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Thermo King X214, Overhaul Manual

The Thermo King X214 Overhaul Manual is the essential guide for maintaining and repairing this advanced refrigeration system. Accessible for free download on our website, this comprehensive manual provides step-by-step instructions and expert advice to ensure optimal performance. Download your copy today at manualshive.com.

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Table of Contents

Safety Precautions  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

General Practices  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Battery Installation and Cable Routing  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Battery Removal  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Refrigerant Hazards   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Refrigerant Oil Hazards   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Electrical Hazards  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

High Voltage  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Low Voltage  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

First Aid  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

First Aid, Refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
First Aid, Refrigerant Oil  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
First Aid, Engine Coolant  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
First Aid, Electrical Shock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Compressor Description   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

General Description   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Compressor Model Identification   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Two Cylinder Compressors   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Four Cylinder Compressors  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Oil Collection Container   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Specifications  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Torque Values   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Special Tools   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

General Compressor Repair Techniques  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Dirt and Moisture can Easily Ruin Compressors!  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Compressor Oil Indications  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Compressor Oil Color Code   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Disassembly and Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Disassembly Sequence   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Reassembly Sequence  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Fastener Torque Procedure   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Cleaning Components   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Drive Coupling   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Removal  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Installation   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Cylinder Head  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Removal  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Repair  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Installation   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Discharge Valve Plates  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Removal  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Repair  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Installation   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Two-piece Compressor Seal Plate and Mounting Flange Assembly   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Seal Plate Assembly  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Removal  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Repair  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Installation of Spring Loaded Neoprene Bellows Type Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Installation of Metal Bellows Seal With Set Screws  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Installation of Metal Bellows Seal With Drive Tangs   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Installation of Metal Bellows Seal With Hex Drive   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Oil Sump and Oil Pickup Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Removal  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Repair  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Installation   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Summary of Contents for X214

Page 1: ... Rand Company Printed in U S A 314 West 90th Street Minneapolis MN 55420 Direct 952 887 2200 Thermo King Corporate Distributed by SB 210 Additional text information to be placed here TK 5XXXX X PL 314 West 90th Street Minneapolis MN 55420 Direct 952 887 2200 Thermo King Corporate SB 210 Additional text information to be placed here TK 5XXXX X PL Distributed by 314 West 90th Street Minneapolis MN 5...

Page 2: ...X214 X418 X426 X430 Compressor TK 6875 8 OM Rev 9 02 14 Copyright 1998 Thermo King Corp Minneapolis MN U S A Printed in U S A Overhaul Manual ...

Page 3: ...ilable 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 ...

Page 4: ...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 ...

Page 5: ...__________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ _________________________________________________________________...

Page 6: ...26 Dirt and Moisture can Easily Ruin Compressors 26 Compressor Oil Indications 26 Compressor Oil Color Code 26 Disassembly and Reassembly 28 Disassembly Sequence 28 Reassembly Sequence 28 Fastener Torque Procedure 28 Cleaning Components 28 Drive Coupling 28 Removal 28 Installation 29 Cylinder Head 32 Removal 32 Repair 32 Installation 32 Discharge Valve Plates 33 Removal 33 Repair 34 Installation 3...

Page 7: ...7 Two piece Compressor Seal Plate and Mounting Flange Assembly 67 Metal Bellows Crankshaft Seal with Set Screws 67 Polyol Ester POE Compressor Oil for HFC Refrigerants 67 Groove Top Pistons 67 Teflon Seal Type Drive End Ball Bearing 67 New Coupling Mounting Washer 67 Large Shaft Compressor 67 Metal Bellows Crankshaft Seal with Drive Tangs 67 8 Pin Coupling and Clutch 67 Fins Eliminated from Crankc...

Page 8: ...etion resulting in suffocation and possible death DANGER Avoid engine operation in confined spaces and areas or circumstances where fumes from the engine could become trapped and cause serious injury or death WARNING Make sure your gauge manifold hoses are in good condition before using them Never let them come in contact with moving belts fans pulleys or hot surfaces Defective gauge equipment can...

Page 9: ...lt in severe damage to equipment and void the warranty CAUTION Set all unit electrical controls to the OFF position before connecting battery cables to the battery to prevent unit from starting unexpectedly and causing personal injury CAUTION Always wear protective clothing gloves and eye wear when handling and installing batteries Battery acid can cause serious burns when exposed to eyes or skin ...

Page 10: ...n times and possible system contamination CAUTION Wipe up spills immediately Refrigerant oil can damage paints and rubber materials DANGER Lethal amounts of voltage are present in some electrical circuits Use extreme care when working on an operating refrigeration unit WARNING Do not make rapid moves when working on high voltage circuits in refrigeration units Do not grab for falling tools because...

Page 11: ...act 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 t...

Page 12: ...he parts used are clean and not nicked or scratched During disassembly parts should be cleaned and inspected and if they are to be used in reassembly they should be wrapped in a clean cloth to prevent marring the surfaces Oil all parts with compressor oil during assembly and be sure they are installed in the same position they were in before disassembly NOTE When replacement parts are required we ...

Page 13: ...th a C5 crankshaft drive end bearing This type includes the X426LSC5 and X430LSC5 The large shaft compressor with a C5 crankshaft drive end bearing a pressurized seal cavity and an internal oil filter This type also includes the X426P and X430P The following table shows the four cylinder compressor models according to the shaft size and the crankshaft drive end bearing used The compressor model is...

Page 14: ...lack oil pump housing as shown in Figure 2 Compressors that have a pressurized seal cavity have a P on the seal cover Therefore a compressor with a pressurized seal cavity can be identified by the P on the seal cover as shown in Figure 3 1 Black Oil Pump Housing Figure 2 Compressor with C5 Bearing 1 1 P Indicates Pressurized Seal Cavity Figure 3 Seal Cover for Compressor with Pressurized Seal Cavi...

Page 15: ...sily The check valve is located on the end of the tube inside the container It is a very tight fit between the check valve and the grommet in the oil collection container NOTE The check valve is no longer required on Pressurized Seal Cavity Compressors If maintenance in the area requires removal of the oil collection container or the tube caution should be observed to prevent damage to the check v...

Page 16: ...tion 15 3 If option 1 or 2 are not feasible and it is necessary to pull the check valve back through the grommet gently twist as pulling back If the check valve does come off the tube install a new check valve from stock ...

Page 17: ...Compressor Description 16 Figure 6 Two Cylinder Compressor ARC018 ...

Page 18: ...ng or Valve 26 Piston Pin 58 Oil Sump 27 Piston Pin Retaining Ring 59 Oil Sump Gasket 31 Connecting Rod Assembly 60 Bolt 32 Connecting Rod Bolt 61 Bolt 33 Connecting Rod Nut 62 Copper Washer 34 Bearing Set Standard 63 Oil Sump Screen Bearing Set 0 005 64 Oil Pickup O ring Bearing Set 0 010 65 Bolt Bearing Set 0 020 66 Lockwasher Bearing Set 0 030 67 Flatwasher 35 Pump Shaft O ring 68 Check Valve A...

Page 19: ...ompressor Description 18 Figure 7 Early Style Four Cylinder Compressor NOTE The early style compressor had a spring loaded shaft seal and the seal plate and mounting flange were made in one piece ARC019 ...

Page 20: ...Crankshaft Oil Pump End Bearing 49 O ring 15 Dowel Pin 50 Oil Pump Shaft 16 Suction O ring and Screen 51 Oil Pump Drive Key 17 Copper Washer and Bolt 52 Seal Plate Mounting Flange 18 Cylinder Sleeve 53 Screw and Washer 19 O ring 54 O ring 20 Discharge Valve Plate Assembly 55 Oil Sump Gasket 21 Sight Glass O ring 56 Oil Sump 22 Sight Glass 57 Oil Sump Bolt and Washer 23 Cylinder Head Gasket 58 Chec...

Page 21: ...tyle Four Cylinder Compressor NOTE The late style compressor has a metal bellows type shaft seal Because of the various types of mounting required on different installations the mounting flange and seal plate are made as separate parts ARC020 ...

Page 22: ...lug 46 Oil Pickup Tube Clamp and Hardware 13 Crankshaft 47 Oil Pickup Tube Mounting Bracket 14 Crankshaft Oil Pump End Bearing 48 Bolt and Lockwasher 15 Dowel Pin 49 Oil Line Fitting or Valve 16 Suction O ring and Screen 50 Oil Pump Assembly 17 Oil Fill Plug and O ring 51 O ring 18 Cylinder Sleeve 52 Oil Pump Drive Shaft 19 O ring 53 Oil Pump Drive Key 20 Discharge Valve Plate Assembly 54 Seal Pla...

Page 23: ...ng locked in bore C3 Bearing unlocked in bore C5 Bearing locked in bore 0 0070 to 0 0125 0 0070 to 0 0470 0 to 0 010 Maximum 0 1778 to 0 3175 0 1778 to 1 1938 0 to 0 254 Maximum Connecting Rod Bearing To Crankshaft Rod Journal 0 0008 to 0 0024 0 0203 to 0 0610 Oil Pump Cover Clearance distance below housing 0 0010 to 0 0040 0 0254 to 0 1016 Piston to Sleeve 0 0018 to 0 0027 0 0457 to 0 0686 Piston...

Page 24: ...0814 to 57 0916 Connecting Rod Wrist Pin Bushing Standard I D 0 6255 to 0 6258 15 8877 to 15 8953 Piston Wrist Pin Standard O D 0 6250 to 0 6252 15 8750 to 15 8801 Oil Pump Gerotor Assembly Thickness 0 3430 to 0 3440 8 7122 to 8 7376 Oil Pump Housing Main Bearing Bore I D Two Cylinder Four Cylinder with C3 Bearing Four Cylinder with C5 Bearing 2 8339 to 2 8345 3 5425 to 3 4531 3 5433 to 3 5443 71 ...

Page 25: ... Flange Late Style Four Cylinder 3 8 16 1 5 8 335 28 0 3 86 37 9 55 2306 6 Seal Plate Late Style Four Cylinder 3 8 16 1 1 8 335 28 0 3 86 37 9 55 9106 3 Seal Plate Four Cylinder without Mounting Flange 3 8 16 1 1 8 335 27 9 3 86 37 9 55 9106 9 Seal Plate Two Cylinder 5 16 18 1 1 4 150 12 5 1 73 17 0 55 172 6 Sight Glass 600 50 6 91 67 8 22 350 A R Manifold 3 8 16 1 3 4 335 28 0 3 86 37 9 55 3641 4...

Page 26: ...tion of Screw or Component Thread Size Torque Dia in Pitch Length in in lb ft lb kgm N m Part No Req Description Part Number Drive Coupling Puller 204 139 Wrench Sight Glass 204 244 Check Valve Removal Tool 204 464 Tool Puller Plate 204 483 Adapter Gauge Fitting 204 626 Puller Pump Bearing Plate Slide Hammer Replacement Parts Plate Adapter 1 2 20 x 5 16 18 204 638 204 639 204 640 Adapter Gauge Fit...

Page 27: ... Once the compressor is opened to the atmosphere get the job done quickly Plan ahead Have your parts and tools ready Only use chemical solvents that leave no oily residue such as naphtha lacquer thinner or brake cleaner to clean compressor components The solvents must be nonchlorinated Do Not Bead Blast compressor components clean If the job must be interrupted cover the compressor A fresh clean p...

Page 28: ...plating should be replaced the oil separator should be replaced and the oil and oil filter should be changed A contaminated system will cause a failure if left uncorrected The contaminate in the system will break down the refrigerant oil causing excessive bearing wear and scoring of parts within the compressor Copper plating and moisture will affect the valve plate rings and break down the refrige...

Page 29: ...th clean compressor oil just prior to assembly 3 Install all bolts and washers and pre tighten to 70 of the recommended torque following a criss cross pattern 4 Use a hand torque wrench and the same criss cross pattern to bring all bolts to final torque Hold bolts On Torque for a few seconds Cleaning Components Drive Coupling Removal There are several different types of drive couplings and clutche...

Page 30: ...tapered area as component fracture may result 3 Using no lubricants set the coupling on the crankshaft and align the keyway using the Keyway Tool P N 204 972 Insert the tapered end of the tool into the keyway and gently move the coupling on the shaft while pressing the tool into the keyway This will align the keyway in the crankshaft with the keyway in the coupler Figure 9 Keyway Tool P N 204 972 ...

Page 31: ...ere manufactured they may have either 6 pins or 8 pins Coupling Mounting Bolt Torque Specifications The following table below shows the torque specifications for the socket head mounting bolts used with compressor couplings If a black washer is found when the coupling is removed from a compressor with 1 0 in diameter crankshaft the washer should be replaced with a silver washer P N 77 2498 Torque ...

Page 32: ... ft lb 122 N m Figure 13 Large Crankshaft Coupling Installation Crankshaft Diameter 1 0 in 1 187 in Mounting Bolt Dimensions 3 8 16 in M12 X 1 75 Metric Type and Color of Washer Thin Silver Thin Silver Washer P N 55 4002 55 9232 Torque Specifications 45 ft lb 61 N m 90 ft lb 122 N m AGA523 1 2 3 1 1 0 in or 1 187 in Diameter Crankshaft 2 Thin Washer P N 55 4002 for 1 0 in Crankshaft P N 55 9232 fo...

Page 33: ...ad To maintain critical alignment of assembled components Thermo King does not recommend resurfacing cylinder heads 3 Inspect all thread holes for striped threads Do not use threaded inserts Helicoils to repair damaged threads Installation 1 Apply clean refrigerant oil to the gaskets 2 Two Cylinder Only Install the cylinder head gasket and head with all the bolts assembled loosely Tighten the bolt...

Page 34: ...inal torque Figure 17 Cylinder Head Torque Sequence Discharge Valve Plates Removal 1 Remove the cylinder head See Cylinder Head on page 32 2 After removing the head and gasket remove the discharge valve plates It may be necessary to turn the valve plate slightly clockwise to loosen it Figure 18 Valve Plate Removal 3 When the valve plate is free turn it by hand and lift it straight out of the compr...

Page 35: ...mbly Remove all traces of solvent before installing the valve plate assembly Installation 1 Apply clean refrigerant oil to the new O rings and install them in the compressor body above the cylinder sleeve See Figure 20 O ring Location on page 33 2 Apply clean refrigerant oil to the valve plate assembly and install the valve plate assembly Turn it slightly to prevent binding See Figure 19 Valve Pla...

Page 36: ...rene bellows seal These seals should be replaced with a metal bellows type if using R404A R407C R134A or R22 refrigerants Metal Bellows Type With Drive Tangs Four Cylinder Compressors with 1 187 in diameter crankshafts Metal Bellows Type With Hex Drive Four Cylinder Compressors with 1 187 in diameter crankshafts and pressurized seal cavity Removal 1 Remove the Seal Plate Mounting Flange Two Piece ...

Page 37: ...the set screws that fasten the seal to the crankshaft Figure 27 Set Screw Location NOTE A modified shortened 3mm or 1 8 inch Allen wrench is needed to loosen the set screws New seals are shipped with a modified 1 8 inch Allen wrench Make sure the wrench fits squarely into the bottom of the socket hole before attempting to loosen the set screws Figure 28 Special Allen Wrench 4 Remove the bellows as...

Page 38: ...eal and apply clean compressor oil to the seal assembly Ensure that the installation tool P N 204 953 is clean Use the installation tool to push the seal with the polished surface toward the installation tool fully into the seal plate If the insertion tool is not available use the pad in the new seal packaging to protect the polished surface of the seal during assembly 1 Lip Side Facing Out 2 Flat...

Page 39: ...ly refrigerant oil to the front gasket and place it on the compressor body 6 Install the seal plate on the compressor Hold the seal plate against the spring tension of the bellows until bolts are snug 7 Torque the seal plate bolts in two steps using a criss cross pattern See Torque Values on page 24 1 Centering Washer 2 Bellows Assembly 3 Primary Ring Figure 33 Spring Loaded Neoprene bellows Type ...

Page 40: ...e O ring If the installation tool is not available use the pad in the new seal packaging to protect the polished surface of the hard ring during assembly 3 Back out the set screws from the new seal and apply a small amount of removable thread locking compound Loctite 242 31 blue P N 203 400 to the set screw threads 1 Lip Side Facing Out 2 Flat Side Toward Compressor Figure 37 Lip Seal Installation...

Page 41: ...age labeled 1 Then clean the polished mating surfaces of both rings with the lint free dry wipes from package number 2 Apply clean compressor oil to the polished surfaces of the seal the lip seal and the seal plate gasket from package number 3 before assembling 9 Install the seal plate and gasket to the compressor body Do not bump the seal hard ring on the end of the crankshaft during assembly 10 ...

Page 42: ...ssor oil to the new hard ring Ensure that the hard ring installation tool P N 204 953 is clean Use the hard ring installation tool to push the hard ring with the polished surface toward the installation tool fully into the seal plate Do not pinch the O ring 3 If the installation tool is not available use the pad in the new seal packaging to protect the polished surface of the hard ring during asse...

Page 43: ...uring assembly 7 Install the seal plate mounting bolts and washers Torque the seal plate bolts in two steps using a criss cross pattern See Torque Values on page 24 Installation of Metal Bellows Seal With Hex Drive In the first quarter of 2014 a pressurized seal cavity was phased into use on large shaft compressors The pressurized seal cavity uses a new seal with a hex drive and a new crankshaft w...

Page 44: ... the lip seal is pressed all the way down into the seal plate Oil the lip seal 4 Apply clean compressor oil to the O ring inside the bellows Slide the bellows on the crankshaft align the hex drive on the bellows with the hex drive collar and then push the bellows firmly against the hex drive collar Leave the protective cap in place during installation If the hex drive does not slide on easily rota...

Page 45: ...e Torque Values on page 24 Oil Sump and Oil Pickup Screen Removal 1 Remove all the bolts from the oil sump 2 Tap the sump with a soft hammer or punch to loosen the gasket 3 Remove bolts from the mounting bracket and remove the oil pickup screen 4 Remove the O ring from the oil intake hole Repair 1 Remove all old gasket material from the sump and the compressor body 2 Clean the oil pickup screen 1 ...

Page 46: ...l force the O ring into the oil intake hole 2 Hold the mounting bracket in place and install and torque the mounting bracket bolts See Torque Values on page 24 3 Apply refrigerant oil to the sump gasket and place it on the compressor body The gasket fits properly in only one position 4 Install the oil sump Install the oil sump bolts and washers Torque the oil sump bolts in two steps using a criss ...

Page 47: ...lter from the oil discharge tube Installation 1 Place the internal oil filter on the oil discharge tube and the stud on the oil pickup tube bracket Be careful to avoid damaging the O ring in the oil filter 2 Install and tighten the nut that fastens the internal oil filter to the stud on the oil pickup tube bracket 3 Install the oil sump see Oil Sump and Oil Pickup Screen on page 44 1 Oil Discharge...

Page 48: ...essure regulator a Replace the o ring seal b Apply clean refrigeration oil to the valve by coating or dipping c Screw the regulator into the housing d Tighten to 23 ft lb 31 N m 6 Remove the outer wear plate and the gerotor assembly See Figure 64 Oil Pump Components on page 48 NOTE Because of the close fit of the oil pump assembly the wear plates must be removed very carefully or they will bind in...

Page 49: ...l pump housing Debris often collects in this area 3 Check the condition of the oil pump drive pin In most cases the drive pin will remain in the crankshaft after the oil pump is removed It is not necessary to remove the drive pin from the crankshaft for inspection 4 Discard the old O rings square key and Y spring NOTE It is strongly recommended you discard all of the oil pump components and replac...

Page 50: ...seating against the housing it should not wobble NOTE Both of the pump wear plates and the gerotor gears can be installed with either face in or out NOTE The new oil pump gerotor and wear plates must be kept clean If the parts pick up any debris they must be wiped clean Parts must be handled carefully to prevent damage or contamination 4 Install the key into the keyway on the shaft 5 Immerse the i...

Page 51: ...r plate must be clean and free of debris 13 Install the oil pump cover bolts and washers Torque the oil pump cover housing bolts in two steps using a criss cross pattern see Torque Values on page 24 14 Immerse new O rings in oil and install them on the oil pressure regulator and the oil pickup plug 15 Install the oil pressure relief valve and the oil pickup plug see Torque Values on page 24 16 Ins...

Page 52: ... from the sleeve 2 Inspect the sleeve for scoring damage or cracks near the ports The cross hatching or honing marks should still be visible in the sleeve There should be no large scratches in the sleeve 3 Inspect the piston for wear and damage Check for large scratches in the piston surfaces 4 Measure piston and the sleeve If the piston or sleeve are worn beyond the maximum allowable operating cl...

Page 53: ...the wrist pin is less than 0 6250 in 15 8750 mm replace the piston assembly 10 Inspect the wrist pin bushing in the small end of the connecting rod for wear or damage Measure the wrist pin bushing Replace the wrist pin bushing if its inside diameter is more than 0 6258 in 15 8953 mm 11 Inspect large end of connecting rod for wear or damage NOTE Thermo King does not recommend reinstalling used conn...

Page 54: ...d have a competent machine shop grind the crankshaft to fit the undersize bearings Assembly 1 Place the piston on the connecting rod and install the wrist pin and the snap rings 2 Install the bearings in connecting rod and rod cap 3 Apply apply refrigerant oil to the piston and place it in the sleeve 4 Place the piston and sleeve in the compressor body Take care to prevent damage to crankshaft fro...

Page 55: ...y slip out of the compressor body before the temperature reaches 200 F 93 C If not use Bearing Removal Tool P N 204 1153 to remove the crankshaft and bearing see the following procedure Do not heat the area around the seal end bearing above 350 F 177 C Do not attempt to drive the bearing out of the compressor body without heating or it will damage the compressor body NOTE If required Bearing Remov...

Page 56: ...end bearing and monitor the temperature with a noncontact thermometer P N 204 1059 or similar Heat the area around the seal end bearing to 325 to 350 F 163 to 177 C Do not heat the area around seal end bearing above 350 F 177 C Figure 85 Heat Area Around Bearing From Inside Compressor Body Figure 86 Check Temperature Of Area Around Bearing 1 Heat Through Both Slots In Tool Figure 84 Heat Area Arou...

Page 57: ...dition of main bearings by pressing on the bearing while turning it NOTE Thermo King recommends replacing all main bearings during compressor repairs that involve removing the crankshaft 2 If necessary use the bearing puller tool P N 204 1000 to remove the ball bearings from the compressor crankshaft 3 Place the crankshaft in the tool so that two vertical bars support the inner race of the ball be...

Page 58: ...led in the oil passageways and that oil pump drive pin and the bearings have been installed See steps 8 9 and 10 above 2 Position the compressor body with the seal end down and support it to allow clearance for the drive end of the crankshaft NOTE Figure 92 on page 57 shows a compressor support fabricated from 1 4 in 6 mm sheet metal It is 10 in 250 mm wide 13 in 330 mm long and 4 in 100 mm high T...

Page 59: ... 95 Then quickly position the cool crankshaft assembly into contact with the shoulder in the bearing bore of the hot compressor body Leave a few moments and the heat will exchange between the compressor body and crankshaft and the bearing will become thermally fixed in the bearing bore Figure 95 Installing Crankshaft Figure 96 Crankshaft Installed With Bearing Fully Seated 1 Check Temperature In T...

Page 60: ...tion and tap it lightly till it contacts the compressor body 6 Place two 3 8 16 X 1 1 4 in bolts and two 3 8 in washers in mounting holes on opposite sides of the oil pump housing and snug the bolts down 7 Allow 15 minutes for the Loctite to fix the parts Full cure of the Loctite requires 12 hours at room temperature or 30 minutes at 250 F 121 C Compressor Crankshaft Precautions 1 Alignment of the...

Page 61: ...ndition To properly regrind a long stroke crankshaft the following procedure must be adhered to 1 Mark the add on counterweights so they will be reinstalled on the same integral counterweight 2 Drill off rivet head and drive out rivet with a punch 3 Regrind the crankshaft shaft to the new undersized diameter Bearing sets are available in 0 005 in 0 127 mm 0 010 in 0 254 mm 0 020 in 0 508 mm and 0 ...

Page 62: ...l the check valves a The two lower check valves are located in the front seal area b The two upper check valves are located in the sump area c The large check valve is located in the passageway between the suction cavity and the sump Use tool P N 204 464 to remove the large check valve NOTE In order to remove the large check valve from four cylinder compressors built after April 1987 it will be ne...

Page 63: ...e compressor body thoroughly Check Valve Installation 1 Install the lower check valves Torque to 10 0 ft lb 13 6 N m 2 Install the upper check valves Torque to 25 0 ft lb 33 9 N m 3 Clean the threads of the large check valve Apply four drops of Loctite 277 equally spaced on the threads Do not use an excessive amount of Loctite 4 Install the large check valve with tool P N 204 464 Torque to 28 0 ft...

Page 64: ...This continues until the solenoid de energizes At this time the discharge pressure builds up seals off the port to the suction cavity and the system pumps with four cylinders Check Out 1 With unloader de energized compressor should pump down normally 15 to 20 in Hg vacuum 51 to 68 kPa and should hold a 15 in Hg vacuum 51 kPa for three minutes 2 Using an auxiliary battery energize and de energize u...

Page 65: ... The valve is non repairable 5 Inspect check valve for wear on sides If wear is present valve must be replaced 6 Inspect unloader valve NOTE It may be necessary to disassemble valve assembly to check spring and clean internal portion of piston To disassemble piston from cover depress piston and remove roll pin Compress spring and remove retaining ring a Inspect piston sides for wear b Remove ring ...

Page 66: ...wed for any compressor that has had an oil pump installed and or has been stored for any length of time 1 Once the compressor is installed in the unit attach a suitable gauge on the compressor oil filter pressure access port if equipped You can also use the oil pressure fitting on the oil pump cover 2 Install a suction gauge below the throttling valve 3 Disconnect the wires to the fuel solenoid CA...

Page 67: ... pounds of oil pressure is not developed in the first thirty seconds allow the starter to cool for a few minutes and crank again for 20 seconds If oil pressure still does not develop check the compressor oil level If the level is above the oil pickup screen the oil pump or relief valve will need to be rechecked 7 As soon as oil pressure is developed reconnect the fuel solenoid CAUTION Do not crank...

Page 68: ...nting Washer In the first quarter of 1998 the black coupling washer was changed to a 0 23 in thick silver washer P N 77 2498 Large Shaft Compressor In August of 1998 the large shaft compressor was introduced The large shaft compressors X426LS and X430LS have a crankshaft drive shaft diameter of 1 187 in These compressors are used in trailer units for improved reliability The large shaft compressor...

Page 69: ...page 11 for more information about identifying compressor models A compressor with a C5 bearing and a cast iron oil pump housing requires special tools and procedures to remove and install the crankshaft See Crankshaft on page 54 Oil Collection Container The oil collection container was added to trailer units starting in the first quarter of 2010 The oil collection container collects the compresso...

Page 70: ...6 M metal bellows seal with drive tangs installation 41 metal bellows seal with hex drive installation 42 metal bellows seal with set screws installation 39 O oil collection container 14 oil pump 47 oil sump and oil pickup screen 44 R reassembly sequence 28 S safety precautions 7 battery installation and cable routing 8 battery removal 8 electrical hazards 9 general practices 7 refrigerant hazards...

Page 71: ... Rand Company Printed in U S A 314 West 90th Street Minneapolis MN 55420 Direct 952 887 2200 Thermo King Corporate Distributed by SB 210 Additional text information to be placed here TK 5XXXX X PL 314 West 90th Street Minneapolis MN 55420 Direct 952 887 2200 Thermo King Corporate SB 210 Additional text information to be placed here TK 5XXXX X PL Distributed by 314 West 90th Street Minneapolis MN 5...

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