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Thermo King 919180, Manual

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Table of Contents

8

Refrigeration Service Operations (continued)
Expansion Valve Assembly  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105

Removal   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Installation  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Cleaning In-line Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106

Heat Exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106

Removal   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Installation  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106

High Pressure Cutout Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

Removal   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Installation  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

High Pressure Relief Valve  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

Removal   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Installation  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

Pilot Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

Removal   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Installation  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

Receiver Tank  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

Removal   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Installation  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

Three-Way Valve Condenser Pressure Bypass Check Valve Repair  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108

Removal   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Installation  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108

Three-way Valve Repair   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109

Removal   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Installation  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110

R-404A   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110

Unit Identification   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Availability  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Leak Detection   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Compressor Oil  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Compressors Shipped with POE Oil  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Equipment Recommendations For Use With R-404A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Gauge Manifold Sets   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Refrigerant Recovery   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112

Suction Pressure Regulator Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112

Removal   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Installation  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112

Hilliard Clutch Maintenance  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Large Truck Unit Centrifugal Clutch Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Clutch Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115

Tools Required  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Grease   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Disassembly Procedure   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Assembly Procedure (Using New Bearings and Seal)  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  . 116

Structural Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Unit And Engine Mounting Bolts  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Unit Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Condenser, Evaporator and Radiator Coils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Fan Location  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Defrost Damper  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
Fanshaft Assembly   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121

Disassembly  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Reassembly   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122

Summary of Contents for 919180

Page 1: ...TS 200 TS 300 TK 50794 1 MM Rev 5 04 03 Copyright 2000 Thermo King Corp Minneapolis MN USA Printed in USA...

Page 2: ...ns 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...

Page 3: ...formation 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 P...

Page 4: ...4...

Page 5: ...ir Switch 20 Maintenance Inspection Schedule 21 Unit Description 23 ThermoGuard P T Controller 23 Data Acquisition System Optional 23 Clutch 23 Unit Features 24 Unit Instruments 25 Unit Protection Dev...

Page 6: ...m Diagnostic Procedures 51 Excessive Voltage Output 52 Battery 53 Unit Wiring 53 Electrical Contacts 53 Charging System 12 Vdc 53 Preheat Buzzer 53 RPM Sensor 53 Glow Plugs 54 Condenser Evaporator Fan...

Page 7: ...mpty Box 90 Testing the Refrigerant Charge with a Loaded Box 91 Checking Compressor Oil 91 High Pressure Cutout HPCO 92 Low Side Pump Down 92 Refrigeration System Checks 93 Three way Valve Condenser P...

Page 8: ...al 109 Installation 110 R 404A 110 Unit Identification 110 Availability 110 Leak Detection 110 Compressor Oil 111 Compressors Shipped with POE Oil 111 Equipment Recommendations For Use With R 404A 111...

Page 9: ...nical Diagnosis 125 Electric Standby Optional Diagnosis 129 Refrigeration Diagnosis 131 Cycle Diagrams 133 Cool Cycle 133 Condenser Evacuation Cycle 134 Heat Defrost Cycle 135 Index 137 Wiring and Sch...

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

Page 11: ...gure 23 Software Revision 45 Figure 24 Viewing Prompt And Display Screens 46 Figure 25 Alarm Code Display 47 Figure 26 Prestolite Terminal Locations 51 Figure 27 Flywheel RPM Sensor 53 Figure 28 RPM a...

Page 12: ...66 Condenser Pressure Bypass Check Valve 108 Figure 67 Three way Valve Assembly 109 Figure 68 R404A Decal 110 Figure 69 Front View and Cross Section 113 Figure 70 Hilliard Centrifugal Clutch 114 Figur...

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: ...age or destruction 1 Disconnect all power to the unit 2 Avoid wearing clothing that generates static electricity wool nylon polyester etc 3 Do wear a static discharge wrist strap see Tool Catalog with...

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: ...l assistance Low Voltage Control circuits used in the temperature control unit are low voltage 24 Vac and 12 Vdc This voltage potential is not considered dangerous but the large amount of current avai...

Page 17: ...Pump 14 degrees BTDC Injection Nozzle Pressure 1700 psig 11722 kPa Low Oil Pressure Sensor 10 2 psig 69 14 kPa shutdown High Coolant Temperature Sensor 220 5 F 100 3 C shutdown Engine Thermostat 180...

Page 18: ...5 liters Compressor Oil Type R 404A Solest 35 Ester base required for Scroll compressor See Tool Catalog Suction Pressure Regulator Valve Setting TS 200 28 to 30 psig 193 to 207 kPa TS 300 36 to 38 p...

Page 19: ...Disconnect components from unit circuit to check resistance Defrost Timer SR Models with P T 2 4 or 6 hours adjustable through controller Thermostat Type P T Controller Electrical Components Current D...

Page 20: ...60 8 2 10 TS 300 Voltage Phase Frequency Horsepower Kilowatts RPM Full Load Amps Overload Relay Setting Amps 230 3 60 7 2 5 4 1750 17 8 21 460 3 60 7 2 5 4 1750 8 0 10 Standby Power Requirements Suppl...

Page 21: ...ed with an air restriction incicator replace air cleaner element at 2 000 hours or 1 year whichever occurs first Clean and service crankcase breather and check air cleaner hose for damage Change stand...

Page 22: ...charge 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 damag...

Page 23: ...nce thereby reducing fuel consumption and unit down time The unit s self check can be run before the daily distribution route to identify any possible malfunctions TherMaxTM defrost heating system inc...

Page 24: ...efilter S S Spin on Fuel Filter O O Fuel Heater S S Spin on Full Flow Oil Filter O O Spin on Bypass Oil Filter O O Silicone Coolant Hoses S S EPDM Coolant Hoses S S 23 Amps Alternator S S Defrost Air...

Page 25: ...n the top of the restriction indicator after servicing the air filter Remote Light Indicators Optional Remote indicator lights in a box that can be mounted on the truck beneath the unit feature these...

Page 26: ...e Sensor This sensor provides an OPS input to the microprocessor interface board If the oil pressure remains too low the controller stops the unit and records an alarm Unit Operation Pretrip Inspectio...

Page 27: ...oint temperature lower display Check the icons that appear on the display These icons identify the operating information that currently appears A control panel allows the operator to select informatio...

Page 28: ...t Check Alarms have been recorded or FAIL Unit has shut down and recorded Shutdown Alarms a View the alarms with the SELECT key see the appropriate Operation and Diagnosis Manual for detailed informat...

Page 29: ...ARROW key until the desired setting shows in the lower display YES CYCLE SENTRY mode no Continuous Run mode 3 When the correct setting shows in the lower display press the ENTER key to load the new se...

Page 30: ...face board and unit controls 3 To clear the alarms after all problems have been corrected start the unit Then press and release the SELECT key until the alarm screen is displayed again 4 While the ala...

Page 31: ...d end automatically NOTE The unit will not defrost unless the evaporator coil temperature is below 42 F 7 C Loading Procedure 1 Make sure the unit is Off before opening the doors to minimize frost acc...

Page 32: ...Unit Description 32 Unit Photographs Figure 3 Front View Figure 4 Back View AJA584 AJA585...

Page 33: ...Unit Description 33 Figure 5 Left Side View Figure 6 Right Side View AJA586 AJA58...

Page 34: ...ressure Regulator 3 Electric Motor 4 Alternator 5 Pilot Solenoid 6 Air Switch 7 Liquid Injection Valve 8 Three way Valve 9 Receiver Tank 10 Discharge Service Port Not Shown 11 Scroll Compressor Not Sh...

Page 35: ...Unit Description 35 Figure 8 North American Power Receptacle Box AJA58...

Page 36: ...oad Contactor Behind Cover Plate 10 K3 Relay 3 Overload Reset Solenoid Behind Cover Plate 11 K2 Relay 4 Remote Control Cab Box Harness Connector 12 K5 Relay 5 Preheat Buzzer 13 K6 Relay 6 K8 Relay 14...

Page 37: ...Unit Description 37 Figure 11 Remote Light Display 1 2 1 Keypad 2 LED Display Figure 10 ThermoGuard Remote Control Panel AEA103...

Page 38: ...Unit Description 38...

Page 39: ...located on the unit frame just below the control box on the side of the unit Main power to the balance of the controls is supplied by the 50 amp circuit breaker CB1 NOTE When the Microprocessor Power...

Page 40: ...quipped with Electric Standby Electric Heat Figure 13 High Voltage Tray with Phase Correction Standard Board Figure 14 High Voltage Tray with Phase Correction and Electric Heat CAUTION The Electric Po...

Page 41: ...through the prompt and display screens UP ARROW Key Chooses prompt screen actions or increases setpoint or other setting DOWN ARROW Key Chooses prompt screen actions or decreases setpoint or other set...

Page 42: ...ntrol panel test but is not used on truck units Defrost Icon Appears when the unit is defrosting CYCLE SENTRY Icon Appears when CYCLE SENTRY mode has been selected Alarm Icon Appears when an alarm con...

Page 43: ...ay wait 10 seconds and it will return automatically Figure 18 Standard Display Changing The Setpoint Figure 19 Changing the Setpoint 1 Press the ON key to turn the unit On 2 Press the or ARROW keys to...

Page 44: ...nged The display will return to the Standard Display and the setpoint will return to the old setpoint in about 10 seconds if the ENTER key is not pressed Starting The Engine Figure 21 Starting The Eng...

Page 45: ...defrost prompt will appear in the display when the unit starts a Defrost cycle The Defrost cycle will terminate automatically If the unit is not running or the coil temperature is not below 45 F 7 C t...

Page 46: ...Hr4 Total accumulated hours on hourmeter 4 only appears if this hourmeter is set to Type 1 2 or 3 Hr5 Total accumulated hours on hourmeter 5 only appears if this hourmeter is set to Type 1 2 or 3 Hr6...

Page 47: ...ion is sensed by the microprocessor an alarm code is generated and saved in memory There can be more than one alarm present at one time An alarm code will remain in memory until it is cleared The Alar...

Page 48: ...ll automatically shut down the Alarm icon will appear and the entire display will flash On and Off To view the complete list of possible alarm codes and their definitions see the P T Microprocessor Di...

Page 49: ...Run X X 37 Check Engine Water Level X 38 Electric Phase Reversed or Motor Overload Tripped X 40 High Speed Circuit X 52 Heat Circuit X 54 Test Mode Timeout X 61 Battery Check X 63 Engine Stopped Reas...

Page 50: ...splayed These settings may be verified by the operator if necessary Defrost Check The operation of the damper door is checked RPM Check The diesel engine RPM is checked in both high and low speed Cool...

Page 51: ...ts and pulleys or loose belts will lower the output of the alternator The battery must be well charged the battery cable connections must be clean and tight and the 2A and excitation circuits must be...

Page 52: ...lternators 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 However the following items are po...

Page 53: ...that will continue until the 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 incl...

Page 54: ...sor from all 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 cont...

Page 55: ...are in proper position and make sure they are not obstructed 1 Remove plastic sensing tubing from both sides of the defrost air switch 2 Disconnect one wire at switch terminal Connect test light or c...

Page 56: ...system The components that have been added to the system are the TherMaxTM solenoid the TherMaxTM solenoid line the receiver outlet check valve The TherMaxTM solenoid controls the flow of refrigerant...

Page 57: ...noid are all energized at the same time The TherMaxTM solenoid remains open while the unit is in the Defrost mode Start Up Mode For the first 20 seconds when the unit is started it runs in the Cool mo...

Page 58: ...Electrical Maintenance 58...

Page 59: ...o the rocker arm shaft flows through a tube on the outside of the engine and into the head through a restrictor fitting Oil pressure is affected by oil temperature viscosity and engine speed Subnormal...

Page 60: ...ion of the air intake system affects horsepower fuel consumption and engine life Inspect the element at every oil change On dry element air cleaners equipped with an air restriction indicator check th...

Page 61: ...the radiator automatically maintains coolant temperature within the specified temperature range All water cooled engines are shipped from the factory with a mixture of 50 permanent type antifreeze co...

Page 62: ...e Coolant ELC is recommended to assure that de ionized water is being used If 100 full strength concentrate is used de ionized or distilled water is recommended over tap water to insure the integrity...

Page 63: ...mpletely drain coolant Observe coolant color If the coolant is dirty proceed with a b and c Otherwise go to step 3 a Run clear water into radiator and allow it to drain out of the drain cock until it...

Page 64: ...ype that should be used The injection pump plungers are activated by an extension on the engine camshaft The governor sleeve and weight assembly is mounted on the end of the crankshaft with governor s...

Page 65: ...a pump with diesel filter Injection line replacement Pump timing Nozzle spray pattern testing and adjustment Minor rebuilding of nozzles Bleeding the Fuel System The fuel system will have to have the...

Page 66: ...Engine Maintenance 66 Figure 37 Fuel and Oil System Components...

Page 67: ...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 Filt...

Page 68: ...als according to the Maintenance Inspection Schedule 1 Remove the filter and discard 2 Lubricate rubber ring of new filter with fuel 3 Install the filter and tighten until the filter is slightly loose...

Page 69: ...s of timing procedures used on the engine One procedure involves checking to make sure the cylinders are timed correctly to each other and the second procedure times the injection pump correctly to th...

Page 70: ...mark on the starter mounting plate is near the air cleaner on the side of the plates that faces the flywheel It cannot be seen when looking through the engine side door opening unless you use a mirro...

Page 71: ...tall 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 the nozzles and test run the engine Timing Individual Cylinder...

Page 72: ...e as viewed next to the flywheel from the water pump end 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 cy...

Page 73: ...ains three vibration mounts two snubber mounts and a chain restraining mount Figure 41 Engine Mounting Components NOTE For details see Chain Restraining Mount on page 75 0 2 in 5 mm Air Gap Between Lo...

Page 74: ...hread 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 Chain Bellevi...

Page 75: ...f balloon items for Engine Mounting Components on page 73 Install chain on DEPRESSED side of eye bolt AGA649 1 Eye Bolt 10 Locknut HH 2 Locknut 3 8 in 11 Stud 3 Belleville Washer 3 8 in 12 Locknut HH...

Page 76: ...8 SS Flatwasher 5 16 Nylock Nut 5 16 18 SS 4 Screw 3 8 16 SS Flatwasher 3 8 Nylock Nut 3 8 16 SS 2 Vibration Mount 5 2 Link Chain 3 Mount Frame Bracket 6 This End Through Existing Hole In Engine Flang...

Page 77: ...ent is applied to the coil creating an electro magnetic field which pulls the plunger in When in the pulled in position the plunger releases tension on the governor linkage The governor linkage then m...

Page 78: ...he jam nut High Speed Adjustment 1 Start the unit and let it run until the engine is warmed up 2 Run the engine in high speed and check the engine speed The engine speed should be 2450 50 RPM 3 If the...

Page 79: ...ey mounting bracket 3 Turn the idler pulley adjustment bolt to obtain the proper belt tension field reset 55 to 60 on TK gauge 4 Tighten the locknut on the idler pulley adjustment bolt and tighten the...

Page 80: ...n the eye bolt This bolt is located directly to the compressor side of the alternator 3 Turn the locknut above the adjusting bracket on the eye bolt to obtain the proper belt tension field reset 55 to...

Page 81: ...is critical that the belt be correctly seated in pulley First and last edge of grooves are higher to improve seating of belts 1 2 3 4 5 6 7 8 AGA643 1 Mounting Bracket 5 Eye Bolt NOTE Use the hole on...

Page 82: ...Remove retaining snap ring and discard the two bearings 1 Seal side of Bearing NOTE If bearing has two seals one seal must be removed 5 Bearing Spacer 6 Wave Washer to Stop Outer Races from Spinning S...

Page 83: ...nd bearing spacer on pin 3 Install grease slinger and add grease Fill cavity 1 2 full between bearings Use Shell Alvania EP2 see Tool Catalog 4 Install second ball bearing seal side out and retaining...

Page 84: ...Engine Maintenance 84...

Page 85: ...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 contaminat...

Page 86: ...geration Maintenance 86 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 49 Evacuation St...

Page 87: ...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 Stand...

Page 88: ...mp still operating open valve V 3 If the micron reading does not return to a level of less than 500 microns locate and correct the problem before continuing 6 With the vacuum pump still operating open...

Page 89: ...ween 1000 and 1500 microns back seat the suction service valve and observe the micron gauge A sharp drop in the micron reading 300 to 500 microns would indicate that refrigerant is present in the oil...

Page 90: ...suction gauge Stop the unit 4 Back seat the suction service valve and remove all remaining hoses 5 Install and tighten service port and valve stem caps 6 Unit is ready for a functional check out Refri...

Page 91: ...high speed cool with a 10 psig 69 kPa minimum suction pressure and 185 psig 1275 kPa minimum discharge pressure for 15 minutes or more After the unit has maintained the above conditions for 15 minute...

Page 92: ...the control circuit operation and secondly by HPCO switch replacement Low Side Pump Down NOTE Operate the unit in COOL for 2 to 5 minutes before performing the low side pump down 1 Install a gauge ma...

Page 93: ...flow Three way Valve Condenser Pressure Bypass Check Valve The condenser pressure bypass check valve is built into the three way valve This check valve controls the bypass flow of refrigerant gas bet...

Page 94: ...y valve seals properly toward the condenser and the condenser pressure bypass check valve seals properly 9 Back seat condenser pressure bypass check valve stem against snap ring Both gauges should ris...

Page 95: ...er line on the valve The valve dome is pre charged with nitrogen at a pressure of 325 psig 2241 kPa at 70 F 21 C The valve opens and closes as the discharge pressure varies to maintain the discharge p...

Page 96: ...Refrigeration Maintenance 96...

Page 97: ...from the compressor 4 Disconnect the high temperature cutout switch the pilot solenoid line and unsolder liquid injection line 5 Remove the compressor stabilization bracket and the compressor mounting...

Page 98: ...2 3 4 5 6 7 8 AGA660 AGA661 9 1 Pulley 6 Shaft Seal Assembly 2 Oil Filter Cover Plate 7 Suction Adapter 3 Oil Filter 8 Compressor Stabilization Bracket 4 High Temperature Cutout Switch 9 Oil Drain Cap...

Page 99: ...screws that secure the bellows to the shaft These set screws typically use an 1 8 inch Allen wrench which is provided with the new seal 9 Remove the old bellows from the shaft Use a small prybar or s...

Page 100: ...allation tool is not available use the pad in the new seal packaging to protect the polished surface of the hard ring during assembly A substitute installation tool should have a diameter approximatel...

Page 101: ...icate new gasket with compressor oil 10 Install spring new gasket cover plate and compressor stabilization bracket using hex screws torquing to 290 to 310 in lb 34 to 36 N m Be certain to install hex...

Page 102: ...th wire channel pointed down Cap will snap into place when in proper location Liquid Injection Fitting Change Procedure The steps for changing the liquid injection fitting are as follows 1 Recover ref...

Page 103: ...htly positive 2 Place a heat sink on the check valve 3 Unsolder lines and remove the check valve Installation 1 Clean the tubes for soldering 2 Place the check valve in position The arrow on the valve...

Page 104: ...oosen the mounting hardware and remove the drier Installation 1 Install the new drier and tighten the mounting screws and nuts Install new o rings 2 Install and tighten the inlet nut to the receiver t...

Page 105: ...ualizer line from the expansion valve 4 Unsolder the inlet liquid line and the distributor from the expansion valve 5 Remove the expansion valve mounting bolt and remove the expansion valve from the u...

Page 106: ...xchanger assembly out of the evaporator housing Installation 1 Clean the tubes for soldering 2 Place the heat exchanger assembly in the evaporator housing and install the mounting hardware loosely 3 S...

Page 107: ...harge the unit with refrigerant and check the compressor oil Pilot Solenoid Removal 1 Recover refrigerant from the unit 2 Disconnect the lines to the solenoid and immediately cap to prevent moisture a...

Page 108: ...with compressor oil use same type of oil that is used in the system and install it on the check valve stem 2 Insert the spring into the hole in the check valve stem and then install the Teflon check v...

Page 109: ...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 110: ...stall pilot solenoid line and pressurize system with refrigerant to check for leaks 11 If there are no leaks evacuate the system and recharge with refrigerant 12 Run the unit to check for proper three...

Page 111: ...Thermo King Evacuation Station is recommended This station is available from service parts see Tool Catalog See Truck and Trailer Service Bulletin T T 061 for additional details Use only recommended...

Page 112: ...atalog 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 f...

Page 113: ...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 69 Front View and Cross Section AGA...

Page 114: ...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 115: ...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 116: ...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 74 Bushing Insertion DO...

Page 117: ...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 118: ...Hilliard Clutch Maintenance 118...

Page 119: ...ons Remove any debris e g leaves or plastic wrap that reduces the air flow Clean dirty coils with compressed air or a pressure washer Be careful not to bend the fins when cleaning a coil If possible b...

Page 120: ...f not proceed to step 1 c c Remove the jumper wire loosen the evaporator outlet adjustment angle and move so when energized the damper will close d Retighten the adjustment angle and repeat steps a an...

Page 121: ...aired NOTE The fanshaft assembly requires a special lubricant see Tool Catalog Disassembly 1 Remove the fanshaft assembly from the unit Remove both oil plugs and drain the oil from the housing 2 After...

Page 122: ...roll pin removed place a pipe over the shaft and drive one bearing down until the opposite bearing and bearing spacer release from the shaft 9 After removing one bearing and the bearing spacer turn th...

Page 123: ...bolts 6 Torque the bolts in a criss cross pattern in equal steps to 80 in lbs 9 04 N m Figure 87 Torquing Retainer Plate Bolts 7 Lock the assembly in a vise and set up a dial indicator to read the en...

Page 124: ...he top plug until it runs out of the side hole The assembly holds 2 2 oz 65 ml Check the condition of the o ring used on the plugs and replace if necessary Install top and side plugs Clean up any spil...

Page 125: ...r defective Repair or replace Engine cranks but fails to start Fuel solenoid defective Replace solenoid No fuel or wrong fuel in tank Fill fuel tank After filling a completely empty tank first bleed f...

Page 126: ...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 127: ...iator 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 hea...

Page 128: ...pair 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 fue...

Page 129: ...ontactor load side contactor closed 5 Overload relay 6 Motor terminals Defective motor contactor Repair or replace motor contactor Defective low oil pressure sensor Replace low oil pressure sensor Ove...

Page 130: ...gn matter prevents contacts from closing Clean contacts Rapid cycling Check for cause of short cycling such as thermostat Short circuit Correct fault Electric heaters do not heat optional indicator li...

Page 131: ...Symptom 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 ambi...

Page 132: ...e or broken electrical connections Thermostat or thermometer out of calibration Suction pressure gauge out of calibration Leaky receiver tank outlet valve Leaky bypass check valve DPR Valve Faulty Rap...

Page 133: ...rain Pan Heater 6 High Pressure Relief Valve 21 Evaporator Coil 7 Three way Valve 22 Accumulator Tank 8 Condenser Pressure By pass Check Valve 23 Suction Pressure Regulator 9 Condenser Coil 24 Suction...

Page 134: ...Drain Pan Heater 6 High Pressure Relief Valve 21 Evaporator Coil 7 Three way Valve 22 Accumulator Tank 8 Condenser Pressure By pass Check Valve 23 Suction Pressure Regulator 9 Condenser Coil 24 Suctio...

Page 135: ...rain Pan Heater 6 High Pressure Relief Valve 21 Evaporator Coil 7 Three way Valve 22 Accumulator Tank 8 Condenser Pressure By pass Check Valve 23 Suction Pressure Regulator 9 Condenser Coil 24 Suction...

Page 136: ...Cycle Diagrams 136...

Page 137: ...59 Engine Air Cleaner 60 Engine Cooling System 61 Engine Fuel System 64 Engine Lubrication System 59 Engine Maintenance 59 Engine Mounts 73 Engine Specifications 17 Engine Speed Adjustments 78 Engine...

Page 138: ...Smart Reefer SR 27 Specifications 17 Standby Power Specifications 20 Structural Maintenance 119 Suction Pressure Regulator Valve 112 T Table of Contents 5 TherMax 56 ThermoGuard Controller 23 Thermos...

Page 139: ...rawing Title Page 5D49383 Truck S Model SR 30 Schematic Diagram 141 142 5D49384 Truck S Model 30 Units with P T Wiring Diagram 143 144 5D48563 Truck S Model 50 Schematic Diagram 145 146 5D48747 Truck...

Page 140: ...Wiring and Schematic Diagrams Index 140...

Page 141: ...141 Truck S Model SR 30 Schematic Diagram Page 1 of 2...

Page 142: ...142 Truck S Model SR 30 Schematic Diagram Page 2 of 2...

Page 143: ...143 Truck S Model 30 Units with P T Wiring Diagram Page 1 of 2...

Page 144: ...144 Truck S Model 30 Units with P T Wiring Diagram Page 2 of 2...

Page 145: ...145 Truck S Model 50 Schematic Diagram Page 1 of 2...

Page 146: ...146 Truck S Model 50 Schematic Diagram Page 2 of 2...

Page 147: ...147 Truck S Model 50 Units with P T Wiring Diagram Page 1 of 2...

Page 148: ...148 Truck S Model 50 Units with P T Wiring Diagram Page 2 of 2...

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