must be installed in the equivalent.
interface board on units equipped with the
Prestolite alternator. If the F8 fuse is not in 2. Make sure the drive belts and pulleys of the
place, the alternator will not charge properly. charging system are in good condition and are
adjusted properly before testing the alternator.
Be sure the pulleys are the correct size. Worn
Test Equipment for Checking belts, loose belts and worn or improperly sized
Voltage and Current pulleys will lower the output of the alternator.
Always use accurate test equipment such as the
3. The battery must be charged and in good
Fluke 23 Digital Multi-Meter and the Fluke
condition, the battery cable connections must
Clamp-On Ammeter accessory when checking
be clean and tight, and the 2A, sense, and
alternator circuit voltage and amperage. See the
excitation circuits must be connected properly.
table below for Thermo King service parts
All charging circuit connections must be clean
numbers. Be sure voltages are measured from the
and secure. If the unit battery is questionable,
designated terminal to the alternator chassis
a known good jumper battery should be
ground. All voltages are DC voltages unless
substituted for alternator testing.
otherwise noted.
NOTE: If the unit battery is questionable, a
Service known good jumper battery should be
Meter Part
Number
substituted for alternator testing.
Fluke 23 Digital Multi-Meter 204-1079 NOTE: Do not perform this test with a
battery charger connected to the unit battery.
Clamp-On Ammeter for above Meter 204-947
NOTE: All voltage readings should be taken
Alternator Load Test between the chassis ground on the alternator
and the terminals indicated, unless stated
Thermo King no longer recommends a full field otherwise.
test for determining the alternator current output.
Full fielding an alternator can cause increases in 4. Check that the resistor bypass fuse (F8) is
alternator output voltage that may damage internal installed on the interface board. Units with
alternator or unit components. This damage may Prestolite alternators must have the resistor
not be readily apparent. bypass fuse (F8) installed for the alternator to
charge properly.
To test the alternator under load, Thermo King
recommends the use of a clamp-on ammeter to
monitor output current, both on initial startup and
82
A positive reading indicates the alternator is

CAUTION: Energizing the circuit with
charging. On unit startup, the current flow
the resistor bypass fuse installed will
should momentarily increase to allow for
damage Bosch and Thermo King Powder
battery current used during preheat and
Coated alternators. Be sure the resistor
cranking. Within a short time the current
bypass fuse is removed with Bosch and
should fall to normal unit load plus charge
Thermo King Powder Coated alternators.
current to the unit battery (typically 5-10
Be sure the resistor bypass fuse is installed
amps).
with Prestolite alternators.
A reading on the clamp-on ammeter at or near
5. Check and note the battery voltage at the
0 amps indicates the alternator is not charging.
battery with the unit turned off.
Checking the unit ammeter will show a
6. With the unit off, check the voltage at the B+ discharge condition. The alternator is
(POS) terminal on the alternator. Battery defective if there are no problems in the
voltage must be present. If not, check the 2A wiring. Recheck the wiring before assuming
circuit. the alternator is defective.
7. Disconnect the EXC and SENS wires in 15. Check the voltage at the B+ (POS) terminal.
interface harness from the voltage regulator. The voltage should increase until it reaches
the anticipated voltage regulator setting as
8. Turn the unit on and enter Non-Running
shown in the table below. Record the voltage.
Service Test Mode. Place the unit in Zone 1
High Speed Cool. Refer to the SPECTRUM The voltage regulator setting varies inversely
TS Microprocessor Diagnostic Manual for with the temperature as shown below.
information about the Service Test Mode. Regulator voltage can vary from
approximately 15.2 Vdc at -40 F (-40 C) to
9. Check the voltage at the sense circuit (SENS
approximately 13.2 Vdc at 176 F (80 C).
circuit). Battery voltage should be present. If
not, check the SENS circuit in the interface Temperature Anticipated Regulator Voltage
harness.
-40 F (-40 C) From 15.2 Vdc to 14.0 Vdc
10. Check the voltage at the excitation circuit 77 F (25 C) From 14.4 Vdc to 13.6 Vdc
(EXC circuit). 10 Vdc or more should be
176 F (80 C) From 14.2 Vdc to 13.2 Vdc
present. If not, check the excitation circuit
(EXC circuit) in the interface harness and
check that the K1 relay is closing. If the voltage does not increase to the
anticipated voltage regulator setting, the
11. Turn the unit off and reconnect the EXC and alternator is defective if there are no problems
SENS wires. in the wiring. Recheck the wiring before
12. Attach a clamp-on ammeter around the 2A replacing the alternator.
wire connected to the B+ (POS) terminal on 16. If the voltage does increase until it reaches the
the alternator. All wires connected to the B+ anticipated voltage regulator setting, compare
(POS) terminal must pass thru the clamp-on the voltage at the B+ (POS) terminal to the
ammeter. voltage between the battery terminals. The
13. Connect a digital multi-meter between the B+ voltage at the B+ (POS) terminal should be no
(POS) terminal at the alternator and chassis more than 1.0 Vdc higher than the voltage
ground. between the battery terminals.
14. Turn the unit on and allow it to start. Using the If the voltage at the B+ (POS) terminal is no
clamp-on ammeter, check the current flow in more than 1.0 Vdc higher than the voltage
the 2A wire. between the battery terminals, continue with
Step 17.
83
If the voltage at the B+ (POS) terminal is This should reduce the voltage to the battery by
more than 1.0 Vdc higher than the voltage 0.2 to 0.3 of a volt.
between the battery terminals, clean and check
the wires and connections in the 2A and 2 Battery
circuits and repeat this check.
NOTE: The Microprocessor Power switch must
17. Increase the charging system load as much as be placed in the Off position before connecting
possible by running run all zones. or disconnecting the battery terminals. The
18. Monitor the alternator output voltage. Microprocessor Power switch is located on the
control box side of the unit.
With the increased load, the alternator output
voltage should decrease no more than 0.5 Vdc. Inspect/clean the battery terminals and check the
The voltage may increase as much as 1.0 Vdc. electrolyte level during scheduled maintenance
If the alternator output voltage decreases no inspections. A dead or low battery can be the
more than 0.5 Vdc the alternator is good. cause of an ammeter indicating discharge due to
lack of initial excitation of the alternator even
If the alternator output voltage decreases more after the unit has been boosted for starting. The
than 0.5 Vdc, the alternator is defective if minimum specific gravity should be 1.235. Add
there are no problems in the wiring. Recheck distilled water as necessary to maintain the proper
the wiring before replacing the alternator. water level.
Alternator Diode Quick Check:
This check confirms proper diode function. Unit Wiring

19. With the unit still running, set the digital Inspect the unit wiring and the wire harnesses
multi-meter connected from the alternator B+ during scheduled maintenance inspections for
output to chassis ground for AC volts. No loose, chafed or broken wires to protect against
more than 1.0 Vac should be present. A unit malfunctions due to open or short circuits.
reading of more than 1.0 Vac indicates
damaged alternator diodes. Electrical Contacts
20. Turn the unit off. Inspect all relay contacts for pitting or corrosion
every 1,000 operating hours, and repair or replace
Excessive Voltage Output as necessary.
12 Volt Alternators With Internal Regular Setting:

Charging System (12 Vdc)
When a Thermo King unit is installed on a truck,
it is often connected to a truck battery. When both Immediately after start-up, the voltmeter may
the Thermo King unit and the truck engine are show a low voltage condition on systems with
running on the truck battery, the charging system brush type alternators. This is due to a light film
with the higher voltage may automatically turn off build-up on the alternator slip rings. The film
the charging system with the lower voltage build-up occurs primarily on units that have been
output. sitting unused for long periods of time. The film
should disappear after a minute or two, and the
If it is determined that the Thermo King regulator voltmeter should show a high voltage that will
setting is higher than the truck charging system or continue until the battery voltage is brought back
the batteries are consuming more water than up to normal. If the voltmeter shows low voltage
normal the following solution may help solve the after start-up, check the alternator belt tension and
problem. all charging circuit connections including the
• Remove the wire labeled SENSE and tape off. battery.
• Add a jumper wire from 2A to the SENSE

terminal on the back of the alternator.
84
NOTE: On installations where the unit is

connected to the truck battery and both units are
running—it is normal for the unit to indicate a
discharge condition while the truck engine is
running because of the truck’s higher voltage
charge rate.
Preheat Buzzer Figure 114: Flywheel (RPM) Sensor
The preheat buzzer module on the circuit board is 2. Disconnect wires RPM+ and RPM- from the
designed to indicate preheat is in operation. sensor.
RPM Sensor
The RPM sensor is in the engine bell housing
adjacent to, but not touching, the flywheel
(backed off 1/4 turn).
The RPM sensor is a device containing an Figure 115: RPM+ and RPM- Wires
inductance coil and magnet. When the magnetic 3. Place the unit in Continuous Run. Run the unit
field is distorted by the passing ring gear teeth, the on low speed and high speed. Check the AC
inductance coil generates an ac electrical signal voltage output across the sensor terminals.
that has a voltage and frequency variation Use a meter with a high ohms per volt internal
proportional to the engine RPM. resistance. A Simpson 260, Fluke digital or
By monitoring the frequency of this signal with any good VOM will work. However, an
the microprocessor, the timing of the starter automotive type meter may not give an
disengagement can be precisely controlled. accurate reading because the meter may load
the circuit heavily and cause the voltage level
If the RPM sensor fails, the starter may not to appear lower than it actually is.
disengage or engage properly and a fault code will
be generated to the microprocessor. a. The output voltage should be 1.0 to
2.0 Vac on low speed.
Testing the RPM Sensor:
b. The output voltage should be 2.0 to
The following equipment is required: 2.5 Vac on high speed.
• AC voltmeter capable of reading up to 10 NOTE: If the voltage is slightly off, the
volts voltage may be increased by turning the
• Ohmmeter sensor in more, and the voltage may be
lowered by turning the sensor out more.
The flywheel (RPM) sensor may be checked as
follows: 4. Reconnect RPM+ and RPM- wires on RPM
sensor.
1. Install the flywheel (RPM) sensor into the
flywheel; bracket of the start-stop unit until it If the RPM sensor passes the above test, the
contacts the ring gear. Back out the sensor 1/4 sensor may be considered good.
turn and tighten the locknut. If the unit is not available, an alternate less
reliable test may be performed as follows:
Disconnect the sensor from all wires, and measure
the resistance across the terminals and from each
terminal to the aluminum case. The resistance
85
should be 250 to 300 ohms across the terminals, NOTE: The cylinder head cover must be
and there should be no continuity from each removed to access the glow plugs on the TK376
terminal to the case. engine.
A shorted glow plug will show excessive current
Glow Plugs draw (more than 12 amps) during preheat. When
Glow plugs heat the combustion chamber to aid in fuse F6 (40 A) is blown, check each glow plug.
quick starting. The glow plugs are energized when
the microprocessor initiates unit start-up. A Condenser Fan Rotation
defective glow plug (burned out) can be detected (Electric Standby Operation)
by placing an external ammeter in series with the
plugs. Normal current draw during preheat is The condenser fan is belt driven. On electric
approximately 21 to 25 amps for the TK 3.95 standby operation, check for correct fan rotation
engine, or 11 to 13 amps for the TK376 engine. A by placing a small cloth or sheet of paper against
current draw in this range means all three glow the condenser fan grille on the front of the unit.
plugs are working. If the current draw during Correct rotation will hold the cloth or paper
preheat is less this, at least one glow plug is bad. against the grille. Improper rotation will blow the
cloth or paper away from the grille. To correct
To isolate an open circuit glow plug, remove the check motor and motor contactor wiring as per
jumper bar or wires and test each glow plug wiring diagram.
individually with an ohmmeter or a jumper wire
and ammeter. Each glow plug should have a
resistance of approximately 1.5 ohms for the
Phase Detect Module for Truck
TK 3.95 engine, or 2.3 ohms for the TK376 Unit Model 50 Applications
engine. The current draw for each glow plug The new phase detect module is designed to
should be approximately 8.3 amps for the TK 3.95 monitor both single and 3 phase voltages from
engine, or 4.3 amps for the TK376 engine. 160 volts AC thru 510 volts AC.
2
Brown
1
THERMO KING
9131C98G06
Blue L1
L2 0202
3 Black
L3
AJA1501
5 Operation
4 The Phase Detection Module will detect missing
1. Remove Bar or Wires phases, phase rotation and low voltage on three
phase or single phase power. The brown, blue and
2. 21 to 25 Amps for TK 3.95 Engine
black wires are used to sample the power at L1,
11 to 13 Amps for TK376 Engine
L2 and L3 respectively. Operating power from 12
3. 8.3 Amps for TK 3.95 Engine to 24 volts is supplied to the module via the #8
4.3 Amps for TK376 Engine
wire and CH wire.
4. Ohmmeter
When the voltage sensed rises above 180 volts
5. 1.5 Ohms for TK 3.95 Engine AC and all three phases are present the module
2.3 Ohms for TK376 Engine
ER wire will output 12-24 volts DC after the
Figure 116: Glow Plug Test conditions exist for 2 to 4 seconds. This signal
informs the microprocessor that electric standby
operation is possible. If the voltage drops below
86
160 volts AC or a phase is lost, the ER output is Outputs

turned off after the condition exists for 8 to 10
seconds. The module continues to monitor the Output Description
power and the module ER wire will again output 7EB If phase rotation is L1, L2, L3 then this
12-24 volts DC within 2 to 4 seconds after the wire will provide either a chassis ground
voltage rises above 180 volts AC and all three or 12-24 volts DC to energize the
appropriate phase rotation contactor.
phases are present. The 7EC wire is interlocked to prevent
If phase rotation is L1, L2, L3 the 7EB wire will both phase contactors from being
energized at once.
output the 7EA voltage to energize the appropriate
phase rotation contactor. If phase rotation is L1, 7EC If phase rotation is L1, L3, L2 then this
L3, L2 the 7EC wire will output the 7EA voltage wire will provide either a chassis ground
or 12-24 volts DC to energize the
to energize the appropriate phase rotation
appropriate phase rotation contactor.
contactor. The 7EB and 7EC wires are interlocked The 7EB wire is interlocked to prevent
to prevent both phase contactors from being both phase contactors from being
energized at once. energized at once.
If the unit printed circuit board jumper J500 is set ER This wire will output 12-24 volts DC 2 to
to single phase or the SP input is grounded, the 4 seconds after the voltage rises above
180 volts AC and all three phases are
module will now be set for single-phase present. If the voltage drops below 160
operation. In this case only the Brown and Blue volts AC or a phase is lost and the
wires are used and the Black wire is taped off. condition remains for 8 to 10 seconds,
the output is turned off. The module
Connections to the module are shown in the tables continues to monitor and will again
below. output 12-24 volts DC 2 to 4 seconds
after the power returns to normal
Power Connections
(voltage rises above 180 volts AC and
Input Description all three phases are present).
8 Nominal 12-24 volt DC power to the phase

Connector Pinout
detect module.
CH Chassis ground Pin Wire Description
1 8 Power to Module
Inputs
2 CH Chassis ground
Input Description 3 ER AC Power OK
L1 This brown wire supplies standby power L1 4 7EA Power or ground input for 7EB or
to the phase detect module. 7EC output
L2 This blue wire supplies standby power L2 to 5 7EB Phase A-B-C
the phase detect module.
6 7EC Phase A-C-B
L3 This black wire supplies standby power L3
to the phase detect module. 7 SP-GRND Internal ground to enable a
jumper circuit for SP logic
7EA If grounded, then outputs 7EB and 7EC are
grounding circuits. If 12-24 volts DC is 8 SP Grounded for single phase mode
supplied, then outputs 7EB and 7EC will be 9 Unused
at 12-24 volts DC
SP If this wire is connected to chassis ground
the module will operate in single-phase
mode.
SP-GR This is an internal ground for the module. If
ND SP-GRND is jumpered to SP then the
module will be set to operate on single
phase.
87
Removal and Replacement Diagnostics - Truck SPECTRUM™ TS

Applications
Procedure
1. Plug the standby power cord into a know good
1. Turn unit off. power supply and turn the unit on.
2. Disconnect the unit battery. 2. Using a Fluke Meter, test the L1, L2, and L3
circuits at the input to the terminals where the
3. Disconnect the standby power.
Brown, Blue and Black wires are connected.
4. Remove the high voltage cover. The voltage should be between 200-500 VAC
between the circuits. If not, repair as necessary
5. Disconnect the three wires from the phase
to supply the needed voltage to the unit.
detect module at the motor contactor.
3. Check the 8 circuit to the Phase Detect
6. Unplug the phase detect module harness.
Module for 12-24 Vdc. If voltage is not
7. Remove the old phase detect module. present, check the Phase Select Module
connector and the Interface Board connector
8. Install the new phase detect module.
for secure connections.
9. (3 Phase Applications) Connect the new phase
4. If correct AC power is present in test #2
detect module wires to the upper contactor as
above, then the ER output should measure
follows:
12-24 Vdc. If no voltage is present, replace the
Connect the brown wire to L1 on the Phase Detector Module.
contactor.
5. If voltage is present on the ER output, then the
Connect the blue wire to L2 on the contactor. D/E LED on the Interface Board should be on.
If not, check the Diesel/Electric Relay circuit
Connect the black wire to L3 on the contactor.
on the Interface Board.
Use crimp-on terminals as required.
6. If voltage is measured on the ER output, and
10. (Single Phase Applications) Connect the new the D/E LED is on, then the 7EA input should
phase detect module wires to the upper measure 12-24 Vdc. If voltage is not present,
contactor as follows: check the Phase Select Module connector and
the Interface Board connector for secure
Connect the brown wire to L1 on the
connections.
contactor.
7. If voltage is present on the ER output and the
Connect the blue wire to L2 on the contactor.
7EA input, and the D/E LED is on, then either
Use crimp-on terminals as required. the 7EB or 7EC output should measure 12-24
Vdc and one of the phase select contactors
Tape the black wire back onto itself. It is not
should be on. If voltage is not present on
used on single-phase installations.
either the 7EB or 7EC output, replace the
11. Connect the plug on the short harness from the Phase Select Module.
phase detect module.
12. Install the high voltage cover.
13. Secure wires and wire harnesses as required
using cable ties.
14. Connect the unit battery.
15. Perform a Unit Self Check test to verify
proper operation.
88
Overload Relay 1
The overload relay protects the standby electric
motor. It is located on the high voltage tray (see
Figure 30 on page 58). The overload relay opens
the circuit to the electric motor if the current
exceeds the overload relay setting. The overload
relay resets automatically.
2
1
2
1. Set Opening Amperage

2. Set to “Aut” (Automatic Reset)
Figure 118: Setting Overload Relay
The new overload relay is now set up correctly.

Note which wires go to which terminals when
removing the old overload relay so the wires are
connected correctly when the new overload relay
1. Overload Relay is installed.
2. Overload Relay Adaptor
Figure 117: Overload Relay
Overload Relay Replacement

When the overload relay is replaced, the new
overload relay must be set up to open at the
correct amperage and reset automatically. See the
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).
89
90
Engine Maintenance
Engine Change EMI 2000

In the first quarter of 2005 the engines in these EMI 2000 is an extended maintenance interval
units changed from a TK 3.95 to a TK376 to meet package. The EMI 2000 package consists of the
EPA Tier 2 requirements. following key components:
The TK 3.95 is an EPA Tier 1 engine. • New EMI 2000-Hour Cyclonic Air Cleaner
Assembly and Air Cleaner Element (Standard
The TK376 is an EPA Tier 2 engine.
equipment on all TS units)
The most noticeable difference is that the valve
• New EMI 2000-Hour Fuel Filter (black with
cover and intake manifold are separate on the
gold lettering)
TK 3.95, but are an assembly on the TK376 (see
the following illustrations). • 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 inspection in
accordance with Thermo King's maintenance
recommendations.
Figure 119: TK 3.95 (Tier 1)
Engine Lubrication System
The engine has a pressure lubrication system. See
the appropriate Engine Overhaul Manual for a
detailed description of the engine lubrication
system.
Oil pressure is affected by oil temperature,
viscosity and engine speed. Subnormal oil
pressures usually may be traced to lack of oil,
faulty relief valve or worn bearings. The use of
improper viscosity oil will also produce low oil
pressure shutdowns.
Figure 120: TK376 (Tier 2)
91
Engine Maintenance
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 of new filter and
install filter.
3. Tighten the filter until the rubber ring makes
contact, then tighten 1/2 turn more.
AJA1521
Figure 121: Engine Oil Pressure Switch
Engine Oil Pressure Switch

Engine oil pressure switch should rise
immediately on starting. If engine oil pressure
drops below 10 ± 2 psig (69 ± 14 kPa), the switch
closes and signals the microprocessor to stop the 1. Spin-on Oil Filter
engine. See SPECTRUM™ TS Microprocessor 2. Pressure Valve Nut
Controller Diagnostic Manual. 3. Oil Pressure Valve
Figure 122: Oil Filter Parts

Engine Oil Change
The engine oil should be changed according to the Crankcase Breather
“Maintenance Inspection Schedule”. Drain the oil
only when the engine is hot to ensure that all the The crankcase breather system ducts crankcase
oil drains out. When changing oil, try to make gases formed in the crankcase directly to the
sure that the truck is not tipped away from the intake manifold. Harmful vapors that would
direction that the oil is supposed to flow from the otherwise collect in the crankcase and
oil pan. It is important to get as much of the contaminate the oil or escape to the outside, are
residual oil out as possible because most of the now drawn back into the engine and burned. The
dirt particles are in the last few quarts of oil to breather hose between the valve cover and the
drain out. Refill the pan with oil (see the intake manifold on the TK 3.95 engine should be
“Specifications” chapter) and check the dipstick inspected yearly to make sure it is not plugged.
level. Run the unit, and then recheck the oil level. The TK376 engine does not use a breather hose
because the valve cover and the intake manifold
NOTE: Fill the crankcase slowly so oil will not are combined in an assembly.
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.
92
Engine Maintenance
Engine Air Cleaner (EMI 2000)

The EMI 2000 air cleaner used with this unit is a 1
dry element air cleaner. The air cleaner filters all
of the air entering the engine. Excessive
restriction 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 2
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
93
Engine Maintenance
Engine Cooling System All water-cooled engines are shipped from the
factory with a mixture of 50 percent permanent
General Description type antifreeze concentrate and 50 percent water
in the engine cooling system.
The engine employs a closed, circulating type,
pressurized cooling system. Correct engine This provides the following:
temperatures are controlled and maintained by a 1. Prevents freezing down to -30 F (-34 C).
radiator, fan and thermostat. The coolant is
circulated through the system by a belt-driven 2. Retards rust and mineral scale that can cause
centrifugal pump. The pump draws the coolant engine overheating.
from the side of the radiator (large header), 3. Retards corrosion (acid) that can attack
circulates it through the cylinder block and head, accumulator tanks, water tubes, radiators and
then back to the radiator. A thermostat mounted in core plugs.
the water outlet from the cylinder head to the
radiator automatically maintains coolant 4. Provides lubrication for the water pump seal.
temperature within the specified temperature
range.
5
4
2
1
8 7 AJA594
6
1. Engine 5. Radiator
2. Water Temperature Sensor 6. Drain Tubing
3. Expansion Tank 7. Drain Cock Adaptor
4. Water Level Sensors 8. Drain Cock
Figure 124: TK 3.95 Engine Cooling Components
94
Engine Maintenance
7
6
5
2
4
1
8
10
9
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
95
Engine Maintenance
ELC (Extended Life Coolant)

CAUTION: Do not add Green or
ELC has been phased into these units as of the
Blue-Green, conventional coolant to
first quarter of 2001. The maintenance interval for
cooling systems using Red, Extended Life
ELC is 5 years or 12,000 hours. A nameplate on
Coolant, except in an emergency. If
the coolant expansion tank identifies units with
conventional coolant is added to Extended
ELC.
Life Coolant, the coolant must be changed
NOTE: The new engine coolant, Texaco after 2 years instead of 5 years.
Extended Life Coolant, is Red in color instead of
NOTE: The use of 50/50 percent pre-mixed
the current Green or Blue-Green colored
Extended Life Coolant (ELC) is recommended to
coolants.
assure that de-ionized water is being used. If
100 percent full strength concentrate is used,
de-ionized or distilled 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
changes were made as of TK 3.95 engine serial
number K19855.
Units with engine serial numbers K19855 and
after can be changed over to ELC coolant. The
cooling system must be flushed until all traces of
Figure 126: ELC Nameplate green or blue-green coolant dye are gone, and the
Located On Expansion Tank
discharge fluid (water) is clear. The system can
The following are the Extended Life Coolants then be filled with extended life coolant (ELC).
currently approved by Thermo King for use in Units with engine serial numbers before K19855
ELC units for five years or 12,000 hours: must have the water pump replaced to change
• Chevron Dex-Cool over to ELC coolant. See Service Bulletin
T&T 275 for information about retrofitting the
• Texaco ELC (nitrite free) new water pump.
• Havoline Dex-Cool (nitrite free)
• Havoline Dex-Cool (nitrite free)
• Shell Dexcool
• Shell Rotella
• Havoline XLC (Europe)
• Saturn/General Motors Dex-Cool
• Caterpillar ELC
• Detroit Diesel POWERCOOL Plus
96
Engine Maintenance
Antifreeze Maintenance Procedures b. Close the drain cock and install a

commercially available radiator and block
As with all equipment containing antifreeze,
flushing agent, and operate the unit in
periodic inspection on a regular basis is required
accordance with instructions of the
to verify the condition of the antifreeze. Inhibitors
flushing agent manufacturer.
become worn out and must be replaced by
changing the antifreeze. Change green or c. Open the drain cock to drain water and
blue-green engine coolant every two years. flushing solution.
Change ELC (red) engine coolant every five years
or 12,000 hours (whichever occurs first). CAUTION: Avoid direct contact with hot
Do not mix green or blue-green engine coolant coolant.
with ELC (red) engine coolant. See “ELC
3. Run clear water into the radiator, and allow it
(Extended Life Coolant)” on page 96 for more
to drain out of the drain cock until it is clear.
information about ELC.
When water has finished draining, close drain
The factory recommends the use of a 50/50 cock.
percent antifreeze mixture in all units even if they
4. Inspect all the hoses for deterioration and the
are not exposed to freezing temperatures. This
hose clamp tightness. Replace if necessary.
antifreeze mixture will provide the required
corrosion protection and lubrication for the water 5. Loosen the water pump belt. Check the water
pump. pump bearing for looseness.
6. Inspect the radiator cap. Replace the cap if the
Checking the Antifreeze
gasket shows any signs of deterioration.
Check the solution concentration by using a
7. Mix one gallon of the appropriate permanent
temperature compensated antifreeze hydrometer
type antifreeze concentrate and one gallon
or a refractometer designed for testing antifreeze.
clean water in a container to make a 50/50
Maintain a minimum of 50 percent permanent
mixture. (Do not add antifreeze and then add
type antifreeze concentrate and 50 percent water
water to the unit. This procedure may not give
solution to provide protection to -30 F (-34 C). Do
a true 50/50 mixture because the exact cooling
not mix antifreeze stronger than 68 percent
system capacity may not always be known).
permanent type coolant concentrate and 32
percent water for use in extreme temperatures. 8. Refill the radiator with the 50/50 mixture.
Changing the Antifreeze Bleeding the Cooling System

1. Run the engine until it is up to operating After filling the radiator, run the unit up to
temperature. Stop the unit. operating temperature to check for overheating
and coolant level and allow the air to be purged
2. Open the drain cock (see Figure 124 on page
for a few minutes.
94 or Figure 125 on page 95) and completely
drain coolant. Observe coolant color. If the
coolant is dirty, proceed with a, b, and c. CAUTION: Do not remove the radiator
Otherwise go to step 3. cap while the engine is hot.
CAUTION: Avoid direct contact with hot

coolant.
a. Run clear water into radiator and allow it

to drain out of the drain cock until it is
clear.
97
Engine Maintenance
Engine Thermostat Engine Fuel System

For the best engine operation, use a 180 F (82 C) The fuel system used on these diesel engines is a
thermostat year round. high pressure system used in conjunction with a
prechamber.
The components of the fuel system are:
• Fuel tank (may be the truck fuel tank)
1
• Electric Fuel pump
2 • Fuel filter
• Injection pump
3
• Injection nozzles.
A 10 psig (69 kPa) electric fuel pump pulls fuel
4 from the fuel tank through a fuel pump filter, then
pushes it to the fuel filter, and to the injection
pump. The prefilter is designed for diesel fuel and
is the only type that should be used.
5 The injection pump raises the pressure of the fuel
and meters the correct amount of fuel to 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.
1. Thermostat Housing
2. Gasket The most common cause of fuel system problems
is contamination. It cannot be stressed enough that
3. Thermostat
the fuel must be clean, fuel tanks must be free
4. Gasket
from contaminants, and the fuel filter must be
5. Water Pump changed regularly. Any time that the fuel system
Figure 127: Water Pump Assembly and Thermostat is opened up, all possible precautions must be
taken to keep dirt from entering the system. This
means all fuel lines should be capped when open.
The work should be done in a relatively clean
area, if possible, and the work should be
completed in the shortest time possible.
98
Engine Maintenance
Thermo King recommends that any major 1

injection pump or nozzle repairs be done by a
quality diesel injection service specialty shop. The 2
investment in equipment and facilities to service
these components is quite high. Therefore, this
equipment is not found in most repair shops.
The following procedures can be done under field
conditions:
• Bleeding air from the fuel system.
• Maintenance involving the fuel tank and filter
system.
• Speed and governor adjustments. 1. Injector Line 2. Bleeder Screw
Figure 129: TK376 Injection Pump
• Electric transfer pump replacement or repair
(10 psig [69 kPa] pump with diesel filter). 2. Turn on the electric fuel pump. The electric
• Injection line replacement. fuel pump is energized when the ON key is
pushed. Tighten the bleeder screw on the
• Pump timing. injection pump when clear flow of fuel
• Nozzle spray pattern testing and adjustment. appears.
• Minor rebuilding of nozzles. NOTE: At initial start-up, open the bleeder

screw at the injection pump and bleed fuel
Bleeding the Fuel System until a clear flow is noted.
The fuel system will have to have the air bled out 3. Loosen the injector lines on the injection
if the engine runs out of fuel, if repairs are made nozzles.
to the fuel system, or air gets into the system for 4. Crank the engine until fuel appears at the
any other reason. nozzles. Tighten the injector lines, and start
NOTE: MAKE SURE to keep the fuel tank vent the engine.
open. If the vent becomes clogged, a partial NOTE: Fuel will not appear at the nozzles by
vacuum develops in the tank, and this increases merely running the electric pump. The
the tendency for air to enter the system. engine must be cranked.
Proceed as follows:
1. Loosen the bleeder screw on the inlet fuel
fitting of the injection pump.
1
1. Injector Line 2. Bleeder Screw

Figure 128: TK 3.95 Injection Pump
99
Engine Maintenance
Figure 130: Early TK 3.95 Fuel and Oil System Components
100
Engine Maintenance
1. Elbow—hose fitting (3/8) 26. Lockwasher

2. Kit—sleeve & eyelet (3/8) 27. Flatwasher
3. Nut (3/8) Washer (nylon)
4. Hose (3/8 od x 35 ft lg) 28. Sensor—oil pressure
5. Not Used Nut—sensor
6. Kit—sleeve & eyelet (1/4) Lockwasher
7. Nut (1/4) Flatwasher
8. Elbow 29. Fitting—engine (3.0 in. lg)
9. Hose 30. Pump—fuel (12V)
10. Elbow Pump—fuel (24V)
11. Tee Kit—filter
12. Plug Gasket—fuel pump
13. Filter—fuel 31. Bushing
Filter—fuel (EMI 2000) 32. Fitting—restricted
Adapter—fuel pickup 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)
Hose—oil drain (23 in.) 40. Valve (after 2/97)
21. Elbow—oil drain Body (after 2/97)
22. Tee Valve (after 2/97)
23. Mat—isolator (oil pressure sensor) Cap (after 2/97)
24. Elbow—flange 41. Body—fitting (after 2/97)
25. Screw—elbow
Early TK 3.95 Fuel and Oil System Components for Figure 130
101
Engine Maintenance
Figure 131: Late TK 3.95 Fuel and Oil System Components
102
Engine Maintenance
1. Elbow—hose fitting (3/8) 26. Lockwasher

2. Kit—sleeve & eyelet (3/8) 27. Flatwasher
3. Nut (3/8) Washer (nylon)
4. Hose (3/8 od x 35 ft lg) 28. Sensor—oil pressure
5. Not Used Nut—sensor
6. Kit—sleeve & eyelet (1/4) Lockwasher
7. Nut (1/4) Flatwasher
8. Elbow 29. Fitting—engine (3.0 in. lg)
9. Hose 30. Pump—fuel (12V)
10. Elbow Pump—fuel (24V)
11. Tee Kit—filter
12. Plug Gasket—fuel pump
13. Filter—fuel 31. Bushing
Filter—fuel (EMI 2000) 32. Fitting—restricted
Adapter—fuel pickup 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)
Hose—oil drain (23 in.) 40. Valve (after 2/97)
21. Elbow—oil drain Body (after 2/97)
22. Tee Valve (after 2/97)
23. Mat—isolator (oil pressure sensor) Cap (after 2/97)
24. Elbow—flange 41. Body—fitting (after 2/97)
25. Screw—elbow
Late TK 3.95 Fuel and Oil System Components for Figure 131
103
Engine Maintenance
Figure 132: TK376 Fuel and Oil System Components
104
Engine Maintenance
1. Elbow—hose fitting (3/8) 18. Filter—oil bypass (EMI 2000)

2. Kit—sleeve & eyelet (3/8) 19. Stud—bypass filter
3. Nut (3/8) 20. Filter—oil (full flow)
4. Hose (3/8 od x 35 ft lg) 21. Tee
5. Adapter—oil line 22. Switch—oil pressure
6. Kit—sleeve & eyelet (1/4) 23. Bushing
7. Nut (1/4) 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. Plug—pipe 32. Tube—fuel pickup
TK376 Fuel and Oil System Components for Figure 132
105
Engine Maintenance
Draining Water from Fuel Tank Electric Fuel Pump

Water run through the system may damage the
Operation
injection pump or nozzles. Damage to the fuel
system will subsequently cause more expensive The electric fuel pump must be mounted next to
damage to the engine. A large accumulation of the fuel tank. This pump is designed to push rather
water in the bottom of the fuel tank will stop a than pull fuel.
diesel engine. Water should be drained off during
Make sure the pump completes a good ground
scheduled maintenance inspections to prevent
with the battery. The pump will not operate at less
breakdowns. Drain the water off after the fuel
than 9 Vdc. The pump is self priming as long as it
tank and unit have remained idle for an hour.
is not higher than 30 in. (762 mm) from the fuel in
1. Place a container under the fuel tank to catch the fuel tank.
the draining water and fuel.
2. Remove the drain plug from the bottom of the
fuel tank.
NOTE: Some fuel tanks have a check valve
in the drain plug fitting. Push the check
valve open with a small screw driver to drain
the tank.
3. Let the water and fuel drain into the container
until no water is visible in the fuel draining
from the tank. If the water and fuel do not
drain freely, the vent may be plugged. If so,
clean or replace the vent. 1. Filter
4. Install the drain plug. 2. Gasket

3. Cover
Fuel Filter Replacement 4. Screw (3)
Replace the fuel filter at intervals according to the 5. Magnet
Maintenance Inspection Schedule.
Figure 133: Electric Fuel Pump
1. Remove the filter and discard.
Maintenance
2. Lubricate rubber ring of new filter with fuel.
Field service is limited to cleaning the bottom
3. Install the filter and tighten until the filter is cover and filter. The filter and cover gasket are
slightly loose (rubber ring not making replaceable.
contact).
4. Bleed the air from the filter by operating the Disassembly
electric pump until fuel bubbles appear at the 1. Remove the three screws from the cover.
top of filter.
2. Remove the filter, cover and cover gasket.
5. Tighten the filter until the rubber ring makes Wash the filter in cleaning solvent and blow
contact, then tighten 1/2 turn more. out the dirt and cleaning solvent with
compressed air. Check the cover gasket and
replace if damaged. Clean the cover.
106
Engine Maintenance
Reassembly Injection Pump Timing

Place the cover gasket on the bottom cover and TK 3.95 Engine
install the filter and cover assembly. Replace the There are two different types of timing procedures
three screws. used on the TK 3.95 engine. One procedure
involves checking to make sure the cylinders are
If pump does not operate, check for: timed correctly to each other, and the other
procedure times the injection pump correctly to
1. The ground to the frame of the unit.
the engine. If the cylinders are not timed correctly
2. Clean and tighten electrical connections. to each other, it is of no value to time the injection
pump to the engine because one or two of the
3. The pump voltage and polarity. It must be the
three cylinders would be out of time. The
same as the unit system.
individual plungers in the injection pump are
timed to each other by the use of spacers in the
If pump operates but does not deliver fuel,
pump plunger base. It is rare that an injection
check for:
pump would change individual cylinder timing
1. Air leaks in the fuel lines or connections. unless it had been through some type of repair
process, but if all other possible problems with a
2. Kinked fuel lines or other restrictions in the
rough running engine have been checked, and
line.
especially if the engine’s injection pump has been
3. A leaking or distorted cover gasket. replaced or repaired recently, it may be
beneficial to check individual cylinder timing.
4. A dirty filter.
Because the possibility of incorrect individual
5. A stuck seat in the outlet fitting. cylinder timing is so minimal, the procedure for
timing the pump to the engine will be covered
Injection Pump first. The procedure for individual cylinder timing
is very similar to timing the injection pump so it
Injection Pump Adjustments will be covered last.
When the diesel engine fails to maintain the
correct engine speed, check the following before CAUTION: The cylinders on the engine
adjusting the speed: are numbered from the flywheel end to the
water pump end. The number 1 cylinder is
1. Check the prefilter screen. Recheck the speed. next to the flywheel. The number 2
2. Bleed air out of the fuel system. Recheck the cylinder is the center cylinder. The
speed. number 3 cylinder is next to the water
pump. The timing marks on the flywheel
3. Bleed air out of the nozzles. Recheck the are matched to this system.
speed.
4. Operation of electric transfer pump.
Make the engine speed adjustments with the
engine fully warmed up.
The unit has one solenoid to control the high
speed function. The speed of the engine should be
checked with the use of a stroboscope tachometer
(see Tool Catalog).
107
Engine Maintenance
1. TDC Mark 4. File V-Notch Here

2. Injection Timing Mark 5. Timing Mark
3. Round Notch
Figure 134: Timing Marks
1. Rotate the engine in the direction of rotation The timing mark on the starter mounting
(clockwise as viewed from the water pump plate is a line stamped on the side of the plate
end) until the number 1 cylinder (closest to facing the flywheel. To locate the timing
flywheel) is at approximately top dead center mark, feel the back side of the plate 0.4 in.
of the compression stroke. The valve cover (10 mm) below the center of round notch in
should be removed to identify the the edge of the plate. To make it easier to
compression stroke. Both rocker arms of the align the timing marks, file a V-notch in the
number 1 cylinder will be loose. Check to see edge of the plate in line with the timing mark
that the number 1 cylinder top dead center on the plate.
mark on the flywheel is aligned with the
2. Remove the injection line from the number 1
timing mark on the starter mounting plate.
injector and the injection pump. Remove the
NOTE: The timing marks for each of the delivery valve holder, delivery valve and
three cylinders are stamped 120 degrees spring. Care must be taken to prevent dirt
apart. Top dead center marks are identified from entering the fuel injection system.
by the number of the cylinder stamped next Replace the delivery valve holder and delivery
to them. Injection timing marks are valve.
unmarked. The timing marks on the engine
3. Install a drip valve on the nozzle holder.
can be difficult to align. This is because the
timing mark on the starter mounting plate is 4. Activate the fuel solenoid and the fuel pump
near the air cleaner, on the side of the plates by energizing the run relay using the Interface
that faces the flywheel. It cannot be seen Board Test mode. Make sure the
when looking through the engine side door Diesel/Electric switch is in the Diesel
opening unless you use a mirror. position. See the SPECTRUM TS
Microprocessor Diagnostic Manual, for
information about the Interface Board Test
mode.
108
Engine Maintenance
CAUTION: The 8S wire on the starter Timing Individual Cylinder Injection

motor should be disconnected. TK 3.95 Engine
This procedure should be used when a poor
running engine has had all possible problems
CAUTION: Loosen the injection lines on
checked but continues to run badly. If the
the injection nozzles of the number 2 and
injection pump has been repaired or replaced, the
3 cylinders to prevent any possibility of the
chance of individual cylinder timing problems has
engine firing.
a greater possibility of occurring.
5. The engine should be close to the top dead
To check individual cylinder timing, follow the
center position with the plunger port in the
pump timing procedure but instead of changing
pump closed. No fuel should flow from the
shims to adjust pump timing, check the timing of
drip tube.
number 2 and number 3 injector to the engine
6. Turn the engine backwards past the injection after checking number 1. The cylinders should
timing mark until fuel flows from the drip time on their respective flywheel timing marks.
tube.
If the injection pump plungers are not correctly
7. Slowly rotate the engine in the direction of timed to each other, the pump must be removed
rotation while watching the drip tube. When and sent to a diesel injection equipment repair
the fuel flow slows to approximately one drip shop for calibration.
every 10 to 15 seconds, check the timing
NOTE: The order of the flywheel timing marks
marks. They should be lined up.
is 1, 2, 3, but the firing order is 1, 3, 2. This is
8. If the timing marks did not line up, a shim or because the engine fires every 240 degrees of
shims will have to be added or subtracted crankshaft rotation. Therefore, when checking
from the injection pump. Adding shims will individual cylinder timing check number 1 first
retard the injection timing, subtracting shims then rotate the engine past number 2 to number
will advance the timing. Increasing or 3 and check number 3. Then rotate the engine
decreasing shim thickness by 0.004 in. past number 1 to number 2 and check number 2.
(0.1 mm) will change the timing by 1 degree.
9. After shims have been added or subtracted,
recheck the timing.
10. When the injection pump has been correctly
timed to the engine, remove the pump and put
a light coat of silicone gasket sealer on the
shim pack and the pump, or dip the new shims
in lacquer thinner to activate the sealer.
11. Reinstall the pump, and torque the nuts to
18 to 20 ft-lb (24 to 27 N•m).
12. Reinstall the delivery valve and spring.
Torque the delivery valve holder to 30 ft-lb
(41 N•m).
13. Reinstall the injector lines, bleed the air from
Figure 135: Individual Cylinder Timing
the nozzles, and test run the engine. and Firing Order
109
Engine Maintenance
Injection Pump Timing 2. Remove the cylinder head cover (valve

TK376 Engine cover/intake manifold assembly).
This is the only timing procedure for the TK376 3. Place the engine at top dead center of the
engine. It is not necessary to check the individual compression stroke for the number one
cylinder timing. cylinder. Refer to steps a through d.
CAUTION: The cylinders on the engine a. Rotate the engine in the normal direction
are numbered from the flywheel end to the of rotation (clockwise viewed from the
water pump end. The number 1 cylinder is water pump end) until the number one
next to the flywheel. The number 2 TDC mark on the flywheel lines up with
cylinder is the center cylinder. The the timing mark on the starter mounting
number 3 cylinder is next to the water plate. See Figure 134 on page 108.
pump. The timing marks on the flywheel b. Check the rocker arms on the number one
are matched to this system. cylinder to see if they are loose.
c. If the rocker arms are loose, the engine is
at top dead center of the compression
stroke for the number one cylinder.
1
d. If the rocker arms are tight, the engine is at
top dead center of the exhaust stroke for
the number one cylinder. Rotate the engine
360 degrees to place the engine at top dead
center of the compression 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
2
information about the Interface Board Test
1. Number One Cylinder Injection Line
mode.
2. Timing Mark 6. Rotate the engine backwards
Figure 136: Component Location (counterclockwise viewed from the water
pump end) until the injection timing mark is
CAUTION: Loosen all of the injection positioned about 1.0 in. (25 mm) below the
lines at the injection nozzles to prevent the the timing mark on the starter mounting plate.
possibility of the engine firing while it is
7. Use a clean towel to remove the fuel from the
being rotated. top end of the delivery valve holder.
1. Remove the injection line for the number one 8. Slowly turn the engine in the normal direction
cylinder from the delivery valve on the of rotation until you see the fuel rise in the end
injection pump and from the injection nozzle. of the delivery valve holder. Stop as soon as
NOTE: The number one cylinder is the you see the fuel rise.
cylinder at the flywheel end of the engine.
110
Engine Maintenance
9. Check position of the timing marks. The

injection timing mark on the flywheel should
be aligned with the timing mark on the starter
mounting plate. Repeat steps 6 through 9 to
recheck the timing.
1 2
1. Injection Timing Mark

2. Timing Mark on Starter Mounting Plate
Figure 137: Correct Injection Timing Mark
Alignment
10. If the timing is off by more than 1 degree (0.1 1. Index Marks
in. [2.5 mm]), loosen the mounting nuts on the
Figure 138: Index Mark Location
studs that fasten the injection pump to the
engine and rotate the injection pump to change
the timing.
a. Pull the top of the injection pump away
from the engine to advance the timing.
b. Push the top of the injection pump toward
the engine to retard the timing.
11. Tighten the injection pump mounting nuts and
recheck the timing. Repeat steps 6 through 11
until the timing is correct.
1 2
12. Install the injection line for the number one
cylinder, the cylinder head cover, tighten the 1. Index Mark on Injection Pump
other injection lines, and reconnect the 8S
2. Index Mark on Gear Case
wire to the starter solenoid when finished with
the procedure. Figure 139: Index Mark Alignment
2. Remove the throttle linkage, fuel lines, wire
Injection Pump Removal and harness, and mounting hardware from the
Installation TK376 Engine injection pump.
Injection Pump Removal 3. Remove the injection pump timing cover from
the gear case.
1. Note the alignment of the index marks on the
injection pump and the gear case. If they are 4. Loosen the injection pump gear mounting nut,
not marked, mark them so the injection pump but do not remove it yet.
can be returned to the same position when it is
reinstalled.
111
Engine Maintenance
NOTE: The injection pump gear assembly is 2. Place the injection pump in the gear case.
made of two pieces, the flange and the gear. Rotate the injection pump shaft to mate the
Do not loosen or remove the four bolts that key in the shaft with the keyway in the
fasten the gear to the flange because that injection pump gear. Take care to make sure
changes the timing. the key mates with the keyway.
5. Use a suitable puller to loosen the injection 3. Secure the injection pump to gear case with
pump gear from the injection pump shaft. previously removed hardware. Make sure to
align the index marks on the injection pump
6. Remove the injection pump gear mounting nut
and the gear case like they were in step 1 of
and lock washer. Use a shop rag to prevent the
“Injection Pump Removal”.
lock washer or nut from falling into the gear
case. NOTE: If a different injection pump is being
installed, see “Injection Pump Timing
7. Remove the injection pump from the gear TK376 Engine” on page 110 to set the
case, but leave the injection pump gear in the timing.
gear case. This keeps the teeth on the injection
pump gear aligned properly with the teeth on 4. Secure the injection pump gear to the injection
the idler gear. If you remove the injection pump shaft with the lock washer and
pump gear from the gear case you will have to mounting nut. Use a shop rag, as before, to
remove the gear case cover to realign the prevent the lock washer or nut from falling
timing marks on the injection pump gear and into the gear case. Torque the nut to 43 to 51
the idler gear. ft-lb (59 to 69 N•m).
5. Install the injection pump timing cover on the
Injection Pump Installation gear case cover, and reinstall all components
1. Place a new O-ring on the injection pump and removed previously to facilitate the injection
lubricate it with engine oil. pump removal.
1
2
4
8
6
5
1. Injection Pump 5. Injection Pump Gear Mounting Nut

2. Gear Case 6. Lock Washer
3. Gear Case Cover 7. Injection Pump Gear
4. Injection Pump Timing Cover 8. O-Ring
Figure 140: TK376 Injection Pump Removal and Installation
112
Engine Maintenance
Fuel Limit Screw 2. The intake valve and exhaust valve are
adjusted to 0.006 to 0.010 in. (0.152 to 0.254
The fuel limit screw is not adjustable. It is
mm) with the temperature at 70 F (21 C).
equipped with an anti-tamper cap to fulfill
requirements for CARB (California Air Resources Turn the engine by using the belt on the
Board) emission regulations. Service technicians crankshaft pulley. Rotate the engine in the
must be CARB certified to perform service on direction of rotation (clockwise as viewed
fuel limit screw for equipment operating in next to the flywheel) from the water pump
California. All other equipment can be serviced end.
per recent service bulletins with special tools and
procedures. California service technicians should CAUTION: Make sure the fuel rack is off
see your local Thermo King dealer for recent to prevent the engine from starting.
bulletins.
a. Turn the engine so number 1 cylinder is on
compression with piston to TDC. Both
push rods should turn freely. Adjust both
valves on number 1 cylinder.
b. Revolve the crankshaft 240° to TDC mark
on number 3 cylinder, and adjust both
valves.
c. Turn the crankshaft 240° to align TDC
mark of number 2 cylinder, and adjust
both valves.
d. Be sure to tighten locking nut while
Figure 141: Emission Control Label
holding the ball head screw in position.
Adjust Engine Valve Clearance 3. Install the valve cover making sure that the
gasket is in position.
1. Remove the valve cover or cylinder head
cover. On the TK 3.95 engine, torque 18 mm
diameter head bolts prior to 26.8 ft-lb
(36.3 N•m) before adjusting the valves. It is
not necessary to torque the head bolts before
adjusting then valves on the TK376 engine.
Valve clearance should be checked after every
2000 operating hours, maximum. It is very
important that valves be adjusted to the correct
specifications for 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.
113
Engine Maintenance
Engine Mounts
TK 3.95 Engine
The engine mounting system for the TK 3.95
engine contains three vibration mounts, two
snubber mounts, and a chain restraining mount.
0.20 Air Gap Between Lower

Snubber and Engine Bracket
When Assembled
(Snubbers Only)
NOTE: For details see

“Chain/Restraining Mount”
on page 118.
Figure 142: TK 3.95 Engine Mounting Components
114
Engine Maintenance
1. Restraining Bracket 14. Mount Screw

Bracket Screw 15. Flatwasher
Belleville Washer 16. Wear Plate Mount
Nut Wear Plate Rivet
2. Nut 17. Engine Screw
3. Belleville Washer 18. Belleville Washer
4. Vibration Mount 19. Vibration Engine Mount (set of two)
5. Engine Mount (roadside) 20. Nut
6. Engine Mount (curbside) Thread (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. Engine Screw 31. Gauge Bracket
12. Special Washer 32. Chain Screw
13. Special Washer
TK 3.95 Engine Mounting Components for Figure 142
115
Engine Maintenance
TK376 Engine
The engine mounting system for the TK376
engine contains three vibration mounts and a
chain restraining mount.
NOTE: For details see

“Chain/Restraining Mount”
on page 118.
Figure 143: TK376 Engine Mounting Components
116
Engine Maintenance
1. Bracket - Snubber 13. Mount - Vibration

2. Plate - Front Bracket 14. Nut
Screw - Plate & Bracket (Socket Head) 15. Washer - Belleville
Washer - Belleville 16. Flatwasher
Sealer - Thread 17. Nut
3. Screw - Mount 18. Bolt - Eye
4. Flatwasher (Front 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 Engine Mounting Components for Figure 143
117
Engine Maintenance
Restraining Mount Adjustment retighten belts using TK Gauge (P/N 204-427).

Set belt tension to a reading of 55 to 60. Recheck
Use this procedure for both the TK 3.95 and restraining mount alignment using a straight edge.
TK376 engines. Install belts and remove slack.
After belt tension has been set (no slack). Check This is a blowup of balloon items for “TK 3.95
seating in pulleys. Then proceed to tighten Engine Mounting Components” on page 114 and
locknut (#2) to compress the mount until the top “TK376 Engine Mounting Components” on
of mount is in the same plane as the gauge page 116.
brackets (#20). Use straight edge.to verify. Next,
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 (HH)
8. Screw (3/8 in. SS) 18. NOTE: Do not torque nuts to the normal
3/8 torque specification. This would cause
unnecessary distortion of the flatwashers. A
snug fit is all that is required.
9. NOTE: Always install chain on indented 19. Flatwasher (3/8 Galv.)
side of eye bolt
10. 3-Link Chain 20. Gauge Bracket
Figure 144: Chain/Restraining Mount
118
Engine Maintenance
1. Screw (5/16-18 SS); Flatwasher (5/16); 4. Screw (3/8-16 SS); Flatwasher (3/8);
Nylock Nut (5/16-18 SS) 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
119
Engine Maintenance
Integral Fuel Solenoid “pulled-in” position, the plunger releases tension

on the governor linkage. The governor linkage
The fuel solenoid is located on the end of the fuel then moves the fuel injector rack, thus controlling
injection pump. the fuel flow and placing it in the “Fuel On”
Operation of the engine is controlled by the position.
operation of the fuel solenoid and the high speed Adjustments made to the throttle (high) speed
(throttle) solenoid. The fuel solenoid consists of a solenoid change governor spring tension which in
spring loaded plunger and electro-magnetic coil. turn adjust speed settings.
When the engine is Off, spring tension on the
plunger maintains the plunger’s “out” position.
When pushed out, this causes the governor Fuel Solenoid Diagnostic and
linkage to move the injection pump rack to the Replacement
“Fuel Off” position. See the Interface Board diagnostic procedures in
When the fuel solenoid is energized, current is the SPECTRUM TS Microprocessor Controller
applied to the coil creating an electro-magnetic Diagnostic Manual.
field, which pulls the plunger in. When in the
1. Throttle Lever 6. Eye Bolt

2. Fuel Solenoid 7. Boot
3. Low Speed Adjustment Screw 8. High Speed (Throttle) Solenoid
4. Rod 9. Ball Joint
5. Clip
Figure 146: Integral Fuel Solenoid Components TK 3.95 Engine
120
Engine Maintenance
4 6 5 4 3 2
1. High Speed (Throttle) Solenoid 4. Ball Joint

2. Low Speed Adjustment Screw 5. Rod
3. Throttle Lever 6. Fuel Solenoid
Figure 147: High Speed Solenoid Components TK376 Engine
Engine Speed Adjustments High Speed Adjustment

1. Start the unit and let it run until the engine is
Low Speed Adjustment warmed up.
1. Start the unit and let it run until the engine is 2. Set the thermostat to make the engine run in
warmed up. high speed and check the engine speed. The
2. Set the thermostat to make the engine run in engine speed should be 2425 ± 25 RPM.
low speed and check the engine speed. The 3. If the engine speed is not correct, loosen the
engine speed should be 1800 ± 25 rpm. jam nut at the end of the ball joint attached to
3. If the engine speed is not correct, loosen the the throttle solenoid.
jam nut on the low speed adjustment screw. 4. Snap the ball joint off of the throttle lever and
4. Turn the low speed adjustment screw to turn it to adjust the engine speed. Reinstall the
change the engine speed. Turn the screw in to ball joint on the throttle lever.
increase the engine speed. Turn the screw out 5. Check the engine speed. Repeat step 4 as
to decrease the engine speed. necessary to set the engine speed at 2425 ± 25
5. Set the engine speed at 1800 ± 25 rpm and RPM and tighten the jam nut.
tighten the jam nut.
121
Engine Maintenance
Belts Electric Motor

(Jackshaft)/Compressor Belt
The unit uses only two belts to transfer power
from the engine and the electric motor (or The electric motor (jackshaft)/compressor belt is a
jackshaft) to the alternator and compressor. polyvee belt that also drives the alternator. Use the
following procedure to adjust this belt.
Engine/Electric Motor (Jackshaft) 1. Loosen the alternator pivot bolt.
Belt
2. Loosen the locknut below the mounting tab on
The engine/electric motor (jackshaft) belt is a 3V the alternator adjustment bolt. This bolt is
belt. Use the following procedure to adjust this located directly to the compressor side of the
belt. alternator.
1. Loosen the idler pulley mounting bolt.Loosen 3. Turn the locknut above the mounting tab on
the locknut on the idler pulley adjustment bolt. the alternator adjustment bolt to obtain the
This bolt is located directly above the idler proper belt tension (field reset—55 to 60 on
pulley on the idler pulley mounting bracket. TK gauge P/N 204-427).
2. Turn the idler pulley adjustment bolt to obtain 4. Tighten the lower locknut on the alternator
the proper belt tension (field reset—55 to 60 adjustment bolt and then tighten alternator
on TK gauge P/N 204-427). pivot bolt.
Tighten the locknut on the idler pulley adjustment
bolt and tighten the idler pulley mounting bolt.
122
Engine Maintenance
Idler pulleys are

crowned to help
6 7
pull belt to center
of idler. 5/11 8
9
1
3 10
NOTE: Pulley and

belt alignment is very
critical for poly-v
12
belts. Feel pulleys
with hand to see that
belt is fully seated in
pulley.
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 Arrangement
123
Engine Maintenance
Alternator Adjustment
Shims may be used to facilitate alignment during
alternator installation. Use adjustment strap and
eye bolt to ensure belt tension reading is between
55 to 60 on TK gauge.
1
5
6 AGA643
NOTE: It is critical that the belt

be correctly seated in pulley. First
and last edge of grooves are
higher to improve seating of
belts.
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 Belt Tension Adjustment
124
Refrigeration Maintenance
Evacuation NOTE: The attached evacuation procedures

have been written to be used with the Thermo
Evacuation is Important and is Critical to System King Evacuation System (see P/N 204-725).
Performance! However, the principles of 3-point evacuation
It has been determined through testing and system and the use of a micron gauge during
analysis that refrigeration systems which contain evacuation should always be practiced.
non-condensables such as nitrogen and/or air can See the diagram of the Thermo King Evacuation
be overcharged with refrigerant when charged Station (Figure 150 on page 126) and note the
using the sight glass method. An overcharge of location of the valves and other components.
refrigerant will cause compressor damage.
Valve #1 (V-1): Is in the open position when the
Therefore, Thermo King recommends that all pump is running to evacuate the hoses and/or the
repairs to the refrigeration system include the unit. When V-1 is closed, the pump has been
removal and reclamation (cleaning) of the isolated from the hoses and/or the unit.
refrigerant, followed by a thorough evacuation
Valve #2 (V-2): Is in the open position during unit
using the proper tools and procedures. (See
evacuation. In the closed position, V-2 isolates the
attached tool list and evacuation procedures.)
micron gauge and thermistor assembly from the
The primary objective of evacuation is to bring hoses and/or the unit.
the system’s pressure to a low micron level to Valve #3 (V-3): Is in the open position during unit
ensure the removal of moisture and evacuation. When closed, V-3 isolates the micron
non-condensables. There are however, certain gauge and the vacuum pump from the other
other principles which must be observed. These evacuation hoses.
are:
Valve #4 (V-4): Is in the open position during unit
• Evacuate from 3-points to access both sides of evacuation. When closed, V-4 isolates the
check valves and solenoids. Energize evacuation hoses and the unit from the evacuation
solenoids during evacuation to prevent system.
trapping of refrigerant or non-condensables.
Iso-Valve™: Is in the open position when the
• Always leave service valve caps on during vacuum pump is running to evacuate the hoses
evacuation and do not exercise the valve stems and/or the unit. When Iso-Valve is closed, the
while the unit is in a deep vacuum. Packing pump has been isolated from the hoses and/or the
glands on older valves are prone to leak. unit. The Iso-Valve is normally not used because
V-1 performs the same function and is more wear
• Never attempt evacuation without a micron or
resistant.
vacuum gauge. The micron gauge will help
determine:
a. If the pump is capable of pulling a deep
vacuum.
b. When 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.
125
11
4 5
10 1
AGA654 6
7
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
126
1. 100 Microns
2. 500 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
127
Set Up and Test of Evacuation NOTE: If the vacuum pump is okay, and
Equipment there are no leaks between V-1 and V-3, the
micron gauge should show less than 500
NOTE: See the previous two pages for the
microns. If not, locate and correct the
following discussion.
problem.
1. Connect the evacuation system to a 110 Vac
5. With the pump still operating, open valve V-3.
power supply. Connect a gauge manifold and
If the micron reading does not return to a level
refrigerant supply to the charging port above
of less than 500 microns, locate and correct
valve V-4. Turn the micron gauge On.
the problem before continuing.
2. Close valves V-1, V-3 and V-4. Valve V-2 is
6. With the vacuum pump still operating, open
open.
valve V-4. The micron level will rise
3. Turn the vacuum pump On. momentarily. If the micron reading does not
return to a level of less than 500 microns,
4. Open valve V-1 at the pump. The micron
locate and correct the problem before
gauge needle will move to the left. (See
continuing.
micron gauge scale diagram—previous page).
7. Evacuate hoses to 100 microns or lowest
achievable level below 500 microns.
8. Once 100 microns is reached, close valve V-1
at the pump. Turn the vacuum pump Off.
Leak Moisture
Isolate the pump from the system by closing the Should the needle show a pressure rise but
proper valve. Watch the movement of the vacuum finally level off to practically a constant mark,
gauge needle. If the needle continues to rise, this is an indication that the system is vacuum
this is an indication that a leak exists in the unit tight but is still too wet, requiring additional
or the connecting line. The leak must then be dehydration and pumping time.
located and eliminated.
Figure 152: Pressure Rise Graphs
128
9. Observe the micron gauge reading. The The Maintenance Menu is accessed from the first
vacuum rise should not exceed 2000 microns Operator Menu screen that appears; either the
in 5 minutes. Language Display or the Alarms Display. The
Alarms Display is shown here. Press and hold
10. If the rise is above 2000 microns in 5 minutes,
both the unlabeled soft key and the Exit key for 5
check all hoses and connections for leaks.
seconds.
Hoses with moisture present will require
additional evacuation time to achieve
satisfactory results.
NOTE: Dirty vacuum pump oil or a defective
vacuum pump will prevent a low micron
reading. Hoses and fittings can be isolated
individually to identify leaks. Figure 154: Press and Hold Exit and Unlabeled Key
Using The Evacuation Mode Menu The Maintenance Hourmeter Menu will appear.
Evacuation Mode opens the system by energizing Evacuation Mode
all normally closed refrigeration valves. This
allows the entire refrigeration system to be Menu. When the Evacuation Mode Menu is
evacuated. shown press the SELECT key.
Evacuation mode is only used with the unit off.

Since a number of refrigeration valves must be
energized for an extended period of time, the
operator is prompted to connect a battery charger
to the unit battery. This maintains the unit battery
in a charged condition and insures ample voltage
to hold all refrigeration valves in the open Figure 155: Evacuation Mode Menu
position during the evacuation process. The display will indicate that the Evacuation
WARNING: Do not set battery charger to Mode is being programmed.
the “crank” or “start” position, otherwise
the HMI display will be damaged.
CAUTION: Disconnect the drain heaters

from the terminal strips in the remote
evaporators while the unit is connected to
a battery charger and being evacuated. It Figure 156: Programming
is possible that the battery charger will
supply voltage that is high enough to The operator is prompted to connect a battery
damage the drain heaters. charger capable of 20 amps to the unit battery.
This maintains the unit battery in a charged
Start at the Standard Display and press the MENU condition and insures ample voltage to hold all
key. refrigeration valves in the open position during
the evacuation process.
Figure 153: Press Menu Key

Figure 157: Connect Battery
129
1. Prepare the unit for evacuation. Recover

WARNING: Do not set battery charger to
refrigerant to 0 psig (0 kPa).
the “crank” or “start” position, otherwise
the HMI display will be damaged. NOTE: New Federal Regulations may
require your recovery machine to pull the
The battery voltage is shown and all normally
system’s pressures lower than 0 psig [0 kPa].
closed refrigeration valves are opened. They will
remain open until the EXIT key is pressed or the
battery voltage falls below a minimum voltage. CAUTION: Do not attempt to evacuate a
unit until you are certain that the unit is
leak free. A unit with less than a full
refrigerant charge should be thoroughly
leak checked and all leaks must be
repaired.
2. Put the unit into Evacuation Mode (see “Using
Figure 158: Battery voltage The Evacuation Mode Menu” on page 129).
Proceed with system leak check or evacuation. 3. Install the evacuation station hoses on the
receiver tank outlet valve, suction service
Leak Check System valve, and discharge service port. A low loss
NOTE: Refer to Diagnosing Thermo King fitting must be used on the hose connected to
Refrigeration Systems (TK-5984-10) for leak the discharge service port.
detection procedures. 4. Mid-seat the receiver tank outlet valve and
1. Put the unit into Evacuation Mode (see “Using suction service valve, and install the valve
The Evacuation Mode Menu” on page 129). stem caps.
2. Connect leak test gas (R-404a) supply to 5. Connect a gauge manifold and refrigerant
center hose of gauge manifold. supply to the charging port above valve V-4.
Bottle valve closed.
3. Attach gauge manifold hoses to the suction
service valve and the discharge service port. A 6. Start the vacuum pump and open valves V-1,
low loss fitting must be used on the hose V-2, V-3, V-4.
connected to the discharge service port. 7. Evacuate the system to 500 microns or the
4. Pressurize the system with leak test gas. If lowest achievable level between 500 and 1000
desired, system pressure may be boosted using microns.
nitrogen gas. NOTE: The presence of refrigerant in the
5. Check connections made during installation compressor oil may prevent a low micron
for leaks using electronic leak detector and/or reading from being achieved. The oil can
soap bubbles. continue to “outgas” for long periods of
time. If the micron level appears to stall after
6. Recover test gas to repair leaks. System must 1/2 hour or 45 minutes between 1000 and
be vented while repairing solder joint leaks. 1500 microns, back seat the suction service
Pressurize system and check again after a leak valve and observe the micron gauge. A sharp
has been repaired. drop in the micron reading (300 to 500
7. If no leaks are found recover test gas to 0 psi. microns) would indicate that refrigerant is
present in the oil or a leak exists in the
compressor area. The micron gauge reads
Unit Evacuation
“ATM” if there is a leak to the atmosphere.
NOTE: Do not attempt to evacuate the unit until See Figure 152 on page 128.
the evacuation equipment has been tested and its
performance has been verified.
130
8. When the desired micron level has been 7. Set all zones to run in High Speed Cool
achieved (500 to 1000 microns), close valve through the HMI Service Test Mode. Refer to
V-1 at the pump. Turn the pump off. the SPECTRUM TS Microprocessor
Diagnostic Manual (TK 51652) for
9. Observe the reading on the micron gauge after
information about the Service Test Mode.
5 minutes have elapsed. The vacuum rise
should not exceed 2000 microns. If the 8. Observe the suction pressure and slowly open
vacuum level exceeds 2000 microns after the low side gauge manifold valve to allow
5 minutes, a leak is present or additional liquid refrigerant to flow into the compressor
evacuation time is required. suction service valve.
10. If the vacuum level is acceptable, start the 9. Control the liquid flow so the suction pressure
pump and open valve V-1 to evacuate the increases approximately 20 to 25 psig (138 to
pressure rise (5 minutes). 172 kPa).
11. Close valve V-1 and stop the pump. Observe 10. Maintain a discharge pressure of at least 300
the micron gauge to confirm that the system psig (2068 kPa) while adding refrigerant.
remains in a deep vacuum. Close valve V-4.
11. Close the low side gauge value when the
The unit is ready to charge.
receiver sight glass shows 1/2 to 3/4 full.
Unit Charging 12. Establish a return air temperature of 0 F
(-18 C), a suction pressure of 13 to 18 psig (90
NOTE: Before charging, make sure that the
to 124 kPa), and a discharge pressure of 300
refrigerant lines from the gauge manifold to the
psig (2069). See See “Testing the Refrigerant
refrigerant supply bottle have been evacuated or
Charge with an Empty Box” on page 132.
purged.
13. Check the receiver tank sight glass. The
1. Backseat the suction service valve and make
refrigerant level should remain between 1/2
sure the receiver tank outlet valve is still open.
and 3/4 full over a period of no less than five
2. Set the refrigerant supply bottle to liquid and minutes.
open the hand valve.
14. When the correct amount of charge has been
3. Open the high side gauge manifold valve. Add added, close the gauge manifold hand valve
a partial charge of 10 lbs (4.5 kg) of liquid and the refrigerant supply bottle hand valve.
refrigerant and close the high side gauge
NOTE: At these conditions the Liquid Injection
manifold valve. The remainder of the charge
Valve will cycle on and off. As this happens the
will be added as a liquid through the low side
refrigerant level in the receiver tank sight glass
gauge manifold valve.
will raise and lower. Therefore, monitoring the
4. Back seat (close) the receiver tank outlet receiver tank sight glass for a period of five
valve, remove the evacuation station hoses, minutes to make sure that the average level of
and install the cap on the service port for the the refrigerant over this five-minute period is
receiver tank outlet valve. between 1/2 and 3/4 full is required.
5. Attach the gauge manifold set to the suction
service valve and the discharge service port, Remove Refrigerant Hoses
and open the suction service valve one turn. A NOTE: Low loss fittings must be used on hoses
low loss fitting must be used on the hose when Schrader port fittings are encountered on
connected to the discharge service port. units.
6. Exit the Evacuation Mode by pressing the 1. With a low loss fitting on the discharge gauge
EXIT key, and remove the battery charger. line, remove this line from the unit.
2. Backseat the suction service valve, and then
crack it open one turn.
131
3. Open both service manifold hand valves. 3. Set all zones to run in High Speed Cool
through the HMI Service Test Mode. Refer to
4. Set all zones to run in Low Speed Cool
the SPECTRUM TS Microprocessor
through the HMI Service Test Mode. Refer to
the SPECTRUM TS Microprocessor
information about the Service Test Mode.
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
5. Front seat the receiver tank outlet valve.
0 F (-18 C). By allowing a box to leak a small
6. Run the unit until a 3 to 5 psig [21 to 35 kPa] amount, you will be able to maintain 0 F
reading is obtained on the suction gauge, then (-18 C).
stop the unit.
5. The discharge or head pressure gauge should
7. Back seat the suction service valve and the read 290 to 310 psig (1999 to 2137 kPa).
receiver tank outlet valve.
If the pressure is below this, it can be raised by
8. Remove all remaining hoses. covering a portion of the condenser coil with a
piece of cardboard.
9. Install and tighten the service port and valve
stem caps. 6. The compound gauge should be indicating 12
to 20 psig (83 to 138 kPa) gauge pressure.
10. Unit is ready for a functional check out.
If there is any doubt about the unit gauge,
Refrigerant Leaks check the calibration.
Use a reliable leak detector (e.g., electronic 7. Under these conditions, the ball in the receiver
detector) to leak test the refrigeration system. tank sight glass should be floating. If there is
Inspect for signs of oil leakage which is the first no indication of refrigerant in the receiver tank
sign of a leak in the refrigeration system. sight glass, the unit is low on refrigerant.
NOTE: It is normal for compressor shaft seals to Testing the Refrigerant Charge with
have a slightly oily film. a Loaded Box
1. Install a gauge manifold (optional).
Refrigerant Charge
2. Run the unit with all zones on the Cool cycle.
Testing the Refrigerant Charge with 3. Cover at least three quarters of the condenser
an Empty Box to drive any excess refrigerant from the
If the unit has an insufficient charge of refrigerant, condenser into the receiver tank.
the evaporator will be “starved” and the box 4. As the head pressure is rising, check the
temperature will rise even though the unit is receiver tank sight glass. The ball should be
operating. The suction pressure will drop as the floating. If there is no indication of refrigerant
refrigerant charge decreases. The charge may be in the receiver tank sight glass, the unit is low
determined by inspection of the refrigerant on refrigerant.
through the receiver tank sight glass with the
following conditions established: NOTE: If the ball floats, there is sufficient
refrigerant in the unit for that load at that
1. Place a test box over the evaporator in each particular box temperature. This test does
zone to separate the zones. not determine if the unit contains a full
2. Install a gauge manifold. charge of refrigerant.
132
Checking Compressor Oil If the box is empty, you can run the unit on the
Heat cycle instead of the Defrost cycle.
The compressor oil should be checked when there
is evidence of oil loss (oil leaks) or when NOTE: Use refrigeration compressor oil ONLY.
components in the refrigeration system have been R-404A systems use a special Ester oil (see Tool
removed for service or replacement. The oil level Catalog). Required for Scroll compressors.
in the compressor oil sight glass should be 1/4 to Oil can be added to the compressor through the
3/4 full. Schrader valve on the throttling valve (see Figure
To check compressor oil level with an ambient air 162 on page 138) while the unit is running. Take
temperature above 50 F (10 C): precautions to prevent contaminants from entering
Install a gauge manifold. the system while adding oil. Also see “Scroll
Compressor Oil Change” on page 141.
Operate the unit with all zones on high speed cool
with a 10 psig (69 kPa) minimum suction pressure
and 185 psig (1275 kPa) minimum discharge
High Pressure Cutout Switch
pressure for 15 minutes or more. (HPCO)
After the unit has maintained the above conditions The high pressure cutout switch is located on the
for 15 minutes, observe the oil level. The oil discharge line. If the discharge pressure rises
should be 1/4 to 3/4 up in the sight glass. above 470 psig (3241 kPa), the switch opens the
8H circuit to stop the unit. To test the switch,
rework a gauge manifold per illustration.
1. Connect the gauge manifold to the discharge
service port with a heavy duty, black jacketed
thick wall #HCA 144 hose with a 900 psig
(6204 kPa) working pressure rating.
AGA658
1. Compressor Oil Sight Glass Location
Figure 159: Scroll Compressor
CAUTION: Oil is under pressure. See

instructions for adding oil.
To check compressor oil level with an ambient air
temperature below 50 F (10 C):
Run the unit through a complete Defrost cycle.

After completing the Defrost cycle, run the unit
with all zones on Cool for ten minutes. Observe
the oil level. The oil should be 1/4 to 3/4 up in the
sight glass. 1. Relief Valve
2. O-ring
If the an evaporator temperature is above 32 F
(0 C), it will be necessary to force defrost. To 3. Adapter Tee Weather Head
force defrost, use the Service Test Mode. Figure 160: High Pressure Cutout Manifold
133
2. Set the sepoints in all zones well below the NOTE: Repeat the pump down procedure if
zone temperatures so that all zones will be in the pressures equalize above 20 psig
High Speed Cool. (138 kPa). If acceptable low pressures
cannot be achieved after the third pump
3. Raise the discharge pressure of the
down, the refrigerant must be recovered to
compressor by blocking the condenser coil air
perform service on the low side.
flow by covering the roadside condenser grille
with a piece of cardboard. NOTE: Valve stem MUST be back seated
during normal unit operation.
NOTE: The discharge pressure should never
be allowed to exceed a pressure of 470 psig 8. Plug in the hot gas bypass solenoid.
(3241 kPa) on R-404A systems.
9. Open the receiver tank return outlet valve,
4. Failure of the HPCO system to stop remove the gauges and return the unit to
compressor operation should be investigated normal operation.
first by checking the control circuit operation
and secondly by HPCO switch replacement. Discharge Pressure Regulator
Valve
Low Side Pump Down
This unit is equipped with a discharge pressure
CAUTION: Do not pull scroll compressor regulator valve, which is located in the hot gas
into a deep vacuum to perform routine line between the hot gas valves and the discharge
maintenance procedures. line. The discharge pressure regulator valve
maintains the compressor discharge pressure at
NOTE: Operate the unit with all zones in COOL 340 to 400 psig (2344 to 2758 kPa) during heat
for 2 to 5 minutes before performing the low side and defrost operation. These higher discharge
pump down. pressures create higher discharge temperatures,
1. Unplug the hot gas bypass solenoid. resulting in enhanced heating capabilities.
2. Install a gauge manifold to the suction service
valve and the discharge service port. A low
loss fitting must be used on the hose
connected to the discharge service port.
3. Operate the unit with all zones in low speed
cool.
4. Front seat the receiver tank outlet valve and
allow the low side to pump down to 0 to 5 in.
Hg vacuum (0 to -17 kPa).
CAUTION: Do not run scroll compressor

in a vacuum for more than 1 minute.
5. Turn the unit Off.

Figure 161: Discharge Pressure Regulator
6. Prepare to perform service on the low side by
equalizing the high side and low side The compressor discharge pressure is regulated by
pressures through the gauge manifold. a spring and bellows. This valve is pre-set at the
factory to maintain the compressor discharge
7. Equalize low side pressure to 1 to 2 psig (7 to
pressure at 340 to 400 psig (2344 to 2758 kPa)
14 kPa).
during heat and defrost operation. This valve
should not require any adjustment.
134
The discharge pressure regulator valve is not

repairable and must be replaced as an assembly.
Refrigeration System Checks

NOTE: The Scroll compressor can not be
pumped down. Check the compressor efficiency
using the following procedure.
1. Install a gauge manifold set. Attach the
compound (low pressure) gauge to the service
port on the suction service valve. Attach the
high pressure gauge to the discharge service
port. A low loss fitting must be used on the
hose 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 kPa).
Check the rest of the system by checking the
system pressures and the refrigerant flow in heat
and cool. The suction and discharge pressures
should be within the normal ranges for a standard
unit. Check the temperatures of the refrigeration
lines by hand to check the refrigerant flow.
135
136
Refrigeration Service Operations
NOTE: It is generally good practice to replace 7. Unsolder the discharge line.
the filter drier whenever the high side is opened
NOTE: When the compressor is removed
or when the low side is opened for an extended
from the unit, the oil level should be noted,
period of time.
or the oil removed from the compressor
should be measured so that the same amount
Accumulator of oil can be added before placing the
replacement compressor in the unit.
Removal
1. Recover refrigerant using approved methods. Installation
2. Unsolder the inlet and outlet refrigerant 1. Solder in the discharge line.
suction lines from the accumulator tank. 2. Lift the compressor into the unit and install
3. Unbolt and remove the accumulator from the the mounting bolts and the stabilization
unit. bracket.
3. Install the service valve using new gaskets
Installation soaked in refrigeration oil.
1. Place the accumulator in the unit and tighten 4. Reconnect the thermister, the discharge line,
the mounting bolts. and liquid injection line.
2. Solder the inlet and outlet suction lines to the 5. Pressurize the compressor and test for
accumulator tank. refrigerant leaks.
3. Pressurize the low side and test for refrigerant 6. If no leaks are found, evacuate the system.
leaks. If no leaks are found, evacuate unit. Replace the compressor/electric motor belt
4. Charge the system with refrigerant. Check and adjust the tension.
refrigerant charge and compressor oil and add 7. Charge the system with refrigerant.
as required.
8. Operate the unit at least 30 minutes and then
inspect the oil level in the compressor. Add or
Compressor remove oil if necessary.
Removal 9. Check the refrigerant charge and add
refrigerant if needed.
1. Recover the refrigerant from the unit using
approved methods.
2. Loosen and remove the compressor/electric
motor belt from the compressor pulley.
3. Unscrew the discharge line or fitting.
Unsolder the liquid injection line, and unbolt
the suction valve from the compressor.
4. 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.
137
8 9
1 2 6
10
3
5
11
18
17 12
16
15
14
13
1. Pulley Bolt (Torque to 18 to 22 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
138
Shaft Seal Change Procedure

Thermo King recommends changing the
compressor shaft seal when there is a major
system interruption, such as component 1
replacement or total loss of refrigerant charge.
When the shaft seal is changed, Thermo King also
recommends changing the oil and oil filter.
The steps for changing the shaft seal are as
follows: AGA576
2
1. Recover refrigerant. Equalize pressure to
slightly positive. 1. Clamp Ring
2. Remove compressor. 2. Orange Protective Cap
3. Remove drive pulley and Woodruff key from Figure 163: Cross Section of
the shaft. Set Screw Type Bellows
4. Clean shaft seal cover of excess dirt.

1
5. Remove four Torx head screws from shaft seal
cover. 2
6. Carefully pry the shaft seal cover out of
compressor body using flats at top and bottom
of shaft seal cover.
7. Remove the old hard ring, lip seal, and o-rings
from the seal cover.
AGA577
8. Loosen the set screws that secure the bellows
5
to the shaft. These set screws typically use an 3
1/8 inch Allen wrench which is provided with 4
the new seal.
1. Set Screw
9. Remove the old bellows from the shaft. Use a
2. Seal Faces
small prybar or screwdriver on each side of
the bellows, but do not scratch the shaft when 3. Hard Ring
removing the bellows. Be careful not to lose 4. O-ring
the spacer that is on the shaft. 5. Bellows
10. Ensure the spacer is properly located on the Figure 164: Set Screw Type Bellows Seal
shaft flat.
12. Apply clean compressor oil to the o-ring
11. Back out the set screws from the new bellows
inside the bellows and place the bellows on
and apply a small amount of blue Loctite 242
the shaft. Leave the orange protective cap on
(P/N 203-400) to the set screw threads.
the bellows.
CAUTION: Keep the orange protective
cap in position until final assembly.
139
13. Use seal installation tool (P/N 204-995) to If the installation tool is not available, use the pad
install the bellows squarely on the shaft. Clean in the new seal packaging to protect the polished
the seal installation tool and place it on the surface of the hard ring during assembly. A
shaft. Turn the knob until the tool bottoms out. substitute installation tool should have a diameter
approximately the same size as the O.D. of the
NOTE: The following illustration shows the
polished surface.
seal installation tool being used on a
reciprocating compressor. The same NOTE: The following illustration shows the seal
procedure applies to the scroll compressor. installation tool being used on a reciprocating
compressor seal cover. The same procedure
1 applies to the scroll compressor seal cover.
2
1 2
3
3
4
5
AGA1256
1. Crankshaft
2. Bellows AGA575
3. Seal Installation Tool

1. Dust Seal
Figure 165: Bellows Installation with Tool
2. Seal Cover
14. Tighten the set screws to approximately 3. O-ring
45 in.-lb (5.0 N•m) with the Allen wrench
4. Hard Ring—Install with Polished Surface
provided. Toward Compressor
15. Remove the seal installation tool. 5. Hard Ring Installation Tool
16. Install the new dust seal in the seal cover with Figure 166: Lip Seal and Hard Ring Installation
the lip side facing out and the flat side facing
toward the compressor. CAUTION: Do NOT touch or damage the
17. Apply clean compressor oil to the new o-ring polished seal face surfaces.
and install it in the seal cover. Apply clean
compressor oil to the new hard ring. Ensure 18. Remove the orange protective cap. Clean the
that the hard ring installation tool hard ring and the primary ring (bronze ring)
(P/N 204-953) is clean. Use the hard ring with the alcohol wipes found in package
installation tool to push the hard ring (with the labeled “1”. Then clean the polished mating
polished surface toward the installation tool) surfaces of both rings with the lint free dry
fully into the seal cover. Do not pinch the wipes from package number “2”. Apply clean
o-ring. compressor oil to polished surfaces of the seal
and to the lip seal from package number “3”
before assembling.
CAUTION: Oil applied to the seal faces
must be absolutely clean.
140
19. Lubricate the new seal cover o-ring with

Parts List (Required)
compressor oil (P/N 203-516) and install on
the seal cover. Oil Filter and O-ring See Parts Manual
Gasket See Parts Manual
20. Install the seal cover on the body and torque
screws to 100 to 110 in-lb (11.2 to 12.4 N•m). .
Do not bump the hard ring into the end of the Parts List (As Needed)
shaft during assembly.
Cover Plate See Parts Manual
21. Install the Woodruff key and drive pulley. Spring See Parts Manual
Torque the pulley bolt to 18 to 22 ft-lb (24 to
Hex Studs See Parts Manual
30 N•m).
Torx Screws See Parts Manual
Parts List (Required)
Seal Cover O-ring See Parts Manual Scroll Compressor Oil Change
Use Seal Kit See Parts Manual 1. Recover refrigerant. Equalize pressure to
slightly positive.
.
Parts List (As Needed) 2. Clean oil drain cap area (bottom and bottom
Torx Screws See Parts Manual rear of compressor) of excess dirt.
3. Remove oil drain plug from bottom rear of
Compressor Oil Filter Replacement compressor to drain oil. Measure amount of
Thermo King recommends changing the oil drained from compressor.
compressor oil filter when there is a major system 4. Remove two screws and oil drain cap from
interruption, such as component replacement or compressor.
total loss of refrigerant charge. When the oil filter
is changed, Thermo King also recommends 5. Scrape gasket from oil drain cap and body.
changing the oil. 6. Remove spring, screen and screen cover from
1. Recover refrigerant. Equalize pressure to body.
slightly positive. 7. Clean screen and cover.
2. Clean oil filter cover plate area of excess dirt. 8. Replace screen cover, ensuring notch in cover
3. Remove cover plate and spring, noting the is aligned with notch in body.
location of hex studs for proper installation. 9. Lubricate new gasket with compressor oil.
4. Scrape gasket off compressor body and cover 10. Replace screen, spring, gasket, cover plate,
plate. and screws.
5. Remove oil filter and o-ring. 11. Torque screws to 290 to 310 in-lb (34 to
6. Clean oil filter cavity of any noticeable debris. 36 N•m).
7. Lubricate new o-ring with compressor oil. 12. Lubricate o-ring on SAE plug with
compressor oil.
8. Press oil filter and o-ring over stem in
compressor body until seated. 13. Replace SAE plug in rear bottom of body,
torquing to 100 to 110 in-lb (11.2 to
9. Lubricate new gasket with compressor oil. 12.4 N•m).
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.
141
14. Measure oil removed and add an equal amount Liquid Injection Fitting Change
or add 40 oz (1.2l) of compressor oil (see Tool Procedure
Catalog), by pouring oil into the oil filter
The steps for changing the liquid injection fitting
cavity.
are as follows:
NOTE: The gasket must be replaced (see Parts
1. Recover refrigerant. Equalize pressure to
Manual).
slightly positive.
Other Parts Which May Be Used (As Needed) 2. Clean compressor body in area of liquid
Are:
injection fitting.
SAE Plug See Parts Manual
3. Sweat tubing out of liquid injection fitting.
Torx Head Screws See Parts Manual
4. Visually inspect screen in liquid injection
Cover Plate See Parts Manual
fitting.
Spring See Parts Manual
5. If plugged, carefully remove liquid injection
Screen See Parts Manual
fitting from compressor body.
Screen Cover See Parts Manual
6. Install new o-ring on new liquid injection
fitting.
Temperature Thermister Change
Procedure 7. Lubricate new o-ring with MobilTM oil (see
Tool Catalog).
NOTE: Thermo King recommends changing the
temperature thermister whenever the insulation 8. Carefully thread new liquid injection fitting
on the leads has been broken or there is other through compressor body into steel block on
reason to suspect a defective thermister. the inside. Make sure the fitting is not
cross-threaded in the steel block.
The steps for changing the high temperature
cutout thermister are as follows: 9. Torque liquid injection fitting to 100 to 120
in-lb (11.2 to 13.6 N•m).
1. Cut through silicone sealant surrounding
plastic cap. 10. Re-attach tubing to liquid injection fitting.
2. Pry plastic cap out of top cap. 11. Pressurize the unit and check for leaks.
3. Remove thermister by pulling it out of top cap 12. Evacuate the unit and recharge system.
well.
Parts List (As Needed)
4. Clean all debris out of top cap well and off of
O-ring See Parts Manual
top cap surface.
Liquid Injection Fitting See Parts Manual
5. Apply 0.25 to 0.50 cubic centimeters of
thermally conductive silicone grease (p/n
CHEMPLEX 1381 Heatsink Silicone into Condenser/Radiator Coil
thermal well.
Removal
6. Apply RTV to underside of plastic cap and
insert thermister back into well. 1. Recover the refrigerant charge by approved
methods.
Parts List (As Needed)
2. Remove the grille assembly.
Thermister Assembly See Parts Manual
3. Drain engine coolant from the expansion tank
Silicone Sealant N/A
and disconnect the coolant hoses from the
RTV See Tool Catalog condenser/radiator coil.
4. Unsolder the hot gas inlet tube and liquid
refrigerant line connections.
142
5. Unbolt and remove the condenser/radiator Dehydrator (Filter-Drier)

cap.
Removal
Installation
1. Pump down the low side and equalize the
1. Clean the tubes for soldering. pressure to slightly positive.
2. Place the coil in the unit and install the 2. Disconnect the nuts at the end of the drier.
mounting hardware.
3. Loosen the mounting hardware and remove
3. Solder the inlet line and liquid line refrigerant the drier.
connections.
4. Pressurize the refrigeration system and test for Installation
leaks. If no leaks are found, evacuate the 1. Install the new drier and tighten the mounting
system. screws and nuts. Install new o-rings.
5. Connect the coolant hoses to the radiator and 2. Install and tighten the inlet nut to the receiver
refill the expansion tank with 50/50 ethylene tank outlet valve line (inlet end of drier is
glycol/water solution. labeled “IN”). Hold the drier with a back-up
6. Recharge the unit with refrigerant and check wrench on the hex behind the flare fitting.
the compressor oil. 3. Tighten outlet nut on the dehydrator to the
7. Reinstall the front grille. evaporator line.
4. Pressurize the low side and inspect for leaks.
Liquid Injection Valve If no leaks are found, evacuate the low side.
5. Open the refrigeration valves and place the
Removal unit in operation.
1. Recover the refrigerant charge.
2. Unsolder the inlet/outlet lines from the liquid High Pressure Cutout Switch
injection valve.
Removal
3. Remove liquid injection valve mounting bolts
and remove the liquid injection valve from the 1. Recover the refrigerant charge.
unit. 2. Disconnect the wires and remove the high
pressure cutout switch from the discharge
Installation tube.
1. Install and bolt the liquid injection valve
assembly in the unit. Installation
2. Solder (95-5 Solder) the inlet liquid line and 1. Apply a refrigerant Loctite to the threads of
the outlet line to the injection valve. the high pressure cutout switch.
3. Pressurize the refrigeration system and test for 2. Install and tighten high pressure cutout switch
leaks. If no leaks are found, evacuate the and reconnect the wires.
system. 3. Pressurize the refrigeration system and test for
4. Recharge the unit with refrigerant and check leaks. If no leaks are found, evacuate the
the compressor oil. system.
5. Test the unit to see that the valve is properly 4. Recharge the unit with refrigerant and check
installed. the compressor oil.
143
High Pressure Relief Valve R-404A

The refrigeration industry has introduced a new
Removal refrigerant called R-404A. This refrigeration is
1. Recover the refrigerant charge. classified as a Hydro-fluorocarbon (HFC) because
it contains hydrogen fluorine and carbon. It does
2. Unscrew and remove the high pressure relief
not contain chlorine.
valve.
The capacities of these new refrigerants are
Installation similar for box temperatures above 0 F (-18 C). At
temperatures below 0 F (-18 C), HFC refrigerant
1. Apply a refrigerant Loctite to the threads of
capacities are slightly less than CFC refrigerants.
the high pressure relief valve.
2. Install and tighten the high pressure relief Unit Identification
valve.
Units charged with R-404A are identified by the
3. Pressurize the refrigeration system and test for following methods:
leaks. If no leaks are found, evacuate the
1. HFC-404A will be stamped on the unit’s serial
system.
plate.
4. Recharge the unit with refrigerant and check
2. “HFC” may be incorporated in the model
the compressor oil.
designation on the sides of the unit.
Receiver Tank 3. Decals will be applied to unit as shown below:
Removal
2. Unsolder the inlet tube from the receiver tank.
Figure 167: R404A Decal
3. Unsolder the filter drier line from the receiver
tank outlet tube. Availability
4. Unbolt the mounting brackets and remove the Refrigerant 404A is available from wholesalers.
receiver tank from the unit. The price will depend upon the quantity
purchased. Thirty (30), 50 and 125 containers are
Installation available.
1. Place the receiver tank in the unit and install
the mounting bolts and nuts loosely. Position Leak Detection
the receiver tank so the sight glass is clearly Leaks can be detected by a electronic leak
visible and the outlet tube lines up. detector such as the G.E. H10G or portable leak
detector (see Tool Catalog). See Truck and Trailer
2. Solder the inlet tube to the receiver tank.
Service Bulletin T&T 048 for additional details.
3. Solder the filter drier line to the receiver tank
outlet valve.
4. Tighten the 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.
144
Compressor Oil Vacuum Pumps

As of January 1, 1993, Thermo King Corporation When evacuating, a two stage three or five CFM
has chosen to use a compressor oil called Polyol pump is recommended. It is also recommended
Ester (POE)—also called ester based oil. POE oil that dry nitrogen be used first. Ideally, a new
is compatible with R-404A and can be used in low vacuum pump should be used and dedicated for
temperature applications. This oil is available use with R-404A systems because residual
from service parts (P/N 203-516). Required for refrigerants may remain in used vacuum pumps.
Scroll compressors.
Pumps used with other Thermo King refrigerants
may be used but extreme care should be taken to
Compressors Shipped with POE Oil prevent contamination of R-404A systems with
Thermo King Scroll compressors are charged with other refrigerants.
Polyol Ester oil (POE). All gauge fittings are
The Thermo King Evacuation Station is
1/4 inch fittings.
recommended. This station is available from
service parts (see Tool Catalog). See Truck and
CAUTION: POLYOL ESTER (POE) IS Trailer Service Bulletin T&T 061 for additional
THE ONLY OIL FOR USE WITH details.
THERMO KING UNITS USING R-404A.
IT SHOULD NOT BE ADDED TO Use only recommended vacuum pump oils and
STANDARD THERMO KING UNITS, change oil after every major evacuation. Vacuum
NOR SHOULD THE STANDARD OR pump oils are highly refined and the use of
SYNTHETIC OIL BE ADDED TO contaminated oils will prevent the desired vacuum
SYSTEMS CONTAINING R-404A. from being obtained. Failure to follow these
COMBINING THE TWO OILS COULD recommendations may result in conditions that
RESULT IN DAMAGE TO THE will destroy the vacuum pump.
SYSTEM.
Gauge Manifold Sets
Because Polyol Ester has an affinity for moisture,
it must be kept in capped containers. In addition, Gauge manifold sets that show the correct
it should be added as the last step in system repair. pressure-temperature relationship should be used.
Rubber gloves are recommended when handling Gauge manifolds and manifold hoses used with
Polyol Ester because it may cause skin irritation. other Thermo King refrigerants maybe used but
extreme care should be taken to prevent
Equipment Recommendations For contamination of the R-404A systems with other
Use With R-404A refrigerants. Purge manifold and hoses with dry
nitrogen before using. Never use equipment that
Dedicated Equipment may be contaminated with automotive type
Polyalkylene Glycol (PAG) oils.
CAUTION: Equipment that has been used
with other refrigerants MUST NOT be
used with R-404A refrigerants. Mixing
R-404A with other refrigerants will cause
contamination of the refrigerant. Using
contaminated refrigerant will cause
system failure.
145
System Clean-up 5. Break the gasket free and remove the end cap.
Existing clean up devices such as suction line 6. Note the number of shims next to the cap.
filter P/N 204-498, adapters and manifold These can be reused.
P/N 204-500, and compressor oil filters may be
7. Remove bellows (discard).
used if they are thoroughly cleaned and new filter
elements are installed. All standard compressor
oils must be removed from clean-up devices to
prevent contamination of R-404A systems.
Dangerous contamination will result if other
refrigerants or standard oils are introduced to
R-404A systems.
NOTE: For additional information on parts and
supplies, consult your local Thermo King dealer
and the Thermo King Tool Catalog.
Refrigerant Recovery
Present systems can be adapted to the recovery of
R-404A but should be dedicated to the recovery of
these refrigerants. Consult the manufacturer of
your recovery equipment for details. 1. Inspect Cap
2. Inspect Spring
Throttling Valve 3. Shims
Removal Figure 168: Throttle Valve, Cap and Spring
1. Pump down the unit using the refrigerant 8. Inspect all the parts (replace if excess wear is
recovery system. found).
2. Front seat the suction service valve. Release a. Piston and cap for wear (scuff marks)
remaining pressure.
b. Body for stripped threads
3. Remove the suction valve and line.
c. Bellows end cap for damage in pilot hole
4. Unbolt and remove the throttling valve from
NOTE: Bellows is normally replaced.
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 and piston.
4. Loosen all the bolts on bellows end cap.
CAUTION: This end cap is under slight

1. Inspect for Wear
spring pressure.
Figure 169: Throttle Valve Piston
146
6. Insert the cotter pin.

.
1. Inspect for Damage

1. Tighten Castle Nut to Bottom—Then
Figure 170: Throttle Valve Housing Back Off 1 Turn Only. Insert Cotter Pin.
9. Clean the parts to be reused. Figure 171: Throttle Valve Piston Assembly
7. Oil the gasket and install the end cap.

Reassembly
8. Throttling valve will have to be recalibrated
1. Install new bellows with O-ring into the
on operating unit. (Refer to “Specifications”
housing.
chapter for setting.)
2. Center the spring on bellows shoulder.
9. Adjust by adding or removing shims under the
3. Oil the gasket (same type of oil that is used in spring.
the system), install on the body, and place
shims in end cap (use same number as Installation
removed). Tighten end cap in place with vent
1. Install the throttling valve using new o-ring
hole closest to outlet opening of the valve
soaked in compressor oil (same type of oil that
body.
is used in the system). Bolt the throttling valve
4. Install the piston, spring and tighten the castle to the compressor.
nut until firmly seated against the bottom of
2. Connect the suction hose from the throttling
the piston.
valve to the accumulator tank. Install line
5. Back off the castle nut, one full turn only. from the compound gauge.
3. Pressurize the system and check for leaks. If
no leaks are found, evacuate the system.
unit in operation.
147
1. Screw—Plate and Flatwasher 10. Test Port—Schrader Valve

2. Schrader Valve and Cap (location may 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
148
Solenoid Valves
NOTE: Valves that have nylon seats must be
disassembled before soldering.
Removal
2. Remove the coil, and disassemble the valve if
necessary.
3. Unsolder the refrigeration lines from the
valve, and remove the valve from the unit. 1. Valve
2. Neoprene Seal
CAUTION: Use a heat sink to prevent
damage. 3. Valve Seat
4. Spring
Installation Figure 173: Cross Section of In-line Check Valve
1. Clean the tubes for soldering. Removal

2. Remove the coil, disassemble the valve if 1. Recover the refrigerant charge.
necessary, and place the valve in position.
2. Place a heat sink on the check valve.
3. Solder the inlet and outlet connections. After
the valve cools, assemble the valve and install 3. Unsolder the lines and remove the check
the coil. valve.
CAUTION: Use a heat sink to prevent Installation

damage.
NOTE: A heat sink must be used on the in-line
4. Pressurize the refrigeration system and test for check valve when it is being soldered in place to
leaks. prevent damage to the neoprene seal.
5. If no leaks are found, evacuate the system. 1. Clean the tubes for soldering.
6. Recharge the unit with proper refrigerant and 2. Place the check valve in position. The arrow
check the compressor oil. on the valve body indicates the direction of
refrigerant flow through the valve.
In-Line Check Valves 3. Place a heat sink on the check valve.

This unit uses some in-line check valves. An 4. Solder the inlet and outlet connections.
in-line check valve is not repairable and must be 5. Pressurize the refrigeration system and test for
replaced if it fails. A heat sink must be used on the leaks.
in-line check valve when it is being soldered in
place to prevent damage to the neoprene seal. 6. If no leaks are found, evacuate the system.
7. Recharge the unit with proper refrigerant and
check the compressor oil.
149
Condenser Inlet Check Valve Condenser Inlet Check Valve

Repair Replacement
Removal Removal
1. Recover the refrigerant charge. 1. Recover the refrigerant charge.
2. Remove the cap nut from the check valve and 2. Unsolder the lines and remove the check
remove the spring and seat. valve.
NOTE: Disassemble the valve before
unsoldering.
1
Installation
2 1. Clean the tubes for soldering.

2. Place the disassembled check valve in
3 position. The arrow on the valve body
indicates the direction of refrigerant flow
4
through the valve.
5 the valve cools, reassemble it.
4. Pressurize the refrigeration system and test for
leaks.
AGA173
5. If no leaks are found, evacuate the system.
1. Cap 6. Recharge the unit with proper refrigerant and
2. Gasket check the compressor oil.
3. Spring
4. Seat
5. Body
Figure 174: Check Valve with Cap Nut
Installation
1. Inspect the inside of the check valve body for
damage or foreign 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.
leaks.
5. Recharge the unit with proper refrigerant and
check the compressor oil.
150
Hilliard Clutch Maintenance
Large Truck Unit Centrifugal

Clutch Change
The centrifugal clutch has three belt grooves and
its engagement speed is 600 ± 100 RPM.
AGA127
Figure 175: Front View and Cross Section
151
1 13
2 14
3 7
4 8
15
6 16
15
8
5 7
14
7
8
9 17
8
7
10 aea558
11
(3 belt grooves)
12
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
152
Clutch Maintenance 3. Remove housing from hub by supporting hub

(in a minimum of three places) in spoke area,
Using an inspection mirror, inspect the clutch and pressing on the housing shaft. The inner
every 1000 hours of operation or yearly, race of the roller bearing will remain on the
whichever occurs first. If shoe wear is uneven on housing shaft.
different shoes, remove the clutch, clean the shoes
and drum, regrease bearings or replace if they are
worn. Inspect anchor bushings, shoe lining and
springs for wear and replace if necessary.
Tools Required
• Internal Retaining Ring Pliers
• 7/16 in. Wrench
• 7/32 in. Allen Wrench or 7/32 x 1/2 in. Socket
Drive
• 1/2 in. Impact Tool Figure 177: Housing Removal
• Rubber or Plastic Hammer 4. Remove the nuts from six 1/4-28 link screws
and remove screws, links, and lockwashers.
• 7/16 in. Socket or Nut Driver
5. Remove the springs and shoes.
• Arbor Press with Various Sized Arbors
6. Pull oil seal and press bearings out of hub.
• Bearing Puller
• Ratchet (Optional)
• Torque Wrench
Grease
MobilTM (Synthetic) (see Tool Catalog).
Disassembly Procedure
1. Remove retaining ring.
2. Remove the 3/8-16 flat head cap screw and
washer.
Figure 178: Bearing Removal
NOTE: This screw was installed using
LoctiteTM (see Tool Catalog) and will require NOTE: Press tool should be slightly smaller
the use of an impact tool for removal. than hub bore.
NOTE: A small amount of heat (propane or NOTE: Make sure the center of the hub is
acetylene torch with small heating tip) supported and not the outer rim of the hub,
applied to the cap screw head may be when pressing bearing out.
required to help loosen the screw.
153
7. Press bushings out of hub.
Figure 179: Bushing Removal
8. Remove inner race of roller bearing from the

housing shaft.
Figure 180: Bushing Insertion
NOTE: This race had LoctiteTM applied and
was pressed in place. A puller will be *DO NOT USE SOAP OR OIL TO
required to remove it. LUBRICATE BUSHING PRIOR TO
ASSEMBLY.
NOTE: Make sure the center of the housing
is supported and not the outer drum of the 2. Remove the inner race from the roller bearing,
housing. apply a small amount of LoctiteTM (see Tool
Catalog) to race I.D. and press onto the
Assembly Procedure (Using New housing shaft, seating against the step.
Bearings and Seal)
1. Press bushings into hub side opposite flange. CAUTION: During all bearing assembly,
care must be taken to prevent LoctiteTM
NOTE: It is important to press bushings in from entering bearing.
straight.
3. Apply LoctiteTM (see Tool Catalog) to O.D. of
The bushings should also be centered in the oil seal, then press seal in end of hub opposite
hub socket leaving relatively equal amounts the flange to a depth of approximately 1/16 in.
of bushing sticking out of the hub on each below the surface.
side.
4. Apply a small amount of LoctiteTM (see Tool
A suggested simple tool for pressing in Catalog) to O.D. of roller bearing and press
bushing to hub is a 1/4 in. screw x 3 in. or 4 in. into hub bore from the flange end until seated
long and 1/4 in. nut. Thread nut onto screw against the step in bore.
approximately 3/4 to 1 in.
5. Slip large and small spacer into hub I.D.
Insert threaded end of screw into bushing. seating against the roller bearing.
Lubricate bushing by dipping in clean water
only. Then press into place.
154
6. Apply MobilTM (see Tool Catalog) grease to

roller bearing and fill cavity between large and
small spacers. A small amount of grease
should also be applied to the seal lip and space
between the seal and roller bearing.
7. Pack ball bearing with MobilTM (see Tool
Catalog) grease.
8. Apply a small amount of LoctiteTM (see Tool
Catalog) to O.D. of ball bearing and press into
hub until seated against spacer. Wipe excess
LoctiteTM from hub.
9. Install retaining ring.
10. Position shoes in a circle on flat surface and
install springs on shoes.
11. Position shoes on the hub.
12. Install 1/4-28 x 1-3/4 in. screws through links,
then external tooth 1/4 in. lockwasher. Then
slide through bushings in shoes and hub.
13. Install remaining lockwashers then links and
1/4-28 in. locknuts, torquing them to
110 ± 5 in.-lbs (12.5 ± 6 N•m).
NOTE: Shoes MUST be held tightly against
hub while nuts are tightened.
1. Roller Bearing, Pack with MobilTM (see Tool
14. Place the hub and shoe assembly into the Catalog) grease
housing and place flatwasher over the bearing.
2. Pack These Areas with MobilTM (see Tool
15. Apply Loctite (see Tool Catalog) to 3/8-16 x
TM Catalog) grease at Assembly
1 in. screw and install through washer into 3. HEX HD Cap Screw (6X), 1-4/28 UNF X 1.75
housing shaft. The housing and hub will be Long. Torque to 110 ± 5 in-lbs (12.5 ±.6 N•m)
drawn together to the proper relative position
NOTE: Shoes must be disengaged while
as the screw is tightened. Tighten the screw to
tightening 6 bolts and MUST be held
30 to 35 ft.-lbs (41 to 48 N•m).
tightly against hub while nuts are
tightened.
4. Bearing, Fill with MobilTM (see Tool Catalog)
grease Approximately 0.32 oz (70 to 80% full)
5. 3/8-16 UNC x 1.00 Long, Flat Head Socket Cap
Screw with Nylox Insert / Apply LoctiteTM (see
Tool Catalog) and Torque to 30 to 35 ft.-lb
(41 to 48 N•m)
6. Serial Nameplate
Figure 181: Clutch
155
156
Structural Maintenance
Unit and Engine Mounting Bolts Fan Location

Periodically check and tighten all unit and engine When mounting the fan and hub assembly on the
mounting bolts. Torque the unit mounting fanshaft, position the assembly in the orifice as
bolts to 60 ft-lb (81.3 N•m). Torque the engine follows for proper fan performance:
mounting bolts to 50 ft-lb (68 N•m).
• For all fans except the ten-blade condenser
fan, position the fan with 30 to 35 percent of
the blade width to the air discharge side.
• For the ten-blade condenser fan, position the
fan with 50 percent of the blade width to the
air discharge side.
Figure 182: Mounting Bolts
Unit Inspection
Inspect the unit during unit pretrip inspection and
scheduled maintenance inspections for loose or
broken wires or hardware, compressor oil leaks,
or other physical damage which might affect unit
performance and require repair or replacement of
parts.
Condenser and Radiator Coils

Clean the coils during scheduled maintenance
inspections. Remove any debris (e.g., leaves or Figure 183: Fan Blade Position in Orifice
plastic wrap) that reduces the air flow. Clean dirty for All Except Ten-Blade Fan
coils 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 ORIFICE
in the direction opposite the normal air flow.
Repair bent fins and any other noticeable damage.
CAUTION: Air pressure should not be
high enough to damage coil fins.
AIR
FLOW
50 Percent
of Blade Depth to
Air Discharge Side
Figure 184: Fan Blade Position in Orifice

for Ten-Blade Fan
157
Structural Maintenance
158
Mechanical Diagnosis
Condition Possible Cause Remedy
Unit switch On—nothing happens Dead battery Recharge or replace battery
Remote switch Off (optional) Turn On
Fuse open Replace
Corroded battery connections Clean and tighten
Main harness fuse blown Check for shorted main harness and
replace fuse
Unit switch On—indicator lights Battery low Replace or recharge battery
come on but engine does not
Fuse blown Replace
crank
Starter solenoid defective Repair or replace
Starter relay defective Replace relay
Corroded battery connections Clean and tighten
Starter clutch defective Replace
Starter defective Repair or replace
Engine cranks but fails to start 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 filters
clean.
Speed/run relay malfunction Check relay or unit thermostat
Insufficient compression Measure compression pressure. If
necessary, grind valves or replace
piston
Electric fuel pump not operating Check pump for running and 8 to
10 psig (55 to 69 kPa). Repair or
replace fuel pump
Injection pump incorrectly timed Adjust timing
Faulty injection nozzle(s) Repair injection nozzle or replace it
Faulty injection pump Have pump repaired
Fuse F6 Open Replace fuse
159

Engine stops after starting Air in injection pump Bleed fuel system
Fuel filter obstructed Replace filter element
High water temperature (coolant) Add coolant. Check for leaks
Low oil pressure Add oil. Check for leaks
Vent of fuel tank obstructed Remove obstruction
Electric fuel pump not operating Check pump for running and 8 to
10 psig (55 to 69 kPa). Repair or
replace fuel pump
Dry air cleaner plugged Change filter element
Fuel solenoid not energized Check run circuit
High refrigerant pressure Locate and correct cause
Engine does not reach full power Air or dirt in fuel system Adjust
Fuel line leaks Tighten connections of fuel lines. If
necessary, replace damaged lines
Speed adjustment wrong Adjust speed
Electric fuel pump does not run Check voltage. Repair or replace
pump
Fuel filter 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 Clean and repair nozzle
injection caused by fouling
Insufficient compression pressure Check cylinder with compression
due to faulty piston or valves tester. If necessary, grind valves or
replace piston
Air filter clogged Clean air filter
Fuel tank vent clogged Unclog vent
Injection rate too low Adjust pump discharge rate
Insufficient injection pressure Readjust or replace nozzle
Pump injects too early or too late Adjust injection pump timing
Air in fuel system Bleed fuel system
Air is drawn into fuel pump Check all fuel lines and fittings
Loose governor assembly Check and repair governor
assembly
Restricted exhaust system Clean or replace restricted parts
160

Engine is sooting heavily, emits Wrong fuel Drain and refill with correct fuel
thick black clouds of smoke
Clogged air intake system Clean air cleaner
(excessive fuel to air ratio)
Restricted exhaust system Clean or replace
Opening pressure of nozzle is Repair nozzle. Replace if necessary
too low or needle sticks
Injection amount too great Have pump repaired
Oil being drawn in Check oil level in oil bath air filter
Injection pump timing Check timing of injection pump
Excessive load Check drive system and engine oil
pressure
Engine knocks Insufficient air Clean air filter
Air in fuel system Bleed fuel system
Engine is cold Warm up
Fuel return line plugged Remove restriction
Injection pump not timed Retime injection pump
Injection nozzle fouled or opening Clean, repair or replace injection
pressure too low 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 Replace cylinder head gasket.
appear in radiator if cylinder gasket Correct gasket
is leaking)
Faulty thermostat Check or replace the thermostat
Faulty temperature sensor Replace sensor
Oil pressure too low or drops Insufficient oil in pan Refill oil base after correcting cause
suddenly of loss
Leak in oil line Tighten oil line fittings
Oil relief valve sticking Disassemble and clean oil pressure
regulator valve
Faulty oil pressure switch Replace if necessary
Worn oil pump, camshaft, main or Repair engine
connecting rod bearings, loose oil
gallery plug, oil in water through
crack
161

High oil consumption Oil leakage Check and eliminate possible
causes
Clogged air cleaner Clean air cleaner
Damaged valve seals Replace seals on valve stem
Worn valve stem or valve guides Replace valves and valve guides
Broken piston rings or cylinder bore Have engine repaired. Replace
worn or scored broken piston rings
Crankcase breather clogged Clean crankcase breather
Blue Smoke (oil consumption) Excessive oil consumption See “High oil consumption”. Repair
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 alternator belt Tighten belt
Loose connections in electrical Check all electrical connections and
system charging system
Worn brushes in alternator Repair
Voltage regulator faulty Replace
Battery defective Replace
Alternator defective Repair or replace
162
Electric Standby (Optional) Diagnosis

Unit switch On—Microprocessor Battery discharged Charge or replace battery
display does not come on
Electric motor reset switch tripping Check for short circuit in unit wiring
(high voltage)
Fuse blown Replace fuse
Dirty battery terminals Clean and retighten terminals
Unit switch On—Microprocessor No standby power Provide power to unit; check power
display comes on but electric at:
motor does not run
1. Power source
2. Power plug
3. Motor contactor hot side
4. Motor contactor load side
(contactor closed)
5. Overload relay
6. Motor terminals
X5 jumper on interface board must Check that X5 jumper is in electric
be set to electric position (left) position
Defective phase detect module Replace phase detect module as
Check: needed
1. D/E LED (Electric On) should be
on
2. Motor Contactor MCA or MCB
should be energized
Defective motor contactor Repair or replace motor contactor
Overload relay tripping Check for shorted motor windings or
wires
Control circuit fuse open Replace fuse and reset alarm codes
Defective motor Replace motor
Batteries discharged Charge or replace batteries
Electric motor hums but does Locked rotor (overload relay will Remove interference
not run open after a period of time)
Locked compressor Repair compressor
Defective clutch on engine (locked Repair or replace clutch
up)
Low line voltage or no voltage on Bring voltage up to within 10% of
one leg motor rating
163
Electric Standby (Optional) Diagnosis

Contact chatter Low battery voltage Check voltage condition. Check
momentary voltage dip during
starting—low voltage prevents
magnet sealing
Defective or incorrect coil Replace coil
Poor contact in control circuit Check auxiliary switch contacts and
overload relay contacts. Check for
loose connections in control circuits
Contact welding or freezing Abnormal in-rush of current Check or grounds, shorts or
excessive motor load current
Low voltage Correct voltage condition. Check
momentary voltage dip during
starting
Foreign matter prevents contacts Clean contacts
from closing
Rapid cycling Check for cause of short cycling
(such as thermostat)
Short circuit Correct fault
Battery is not recharging Loose connections in electrical Check all electrical connections and
system charging system
Worn brushes in alternator Replace brushes
Voltage regulator faulty Repair or replace regulator
Battery defective Replace battery
Alternator defective Repair or replace alternator
Loose belt Tighten belt
Dirty battery terminals Clean and retighten
Alternator relay defective Replace relay
Fuse F8 open or removed Replace fuse
164
Refrigeration Diagnosis
Rapid cycling between Cool and Heat
Unit cools in Heat and Defrost cycle
Unable to hold vacuum in low side

Unable to pull vacuum in low side
Unit heats in Refrigeration cycle
Unable to pump down system
Unit not heating or defrosting

Receiver sight glass empty
Unit operating in a vacuum
Suction line frosting back
Symptom
High suction pressure
Low suction pressure
Unit not refrigerating

No suction pressure
High head pressure
Low head pressure
Noisy compressor
No head pressure
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
• Compressor discharge valves leaking
• • Scroll compressor seals leaking
• Too much compressor oil in system
• Faulty oil pump in compressor
• Loose compressor pulley
• Compressor bearing loose or burned out
• • • • • Broken discharge check valve in compressor
• • Expansion valve power element lost its charge
165
Refrigeration Diagnosis
Rapid cycling between Cool and Heat

Unit cools in Heat and Defrost cycle
Unable to hold vacuum in low side

Unable to pull vacuum in low side
Unit heats in Refrigeration cycle
Unable to pump down system
Unit not heating or defrosting

Receiver sight glass empty
Unit operating in a vacuum
Suction line frosting back
Symptom
High suction pressure
Low suction pressure
Unit not refrigerating

No suction pressure
High head pressure
Low head pressure
Noisy compressor
No head pressure
Possible Causes
• • • Expansion valve feeler bulb making poor contact

• • Expansion valve open too much
• • Expansion valve closed too much
• • Expansion valve needle eroded or leaking
• • • Expansion valve partially closed by ice, dirt or wax
• • • Liquid refrigerant entering compressor
• • Restricted line on the low side
• • • • Restricted line on the high side
• • • • Restricted drier
• Evaporator shutter open
• • • Evaporator shutter stuck closed
• Suction service valve back seated
• • • • • • • Faulty CIS
• • • • • Faulty Hot Gas Solenoid
• • 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
166
Remote Evaporator Specifications
Refrigeration System
Evaporator Coil Type Direct Expansion
Refrigerant Type R404a
Heat/Defrost Method Hot Gas
Electrical
Control System Voltage 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
167
Remote Evaporator Specifications
168
Remote Evaporator Maintenance Inspection
Schedule
Every Annual /
Pre-Trip 1,500 4,500 Inspect/Service These Items
Hours Hours
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.
169
Remote Evaporator Maintenance Inspection Schedule
170
Remote Evaporator Unit Description
Discharge & Return Air

1. Coil Temperature Sensor, Ungraded) 5. 9. Terminal Board Bracket
Sensor (Graded)
2. Hot Gas Solenoid 6. Variable Blower (12 V) 10. Terminal Board
3. Liquid Line Solenoid 7. Blower Housing 11. Terminal Board Markstrip
Resistance Wire
4. Hot Gas Solenoid 8. Blower Cover 12.
(Drain Heater)
Figure 185: SPECTRUMTM Evaporator
171
AJA984
Figure 186: SPECTRUM™ TS Evaporator-Front View
AJA985
Figure 187: SPECTRUM™ TS Evaporator-Back View
172
The SPECTRUM™ multi-temperature Defrost

refrigeration system provides heavy duty
temperature control for multiple compartment The Defrost mode can be initiated any time the
trucks. The system provides direct expansion evaporator coil temperature is below 45 F (7 C).
cooling in all cargo compartments. Defrost is initiated automatically by the controller
or manually by selecting the manual defrost.
Heat and defrost is provided in all compartments
by circulating hot refrigerant gas through the The evaporator fan stops during defrost. The
evaporators. Defrost mode will continue until the evaporator
coil temperature rises to 52 F (11 C), causing the
The remote evaporator are ceiling mounted units. controller to terminate defrost. After defrost, the
Controls for the remote evaporator(s) are located evaporator may shift back to cool, null or heat.
in the SPECTRUM™ TS HMI.
Operating Modes
Unit Operation Remote evaporator operating modes are:
The remote evaporator cycles between cool, null • Cool
and heat to maintain the cargo’s compartment(s)
• Null
at the setpoint. The operating modes include Cool,
Null, Heat and Defrost. • Heat
Power to run the direct current fan motor is • Defrost
supplied by the alternator in the condensing unit. NOTE: The controller locks out heat at setpoints
When cooling is required, the SPECTRUM™ TS below 15 F (-9.5 C).
microprocessor energizes the remote liquid line
solenoid valve. Refrigerant flows through the Unit Features
evaporator coil to provide cooling.
• Direct Expansion Evaporator Coil
When the compartment temperature is near
setpoint, the SPECTRUM™ TS microprocessor • SPECTRUM™ TS Microprocessor
de-energizes the remote liquid line solenoid valve • 12 Vdc Fan Motor
and switches the remote evaporator to null.
• Aluminum Housing
The SPECTRUM™ TS microprocessor energizes
the remote hot gas solenoid when the remote • Liquid Line Solenoid
compartment requires heat or defrost. • Hot Gas Solenoid
• Suction Line Solenoid
• Liquid Return Check Valve
173
Unit Protection Devices

• Fuses in Host Unit (located on interface
board)
Serial Number Location

Unit: Nameplate on the right end of the unit frame.
AJA985
1. Nameplate on Right End of Unit Frame

Figure 188: Serial Number Location
174
Remote Evaporator Electrical Maintenance
SPECTRUM™ Microprocessor
Controlled Components
Refer to the appropriate SPECTRUM™
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.
175
Remote Evaporator Electrical Maintenance
176
Remote Evaporator Refrigeration Service
Operations
NOTE: It is generally good practice to replace 8. Test the unit to see that the expansion valve is
the filter drier whenever the high side is opened properly installed.
or when the low side is opened for an extended
period of time. Evaporator Coil
Expansion Valve Assembly Removal
1. Recover refrigerant by approved methods.
Removal
2. Remove evaporator assembly.
pressure to slightly positive. Remove the 3. Remove the access panels.
evaporator access panels.
4. Disconnect the distributor from the expansion
2. Disconnect the liquid inlet line and distributor valve.
from the expansion valve.
5. Remove the insulating tape and feeler bulb
3. Remove the feeler bulb from the clamp. Note from the suction line. Note the position of the
the position of the feeler bulb on the suction feeler bulb on the suction line. Disconnect the
line. equalizer line from the suction line.
4. Disconnect the equalizer line. 6. Heat and unsolder the suction line connection
to the evaporator coil.
5. Remove the mounting U-bolt.
7. Remove the mounting bolts and slide the coil
6. Remove the expansion valve assembly from
from the housing.
the unit.
Installation Installation
1. Place the evaporator coil in the evaporator
1. Place the expansion valve in the unit and
housing and install the mounting bolts.
install the mounting U-bolt.
2. Clean and solder the suction line connections
2. Connect the equalizer line to the expansion
to the evaporator coil.
valve.
3. Connect the distributor to the expansion valve.
3. Connect the liquid inlet line and distributor to
the expansion valve. 4. Clean the suction line to a bright polished
condition. Install the feeler bulb clamps and
4. Clean the suction line to a bright polished
the feeler bulb on the suction line. Locate the
condition. Install the feeler bulb clamps and
bulb on the side of the suction line in its
feeler bulb on the side of the suction line in its
former position. The feeler bulb must make
former position. The feeler bulb must make
good contact with the suction line or the
good contact with the suction line or the
operation will be faulty. Wrap it with
operation will be faulty. Wrap it with
insulating tape.
insulating tape.
5. Connect the equalizer line to the suction line.
5. Pressurize the low side and test for leaks. If no
leaks are found, evacuate the low side. 6. Pressurize the low side and test for leaks. If no
leaks are found, evacuate the low side.
6. Install the access panels.
unit in operation. 8. Install evaporator assembly. Leak test,
evacuate and charge the unit.
177
Remote Evaporator Refrigeration Service Operations
Solenoid Valves Check Valve Replacement

NOTE: Valves that have nylon seats must be
disassembled before soldering. Removal
Removal pressure to slightly positive.
1. Pump down the low side and equalize the 2. Remove the access panels.
pressure to slightly positive.
3. Unsolder lines and remove the check valve.
2. Remove the access panels.
NOTE: Disassemble the valve before
3. Remove the coil and disassemble the valve. unsoldering.
4. Unsolder the refrigeration lines from the
valve, and remove the valve from the unit. Installation
1. Clean the tubes for soldering.
CAUTION: Use a heat sink to prevent
damaging the valve 2. Place the disassembled check valve in
position. The arrow on the valve body
indicates the direction of refrigeration flow
Installation through valve.
1. Clean the tubes for soldering.
2. Remove the coil, disassemble the valve, and the valve cools, reassemble it.
place the valve in position.
3. Solder the inlet and outlet connections. After leaks are found, evacuate the low side.
the valve cools, assemble the vale and install
the coil.
CAUTION: Use a heat sink to prevent unit in operation. Check the refrigerant charge
damaging the valve. and the compressor oil. Add as required.
leaks.
7. Open the refrigeration valves and run the unit.
Check the refrigerant charge and compressor
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.
178
Check Valve Repair

Removal
pressure to slightly positive.
2. Remove the access panels.
3. Remove the cap nut from the check valve and
remove the spring and seat.
AGA173
1. Cap
2. Gasket
3. Spring
4. Seat
5. Body
Figure 189: Check Valve with Cap Nut
Installation
1. Inspect the inside of the check valve body for
damage or foreign 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.
leaks are found, evacuate the low side.
unit in operation. Check the refrigerant charge
and the compressor oil. Add as required.
179
180
Remote Evaporator Structural Maintenance
Unit Inspection
Inspect the unit during the unit pre-trip inspection
and scheduled maintenance inspections for loose
or broken wires or hardware, compressor oil
leaks, or other physical damage which might
affect unit performance and require 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 if necessary.
CAUTION: Air pressure should not be
high enough to damage the coil fins.
181
Remote Evaporator Structural Maintenance
182
Remote Evaporator System Diagnosis
Load temperature too high Refrigerant shortage Repair leak and recharge
Setpoint too high Adjust setpoint
Expansion valve plugged Clean or replace
Partial obstruction in low side of

Locate obstruction and repair
refrigeration system
Iced or dirty evaporator coil 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

Repair or replace
or defective
Evaporator fan not operating Check and correct evaporator fan
Evaporator fan motor does not Check for short circuit in unit wiring
Fuse blown
run and replace fuse
Open in FM circuit Locate open and repair
Defective fan relay Replace fan relay
Defective fan motor Replace fan motor
Bad ground Tighten connection at ground stud
183
Remote Evaporator System Diagnosis
184
Index
A engine mounts 114
accumulator 137 engine oil dipstick 32
alternator 81 engine specifications 21
alternator adjustment 124 engine speed adjustments 121
antifreeze high speed 121
changing 97 low speed 121
checking 97 engine valve clearance adjustment 113
maintenance procedure 97 evacuation 125, 130
B F
battery 84 fan location 157
belt tension specifications 22 first aid 18
belts 122 electrical shock 19
engine coolant 18
C refrigerant 18
charging system 84 refrigerant oil 18
charging, unit 131 fuel limit screw 113
clutch maintenance 151 fuel solenoid 120
clutch specifications 23 fuel system, engine 98
compressor 29, 137 bleeding 99
compressor oil
checking 133 G
compressor oil sight glass 32 glow plugs 86
condenser coil 142, 157
condenser fan rotation 86 H
condenser inlet check valve high pressure cutout switch (HPCO) 133, 143
repair 150 high pressure relief valve 144
replacement 150
coolant expansion tank 32 I
cooling system, engine 94 injection pump 107
bleeding 97 adjustments 107
crankcase breather 92 removal and installation, TK376 engine 111
timing, TK 3.95 engine 107
D timing individual cylinder injection 109
DAS - Data Acquisition System 30 timing, TK376 engine 110
defrost 30 in-line check valves, replacement 149
defrost timer specifications 23
dehydrator (filter-drier) 143 L
design features 27 leak check 130
discharge pressure regulator valve 134 liquid injection valve 143
draining water from fuel tank 106 loading 79
low side pump down 134
E
ELC (extended life coolant) 28, 96 M
electric fuel pump 106 maintenance inspection schedule 25
electric standby 31 maintenance inspection schedule, remote evaporator
electric standby diagnosis 163 169
electric standby specifications 24 mechanical diagnosis 159
electrical components specifications 24 mounting bolts 157
electrical contacts 84
electrical control system specifications 23 O
electrical maintenance 81
operating modes, remote evaporator 173
EMI 2000 29, 91
overload relay 89
engine 28
replacement 89
engine air cleaner 93
engine change 91
engine lubrication system 91
P
engine maintenance 91 phase detect module 86
185
Index
preheat buzzer 85 unit operation, remote evaporator 173

unit options 27
R unit protection devices, remote evaporator 174
R-404A 3, 144
radiator coil 142, 157 W
receiver tank 144 wiring 84
receiver tank sight glass 32 wiring diagrams index 187
recover refrigerant 3
refrigerant charge 132
refrigerant leaks 132
refrigeration diagnosis 165
refrigeration maintenance 125
refrigeration service operations 137
refrigeration system checks 135
refrigeration system specifications 23
remote evaporator
check valve repair 179
check valve replacement 178
electrical maintenance 175
evaporator coil 177
expansion valve assembly 177
maintenance inspection schedule 169
refrigeration service operations 177
solenoid valve, replacement 178
specifications 167
structural maintenance 181
system 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 location, remote evaporator 174
solenoid valve, replacement 149
specifications 21
standby power specifications 24
structural maintenance 157
system clean-up 146
system controller specifications 24
T
thermostat, engine 98
throttling valve 146
U
unit description 27
unit features, remote evaporator 173
unit inspection 157
186
Wiring and Schematic Diagrams Index
Dwg No. Drawing Title Page

5D55036 Wiring Diagram 189-191
5D55037 Schematic Diagram 192-195
187
Wiring and Schematic Diagrams Index
188
Wiring Diagram — Page 1 of 4
189
190
191
192
Schematic Diagram — Page 1 of 3
193
194
195
196

Spectrum Ts Series

Uploaded by

Copyright:

Available Formats

Spectrum Ts Series

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Spectrum Ts Series

Uploaded by

Copyright:

Available Formats

SPECTRUM™ TS

TK 51448-1-MM (Rev. 1, 03/06)

Copyright© 2002 Thermo King Corp., Minneapolis, MN, USA.

No warranties, express or implied, including warranties of fitness for a particular

We strictly adhere to a policy that promotes the recovery and limits

In addition, service personnel must be aware of Federal regulations

Refrigerant Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132

Clutch Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153

Figure 59: Select Zone To Defrost Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

Figure 119: TK 3.95 (Tier 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

Figure 179: Bushing Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154

DANGER: Refrigerant in the presence of WARNING: Do not apply heat to a closed

NOTE: In the USA, EPA Section 608

Auto Start/Stop CAUTION: Refrigerant in a liquid state

Refrigerant Hazards CAUTION: Do not mix refrigerant oils

CAUTION: Wipe up spills immediately. WARNING: Safety glasses, rubber-

INGESTION: Do not induce vomiting.

First Aid, Electrical Shock

Engine Clutch - Hilliard

Electrical Control System

Electric Standby (Model 50 Unit Only)

Standby Power Requirements

Pretrip 1,200 2,000 Annual/ Inspect/Service These Items

Pretrip 1,200 2,000 Annual/ Inspect/Service These Items

Figure 1: SPECTRUM™ TS Front View • Diesel/Electric Autoswitching

Design Features • Door Switch

• Air Cleaner, Dry Type • Electric Standby

• Alarm Code Display • Engine Block Heater

• Alternator, 90 amp • Remote Status Light

• Automatic Phase Correction (Model 50) • Synthetic Engine Oil

• Battery Voltage Display • Hose Management Kit

• Bypass Oil Filter • Three Cargo Compartment Temperature

ELC (Extended Life Coolant)

NOTE: The use of 50/50 percent pre-mixed ELC

Figure 5: HMI Control Panel

Microprocessor Power Switch Defrost is accomplished by passing hot refrigerant

Electric Standby (Model 50 High Voltage Tray

Unit Instruments coil temperature and ambient temperature since

information is used by the microprocessor and coolant condition is assumed to exist. It is

Refrigeration Cycles Gauges Display Menu: The Gauges Display allows

Refrigeration System Diagrams

1. Scroll Compressor 18. Evaporator Coil

Figure 9: Zone 1 Cool and Zone 2 Cool

Figure 10: Zone 1 Heat and Zone 2 Heat

Zone 1 Heat and Zone 2 Heat Zone 2 Evaporator

Figure 11: Zone 1 Cool and Zone 2 Heat

Figure 12: Zone 1 Cool and Zone 2 Null

Zone 1 Cool and Zone 2 Null Zone 2 Evaporator

Figure 13: Zone 1 Heat and Zone 2 Null

Figure 14: Zone 1 Cool and Zone 2 Defrost

Figure 15: Zone 1 Heat and Zone 2 Defrost

Zone 1 Heat and Zone 2 Defrost Zone 2 Evaporator

Figure 16: Zone 1 Defrost and Zone 2 Null

Zone 1 Defrost and Zone 2 Null Zone 2 Evaporator

Figure 17: Zone 1 Cool, Zone 2 Heat, and Zone 3 Heat

Zone 1 Cool, Zone 2 Heat, and Zone Zone 3 Evaporator

Figure 18: Zone 1 Cool, Zone 2 Heat, and Zone 3 Defrost

Zone 1 Cool, Zone 2 Heat and Zone Zone 3 Evaporator

Inverted Heat Mode Defrost Mode