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Recover Refrigerant

At Thermo King, we recognize the need to preserve the environ-
ment and limit the potential harm to the ozone layer that can
result from allowing refrigerant to escape 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 regula-
tions concerning the use of refrigerants and the certification of
technicians. For additional information on regulations and tech-
nician certification programs, contact your local THERMO KING
dealer.

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Содержание SB-III 30 SR+

Страница 1: ...Whisper TK 50200 2 MM Rev 4 04 02 For units with and without EMI 3000 Copyright 1998 Thermo King Corp Minneapolis MN U S A Printed in U S A ...

Страница 2: ...as all inclusive or covering all contingencies If further information is required Thermo King Corporation should be consulted Sale of product shown in this manual is subject to Thermo King s terms and conditions including but not limited to the Thermo King Limited Express Warranty Such terms and conditions are available upon request Thermo King s warranty will not apply to any equipment which has ...

Страница 3: ...to 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 regula tions concerning the use of refrigerants and the certification of technicians For additional information on regulations and tech nician certification programs contact your local THERMO KING dealer ...

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Страница 5: ...Pretrip Inspection Before Starting Unit 21 Starting Unit With Electronic Full Pretrip 21 Selection of Operating Modes 22 Restarting Unit 23 After Start Inspection 23 Loading Procedure 24 Post Load Procedure 24 Post Trip Checks 24 Electrical Maintenance 25 Alternator Australian Bosch 25 Charging System Diagnostic Procedures 25 Battery 29 Unit Wiring 29 Fuses 29 Fuse Link 29 Air Heater 30 Thermoguar...

Страница 6: ...and Installation 54 Refrigeration Maintenance 57 Refrigerant Charge 57 Refrigerant Leaks 59 Checking Compressor Oil 59 High Pressure Cutout Switch HPCO 60 Three way Valve Condenser Pressure Bypass Check Valve 60 Modulation Valve Optional 62 Hot Gas Solenoid Optional 62 Refrigeration Service Operations 63 Compressor 63 Compressor Coupling Removal 63 Compressor Coupling Installation 64 Condenser Coi...

Страница 7: ...alve Optional 79 Structural Maintenance 81 Unit And Engine Mounting Bolts 81 Unit Inspection 81 Condenser Evaporator And Radiator Coils 81 Defrost Drains 81 unit installation 81 Defrost Damper 82 Condenser And Evaporator Fan Location 83 Fan Shaft Assembly Overhaul 84 Idler assembly 86 Idler Assembly Overhaul 86 Mechanical Diagnosis 89 Refrigeration Diagnosis 93 Refrigeration Diagrams 95 Wiring Dia...

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Страница 9: ...nds to displace air and can cause oxygen depletion resulting in suffocation 11 EPA Section 608 Certification is needed to work on refrigeration systems REFRIGERANT Although fluorocarbon refrigerants are classified as safe refrigerants certain precautions must be observed when handling them or servicing a unit in which they are used When exposed to the atmosphere in the liquid state fluoro carbon r...

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Страница 11: ... in high speed Intake Valve Clearance 0 006 to 0 010 in 0 15 to 0 25 mm Exhaust Valve Clearance 0 006 to 0 010 in 0 15 to 0 25 mm Valve Setting Temperature 70 F 21 C Fuel Injection Timing 11 to 13 BTDC timed on No 1 cylinder Low Oil Pressure Switch Normally Closed 17 3 psi 117 21 kPa Engine Coolant Thermostat 180 F 82 C Engine Coolant Type Conventional Conventional coolant antifreeze is green or b...

Страница 12: ...h Pressure Cutout 470 7 psi 3241 48 kPa Automatic reset 375 38 psi 2586 262 kPa When the compressor is removed from the unit oil level should be noted or the oil removed from the compressor should be measured so that the same amount of oil can be added before placing the replacement compressor in the unit ELECTRICAL CONTROL SYSTEM Voltage 12 5 Vdc Battery One group C31 12 volt battery 2 Circuit Fu...

Страница 13: ... 5 Vdc THERMOGUARD µP V MICROPROCESSOR TEMPERATURE CONTROLLER Temperature Controller Type Electronic THERMOGUARD µP V Microprocessor with digital thermostat thermometer and fault indicator monitor Setpoint Range 20 to 80 F 29 to 27 C Programmable setpoint range to 90 F 32 C Digital Temperature Display 40 to 99 9 F 40 to 40 C Internal Defrost Timer Temperature Pulldown 2 4 6 8 or 12 hours selectabl...

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Страница 15: ...r has not reached 25 in Drain water from fuel tank and check vent Inspect clean fuel transfer pump inlet strainer Check and adjust engine speeds high and low speed Check condition of drive coupling bushings per Service Bulletin T T 171 Check condition of engine mounts Replace standard silver fuel filter water separator Replace EMI 3000 black fuel filter water separator ENGINE OIL CHANGE INTERVALS ...

Страница 16: ...ction pressure Check compressor oil level and condition Check throttling valve regulating pressure Check compressor efficiency and pump down refrigeration system Replace dehydrator and check discharge and suction pressure every 2 years Structural Visually inspect unit for fluid leaks Visually inspect unit for damaged loose or broken parts includes air ducts and bulkheads Inspect tapered roller bea...

Страница 17: ...Controls A CYCLE SENTRY Start Stop fuel saving system provides optimum operating economy Selecting Continuous or CYCLE SENTRY operation on units equipped with CYCLE SENTRY is accomplished using the microproces sor keypad WARNING With the unit On Off switch in the ON position the unit may start at anytime without prior warning NOTE A buzzer sounds when the unit is automatically preheating NOTE The ...

Страница 18: ...ng The Tracker trans mits data at preset intervals or on demand depending on the type of SCS Data can also be transmitted through a Tracker to the microprocessor with some systems Thermo King X430 Compressor The unit is equipped with a Thermo King X430 four cylinder compressor with 30 cu in 492 cm3 displacement Refrigeration Modulation System Optional The refrigeration modulation system provides p...

Страница 19: ...he temperature is within a few degrees of setpoint the tem perature is considered to be in range and the in range icon will turn on The microprocessor will select the operating mode from the list of possible modes below High Speed Cool Low Speed Cool Low Speed Modulated Cool Optional Low Speed Modulated Heat Optional Low Speed Heat High Speed Heat Defrost CYCLE SENTRY Mode Setpoint at or Above Fre...

Страница 20: ...cur if the difference between the return air temperature discharge air temperature and coil temperature becomes excessive Two defrost timers are used When the unit is In Range within a few degrees of setpoint defrost intervals are con trolled by the Defrost Interval In range timer DEFI This timer can be set for 4 6 8 or 12 hours When the unit is not in range defrost intervals are determined by the...

Страница 21: ...lts Heavy Duty Dry Element Air Cleaner Inside Unit Frame THERMOGUARD Microprocessor Controller Fuel Filter with Water Separator Spin On Full Flow Bypass Dual Element Oil Filter Dealer Installed Synthetic Engine Oil Opt Side Mount Coolant Expansion Tank Defrost Timer CYCLE SENTRY System 37 Amp Alternator Refrigerant R 404A Silicone Coolant Hoses Opt Fuel Heater Opt Fresh Air Exchange Opt Condenser ...

Страница 22: ...ssure Switch Engine Low Oil Level Switch Evaporator Temperature Sensor Refrigerant High Pressure Cutout Switch High Refrigerant Pressure Relief Valve 12 Volt Fuse Link Fuse in Main Power Circuit Fuse in Control Circuit Fuse in Modulation Valve Circuit Opt Fuse in Microprocessor Power Circuit Relay Fuses Remote Status Light Fuse ...

Страница 23: ... Nameplate on the curbside of the unit inside the top service access grille and on the roadside of the unit frame below control panel Engine Nameplate on rocker arm cover Compressor Stamped on the end above the oil pump 1 Serial Number Location 1 AGA231 1 1 1 ...

Страница 24: ...Unit Description Rev 04 02 14 Unit Photos Front View AGA231 ...

Страница 25: ...Unit Description Rev 04 02 15 1 Defrost Damper 2 X430 Compressor 3 TK 486 Engine Back View AEA698 2 3 1 ...

Страница 26: ...alve 12 Battery Tray 4 Throttle Solenoid 13 Hand Primer Pump 5 Fuel Solenoid 14 Dipstick 6 Air Restriction Indicator 15 Oil Filter Standard Blue Filter Shown 7 Fuel Bleed Screw 16 Starter 8 Alternator 17 Compressor Sight Glass 9 Three way Valve 18 Compressor Oil Filter Engine Compartment 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 ara193 ...

Страница 27: ...Unit Description Rev 04 02 17 1 Display 3 Keypad 2 Microprocessor Control Panel 4 Switch Panel Control Panel AEA737 1 2 3 4 ...

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Страница 29: ...sor also continu ously monitors discharge and return air sensor temperatures and unit operational information The Microprocessor Control Panel contains the display screen and the keypad The display shows various informa tion The keypad controls the operation of the microproces sor Refer to the appropriate Operation Manual or Operation and Diagnosis Manual for detailed information about oper ating ...

Страница 30: ...rt in the 2 circuit 2 FUSES A number of fuses located on the relay board protect various circuits and components A 40 amp fuse F9 2 Circuit protects the 2AA cir cuit which is the main power circuit A 15 amp fuse F3 Damper protects the 29F circuit which supplies power to the damper solenoid A 15 amp fuse F18 High Speed Solenoid protects the 7D circuit which supplies power to the high speed solenoid...

Страница 31: ...p while coolant is hot CAUTION Do not add RED Extended Life Coolants to cooling systems using GREEN or BLUE GREEN coolants Do not add GREEN or BLUE GREEN coolants to cooling systems using RED Extended Life Coolants See ELC Extended Life Coolant on page 32 for more information 4 BATTERY The terminals must be clean and tight 5 BELTS The belts must be in good condition and adjusted to the proper tens...

Страница 32: ...e Alarms with the CODE key refer to the appropriate Operation and Diagnosis Manual for detailed information about alarms a Correct the alarm conditions b Clear the alarms with the CLEAR key refer to the appropriate Operation and Diagnosis Manual for detailed information about alarms c Repeat the PRE TRIP test until PASS appears the unit passes the PRETRIP 6 Recheck the setpoint 7 Complete the Afte...

Страница 33: ...ay the unit should preheat and start automatically NOTE When the CYCLE SENTRY Icon is active the unit may not start if the compartment temperature is near the setpoint the engine is warm and the battery is fully charged If cooling or heating is required and the engine temperature is below approximately 90 F 32 C but the engine fails to start automatically Turn the On Off switch to the OFF position...

Страница 34: ...ke sure the unit is OFF before opening the doors to minimize frost accumulation on the evaporator coil and heat gain in the trailer Unit may be running when loading the trailer from a warehouse with door seals 2 Spot check and record load temperature while loading Especially note any off temperature product 3 Load the product so that there is adequate space for air circulation completely around th...

Страница 35: ...UTION The F15 fuse must be removed from the relay board on units equipped with the Australian Bosch alternator The voltage regulator will be dam aged if the unit is turned ON with the F15 fuse in place on the relay board Complete the following checkout procedure before replac ing the voltage regulator or the alternator When testing alternators use accurate equipment such as a Thermo King P N 204 6...

Страница 36: ...hould be at battery voltage If not check the sense circuit 2 or equivalent in the alternator harness and in the main wire harness b The B pin is the excitation circuit and should be at 10 volts or higher If not check the excitation cir cuit 7K or equivalent in the alternator harness and in the main wire harness 8 If battery voltage is present on the sense and excitation circuits connect the altern...

Страница 37: ...ulator defective Replace volt age regulator and brush assembly Approximately 60 of rated output Approximately equal to battery voltage and does not change or rises slightly Receiver diode defective Repair or replace alternator Low or no output Less than or equal to battery voltage and decreasing Stator windings field windings brush or diode defective Perform Field Current Test to check brushes and...

Страница 38: ...Electrical Maintenance Rev 04 02 28 1 Check Point for 2A Amperage 2 Position for Full Fielding Jumper Full Field Test AEA694 ...

Страница 39: ...mponents The relay board is located inside the control box Refer to the appropriate THERMO GUARD Microprocessor Controller Operation Diagnosis Manual for a complete list of the size and function of the fuses A 40 amp fuse F9 2 Circuit protects the 2AA cir cuit which is the main power circuit A 15 amp fuse F3 Damper protects the 29F circuit which supplies power to the damper solenoid A 15 amp fuse ...

Страница 40: ...with an ohm meter between the M6 terminal on the front of the heater and the screw on the back of the heater or the heater case The resistance should be 0 1 to 0 2 ohms 1 Fuse Link 2 Bracket 3 Battery Fuse Link Location Early Models Only 1 3 2 aea823 Check the current draw of the heater with a clamp on ammeter at the H1 wire near the M6 terminal on the front of the heater Hold the Preheat Start sw...

Страница 41: ...picking up any of the residue that tends to settle on the bottom of the pan The oil then passes through the intake pipe to the oil pump The oil pump forces the oil through an oil gallery to the dual element full flow bypass oil filter Dirt and other particles are trapped in the filter element as the oil passes through the oil filter If the filter element becomes clogged a bypass valve built into t...

Страница 42: ...Use a genuine Thermo King oil filter 1 Remove the filter 2 Apply oil to the rubber ring of the new filter and install the filter 3 Tighten the filter until the rubber ring makes contact then tighten 1 2 turn more 4 Start the unit and check for leaks ENGINE COOLING SYSTEM The engine employs a closed circulating type pressurized cooling system Correct engine temperatures are controlled and maintaine...

Страница 43: ...e of 50 50 pre mixed Extended Life Cool ant 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 of the cooling system is main tained ELC cannot be used in older units The water pump seal bel lows and O rings used on older units are not compatible with ELC To upg...

Страница 44: ...ars or 12 000 hours whichever occurs first ARA114 1 Expansion Tank 5 Water Pump 2 Radiator Cap 6 Thermostat 3 Coolant Level Sensor 7 Thermostat Housing 4 Radiator Engine Cooling System 1 2 3 4 5 6 7 Do not mix green or blue green engine coolant with ELC red engine coolant See ELC Extended Life Coolant on page 32 for more information about ELC The factory recommends the use of a 50 50 antifreeze mi...

Страница 45: ...cessary 5 Loosen the water pump belt Check the water pump bearing for looseness 6 Inspect the radiator cap Replace the cap if the gasket shows any signs of deterioration 7 Determine which type of antifreeze to use Conven tional coolants are green or blue green ELC is red Do not mix conventional coolants and ELC See ELC Extended Life Coolant on page 32 to help determine which type of antifreeze to ...

Страница 46: ...el transfer pump The fuel transfer pump delivers fuel to the fuel filter water separator Two orifices in the filter head control the pressure in the fuel system by allowing a certain amount of fuel to return to the tank One orifice is located in the center of the filter head It bleeds off water The other orifice is located off center on the filter head It bleeds off air Filtered fuel passes throug...

Страница 47: ...Engine Maintenance Rev 04 02 37 2 3 5 6 7 4 1 Check Valve 5 Fuel Transfer Pump 2 Filter Head 6 Priming Pump 3 Injection Pump 7 Fuel Filter Water Separator 4 Bleed Screw Engine Fuel System 1 ARA014 ...

Страница 48: ...leeding air from the fuel system 2 Fuel tank and filter system maintenance 3 Priming pump hand replacement or repair 4 Fuel pump replacement or repair 5 Injection line replacement 6 Injection pump and governor adjustments 7 Injection pump timing 8 Nozzle spray pattern testing and adjustment 9 Minor rebuilding of nozzles Bleeding the Fuel System If the engine runs out of fuel repairs are made to th...

Страница 49: ...e open with a small screw driver to drain the tank 1 Bleed Screw Injection Pump aea759 1 3 Let the water and fuel drain into the container until no water is visible in the fuel draining from the tank If the water and fuel do not drain freely the vent may be plugged If so clean or replace the vent 4 Install the drain plug Fuel Filter Water Separator The fuel filter water separator removes water fro...

Страница 50: ...e high speed solenoid 5 Pull the plunger out of the solenoid enough to loosen the jam nut An Allen wrench placed in the hex opening in the face of the plunger will keep the plunger from turning Turn the plunger eye bolt clockwise to increase the speed and counterclockwise to decrease the speed 6 Replace the ball joint start the unit and check the speed When the speed is correct tighten the jam nut...

Страница 51: ...s to prevent the possibility of the engine firing while it is being rotated a Rotate the engine in the normal direction of rota tion clockwise viewed from the water pump end until the 1 4 timing mark on the flywheel lines up with the index mark in the timing mark access hole b Check the rocker arms on the number one cylinder to see if they are loose c If the rocker arms are loose the engine is at ...

Страница 52: ...e in the end of the delivery valve holder Stop as soon as you see the fuel rise 1 Index Mark 2 Injection Mark Timing Mark Alignment aea702 1 2 15 Check position of the timing marks The injection tim ing mark on the flywheel should be aligned with the index mark on the side of the timing mark access hole Repeat steps 11 through 15 to recheck the timing 16 If the timing is off by more than 1 degree ...

Страница 53: ...e gear case Remove the nut and lockwasher which secure the gear to the injec tion pump shaft Use a shop rag to prevent the lock washer or nut from falling into the gear case 3 Use the hardware from the cover plate to attach the tool plate with the marked side pointing up and out to the gear case 4 Align the threaded holes in the injection pump gear with the two holes in the tool plate by rotating ...

Страница 54: ...kwasher and nut use a shop rag as before to prevent the lock washer or nut from falling into the gear case Torque the nut to 84 to 90 ft lb 113 to 122 N m 5 Fasten cover plate to gear case and reinstall all compo nents removed previously to facilitate injection pump removal Fuel Solenoid System The fuel solenoid is located on the end of the injection pump It contains two coils the pull in coil and...

Страница 55: ...zed it supplies power to the fuel solenoid hold in coil and to the fuel solenoid relay coil The hold in coil is energized and remains energized as long as there is power on 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 solenoid relay by open ing the ...

Страница 56: ...ge is not present on the 8D circuit check the 8D circuit and the related circuits and components for a fault b If battery voltage is present on the 8D circuit go to step 5 Main Wire Harness Connector Pin Identification aea704 5 Check the CH circuit pin C in the main wire harness connector for continuity to a good chassis ground a If there is no continuity between the CH circuit a good chassis grou...

Страница 57: ...k when the hold in coil is de energized d If the hold in coil does not function properly check the resistance of the hold in coil by placing an ohmmeter between the red wire 8D pin A and the black wire CH pin C in the fuel sole noid connector The resistance of the hold in coil should be 24 to 29 ohms If the resistance of the hold in coil is not in this range replace the fuel solenoid e If the hold...

Страница 58: ...uel solenoid must be energized when it is being installed If it is not the plunger and the linkage may not line up correctly and the fuel solenoid will not function properly 5 Place the O ring in the groove in the end of the fuel injection pump Make sure that the O ring is positioned correctly during installation to avoid damage and leaks 6 Install the new fuel solenoid 7 Place the On Off switch i...

Страница 59: ...If the rocker arms are tight the engine is at top dead center of the exhaust stroke for the number one cylinder Rotate the engine 360 to place the engine at top dead center of the compression stroke for the number one cylinder 5 Check the valve clearance of both valves for the num ber one cylinder with a feeler gauge The valve clear ance for both the intake valve and the exhaust valve should be 0 ...

Страница 60: ...ccess hole and tighten the fuel injection lines when finished aea705 CRANKCASE BREATHER The crankcase breather is located on top of the rocker arm cover The crankcase breather system ducts crankcase gases formed in the crankcase directly to the air intake Harmful vapors that would otherwise collect in the crankcase and contaminate the oil or escape to the outside are drawn back into the engine and...

Страница 61: ...essive restriction of the air intake system reduces the flow of air to the engine affecting horsepower output fuel consumption and engine life An air restriction indicator is installed in the air intake man ifold Visually inspect the restriction indicator periodically to assure the air filter is not restricted Service the air filter when the yellow diaphragm indicates 22 in of vacuum Press the res...

Страница 62: ...sing belt tension gauge P N 204 427 is the best method of checking belts for tightness Install the belt gauge in the center of the longest belt span Press the plunger so the hook will engage the belt Make sure the hook is on the face of the belt not in a notch Release the plunger with a quick motion and without pulling on the belt Then read the dial Use an average of three readings NOTE Do not att...

Страница 63: ... Upper Fan Belt 2 Condenser Fan Pulley 3 Condenser Fan Blower 4 Condenser Inlet Ring 5 Idler Assembly 6 Belt Guide 7 Lower Fan Belt 8 Engine Pulley 9 Idler Adjusting Arm 10 Alternator Belt Belt Arrangement aea709 1 2 3 5 4 6 7 8 9 8 10 ...

Страница 64: ...me off the engine pulley Move the arm OUT far enough to clear the roadside idler mounting bracket Installation 1 Slip the belt into the groove of the idler pulley 2 Push the idler adjusting arm back in toward the unit 3 Slip the belt onto the pulley groove on the engine 4 Pull the idler adjusting arm back OUT and adjust the belts to the proper tension 5 Tighten the idler assembly pivot bolts and t...

Страница 65: ...wheel 4 Check the radial clearance between the blower wheel and inlet ring with a gauge wire Check around the entire circumference to the inlet ring and blower wheel see Condenser and Evaporator Fan Location under Structural Maintenance 5 Torque the blower hub clamping bolts to 18 ft lb 24 N m 6 Seat the upper belt in the blower wheel pulley groove 7 Push inward on the idler adjusting arm and slip...

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Страница 67: ...sor thermometer to monitor the return air temperature 5 Run the unit on high speed cool until the air in the box is at 0 F 18 C By allowing the box to leak a small amount you will be able to maintain 0 F 18 C 6 The suction pressure should be 13 to 18 psi 90 to 124 kPa 7 The discharge pressure should be at least 275 psi 1896 kPa If the pressure is below this it can be raised by cover ing a portion ...

Страница 68: ...nt The refrigerant level should be adjusted To adjust the refrigerant level 1 Stop the unit and remove some refrigerant with an approved refrigerant recovery device such as the COLLECTOR P N 204 884 2 Perform a refrigerant level check and repeat the over charge test 3 If the liquid level is low add refrigerant as follows a Connect a refrigerant tank to the gauge manifold service line and purge the...

Страница 69: ...e been removed for service or replacement 1 Floating Ball 2 Colored Ring Moisture Indicating Sight Glass AEA672 1 2 To check compressor oil level with an ambient air temperature above 50 F 10 C Install a gauge manifold on the compressor Operate the unit on Cool with a 20 psi 138 kPa minimum suction pressure and a 185 psi 1275 kPa minimum dis charge pressure for 15 minutes or more After the unit ha...

Страница 70: ...pressure of the compressor first by blocking the condenser coil air flow by covering the condenser grille with a piece of cardboard If this does not raise the discharge pressure to the cutout level of the HPCO increase the engine speed by overriding the throttle solenoid This should increase the discharge pressure enough to cause the HPCO to cut out NOTE The discharge pressure should never be allo...

Страница 71: ...lve 5 Operate the unit on cool and pump down the low side to 20 in Hg 68 kPa of vacuum 6 Stop the unit The condenser and suction pressures should remain stable indicating no leaks 7 Shift the three way valve to the heat position Low side gauge will raise slightly High side gauge will drop to approximately zero Gauges will equalize 8 Gauges will remain in this position approximately zero if the thr...

Страница 72: ... modulation valve is not repairable but the electric coil can be replaced 1 Outlet 2 Electric Coil 3 Armature 4 Inlet 5 Opening Spring 6 Seats Modulation Valve AEA712 1 2 3 4 5 6 Refer to the appropriate Microprocessor Operation and Diagnosis Manual for information about testing the modula tion valve See the Refrigeration Service Operations section of this manual for removal and installation proce...

Страница 73: ... replacement compressor in the unit Installation 1 Slide the compressor into the unit 2 Place the compressor in position and install the mount ing bolts NOTE The compressor drive coupling will only slide onto the coupling pins in either of two positions which are 180 degrees apart 3 Install the service valves using new gaskets soaked in compressor oil Connect the high pressure cutout switch and th...

Страница 74: ... the flange If a nut is used to prevent the bolt from falling out the nut should not be tightened 3 Use torque wrench and the appropriate Allen tool to unscrew the coupling mounting screw Apply a maxi mum of 90 ft lb 122 N m of torque to the screw 4 Once the center screw has been loosened back the head against the tool and it should push the coupling off the crankshaft as you continuing turning th...

Страница 75: ...key will not fit and it will hold the taper in the coupler off the taper on the shaft Check both keyways for burrs or corrosion A key can be coated with fine lapping compound and used as a lapping tool to clean the keyways AGA333 4 Remove the Keyway Tool and check the fit of the new key P N 55 9024 It should fit into the keyway with a light press fit requiring only a minimum of light tap ping If t...

Страница 76: ...or Coupling Installation 1 2 3 4 5 AGA335 4 Remove the condenser coil mounting bolts Remove the mounting clamps from the condenser inlet line 5 Unsolder the inlet line and liquid line connections Lift the coil from the unit Installation 1 Clean the fittings for soldering 2 Place the coil in the unit and install the mounting bolts 3 Solder the inlet line and liquid line connections 4 Pressurize the...

Страница 77: ...eck valve Installation NOTE A heat sink must be used on the in line check valve when it is being soldered in place to prevent damage to the neoprene seal 1 Clean the tubes for soldering 2 Place the check valve in position The arrow on the valve body indicates the direction of refrigerant flow through the valve 3 Place a heat sink on the check valve 4 Solder the inlet and outlet connections 5 Press...

Страница 78: ...valve line to the receiver tank 4 Connect the bypass check valve and filter drier inlet lines 5 Tighten the receiver tank mounting hardware securely 6 Pressurize the refrigeration system and check for leaks If no leaks are found evacuate the system 7 Recharge the unit with proper refrigerant FILTER DRIER Removal 1 Pump down the refrigeration system and equalize the pressure to slightly positive 2 ...

Страница 79: ...ss panels 7 Open the refrigeration valves and place the unit in oper ation 8 Test the unit to see that the expansion valve is properly installed HEAT EXCHANGER Removal 1 Pump down the low side and equalize the pressure to slightly positive 2 Remove the upper and lower evaporator access panels 3 Remove the mounting bolts that hold the heat exchanger on the bulkhead 4 Disconnect the equalizer line f...

Страница 80: ...ounting channels 4 Disconnect the sensors 5 Remove the feeler bulb from the suction line clamp Note the position of the feeler bulb on the suction line 6 Unsolder the distributor from the expansion valve 7 Unsolder the hot gas line and the suction line from the evaporator coil 8 Remove the mounting bolts lift and slide the coil from the housing Installation 1 Place the evaporator coil in the evapo...

Страница 81: ...refrigerant charge and the compressor oil and add as required THREE WAY VALVE REPAIR NOTE The three way valve can be repaired in the unit if leakage or damage to the Teflon seals should occur There is usually enough give in the copper tubing to separate the three sections of the valve without unsoldering any tubes Removal Disassembly 1 Remove the refrigerant charge 2 Clean the exterior surface of ...

Страница 82: ...e must be removed at the compressor NOTE The valve body cannot be reconditioned Seat positions change and improper sealing will result 1 Seal Groove in Piston 2 Connecting Notch in Piston 3 Internal Spring in Seal 4 Connecting Groove in Stem 5 Retaining Clip Piston Stem Parts 2 5 4 3 1 1 Cap 7 Clip 2 Top Cap 8 Seat 3 Check Valve 9 Gaskets 4 Spring 10 Stem Assembly 5 Piston 11 Screen 6 Seal 12 Bott...

Страница 83: ...the piston 5 Place the piston slot on the stem and secure with spring clip The open part of the clip should be on the opposite side of the piston slot 6 Install the spring and top cap 7 Line up the passageways in the cap and body Failure to line up the holes will result in improper operation of the valve 8 Install the bolts and tighten in rotating sequence 9 Install the pilot line and pressurize t...

Страница 84: ...flon Check Valve Assembly AEA715 4 Screw the check valve stem into the three way valve until the snap ring can be installed 5 Install the snap ring 6 Unscrew back seat the check valve stem against the snap ring NOTE The valve stem must be back seated during normal unit operation 7 Coat sealing area in the cap with compressor oil install and tighten the cap on the three way valve 8 Pressurize the r...

Страница 85: ...ualize the pressure to slightly positive 2 Front seat the discharge and suction service valves Release the remaining pressure 3 Disconnect the wires and remove the high pressure cut out switch from the compressor discharge manifold Installation 1 Apply a refrigerant locktite to the threads of the high pressure cutout switch 2 Install and tighten the high pressure cutout switch and reconnect the wi...

Страница 86: ...NG piston 4 GASKET end plate 13 NUT adjusting 5 WASHER adjusting 14 PIN cotter 6 SPRING bellows 15 HOUSING piston 7 BELLOWS SHAFT assy 16 O RING valve to compressor 8 O RING 17 CAP rubber 9 HOUSING Throttling Valve Assembly AEA717 2 Front seat the discharge and suction service valves Release the remaining pressure 3 Remove the suction service valve and line from the compound gauge 4 Unbolt and rem...

Страница 87: ...p is under slight spring pressure 5 Break the gasket free and remove the end cap 6 Note the number of shims next to the cap These can be reused 7 Remove the bellows 1 Inspect Cap 2 Inspect Spring 3 Shims 8 Inspect all the parts a Piston and cap for wear scuff marks b Body for stripped threads c Bellows end cap for damage in the pilot hole NOTE The bellows is normally replaced 9 Clean the parts tha...

Страница 88: ... pressor 2 Install the suction valve and the line from the com pound gauge 3 Pressurize the low side and check for leaks If no leaks are found evacuate the low side 4 Open the refrigeration valves and place the unit in oper ation COMPRESSOR OIL FILTER CHANGE This unit is equipped with a compressor oil filter The com pressor oil filter should be changed when the drier is replaced 1 Pump down the lo...

Страница 89: ...the valve Installation 1 Clean the tubes and elbow for soldering 2 Properly position the modulation valve the tube and the elbow between the evaporator outlet and the heat exchanger inlet 3 Solder the connections CAUTION Use a heat sink or wrap the valve with wet rags to prevent damaging the valve 4 Pressurize the low side and test for leaks If no leaks are found evacuate the low side 5 Install th...

Страница 90: ...older the inlet and outlet connections After the valve cools install the coil 4 Pressurize the refrigeration system and test for leaks 5 If no leaks are found evacuate the system 6 Recharge the unit with proper refrigerant and check the compressor oil ...

Страница 91: ...heduled maintenance inspections 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 blow the air or water through the coil in the direction opposite the normal airflow Repair bent fins and any other noticeable damage DEFROST DRAINS Clean the defrost drains ...

Страница 92: ...hat air flow is stopped on the top and bottom edges with the solenoid plunger bottomed out AEA719 1 Stop 6 Eye Bolt 2 Mounting Bolts 7 Round Stop 3 Closed Position 8 Distance A 2 75 in 69 85 mm 4 Open Position 9 Solenoid 5 Damper Link Defrost Damper Adjustment 1 2 9 8 1 7 4 3 5 6 To adjust the damper 1 Remove the damper assembly from the evaporator 2 Disconnect the damper link from the eye bolt ...

Страница 93: ...re that the damper operates correctly and seals properly 9 Make sure the damper blade rests on the round stops when the damper is open Adjust the round stops if nec essary 10 Install the damper assembly in the evaporator CONDENSER AND EVAPORATOR FAN LOCATION When mounting the condenser or evaporator fan and hub assembly on the fanshaft the blowers and inlet orifices must be properly aligned for pr...

Страница 94: ...used except after removal and repair of the fan shaft assembly The condenser and evaporator end oil seals should be checked during the pre trip inspection for oil leakage If there is any sign of leakage the fan shaft assembly should be removed and repaired NOTE The fan shaft assembly requires a special lubri cant Thermo King P N 203 278 Fan Shaft Assembly Overhaul Disassembly 1 Remove the fan shaf...

Страница 95: ...k the assembly in a vise and set up a dial indicator to read end play To measure the end play rotate the shaft while pushing in one direction and set the dial indicator to 0 Now rotate the shaft and pull in the opposite direction while reading the dial indicator End play should be 0 001 to 0 005 in 0 025 to 0 127 mm If end play is incorrect use different shims to obtain correct end play Shims avai...

Страница 96: ...nd of the assem bly 3 To remove the shaft from the assembly tap the opposite end of the shaft with a soft hammer After the shaft has been removed clean all the parts in clean solvent 4 Using a punch remove the oil seal from the curbside end of the assembly With the seal removed clean the housing in solvent 5 Check the condition of the vent If it is loose or dam aged it must be repaired or replaced...

Страница 97: ...e top plug until it runs out of the side hole Check the condition of the O ring used on the plugs and replace if necessary Install the top and side plugs Clean up any spillage 8 Place the assembly on the workbench with the vent up Rotate the shaft by hand The shaft should be free enough to rotate without having to hold the housing CAUTION Reinstall the assembly into the unit making sure the vent i...

Страница 98: ...88 ...

Страница 99: ...opriate Microprocessor Operation and Diagnosis Manual Fuel solenoid defective or stuck Replace Fuel injection pump defective Replace pump Air heater defective Replace No fuel or wrong fuel Fill with proper fuel Fuel pump defective Replace pump Air in fuel system Bleed air Compression low Overhaul engine Injection nozzles defective Replace nozzles Incorrect timing Adjust timing Air cleaner clogged ...

Страница 100: ...ive injection rate too low gum formations Repair or replace pump Engine speed too high Misadjusted high speed solenoid Adjust high speed solenoid Defective injection pump Repair injection pump Engine fails to stop when unit is OFF Fuel solenoid defective Replace Injection pump defective Replace pump Engine knocks heavily Air in system Bleed fuel system Injection pump not timed Retime injection pum...

Страница 101: ... oil pressure switch Replace if necessary Oil control valve defective Check oil pressure control valve Worn oil pump camshaft main or connecting rod bearings loose oil gallery plug Repair engine High oil consumption Oil leakage Check and eliminate possible causes at rocker arm cover oil lines oil filter front timing cover or crankshaft seals Damaged valve seals Replace seals on valve stem Worn val...

Страница 102: ...ot burning Excessive Fuel to Air Ratio Oil Consumption Air or water in fuel Type of fuel used Poor compression Incorrect timing Cold engine Defective valve seals Poor compression Excessive load Faulty injectors Clogged air intake system Faulty nozzles Poor compression Restricted exhaust Faulty injection pump ...

Страница 103: ...efrigerant Shortage of refrigerant No refrigerant Air through condenser too hot ambient Air flow through condenser restricted Air through condenser too cold ambient Air in refrigerant system Condenser fan blades bent or broken Air short cycling around evaporator coil Air through evaporator restricted Evaporator needs defrosting Compressor discharge valves leaking Compressor suction valves leaking ...

Страница 104: ...e gauge out of calibration Leaky receiver tank outlet valve Leaky bypass check valve Leaky condenser check valve Faulty three way condenser pressure bypass check valve Modulation valve stuck closed Hot gas bypass valve stuck open or leaking Rapid cycling between cool and heat Unit cools in heat and defrost cycle Unit heats in refrigeration cycle High head pressure Low head pressure No head pressur...

Страница 105: ...igh Pressure Relief Valve 10 Receiver Tank 11 Sight Glass 12 Receiver Outlet Valve 13 Liquid Line 14 Drier 15 Heat Exchanger 16 Expansion Valve 17 Feeler Bulb 18 Equalizer Line 19 Distributor 20 Evaporator Coil 21 Suction Line 22 Accumulator 23 Suction Vibrasorber 24 Suction Service Valve 25 Throttling Valve 26 Pilot Solenoid 27 Hot Gas Line 28 Defrost Pan Heater 29 Bypass Check Valve 30 Bypass Se...

Страница 106: ...Pressure Relief Valve 10 Receiver Tank 11 Sight Glass 12 Receiver Outlet Valve 13 Liquid Line 14 Drier 15 Heat Exchanger 16 Expansion Valve 17 Feeler Bulb 18 Equalizer Line 19 Distributor 20 Evaporator Coil 21 Suction Line 22 Accumulator 23 Suction Vibrasorber 24 Suction Service Valve 25 Throttling Valve 26 Pilot Solenoid 27 Hot Gas Line 28 Defrost Pan Heater 29 Bypass Check Valve 30 Bypass Servic...

Страница 107: ...10 Receiver Tank 11 Sight Glass 12 Receiver Outlet Valve 13 Liquid Line 14 Drier 15 Heat Exchanger 16 Expansion Valve 17 Feeler Bulb 18 Equalizer Line 19 Distributor 20 Evaporator Coil 21 Suction Line 22 Accumulator 23 Suction Vibrasorber 24 Suction Service Valve 25 Throttling Valve 26 Pilot Solenoid 27 Hot Gas Line 28 Defrost Pan Heater 29 Bypass Check Valve 30 Bypass Service Valve 31 Modulation ...

Страница 108: ...f Valve 10 Receiver Tank 11 Sight Glass 12 Receiver Outlet Valve 13 Liquid Line 14 Drier 15 Heat Exchanger 16 Expansion Valve 17 Feeler Bulb 18 Equalizer Line 19 Distributor 20 Evaporator Coil 21 Suction Line 22 Accumulator 23 Suction Vibrasorber 24 Suction Service Valve 25 Throttling Valve 26 Pilot Solenoid 27 Hot Gas Line 28 Defrost Pan Heater 29 Bypass Check Valve 30 Bypass Service Valve 31 Mod...

Страница 109: ...314 Early Model Coiled Wire Fuse Link Wiring Schematic 101 5D49313 Early Model Coiled Wire Fuse Link Wiring Diagram 102 105 5D52378 Late Model Fuse Link in Battery Cable Wiring Schematic 106 5D54669 Late Model Fuse Link in Battery Cable Wiring Diagram 107 110 ...

Страница 110: ...100 ...

Страница 111: ...101 Early Model Coiled Wire Fuse Link Wiring Schematic ...

Страница 112: ...102 Early Model Coiled Wire Fuse Link Wiring Diagram Page 1 of 4 ...

Страница 113: ...103 Early Model Coiled Wire Fuse Link Wiring Diagram Page 2 of 4 ...

Страница 114: ...104 Early Model Coiled Wire Fuse Link Wiring Diagram Page 3 of 4 ...

Страница 115: ...105 Early Model Coiled Wire Fuse Link Wiring Diagram Page 4 of 4 ...

Страница 116: ...106 Late Model Fuse Link in Battery Cable Wiring Schematic ...

Страница 117: ...107 Late Model Fuse Link in Battery Cable Wiring Diagram Page 1 of 4 ...

Страница 118: ...108 Late Model Fuse Link in Battery Cable Wiring Diagram Page 2 of 4 ...

Страница 119: ...109 Late Model Fuse Link in Battery Cable Wiring Diagram Page 3 of 4 ...

Страница 120: ...110 Late Model Fuse Link in Battery Cable Wiring Diagram Page 4 of 4 ...

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