Thermo King 002008, Manual

Page: 82 / 155

Refrigeration Maintenance
82
Compressor Removal and Installation
The 7-quart sump extends below the top of the
lower frame rails. Therefore, a flat board cannot
be used as a support when removing or installing
a compressor with a 7-quart sump. A Compressor
Installation Tool P/N 204-1087 (two pieces) has
been developed to aid in the removal and
installation of the 7-quart sump compressor. See
Compressor Removal and Installation on pages 87
and 88 for more information.
Compressor Disassembly and Assembly
All compressor repair procedures and torque
specifications are the same for the 7-quart sump
compressor as for the 4-quart sump compressor.
See the X214, X418, X426 & X430 Compressor
Overhaul Manual TK 6875 for complete details.
Compressor Conversion
A 4-quart sump compressor can be converted to a
7-quart sump compressor. The following parts
must be replaced:
IMPORTANT: The sump gasket for the 4-quart
sump is different and must not be used with the
7-quart sump.
Checking Compressor Oil
The compressor oil should be checked when there
is evidence of oil loss (oil leaks) or when
components in the refrigeration system have been
removed for service or replacement. Use the
compressor sight glass to check the oil level. See
Figure 54 or Figure 55 on page 81.
To check compressor oil level with an
ambient air temperature above 50 F (10 C):
Install a gauge manifold on the compressor.
Operate all the evaporators on cool with a 20 psig
(138 kPa) minimum suction pressure and a
185 psig (1275 kPa) minimum discharge pressure
for 15 minutes or more.
After the unit has maintained the above conditions
for 15 minutes, observe the oil level. The oil
should be 1/4 to 1/2 up in the sight glass.
To check compressor oil level with an
ambient air temperature below 50 F (10 C):
Run all the evaporators through a complete
defrost cycle. After completing the defrost cycles,
run all the evaporators on cool for ten minutes.
Observe the oil level. The oil should be 1/4 to 1/2
up in the sight glass.
If the compartment is empty, you can run the
evaporator on the heat cycle instead of the defrost
cycle.
NOTE: Use refrigeration compressor oil ONLY.
Polyol Ester type (P/N 203-513) is required on
R-404A systems.
High Pressure Cutout Switch
(HPCO)
The HPCO is located on the compressor discharge
manifold. If the discharge pressure rises above
470 psig (3241 kPa), the HPCO opens. This opens
the 8P-8D circuit, which de-energizes the fuel
solenoid and shuts down the unit. The
microprocessor then records Alarm Code 10. To
test the HPCO; rework a gauge manifold. See
Figure 56 on page 83.
1. Connect the gauge manifold to the compressor
discharge service valve with a heavy duty,
black jacketed thick wall #HCA 144 hose with
a 900 psig (6204 kPa) working pressure
rating.
2. Use the Service Test mode to run the host unit
in High Speed Cool. Refer to the appropriate
Diagnosis Manual for specific information
about the Service Test Mode.
Description P/N Qty
Sump Oil Machined 7 Quart 22-1181 1
Tube/Screen Oil Pickup 7 Quart 22-1182 1
Bracket Pickup Tube 92-2921 1
Gasket Sump 7 Quart 33-3797 1
Screw HH 3/8-16 x 5.5 Inch SZN 51-0575 16