Name: Thermo King TS-500 NAD
Brand: Thermo King
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TS-500 NAD

TK 50799-1-MM (Rev. 5, 04/03)

Printed in USA.

Table of Contents5
List of Figures11
Safety Precautions13
General Practices13
Auto Start/Stop13
Refrigerant13
First Aid13
Refrigeration Oil14
First Aid14
Electrical Hazards14
Microprocessor Service14
Welding of Units or Truck Bodies15
High Voltage15
Low Voltage16
Unit Decals16
Figure 1: Refrigerant Decal Locations16
Figure 2: Refrigerant Decal16
Specifications17
Engine17
Belt Tension18
Refrigeration System18
Engine Clutch - Hilliard18
Electrical Control System19
Defrost Timer19
Thermostat19
Electrical Components19
Electric Standby (Model 50 Unit Only)20
Standby Power Requirements20
Air Switch20
Maintenance Inspection Schedule21
Unit Description23
Thermoguard Μp-T Controller23
Data Acquisition System (Optional)23
Clutch23
Unit Features24
Unit Instruments25
Unit Protection Devices25
Unit Operation26
Pretrip Inspection (before Starting Unit)26
Thermoguard Μp-T Smart Reefer27
TM (SR) Microprocessor27
Displaying Operating Data27
Entering Setpoint Temperature27
Starting Unit (Full Unit Self Check)28
Selection of Operating Modes on CYCLE-SENTRY Equipped Units28
Products Requiring Continuous Run Operation for Air Flow28
Products Acceptable for CYCLE-SENTRY Operation29
Selecting CYCLE-SENTRY or Continuous Run Mode (Diesel or Electric Operation)29
Initiating Manual Defrost29
Displaying and Clearing Alarm Codes30
Restarting the Unit30
After Start Inspection31
Loading Procedure31
Post Load Procedure31
Post Trip Checks31
Unit Photographs32
Figure 3: Front View32
Figure 4: Back View32
Figure 5: Side View33
Figure 6: Components34
Figure 7: Control Box with High Voltage Shield in Place35
Figure 8: Power Receptacle Box-Model 5036
Figure 9: Thermoguard Remote Control Panel37
Figure 10: Remote Light Display Kit37
P-T System Description39
General Description39
P-T Control System39
Microprocessor Power Switch39
Optional Electric Standby (Model 50 Units Only)39
Figure 11: Microprocessor Power Switch39
Standard Model 50 Features40
Optional Model 50 Features40
Figure 12: High Voltage Contactors with Shield Removed41
Remote Control Panel Features43
Keypad Keys43
Figure 13: Remote Control Panel43
Understanding the Display44
Display Icons44
Reading a Typical Display44
Figure 14: Display Screen Features44
Figure 15: Typical Display44
The Standard Display45
Changing the Setpoint45
Figure 16: Standard Display45
Figure 17: Changing the Setpoint45
Selecting CYCLE-SENTRY or Continuous Mode46
Starting the Engine46
Figure 18: Selecting CYCLE-SENTRY or Continuous Mode46
Figure 19: Starting the Engine46
Initiating a Manual Defrost Cycle47
Checking the Software Revision47
Figure 20: Initiating a Manual Defrost Cycle47
Figure 21: Software Revision47
Viewing Prompt and Display Screens48
Figure 22: Viewing Prompt and Display Screens48
Viewing and Clearing Alarm Codes49
Figure 23: Alarm Code Display49
P-T Unit Self Check Test52
Electrical Maintenance53
Alternator (Prestolite) Charging System Diagnostic Procedures53
Figure 24: Prestolite Terminal Locations53
Excessive Voltage Output54
Battery55
Unit Wiring55
Electrical Contacts55
Charging System (12 VDC)55
Preheat Buzzer55
RPM Sensor55
Figure 25: Flywheel (RPM) Sensor55
Glow Plugs56
Figure 26: RPM+ and RPM- Wires56
Figure 27: Glow Plug Test56
Condenser/Evaporator Fan Rotation (Electric Standby Operation)57
Defrost Air Switch Checkout and Adjustment57
Figure 28: Testing Air Switch57
Figure 29: Air Switch57
High Capacity Thermax58
TM Heating System58
Cool Mode58
Heat/Condenser Evacuation Mode58
Defrost Mode59
Start up Mode59
Engine Maintenance61
Emi 200061
Engine Lubrication System61
Engine Oil Pressure Sensor61
Engine Oil Change61
Oil Filter Change62
Crankcase Breather62
Engine Air Cleaner (EMI 2000)62
Figure 30: Oil Filter Parts62
Figure 31: Dry Type Air Cleaner62
Engine Cooling System63
General Description63
Figure 32: Engine Cooling Components63
ELC (Extended Life Coolant)64
Figure 33: ELC Nameplate-Located on Expansion Tank64
Engine Thermostat66
Engine Fuel System66
Figure 34: Water Pump Assembly and Thermostat66
Bleeding the Fuel System67
Figure 35: Fuel and Oil System Components68
Draining Water from Fuel Tank70
Fuel Filter Replacement70
Electric Fuel Pump70
Figure 36: Electric Fuel Pump70
Injection Pump71
Engine Maintenance (Continued)71
Figure 37: Timing Marks72
Figure 38: Individual Cylinder Timing and Firing Order73
Adjust Engine Valve Clearance74
Fuel Limit Screw74
Engine Mounts75
Figure 39: Engine Mounting Components75
Restraining Mount Adjustment77
Figure 40: Chain/Restraining Mount77
Figure 41: Chain/Restraining Mount Bracket78
Integral Fuel Solenoid79
Fuel Solenoid Diagnostic and Replacement79
Figure 42: Integral Fuel Solenoid Components79
Engine Speed Adjustments80
Low Speed Adjustment80
High Speed Adjustment80
Belts81
Engine/Electric Motor Belt81
Figure 43: Front View Belt Arrangement81
Electric Motor/Compressor Belt82
Alternator Adjustment83
Figure 44: Alternator Mounting and Belt Tension Adjustment83
Idler Pulley Bearing and Seal Installation84
Figure 45: Idler Pulley Assembly84
Assembly Instructions85
Refrigeration Maintenance87
Evacuation87
Figure 46: Evacuation Station88
Figure 47: Vacuum Gauge89
Set up and Test of Evacuation Equipment90
Unit Evacuation91
Unit Charging91
Remove Refrigerant Hoses92
Refrigerant Leaks92
Refrigerant Charge92
Testing the Refrigerant Charge with an Empty Box92
Testing the Refrigerant Charge with a Loaded Box93
Checking Compressor Oil93
Figure 48: Scroll Compressor93
High Pressure Cutout (HPCO)94
Low Side Pump down94
Figure 49: High Pressure Cutout Manifold94
Refrigeration System Checks95
Three-Way Valve Condenser Pressure Bypass Check Valve95
Figure 50: Gauge Manifold Installation95
Figure 51: Three-Way Valve Condenser Pressure Bypass Check Valve96
Discharge Pressure Regulator Valve97
Figure 52: Discharge Pressure Regulator Valve Assembly97
Refrigeration Service Operations99
Accumulator99
Removal99
Installation99
Compressor99
Figure 53: Compressor Components100
Shaft Seal Change Procedure101
Figure 54: Cross Section of Set Screw Type Bellows101
Figure 55: Set Screw Type Bellows Seal101
Figure 56: Bellows Installation with Tool102
Figure 57: Lip Seal and Hard Ring Installation102
Compressor Oil Filter Replacement103
Scroll Compressor Oil Change103
High Temperature Cutout Switch Change Procedure104
Liquid Injection Fitting Change Procedure104
Condenser/Radiator Coil105
Removal105
Installation105
Receiver Outlet Check Valve105
Liquid Injection Valve105
Installation106
Dehydrator (Filter-Drier)106
Removal106
Refrigeration Service Operations (Continued)106
Evaporator Coil106
Figure 58: Location of Injection Valve Bulb106
Figure 59: Completely Wrap Bulb with Tape106
Installation107
Expansion Valve Assembly107
Removal107
Figure 60: Location of Expansion Valve Bulb107
Figure 61: Completely Wrap Bulb with Tape107
Cleaning In-Line Screen108
Heat Exchanger108
Removal108
Installation108
Figure 62: Expansion Valve108
High Pressure Cutout Switch109
Removal109
Installation109
High Pressure Relief Valve109
Pilot Solenoid109
Receiver Tank109
Three-Way Valve Condenser Pressure Bypass Check Valve Repair110
Removal110
Installation110
Figure 63: Condenser Pressure Bypass Check Valve110
Three-Way Valve Repair111
Removal111
Figure 64: Three-Way Valve Assembly111
Installation112
Unit Identification112
Availability112
Leak Detection112
Figure 65: R404A Decal112
Compressor Oil113
Compressors Shipped with POE Oil113
Equipment Recommendations for Use with R-404A113
Gauge Manifold Sets113
Refrigerant Recovery114
Throttling Valve114
Removal114
Disassembly114
Figure 66: Throttle Valve, Cap and Spring114
Figure 67: Throttle Valve Piston114
Reassembly115
Installation115
Figure 68: Throttle Valve Housing115
Figure 69: Throttle Valve Piston Assembly115
Figure 70: Throttling Valve116
Hilliard Clutch Maintenance117
Large Truck Unit Centrifugal Clutch Change117
Figure 71: Front View and Cross Section117
Figure 72: Hilliard Centrifugal Clutch118
Clutch Maintenance119
Tools Required119
Grease119
Disassembly Procedure119
Figure 73: Housing Removal119
Figure 74: Bearing Removal119
Assembly Procedure (Using New Bearings and Seal)120
Figure 75: Bushing Removal120
Figure 76: Bushing Insertion120
Figure 77: Clutch121
Structural Maintenance123
Unit and Engine Mounting Bolts123
Unit Inspection123
Condenser, Evaporator and Radiator Coils123
Fan Location123
Figure 78: Fan Blade Position in Orifice123
Defrost Damper124
Figure 79: Defrost Damper Adjustment124
Fanshaft Assembly125
Disassembly125
Figure 80: Fan Shaft Assembly125
Figure 81: Removing Bearing Retainer Bolts125
Figure 82: Removing Shaft125
Reassembly126
Figure 83: Removing Oil Seal126
Figure 84: Removing Roll Pin126
Figure 85: Installing Bearings126
Figure 86: Installing Splash Guard126
Figure 87: Installing Oil Seal127
Figure 88: Shims and O-Ring127
Figure 89: Torquing Retainer Plate Bolts127
Figure 90: Checking End Play127
Mechanical Diagnosis129
Electric Standby (Optional) Diagnosis133
Refrigeration Diagnosis135
Cycle Diagrams137
Cool Cycle137
Figure 91: Cool Cycle Diagram137
Condenser Evacuation Cycle138
Figure 92: Condenser Evacuation Cycle Diagram138
Heat/Defrost Cycle139
Figure 93: Heat/Defrost Cycle Diagram139
Index141
Wiring and Schematic Diagrams Index143

Thermo King TS-500 NAD User Manual

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Thermo King TS-500 NAD Specifications

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Brand	Thermo King
Model	TS-500 NAD
Category	Refrigerator
Language	English