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Engine Maintenance

114

Compressor—Alternator Belt
Adjustment

1. Loosen the alternator pivot bolt and the

alternator mounting bolt.

2. Turn the alternator adjustment nut to obtain a

reading of 50 ± 5 on the Thermo King Belt
Tension Gauge or 1/2 in. (13 mm) deflection

at the center of the compressor-alternator belt.
If necessary, loosen the alternator bracket
mounting bolts and turn the alternator bracket
adjustment bolt to obtain the proper tension.

3. Tighten the alternator pivot bolt, the alternator

mounting bolt, and the alternator bracket
mounting bolts.

Compressor—Electric Motor Belt
Adjustment

1. Loosen the electric motor mounting bolts.

2. Position the electric motor to obtain a tension

of 67 ± 3 on the Thermo King Belt Tension
Gauge, or 1/2 in. (13 mm) deflection at the
center of the belt.

3. Tighten the mounting bolts.

Water Pump Belt

Add or remove shims between the water pump
pulley sheaves to obtain 1/2 in. (13 mm)
deflection at the center of the belt between the
crankshaft and the water pump.

AEA640

1.

Alternator Bracket Mounting Bolt

4.

Alternator Mounting Bolt

2.

Alternator Bracket Adjustment Bolt

5.

Alternator Bracket

3.

Alternator Pivot Bolt

6.

Alternator Adjustment Nut

Figure 41: Alternator Belt Adjustment

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Summary of Contents for 914970

Page 1: ...RD II MAX w TK 3 95 TK 41023 1 MM Rev 1 10 03 Copyright 2000 Thermo King Corp Minneapolis MN USA Printed in USA...

Page 2: ...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 produc...

Page 3: ...3...

Page 4: ...ormation 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 Pa...

Page 5: ...ctrical Components 19 Thermostat 20 Electrical Standby Compressor Motors 20 Standby Power Requirements 20 Maintenance Inspection Schedule 21 Unit Description 23 General Description 23 X426 Compressor...

Page 6: ...e of Display Range 53 Guarded Access Mode 54 Programming 54 Testing the TG V Thermostat 72 TG V Calibration 72 Ice Water Bath Preparation 72 Sensor Test 72 Preparing TG V Module for Bench Test 73 TG V...

Page 7: ...to the Engine 108 Timing Individual Cylinder Injection 110 Fuel Limit Screw and Maximum Speed Stop Screw 110 Engine Valve Clearance Adjustment 110 Belts 111 Engine Compressor Belt Adjustment 112 Compr...

Page 8: ...stallation 129 Pilot Solenoid 130 Removal 130 Installation 130 Pressure Regulator Valve 130 Removal 130 Installation 130 Receiver Tank 130 Removal 130 Installation 130 Three Way Valve Condenser Pressu...

Page 9: ...assembly 143 Fanshaft Assembly 144 Disassembly 144 Reassembly 145 Mechanical Diagnosis 147 CYCLE SENTRY Diagnosis 151 Electric Standby Optional Diagnosis 153 Refrigeration Diagnosis 155 Refrigeration...

Page 10: ...Table of Contents 10...

Page 11: ...ponents 96 Figure 24 Accumulator Tank Drain 97 Figure 25 Thermostat 98 Figure 26 Fuel System 99 Figure 27 Electric Fuel Pump 101 Figure 28 Fuel Solenoid Timer 102 Figure 29 Fuel Solenoid Location 102...

Page 12: ...olts For Tightness 141 Figure 63 Lift Points 141 Figure 64 Defrost Damper Adjustment 142 Figure 65 Jackshaft Assembly 142 Figure 66 Installing Oil Sling Retainer 143 Figure 67 Removing Bearing Retaine...

Page 13: ...uck body or garage Refrigerant tends to displace air and can cause oxygen depletion resulting in suffocation and possible death 12 When using ladder or scaffolding use caution and follow manufacturer...

Page 14: ...e a small spark from a finger to a door knob can severely damage or destroy solid state integrated circuit components The following procedures must be rigidly adhered to when servicing units to avoid...

Page 15: ...h is turned Off before connecting or disconnecting the standby power plug Never attempt to stop the unit by disconnecting the power plug 2 Be certain the unit power plug is clean and dry before connec...

Page 16: ...spiration If a pulse is not present start CPR Cardiopulmonary Resuscitation and call for emergency medical assistance If a pulse is present respiration may be restored by using mouth to mouth resuscit...

Page 17: ...0 psig 241 to 414 kPa Intake Valve Clearance 0 0079 in 0 20 mm Exhaust Valve Clearance 0 0079 in 0 20 mm Valve Setting Temperature Room temperature Timing Injection Pump 14 degrees BTDC Injection Nozz...

Page 18: ...fore placing the replacement compressor in the unit R 404A Refrigeration System Compressor Model Thermo King X426 Refrigerant Charge 8 lb 3 63 kg R 404A Compressor Oil Charge 4 qt 6 oz 3 9 liters Comp...

Page 19: ...longest span NOTE Belts should be tensioned cold and again tensioned cold after 10 hours of unit running Electrical Control System Control System Voltage 12 5 Vdc Alternator 12 V 23 amp brush type int...

Page 20: ...lectrical Standby Compressor Motors Model 50 Units Only Voltage Phase Frequency Horse power Kilowatts RPM Full Load Amps Locked Rotor Amps 230 3 60 7 5 5 6 1765 21 2 70 1 460 3 60 7 5 5 6 1765 10 6 35...

Page 21: ...rations etc Change engine oil and filters hot Change oil bath air cleaner element replace dry type element clean and service crankcase breather and check air cleaner hose for damage Change fuel filter...

Page 22: ...sually inspect unit for damaged loose or broken parts includes air ducts and bulkheads if so equipped Inspect clutch Inspect idler bearings for leakage and bearing wear Clean entire unit including con...

Page 23: ...stops the unit according to temperature demands In addition a range of programmable modes like high speed pull down allow you to tailor your unit s performance to the load you are distributing The clu...

Page 24: ...Defrost cycle initiation or engine block temperature thermostat demand In cold ambients the CYCLE SENTRY system demand automatically maintains engine temperature by restarting the unit if the engine...

Page 25: ...the switch panel Engine Nameplate on top of the rocker arm cover Compressor Stamped on the side below the sight glass Electric Motor Nameplate attached to the motor housing Unit Features TK 3 95 Dies...

Page 26: ...r High Temperature Cutout Switch Model 50 only with Heater Option Refrigerant High Pressure Cutout Refrigerant High Pressure Relief Valve 20 Ampere Circuit Breaker in Control Circuit 12 V Fuse Link 50...

Page 27: ...Unit Description 27 Unit Photographs Figure 1 Roadside View Figure 2 Curbside View PUB122 PUB123...

Page 28: ...ription 28 1 2 3 4 5 6 7 8 9 10 11 1 Engine 7 Air Defrost Switch 2 Muffler 8 Drier 3 Compressor 9 Condenser Coil 4 Alternator 10 Three Way Valve 5 Nameplate 11 Expansion Tank 6 Receiver Tank Figure 3...

Page 29: ...itch 3 Auto Start Stop Continuous Run Switch Optional 10 Manual Defrost Switch 4 Start Stop Light Optional 11 Microprocessor Controller TG V 5 Defrost Light 12 Run Hourmeter Optional on Model 50 6 Eng...

Page 30: ...ription 30 1 7 8 9 10 2 3 4 5 6 1 Temperature Display 6 UP Key 2 Power Cord Indicator Light 7 DOWN Key 3 ON Key 8 DEFROST Key 4 OFF Key 9 ENTER Key 5 SELECT Key 10 LOW NOISE Key Figure 5 TG V In Cab C...

Page 31: ...Start Stop Continuous Run Switch is set to Auto Start Stop and the light is off In this situation the unit will not run The Engine Reset may be tripped Engine Reset The Engine Reset is a pushbutton s...

Page 32: ...tional The Oil Pressure gauge shows the engine oil pressure This pressure should rise immediately after the engine starts Suction Pressure Gauge Optional The Suction Pressure gauge indicates the press...

Page 33: ...ergize relays on the option board to control the operation of the unit The remote On Off switch and the unit On Off switch must both be in the On position for the unit to operate Either switch will tu...

Page 34: ...tick Use the engine oil dipstick to check the engine oil level Coolant Tank This gauge indicates the engine coolant level If the pointer is in the FULL white range the coolant level is acceptable If t...

Page 35: ...excess pressure within the refrigeration system Located on a high pressure line near the condenser it is non repairable and requires no adjustment When pressure is released from the valve it is direc...

Page 36: ...tart sequence once initiated is the same for both systems Refer to the CYCLE SENTRY sections of this manual for further information on the start sequence as it applies to the Auto Start system Manuall...

Page 37: ...he unit when the compartment temperature reaches the thermostat setpoint and restarts the unit on thermostat demand On CYCLE SENTRY equipped units the unit start ups may also be initiated by Defrost c...

Page 38: ...or Heat the glow plugs will automatically heat for the required amount of time depending on the engine temperature 5 seconds at 150 F 66 C to 120 seconds at 20 F 29 C 7 At the end of the preheat peri...

Page 39: ...will remove residual body heat and moisture from the truck interior and provide a good test of the refrigeration system Defrost When the unit has finished pre cooling the truck interior evaporator coi...

Page 40: ...Operating Instructions 40...

Page 41: ...ically initiated every 4 hours during pull down until the return air temperature is in range At in range temperatures between approximately 7 degrees above and 7 degrees between point the controller i...

Page 42: ...have the following part numbers P N 41 1544 12V No Modulation P N 41 1545 12V Modulation P N 41 1546 24V No Modulation P N 41 1547 24V Modulation The software and alarm codes were updated in the firs...

Page 43: ...eturning from thermometer to unit Indicates that the return air temperature is being displayed Discharge Air Symbol Arrow from unit pointing at thermometer Indicates that the discharge air temperature...

Page 44: ...temperature in whole degrees A decimal point and 1 2 size number indicates temperature in tenths of a degree Alarm Symbol Exclamation point within a triangle When this flashing symbol is displayed an...

Page 45: ...n ENTER Key Equals sign is used to enter new information into the controller UP Key Arrow pointing upward When the setpoint symbol is on the screen this key is used to increase the setpoint temperatur...

Page 46: ...ll symbols and readouts will be displayed for about 5 seconds Make sure that all display segments are operational After 5 seconds the Standard Display will appear This display remains on the screen du...

Page 47: ...nit is switched Off it is normal for the display to remain On for about 30 seconds as it slowly fades NOTE With the power Off or battery disconnected all settings are saved in the controller memory an...

Page 48: ...ctory Standard Display setting this may be changed Other operating data can also be displayed To view other operating data repeatedly press and release the SELECT key In addition to Return Air Tempera...

Page 49: ...49 Alarms Can be displayed only when an alarm condition has been sensed by the controller When viewing a display If no keys are pressed the Standard Display will automatically reappear on the screen...

Page 50: ...down will cause the temperature to scroll automatically one degree at a time 3 To enter the new setpoint into memory Press and release the ENTER key within 5 seconds The display will blink once as the...

Page 51: ...lure The Return Air Sensor has failed or is disconnected 03A Return Air Sensor Failure The Return Air Sensor has failed or is disconnected Zone 2 04 Discharge Air Sensor Failure Optional The Discharge...

Page 52: ...est In Cab TG V with tester P N 204 83 76 Microprocessor EEPROM Faulty Test In Cab TG V with tester P N 204 83 77 EPROM Faulty Test In Cab TG V with tester P N 204 83 87 Field Test Error 88 Microproce...

Page 53: ...ange The Microprocessor Controller TG V is capable of displaying temperatures ranging from 40 to 99 9 F 40 to 37 8 C A blinking temperature display of 40 or 99 9 F 40 or 37 8 C without an alarm symbol...

Page 54: ...ammed by entering a two digit set up code into each screen Set up code 68 is the standard set up code for Screen 1 on CD II MAX NAD units Programming the controller requires the following Choosing the...

Page 55: ...tronic Controls 55 Before entering the Guarded Access mode or changing set up codes 1 Choose the set up codes for each screen 2 Write the set up codes in the space provided or on a separate piece of p...

Page 56: ...til the setpoint symbol is on the screen NOTE Record the setpoint so that the unit may be returned to the original setting when programing is finished 2 Press the UP or DOWN key until the setpoint is...

Page 57: ...own 5 While holding down the SELECT key press the UP key and the DOWN key at the same time Screen 1 in the Guarded Access mode will appear To select other Guarded Access screens press and release the...

Page 58: ...entered into memory The new code will remain on the screen for about 5 seconds and then The standard screen will automatically appear or You may go to another Guarded Access screen by pressing and re...

Page 59: ...rned back On the timer will reset and start timing again from the beginning The timer could initiate defrost 2 hours from the time the unit was turned back On The Microprocessor Controller should be s...

Page 60: ...discharge air temperature NO Discharge sensor not connected do not display discharge air temperature NOTE If the unit does not have a discharge air sensor but the discharge sensor setting is set to YE...

Page 61: ...NOTE Factory standard settings are in bold type Save Elapsed Time Defrost Terminate Time High Speed Delay Code No 30 min No 0 No 30 min Yes 1 No 45 min No 2 No 45 min Yes 3 Yes 30 min No 4 Yes 30 min...

Page 62: ...with this screen Defrost Time Interval Above Lockout Sets the defrost interval for setpoint temperatures above 15 F 9 4 C Settings 2 4 6 8 10 12 14 or 16 hours Defrost Time Interval Below Lockout Set...

Page 63: ...that matches the correct setting from the bottom table This becomes the right digit NOTE Factory standard settings are listed in the wiring and schematic diagrams for each unit Defrost Time Above Lock...

Page 64: ...setting would be 4 For ungraded sensors set the controller to grade 0 Directions for choosing the set up codes for Screen 3 are on the next page Discharge Sensor Grade Optional Matches controller oper...

Page 65: ...ade from the top table This becomes the left digit 2 Select the code number that matches the return air sensor grade from the bottom table This becomes the right digit NOTE Factory standard settings a...

Page 66: ...ional NOTE This screen is available only when the Discharge Sensor setting Screen 1 is set to YES Alternate between Return Air Temperature and Setpoint Temperature Return Air 30 seconds Setpoint 5 sec...

Page 67: ...g and schematic diagrams for each unit Defrost Model Display The purpose of this modification is to allow the default display to include a periodic indication that the system is in the Defrost mode Th...

Page 68: ...n switching from low speed heat to low speed cool as necessary As operation continues In Continuous Run or CYCLE SENTRY if setpoint has not been reached in eight minutes while running low speed cool t...

Page 69: ...the unit will resume normal operation This setting functions only while the unit is operating in Continuous Run Settings YES Enable 2 minute low speed start NO Normal operation Do not enable 2 minute...

Page 70: ...dard settings are listed in the appropriate wiring and schematic diagrams for each unit Code 0 High Speed Pull Down Fresh High Speed Pull Down Frozen 2 Minute Low Speed Start Reduced Setpoint Range Co...

Page 71: ...us readouts Fahrenheit 0 0 F OFF 6 10 14 and 18 degrees Celsius 0 0 F OFF 3 6 and 10 degrees Figure 8 In Range Temperature Differential Setting Directions To determine the setting for Screen 5 choose...

Page 72: ...Stir the ice water bath for one minute or until stabilized at 32 F 0 C 4 Monitor the ice water bath temperature with a mercury thermometer during testing to ensure test accuracy NOTE Before testing a...

Page 73: ...l the setpoint symbol is on the screen 3 Press the UP and DOWN key until the setpoint is at exactly 32 F or 0 C 4 Press the ENTER key within 5 seconds to enter this setpoint 5 With the setpoint temper...

Page 74: ...Controls 74 6 Press the UP or DOWN key until the set up code on Screen 1 reads 68 7 Press the ENTER key If no keys are pressed the Standard Display will automatically reappear on the screen in about...

Page 75: ...and CH Zero volts should be present The heat relay should be de energized 9 Set the thermostat module setpoint to 29 F 1 7 C The thermostat is now in low speed cool a Check for voltage between termina...

Page 76: ...the voltage at terminal 10T after the eight minute interval 12 volts should be present 18 Connect pin 86 of the third relay to the 11 terminal in order to simulate the defrost relay Connect pin 85 of...

Page 77: ...Vdc 12 Vdc 12 Vdc 12 Vdc CH 0 Vdc 0 Vdc 0 Vdc 0 Vdc 29 0 Vdc 0 Vdc 0 Vdc 0 Vdc 10T 12 Vdc 0 Vdc 0 Vdc 12 Vdc See note below 14T 0 Vdc 0 Vdc 12 Vdc 12 Vdc Return Air Sensor SN SN HFL 0 Vdc 0 Vdc 0 Vdc...

Page 78: ...dule 3 Ch Thermostat Module Ground Circuit 4 29 Force To High Speed Input During Defrost 5 10t Applies Voltage To Speed Relay Coil When Calling For High Speed 6 14t Applies Voltage To Heat Relay Coil...

Page 79: ...l Identification 2 3 4 5 6 7 8 1 aea958 1 Specialized Terminal Functions 2 Hfl Force Heat Lockout 3 Hlo Heat Lockout Output 4 38 In range Output 5 7t Force High Speed Cool 6 Sp Setpoint Output 7 12 De...

Page 80: ...alve 3 7k Accumulative Defrost Time And High Speed Delay Input 4 Output To Modulation Valve Not Connected To Ch Ground 5 Output To Modulation Valve 6 8b CYCLE SENTRY Is In Operation Input 7 Disc Senso...

Page 81: ...0 to 3500 ohms Use the following method to give the sensor a more accurate test a Cool the sensor down to 32 0 F 0 0 C and check the resistance The reading should be 3266 3 4 ohms b Warm the sensor up...

Page 82: ...Electronic Controls 82...

Page 83: ...od condition and are adjusted properly before testing the alternator Worn belts and pulleys or loose belts will lower the output of the alternator The battery must be well charged the battery cable co...

Page 84: ...Full alternator output the alternators rated output indicates the alternator is good but the voltage regulator needs replacement b If there is low or no output the alternator is probably faulty Howeve...

Page 85: ...battery voltage is brought back up to normal If the voltmeter shows low voltage after start up check the alternator belt tension and all charging circuit connections including the battery NOTE On ins...

Page 86: ...wires and measure the resistance across the terminals and from each terminal to the aluminum case The resistance should be 250 to 300 ohms across the terminals and there should be no continuity from...

Page 87: ...ound or shorter circuit in the electrical system does not cause the reset switch to pop out Low Oil Pressure Switch LOP The engine oil pressure should rise immediately after the engine is started The...

Page 88: ...mulation increase the pressure setting Turn the adjustment screw clockwise High Capacity TherMaxTM Heating System The high capacity heating system increases the capacity of the Heat mode by making mor...

Page 89: ...y opening energizing the hot gas solenoid and closing energizing the condenser inlet solenoid The TherMaxTM solenoid remains open while the unit is in the Heat mode The receiver outlet check valve pre...

Page 90: ...y all segments a The Turtle icon must be displayed If not press the TURTLE key Alarm Code 19 will be recorded if the Turtle icon is not displayed b If the Alarm icon is displayed press the SELECT key...

Page 91: ...at Relay 9 WHT BRN 10 ACC Accessory Wire to Truck Ignition 11 PC WHT BLK VOIL Power Cord Electric Standby 12 8B WHT BLK BLU CYCLE SENTRY Input 13 10T VIOLET High Speed Relay 14 38 WHT BLK BRN In Range...

Page 92: ...Electrical Maintenance 92...

Page 93: ...he connecting rod bearings This oil is thrown around the bottom end of the engine as it flows out of the bearings while the crankshaft rotates Some of this oil lubricates the cylinder walls Some of th...

Page 94: ...ath air cleaner filters all of the air entering the engine Excessive restriction of the air intake system reduces the flow of air to the engine affecting horsepower output fuel consumption and engine...

Page 95: ...n air restriction indicator is installed in the air intake elbow Visually inspect the restriction indicator periodically to assure the air filter is not restricted Service the air filter when the yell...

Page 96: ...ins the coolant temperature within the specified temperature range All water cooled engines are shipped from the factory with a 50 permanent type antifreeze concentrate and 50 water mixture in the eng...

Page 97: ...ate and 32 water for use in extreme temperatures Changing the Antifreeze 1 Run the engine until it is up to operating temperature Stop the unit 2 Open the engine block drain and accumulator tank drain...

Page 98: ...pump The injection pump plungers are activated by a gear driven injection pump camshaft The governor sleeve and weight assembly is mounted on the end of the injection pump camshaft The governor s spee...

Page 99: ...Engine Maintenance 99 AEA628 1 Fuel Injection Pump 3 Fuel Pickup Tube 2 Fuel Filter 4 Electric Fuel Pump Figure 26 Fuel System...

Page 100: ...mp 3 Energize the electric fuel pump by placing the On Off switches in the On position and pressing the ON key Tighten the air bleed screw and press the OFF key when a clear flow of fuel appears NOTE...

Page 101: ...r in cleaning solvent and blow out the dirt and cleaning solvent with compressed air Check the cover gasket and replace if damaged Clean the cover Reassembly Place the cover gasket on the bottom cover...

Page 102: ...l on position the hold in coil will keep it in fuel on position until the 8D circuit is de energized The pull in coil must be de energized after a few seconds to keep it from being damaged A fuel sole...

Page 103: ...8D The fuel solenoid relay is energized momentarily by the fuel solenoid timer when the 8D circuit is first energized After approximately 2 5 seconds the fuel solenoid timer de energizes the fuel sole...

Page 104: ...o step 7 7 Check the CH circuit pin C in the main wire harness at the fuel solenoid connector for continuity to a good chassis ground a If there is no continuity between the CH circuit and a good chas...

Page 105: ...move the fuel solenoid relay from its socket and make sure the On Off switch is in the On position 13 Check the voltage on the 8D circuit at the 85 terminal in the fuel solenoid relay socket Refer to...

Page 106: ...gine fails to maintain the correct engine speeds check the following before adjusting the speed 1 Bleed air out of the fuel system Recheck the speed 2 Bleed air out of the nozzles Recheck the speed 3...

Page 107: ...uel injection lines and the fuel lines Remove the four nuts holding the pump to the timing cover and the fuel supply line 2 Remove the inspection plate on the side of the timing cover 3 Remove the cli...

Page 108: ...cylinder timing is so minimal the procedure for timing the pump to the engine will be covered first The procedure for individual cylinder timing is very similar to timing the injection pump so it will...

Page 109: ...s did not line up a shim or shims will have to be added or subtracted from the injection pump Adding shims will retard the injection timing subtracting shims will advance the timing Increasing or decr...

Page 110: ...crew The fuel limit screw and the maximum speed stop screw are both covered with anti tamper caps and are not adjustable Engine Valve Clearance Adjustment The valve clearance should be checked after t...

Page 111: ...the number 2 cylinder is at top dead center of the compression stroke a Check the rocker arms and push rods on the number 2 cylinder b If the rocker arms and push rods are loose the number 2 cylinder...

Page 112: ...t is at the proper tension Use one of the following methods to check or set the belt tension a The belt tension should be set at a reading of 70 3 on the Thermo King Belt Tension Gauge b The belt shou...

Page 113: ...Engine Maintenance 113 AEA638 1 Engine Compressor Belt 3 Compressor Jackshaft Electric Motor Belt 2 Compressor Alternator Belt 4 Water Pump Belt Figure 40 Belt Arrangement...

Page 114: ...bolt and the alternator bracket mounting bolts Compressor Electric Motor Belt Adjustment 1 Loosen the electric motor mounting bolts 2 Position the electric motor to obtain a tension of 67 3 on the The...

Page 115: ...e prone to leak Never attempt evacuation without a micron or 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 contamina...

Page 116: ...eration Maintenance 116 1 2 3 4 5 6 7 8 9 AGA654 1 V 4 6 Two Stage Vacuum Pump 2 Thermistor 7 To 110 Vac Power 3 V 3 8 Calibration Standard 4 V 2 9 Vacuum or Micron Gauge 5 V 1 Figure 42 Evacuation St...

Page 117: ...0 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 Stan...

Page 118: ...Figure 44 Leak Isolate the pump from the system by closing the proper valve Watch the movement of the vacuum gauge needle If the needle continues to rise this is an indication that a leak exists in th...

Page 119: ...sent or additional evacuation time is required 8 If the vacuum level is acceptable start the pump and open valve V 1 to evacuate the pressure rise 5 minutes 9 Close valve V 1 and stop the pump Observe...

Page 120: ...coil with a piece of cardboard 5 The compound gauge should be indicating 13 to 18 psig 90 to 124 kPa gauge pressure If there is any doubt about the unit gauge check the calibration 6 Under these cond...

Page 121: ...rmostat well below the box temperature so that the unit will be in High Speed Cool 3 Raise the discharge pressure of the compressor by blocking the condenser coil air flow by covering the roadside con...

Page 122: ...s bled off until it drops to the level of the discharge pressure The purpose of the valve is to improve heating defrosting ability and three way valve response To check the operation of the valve 1 Re...

Page 123: ...enser pressure bypass check valve stem against snap ring Both gauges should rise indicating the condenser pressure bypass check valve is properly releasing condenser pressure into the discharge tube a...

Page 124: ...Refrigeration Maintenance 124...

Page 125: ...vacuum 0 to 17 kPa 5 Turn the unit Off 6 Prepare to perform service on the low side by equalizing the high side and low side pressures through the gauge manifold 7 Equalize low side pressure to 1 to 2...

Page 126: ...e and compound pressure gauge hoses 4 Pressurize the compressor and test for refrigerant leaks 5 If no leaks are found evacuate the compressor Replace the compressor electric motor belt and adjust the...

Page 127: ...nt to purge the air through the drier Then tighten outlet nut on the dehydrator to the evaporator line 4 Pressurize the system and inspect for leaks If no leaks are found open the refrigeration valves...

Page 128: ...e side of the suction line in its former position The feeler bulb must make good contact with the suction line or the operation will be faulty Wrap with insulating tape 5 Pressurize the low side and t...

Page 129: ...izer line flare fitting to the suction line and liquid outlet line flare fitting to the expansion valve 7 Pressurize the low side and test for leaks If no leaks are found evacuate the unit 8 Clean the...

Page 130: ...line from the three way valve first Connect wires to the valve 3 Open the refrigeration valves and place the unit in operation 4 Check for leaks Soldered Connections 1 Clean the tubes for soldering 2...

Page 131: ...ust be used which includes the Teflon valve spring o ring valve stem and snap ring Installation 1 Coat the o ring with compressor oil use same type of oil that is used in the system and install it on...

Page 132: ...ove the spring clip Observe the slot in the spool shaft and slide piston away from this slot 9 Remove the piston 10 Remove the center section and stem assembly 11 Inspect the following parts for wear...

Page 133: ...re charged with Polyol Ester oil POE TK No 203 413 All gauge fittings are 1 4 inch fittings Because Polyol Ester has an affinity for moisture it must be kept in capped containers In addition it should...

Page 134: ...utomotive type polyalkylene glycol PAG oils System Clean up Existing clean up devices such as suction line filters and compressor oil filters may be used if they are thoroughly cleaned and new filter...

Page 135: ...135 Hilliard Clutch Maintenance Large Truck Unit Centrifugal Clutch Change The centrifugal clutch has three belt grooves and its engagement speed is 600 100 RPM Figure 55 Front View and Cross Section...

Page 136: ...oves 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 Spr...

Page 137: ...move retaining ring 2 Remove the 3 8 16 flat head cap screw and washer NOTE This screw was installed using LoctiteTM see Tool Catalog and will require the use of an impact tool for removal NOTE A smal...

Page 138: ...in nut Thread nut onto screw approximately 3 4 to 1 in Insert threaded end of screw into bushing Lubricate bushing by dipping in clean water only Then press into place Figure 60 Bushing Insertion DO...

Page 139: ...12 5 6 N m NOTE Shoes MUST be held tightly against hub while nuts are tightened 14 Place the hub and shoe assembly into the housing and place flatwasher over the bearing 15 Apply LoctiteTM see Tool Ca...

Page 140: ...Hilliard Clutch Maintenance 140...

Page 141: ...posite normal air flow Inspect the coil and fins for damage and repair if necessary Defrost Damper Check the damper during scheduled maintenance inspections for shaft wear end play and sealing against...

Page 142: ...1 Remove jackshaft assembly from the unit and remove the pulleys 2 Remove the level and fill plugs and drain oil reservoir 3 Remove bearing retainer cap from fill plug end of the jackshaft assembly N...

Page 143: ...ing retainer enough to fit inside the jackshaft housing 5 Install the shaft into the jackshaft housing with oil sling retainer on the shaft with bearing Align the opening in the oil sling retainer wit...

Page 144: ...fanshaft assembly from the unit Remove both oil plugs and drain the oil from the housing Figure 67 Removing Bearing Retainer Bolts 2 After draining the oil from the housing remove the four retaining...

Page 145: ...me manner Reassembly 1 Install the new bearings on the shaft with a pipe in the same way they were removed Figure 71 Installing Bearings 2 When replacing the bearing race on the evaporator end of the...

Page 146: ...ained add grease for the bearings NOTE Use ONLY Thermo King special fanshaft grease P N 203 278 in this assembly Lock the assembly in a vise with the vent facing up Pour grease through the top plug un...

Page 147: ...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 sys...

Page 148: ...lter 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 Pi...

Page 149: ...irty 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 sy...

Page 150: ...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 cle...

Page 151: ...Test D7 or D8 diodes Defective CYCLE SENTRY module Test CYCLE SENTRY module Open CH circuit to CYCLE SENTRY module Test CH circuit Open 7A circuit from selector switch to the preheat relay Test 7A cir...

Page 152: ...ll not initiate start from defrost Open 29 circuit Test 29 circuit to PC board Open D11 diode or R9 resistor or 29T circuit on PC board Test D11 diode or R9 resistor and 29T circuit on PC board to the...

Page 153: ...tor contactor Repair or replace motor contactor Defective low oil pressure switch Replace low oil pressure switch Overload relay tripping Check for shorted motor windings or wires Defective motor Repl...

Page 154: ...aters do not heat optional indicator lights come On Defective heater contactor Replace contactor 26 wire open Locate open and repair Defective high temperature switch or sensor Replace switch or senso...

Page 155: ...not heating or defrosting Symptom Possible Causes Overcharge of refrigerant Shortage of refrigerant No refrigerant Air through condenser too hot ambient Air flow through condenser restricted Air thro...

Page 156: ...id 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 Rapid cycling between...

Page 157: ...1 Receiver Outlet Check Valve 3 Condenser Coil 12 Accumulator Tank 4 Pilot Solenoid 13 Suction Pressure Regulator 5 Heat Solenoid 14 Heat Exchanger 6 High Pressure Relief Valve 15 Expansion Valve 7 Re...

Page 158: ...1 Receiver Outlet Check Valve 3 Condenser Coil 12 Accumulator Tank 4 Pilot Solenoid 13 Suction Pressure Regulator 5 Heat Solenoid 14 Heat Exchanger 6 High Pressure Relief Valve 15 Expansion Valve 7 Re...

Page 159: ...1 Receiver Outlet Check Valve 3 Condenser Coil 12 Accumulator Tank 4 Pilot Solenoid 13 Suction Pressure Regulator 5 Heat Solenoid 14 Heat Exchanger 6 High Pressure Relief Valve 15 Expansion Valve 7 Re...

Page 160: ...Refrigeration Diagrams 160...

Page 161: ...refrigeration 155 digital thermometer 34 E electric fuel pump 101 electric motor reset switch 34 electric operation 24 38 electric standby diagnosis 153 electrical components specifications 19 electri...

Page 162: ...3 electrical hazards 14 general practices 13 high voltage 15 low voltage 16 microprocessor service 14 refrigerant 13 refrigeration oil 14 welding 15 schematic diagrams 165 serial number locations 25 s...

Page 163: ...Index 163 W wiring 85 wiring diagrams 165...

Page 164: ...Index 164...

Page 165: ...ol w Thermostat Schematic Diagram 170 5D44874 RD 50 STD 3 Phase Wiring Diagram 171 172 5D44875 RD 50 STD 3 Phase Schematic Diagram 173 174 5D44892 RD 30 STD Wiring Diagram 175 176 5D44895 RD 30 STD Sc...

Page 166: ...Wiring and Schematic Diagrams Index 166...

Page 167: ...167 Cab Control RD Wiring Diagram...

Page 168: ...168 RD w o Thermostat Cab Control Schematic...

Page 169: ...169 RD Cab Box Wiring Diagram...

Page 170: ...170 RD Cab Control w Thermostat Schematic Diagram...

Page 171: ...171 RD 50 STD 3 Phase Wiring Diagram Page 1 of 2...

Page 172: ...172 RD 50 STD 3 Phase Wiring Diagram Page 2 of 2...

Page 173: ...173 RD 50 STD 3 Phase Schematic Diagram Page 1 of 2...

Page 174: ...174 RD 50 STD 3 Phase Schematic Diagram Page 2 of 2...

Page 175: ...175 RD 30 STD Wiring Diagram Page 1 of 2...

Page 176: ...176 RD 30 STD Wiring Diagram Page 2 of 2...

Page 177: ...177 RD 30 STD Schematic Diagram Page 1 of 2...

Page 178: ...178 RD 30 STD Schematic Diagram Page 2 of 2...

Page 179: ...179 RD 30 C S Wiring Diagram Page 1 of 2...

Page 180: ...180 RD 30 C S Wiring Diagram Page 2 of 2...

Page 181: ...181 RD w CYCLE SENTRY Schematic Diagram Page 1 of 2...

Page 182: ...182 RD w CYCLE SENTRY Schematic Diagram Page 2 of 2...

Page 183: ...183 RD 50 C S 3 Phase Wiring Diagram Page 1 of 2...

Page 184: ...184 RD 50 C S 3 Phase Wiring Diagram Page 2 of 2...

Page 185: ...185 RD w CYCLE SENTRY Schematic Diagram Page 1 of 2...

Page 186: ...186 RD w CYCLE SENTRY Schematic Diagram Page 2 of 2...

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