Thermo King RD-II SR 30 Manual
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Thermo King RD-II SR 30 Manual

Thermo King RD-II SR 30 Manual

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RD-II SR
TK 41131-1-MM (Rev. 04/03)
Copyright
©
1996 Thermo King Corp., Minneapolis, MN, U.S.A.
Printed in U.S.A.

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  • Page 1 RD-II SR TK 41131-1-MM (Rev. 04/03) Copyright © 1996 Thermo King Corp., Minneapolis, MN, U.S.A. Printed in U.S.A.
  • Page 2 If further information is required, Thermo King Corporation should be consulted. Sale of product shown in the 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.
  • Page 3 Recover Refrigerant At Thermo King, we recognize the need to preserve the environment 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.

  • Page 5: Table Of Contents

    Table of Contents Safety ..................i Specifications .
  • Page 6 Table of Contents (Continued) Engine Maintenance............... 40 Engine Lubrication System .
  • Page 7 Table of Contents (Continued) Refrigeration Service Operations.............73 Accumulator .
  • Page 9 This should also be REFRIGERANT considered when opening and closing the compressor At Thermo King we recognize the need to preserve the service valves. environment and limit the potential harm to the ozone layer Make sure gauge manifold hoses are in good condition.

  • Page 10: Safety

    Safety Precautions (Rev. 04/03) • SKIN: Flush area with large amounts of lukewarm Use tools with insulated handles that are in good condi- water. Do not apply heat. Remove contaminated cloth- tion. Never hold metal tools in your hand if exposed, ing and shoes.
  • Page 11 Safety Precautions (Rev. 04/03) Low Voltage Control circuits used in the refrigeration unit are low volt- age (12 volts dc). This voltage potential is not considered dangerous, but the large amount of current available (over 30 amperes) can cause severe burns if shorted or ground. Do not wear jewelry, watch or rings when working on the unit.
  • Page 12 Safety Precautions (Rev. 04/03) PUB126...
  • Page 13 Safety Precautions (Rev. 04/03) aea105...

  • Page 15: Specifications

    Specifications ENGINE SPECIFICATIONS Engine TK 3.95 Fuel Type No. 2 Diesel fuel under normal conditions No. 1 Diesel fuel is acceptable cold weather fuel Oil Capacity: Crankcase & Oil Filter 12 quarts (11 liters) w/Bypass Oil Filter 13 quarts (12.3 liters) Fill to full mark on dipstick Oil Type API Type CD-SD...
  • Page 16 Specifications (Rev. 04/03) R-134A REFRIGERATION SYSTEM Compressor Model X426 Refrigerant Charge 9 lb. (4.1 kg) R-134a Compressor Oil Charge 4 qt. 6 oz. (3.9 liters)* Compressor Oil Type: R-134a (Solest 35) TK No. 203-413 (Ester base) required Throttling Valve Setting 18 to 20 psig (124 to 138 kPa) Heat/Defrost Method: Engine Operation Hot gas...
  • Page 17 Specifications (Rev. 04/03) ELECTRICAL COMPONENTS Current Draw (Amps) Resistance— at 12.5 Vdc (Ohms) Glow Plug 1.5 ± .15 Fuel Solenoid: Pull In 30 to 40 .41 to.31 Hold In 12.8 Pilot Solenoid .657 Starter Motor 90 to 105 (cranking) Damper Solenoid DC Circuit Breakers 50 amp 20 amp...

  • Page 18: Maintenance Inspection Schedule

    Maintenance Inspection Schedule Fuel Every Annual/ Maintenance interval may be extended to 1000 hours when Island 3,000 equipped with bypass oil filter. Pre-trip Hours Hours Inspect/Service These Items Engine • Check engine oil level. Check radiator coolant. (CAUTION: DO NOT remove radiator cap •...
  • Page 19 Maintenance Inspection Schedule (Rev. 04/03) Fuel Every Annual/ Maintenance interval may be extended to 1000 hours when Island 3,000 equipped with bypass oil filter. Pre-trip Hours Hours Inspect/Service These Items Refrigeration • Check refrigerant level and compressor oil condition. Check suction pressure regulator regulating pressure on defrost or •...

  • Page 20: Unit Description

    The clutch engages fully at 900 ± 100 rpm on engine opera- • RD-II SR 30: Cooling and heating on engine operation. tion, constantly turning the compressor and fans at both high and low speed. •...

  • Page 21: Unit Instruments

    Unit Description (Rev. 04/03) • Automatic Diesel/Electric Selection ALARM ICON. The alarm icon comes on whenever there is an alarm code stored in the microprocessor • Select up to 13 Readouts Covering All Key Operating memory. Parameters RECEIVER TANK SIGHT GLASS. The receiver tank •...

  • Page 22: Unit Protection Devices

    Unit Description (Rev. 04/03) UNIT PROTECTION DEVICES help the valve reseat and SEAL PROPERLY. The valve is non-repairable and requires no adjustment. If the FUSES. A number of fuses are located on the relay valve fails to reseat properly, remove the refrigerant board.

  • Page 23: Selection Of Operating Modes On Cycle-Sentry Equipped Units

    This procedure is automatic and can be performed on CYCLE-SENTRY Equipped Units the way to the loading area or while waiting to load. The Thermo King CYCLE-SENTRY system is designed to Press the On button. save refrigeration fuel costs. The savings vary with the com- modity, ambient temperatures and trailer insulation.

  • Page 24: Restarting The Unit

    Unit Description (Rev. 04/03) Restarting the Unit highly sensitive products normally require continuous air circulation. These procedures are used when starting units that have The microprocessor has a CYCLS screen, which is used to been shut off for short periods of time. When a unit has been select CYCLE-SENTRY (CYCLS YES) or Continuous Run shut off for a long period of time is first started, it should be (CYCLS NO) operation.

  • Page 25: Loading Procedure

    Unit Description (Rev. 04/03) When first starting a cold engine, the oil pressure may Load the product so that there is adequate space for air be higher. circulation completely around the load. DO NOT block the evaporator inlet or outlet. COMPRESSOR OIL.
  • Page 26 Unit Description (Rev. 04/03) aea104 Front Curbside View—RD-II SR aea096 Front Roadside View—RD-II SR...
  • Page 27 Unit Description (Rev. 04/03) Engine Air Filter Fuel Filter Throttle Solenoid aea099 Oil Filter Access Panel Open (Curbside)—RD-II SR...
  • Page 28 Unit Description (Rev. 04/03) aea105 Evaporator Rear View (Curbside)—RD-II SR...
  • Page 29 Unit Description (Rev. 04/03) aea106 Coil Sensor Return Air Location Sensor Microprocessor Switch Side View (Roadside)
  • Page 30 Unit Description (Rev. 04/03) Alternator Evaporator High Pressure Throttling Nameplate Valve Relief Valve Compressor Muffler Defrost Switch Filter- Drier aea097 Fuel Filter Three-Way Expansion Condenser Valve Tank Coil Top View...
  • Page 31 Unit Description (Rev. 04/03) Caution High Motor Contactor B Voltage Module K4 Relay K6 Relay K5 Relay K2 Relay K3 Relay K1 Relay K9 Relay aea41 K7 Relay K8 Relay Overload Motor Remote Control Overload Preheat Reset Contactor A Cab Box Harness Contactor Buzzer Solenoid...
  • Page 32 Unit Description (Rev. 04/03) aea102 Power Receptacle Box—RD-II SR 50...
  • Page 33 Unit Description (Rev. 04/03) aea43 Keypad LED Display Thermoguard™ Remote Control Panel aea103 Remote Light Display...

  • Page 34: Μp-T System Description

    µP-T System Description GENERAL DESCRIPTION Microprocessor Power Switch The µp-T microprocessor controllers are self contained tem- The microprocessor power switch applies 12 volts DC con- perature control units designed for RD-II Smart Reefer trol power to the microprocessor. It is located just below the truck units.

  • Page 35: Optional Model 50 Features

    µP-T System Description (Rev. 04/03) to a power outlet. Under these conditions, when the micro- Optional Model 50 Features processor power switch is turned on and the O key is The following features are available as options on units pressed, the unit will start and run on diesel automatically. equipped with Electric Standby.
  • Page 36 µP-T System Description (Rev. 04/03) High Voltage Tray High Voltage Tray No Options with Electric Heat High Voltage Tray High Voltage Tray with Phase Correction with Phase Correction and Electric Heat...

  • Page 37: Remote Control Panel Features

    Remote Control Panel Features The remote panel is connected to the microprocessor and is used to operate the unit. It may be located in the truck dashboard using the supplied DIN mounting ring, under the dashboard using the supplied under dash mounting kit or on the dashboard using the supplied plastic mounting strips.
  • Page 38 Remote Control Panel Features (Rev. 04/03) ENTER KEY. Executes prompts or loads setpoints or other new settings. DEFROST KEY. Initiates a manual defrost cycle. WHISPER KEY. Disables high speed diesel mode operation. LOGO KEY. Initiates the Unit Self Check test and displays software revision. UNDERSTANDING THE DISPLAY The display normally shows the Standard Display of return air tempera- ture and setpoint.
  • Page 39 Remote Control Panel Features (Rev. 04/03) ALARM ICON. Appears when an alarm condition has been detected by the microprocessor. ELECTRIC ICON. Appears when AC power is connected and the phases are correct. SETPOINT ICON. Appears when the setpoint is being shown in the lower display. WHISPER ICON.
  • Page 40 Remote Control Panel Features (Rev. 04/03) THE STANDARD DISPLAY The Standard Display appears when the unit is turned ON and no other functions have been selected. The box temperature appears in the upper display and the setpoint appears in the lower display. This display shows a box temperature of 35.8 F and a setpoint of 35 F.
  • Page 41 Remote Control Panel Features (Rev. 04/03) Press the Enter key to load the new setpoint into the microprocessor. The display will briefly show [Lod] and then the new setpoint will reappear in the display. IMPORTANT: The Enter key must be pressed or the setpoint will not be changed. The display will return to the Stan- dard Display and the setpoint will return to the old setpoint in about 10 seconds if the Enter key is not pressed.
  • Page 42 Remote Control Panel Features (Rev. 04/03) STARTING THE ENGINE CAUTION: This unit will start automatically in either CYCLE SENTRY or CONTINUOUS mode after the ON key is pressed. Press the ON key to turn the unit ON. If no other key is pressed, the engine will automatically preheat and start in about 10 seconds in either CYCLE SENTRY or CONTINUOUS mode.
  • Page 43 Remote Control Panel Features (Rev. 04/03) CHECKING THE SOFTWARE REVISION Press the ON key to turn the unit ON. Press and hold the TK Logo key to display [USC]. Press the Select key to display [rEU] and the software revision. The software revision shown here is Revision 1520.
  • Page 44 Remote Control Panel Features (Rev. 04/03) Press the Select key repeatedly to show the prompt and display screens. The prompt and display screens will appear in the order shown below: [ALr] Alarm codes if present. If no codes exist this screen will not appear. [CYCLS] CYCLE SENTRY or Continuous mode prompt screen.
  • Page 45 Remote Control Panel Features (Rev. 04/03) VIEWING and CLEARING ALARM CODES Press the ON key to turn the unit ON. If the Alarm icon is present, one or more alarms have been detected. To View Alarm Codes Press the Select key to show the Alarm display screen. If more than one alarm code exists, each will be displayed for several seconds.

  • Page 46: Μp-T Alarms

    Remote Control Panel Features (Rev. 04/03) µP-T ALARMS • Check Alarm. Notice to take corrective action before an abnormal condition becomes severe. The Alarm icon Alarms and Alarm Codes will appear and remain ON. If an abnormal condition is sensed by the microprocessor, •...
  • Page 47 Remote Control Panel Features (Rev. 04/03) Unit Self Check Report Display Check All segments of the display will be lighted at the same time. At the completion of the Unit Self Check, the check results will appear on the display. They will remain until any key Show Programmable Settings on the controller is pressed.

  • Page 48: Electrical Maintenance

    Electrical Maintenance Charging System Diagnostic Procedures Complete the following checkout procedure before replac- ing the voltage regulator or the alternator. With the unit switch OFF, attach a voltmeter to termi- nal SENSE and the alternator chassis. Voltmeter should indicate battery voltage. With the unit switch ON, attach a voltmeter to terminal EXC and the alternator chassis.

  • Page 49: Excessive Voltage Output

    12V ALTERNATORS WITH INTERNAL REGULAR SETTING CHARGING SYSTEM (12 VDC) When a Thermo King unit is installed on a truck, it is often Immediately after start-up, the voltmeter may show a connected to a truck battery. When both the Thermo King discharge condition on systems with brush type alternators.

  • Page 50: Glow Plugs

    Electrical Maintenance (Rev. 04/03) electrical signal that has a voltage and frequency variation Disconnect wires RPM+ and RPM- from the sensor. proportional to the engine rpm. Place the unit in CONTINUOUS RUN. Run the unit o By monitoring the frequency of this signal with the µP-T, low speed and high speed.

  • Page 51: Condenser/Evaporator Fan Rotation (Electric Standby Operation)

    Electrical Maintenance (Rev. 04/03) nal ammeter in series with the plugs. Normal current draw is improper condenser fan rotation, reverse any two power approximately 21 to 25 amps when preheating. A current cord leads at the power cord. (DO NOT move the ground draw of 21 to 25 amps means all three glow plugs are work- wire which is normally GREEN.) ing.

  • Page 52: High Capacity Thermax Heating System

    Electrical Maintenance (Rev. 04/03) Air Switch If the switch is out of calibration, pressurize the hose again until the tester indicates 0.9 in. (22.7 mm) H Adjust the screw clockwise or counterclockwise until the switch closes and the continuity tester indicates a completed circuit with the gauge reading 0.9 in.
  • Page 53 Electrical Maintenance (Rev. 04/03) The components that have been added to the system are: the erant transfer mode will perform this way in every SR unit, TherMax™ solenoid, the TherMax™ solenoid line, and the regardless of ambient temperature or refrigerant type. receiver outlet check valve.

  • Page 54: Engine Maintenance

    Engine Maintenance ENGINE LUBRICATION SYSTEM Add oil as necessary to reach the full mark. See Specifica- tions page for correct type of oil. The TK 3.95 diesel engine has a pressure lubrication sys- tem. Oil is circulated by a trochoid type oil pump driven by Oil Filter Change the crankshaft timing gear and has several times the capac- The oil filters should be changed along with the engine oil.

  • Page 55: Engine Air Cleaner

    Engine Maintenance (Rev. 04/03) ENGINE AIR CLEANER Dry Type (Optional) A dry element air cleaner filters all of the air entering the Oil Bath Type engine. Excessive restriction of the air intake system affects A heavy duty, oil bath air cleaner filters all of the air enter- horsepower, fuel consumption and engine life.

  • Page 56: Engine Cooling System

    Engine Maintenance (Rev. 04/03) ENGINE COOLING SYSTEM All water-cooled engines are shipped from the factory with a 50% permanent type antifreeze concentrate and 50% The engine employs a closed, circulating type, pressurized water mixture in the engine cooling system. cooling system. Correct engine temperatures are controlled This provides the following: and maintained by a radiator, fan and thermostat.

  • Page 57: Antifreeze Maintenance Procedure

    Engine Maintenance (Rev. 04/03) Checking the antifreeze Open the engine block and accumulator drain to drain water and flushing solution. Check the solution concentration by using a temperature compensated antifreeze hydrometer or a refractometer CAUTION: Avoid direct contact with hot coolant. designed for testing antifreeze.
  • Page 58 Engine Maintenance (Rev. 04/03) the required corrosion protection and lubrication for the water pump. Bleeding Cooling System After filling the radiator, run the unit up to operating tem- perature to check for overheating and coolant level and allow the air to be purged for a few minutes. CAUTION: Do not remove the radiator cap while the engine is hot.

  • Page 59: Engine Fuel System

    Engine Maintenance (Rev. 04/03) ENGINE FUEL SYSTEM Fuel filter. Injection pump. The fuel system used on the Thermo King TK 3.95 diesel is a high pressure system used in conjunction with a Injection nozzles. prechamber. A 10 psig (69 kPa) electric fuel pump pulls fuel from the...

  • Page 60: Bleeding The Fuel System

    NOTE: At initial start-up, open the bleeder screw at Thermo King recommends that any major injection pump or the injection pump and bleed fuel until a clear flow is nozzle repairs be done by a quality diesel injection service noted.

  • Page 61: Fuel Filter Replacement

    Engine Maintenance (Rev. 04/03) diesel engine. Water should be drained off periodically to Reassembly avoid breakdowns. This should be done after the tank has Place the cover gasket on the bottom cover and install the set idle for an hour. DO NOT steam clean fuel tank caps. filter and cover assembly.

  • Page 62: Injection Pump Adjustments

    Engine Maintenance (Rev. 04/03) Injection Pump Adjustments for individual cylinder timing is very similar to timing the injection pump so it will be covered last. When the diesel engine fails to maintain the correct engine CAUTION: The cylinders on the engine are numbered speed, check the following before adjusting the speed: from the flywheel end to the water pump end.
  • Page 63 Engine Maintenance (Rev. 04/03) Remove the injection line from the number 1 injector If the timing marks did not line up, a shim or shims and the injection pump. Remove the delivery valve will have to be added or subtracted from the injection holder, delivery valve and spring.
  • Page 64 Engine Maintenance (Rev. 04/03) Timing Marks then rotate the engine past number 2 to number 3 and check number 3. Then rotate the engine past number 1 to Timing Individual Cylinder Injection number 2 and check number 2. This procedure should be used when a poor running engine has had all possible problems checked but continues to run badly.

  • Page 65: Adjust Engine Valve Clearance

    2000 operating hours, maximum. It is very important with special tools and procedures. California service techni- that valves be adjusted to the correct specifications for cians should see your local Thermo King dealer for recent satisfactory engine operation. Insufficient valve clear- bulletins.

  • Page 66: Engine Mounts For Rd-Ii Sr Unit

    Engine Maintenance (Rev. 04/03) Engine Mounts for RD-II SR Unit The engine mounting system contains three vibration mounts and two snubber mounts. Engine Mounting Components...

  • Page 67: Rd-Ii Idler Assembly

    Engine Maintenance (Rev. 04/03) RD-II Idler Assembly Idler Assembly—Complete AUTO START/STOP CAUTION: The unit may start automatically and at any time when the unit On-Off switch is in the ON position. Units with the CYCLE-SENTRY option start automati- cally in both CYCLE-SENTRY mode and Continuous mode.
  • Page 68 The belt tension should be set at a reading of 70 to the compressor pulley and check to see that it is cen- 80 on the Thermo King Belt Tension Gauge P/N tered in the slot on the left side of the idler bracket. If 204-427.
  • Page 69 The compressor/jackshaft (electric motor) belt tension the proper tension. The belt tension should be set at a should be set at a reading of 64 to 70 on the Thermo King reading of 64 to 70 on the Thermo King Belt Tension Belt Tension Gauge P/N 204-427.
  • Page 70 Engine Maintenance (Rev. 04/03) Compressor/Evaporator/Alternator and Alternator/ Belts should be tensioned cold and retensioned cold after 10 Evaporator Fan Belts hours of unit running. Move the alternator upward to tighten the belts enough to obtain 1/2 inch (13 mm) deflection at the center of the long- est span of the Compressor/Evaporator Fan/Alternator belts, and 1/2 inch (13 mm) deflection at the center of the span on the Alternator/Evaporator Fan belt.
  • Page 71 Engine Maintenance (Rev. 04/03) Integral Fuel Solenoid The fuel stop solenoid is located on the end of the fuel injec- tion pump. Integral Fuel Solenoid Components...

  • Page 72: Tk 3.95 Engine

    Engine Maintenance (Rev. 04/03) TK 3.95 ENGINE governor linkage then moves the fuel injector rack, thus controlling the fuel flow and placing it in the “Fuel On” Operation of the TK 3.95 engine is controlled by the opera- position. tion of the fuel solenoid and the throttle (high speed) sole- Adjustments made to the throttle (high) speed solenoid noid.

  • Page 73: Engine Speed Adjustments

    Engine Maintenance (Rev. 04/03) Engine Speed Adjustments High Speed Adjustment Start the unit and let it run until the engine is warmed Low Speed Adjustment Start the unit and let it run until the engine is warmed Set the thermostat to make the engine run in high speed and check the engine speed.

  • Page 74: Refrigeration Maintenance

    Refrigeration Maintenance SYSTEM EVACUATION Evacuation Quality Hoses Thermistor Sensor Micron Gauge Calibration Standard Two Stage Vacuum Pump Evacuation Station—TK No. 204-725...

  • Page 75: Evacuation Is Important And Is Critical To System Performance

    Refrigeration Maintenance (Rev. 04/03) Evacuation is Important and is Critical to NOTE: The attached evacuation procedures have been written to be used with the Thermo King Evacuation Sys- System Performance! tem (Tool No. 204-725). However, the principles of 3-point It has been determined through testing and system analysis...
  • Page 76 Refrigeration Maintenance (Rev. 04/03)
  • Page 77 Refrigeration Maintenance (Rev. 04/03)

  • Page 78: Set Up And Test Of Evacuation Equipment

    Refrigeration Maintenance (Rev. 04/03) Set Up and Test of Evacuation Equipment NOTE: If the vacuum pump is okay, and there are no leaks between V-1 and V-3, the micron gauge should NOTE: Refer to the previous two pages for the following show less than 500 microns.

  • Page 79: Unit Evacuation

    Refrigeration Maintenance (Rev. 04/03) Evacuate hoses to 100 microns or lowest achievable With the service valves fully back seated, turn the evac- level below 500 microns. uation pump ON. Open valve V-1 at the pump. The micron gauge should move to a deep vacuum. Once 100 microns is reached, close valve V-1 at the pump.

  • Page 80: Unit Charging

    Refrigeration Maintenance (Rev. 04/03) 11. If the vacuum level is acceptable, start the pump and After the liquid refrigerant is added, close the gauge open valve V-1 to evacuate the pressure rise (5 min- manifold hand valve. Close the valve on the refrigerant utes).
  • Page 81 Refrigeration Maintenance (Rev. 04/03)

  • Page 82: Refrigerant Leaks

    Refrigeration Maintenance (Rev. 04/03) Remove Evacuation Hoses Place a thermometer (TK No. 204-135) test lead in the box near the evaporator return air opening. Run the unit in high speed cool with the receiver outlet Install the gauge manifold. and discharge valves back seated. Run the unit on Cool until the air in the box indicates 0 F Front seat the suction service valve and allow the com- (-18 C).

  • Page 83: Checking Compressor Oil

    Refrigeration Maintenance (Rev. 04/03) NOTE: If the ball floats, there is sufficient refrigerant in the unit for that load at that particular box temper- ature. This test does not determine if the unit contains a full charge of refrigerant. CHECKING COMPRESSOR OIL The compressor oil should be checked when there is evi- dence of oil loss (oil leaks) or when components in the refrigeration system have bee removed for service or...

  • Page 84: Compressor Pump Down And Checkout

    Refrigeration Maintenance (Rev. 04/03) NOTE: Use refrigeration compressor oil ONLY. R-134a circuit operation and secondly by HPCO switch and R-404A systems use a special Ester oil TK No. 203- replacement. 413. To add oil to the compressor, pump down compressor, see “Compressor Pump Down and Checkout.”...

  • Page 85: Three-Way Valve Condenser Pressure Bypass Check Valve

    Refrigeration Maintenance (Rev. 04/03) Set the thermostat well below box temperature, and run Front seat discharge service valve, and equalize the the unit in cooling mode until temperature is stabilized compressor to slightly positive. Disassemble and (at least 5 minutes). inspect the discharge valve plates.
  • Page 86 Refrigeration Maintenance (Rev. 04/03) Using a screwdriver, gently turn the check valve stem in until the valve is front seated. Install a service gauge manifold set on compressor. Close (front seat) the receiver tank outlet valve. Operate the unit on cooling, and pump down the low side to 20 in.

  • Page 87: Refrigeration Service Operations

    Refrigeration Service Operations NOTE: It is generally good practice to replace the filter drier whenever the high side is opened or when the low side is opened for an extended period of time. Refer to the Refrigeration Manual (TK 5715) for system cleanup after a compressor failure or repair or replacement of basic components.

  • Page 88: Condenser/Radiator Coil

    Refrigeration Service Operations (Rev. 04/03) If no leaks are found, evacuate the compressor. Recharge the unit with refrigerant and check the com- Replace the compressor/electric motor belt and adjust pressor oil. the tension. Reinstall the front grille. Back seat the suction and discharge service valves. LIQUID LINE CHECK VALVE Operate the unit at least 30 minutes and then inspect the REPLACEMENT...

  • Page 89: Evaporator Coil

    Refrigeration Service Operations (Rev. 04/03) Installation Solder the suction line and drain pan hot gas line con- nections to the evaporator coil. Install the new drier and tighten the mounting screws and nuts. Install new O-rings. Connect the distributor to the expansion valve assembly.

  • Page 90: Heat Exchanger

    Refrigeration Service Operations (Rev. 04/03) Clean the suction line to a bright polished condition. Clean the screen and reinstall. Install the feeler bulb clamps and the feeler bulb on the NOTE: Outlet screen points toward the distributor. side of the suction line in its former position. The feeler bulb must make good contact with the suction line or the operation will be faulty.

  • Page 91: High Pressure Cutout Switch

    Refrigeration Service Operations (Rev. 04/03) Installation Disconnect the wires and remove the high pressure cut- out switch from the compressor cylinder head. Clean the tubes for soldering. Place the heat exchanger assembly in the evaporator Installation housing and install the mounting hardware loosely. Apply a refrigerant locktite to the threads of the high pressure cutout switch.

  • Page 92: Pressure Regulator Valve

    Refrigeration Service Operations (Rev. 04/03) RECEIVER TANK Disconnect the lines to the solenoid and immediately cap to prevent moisture and air from entering the Removal system. Remove the refrigerant charge. NOTE: The lines from the three-way valve to the pilot solenoid will leak refrigerant at a high velocity and Unsolder the condenser check valve tube and bypass should be capped.

  • Page 93: Three-Way Valve Repair

    Refrigeration Service Operations (Rev. 04/03) Remove the snap ring. Screw the check valve stem into the three-way valve until the snap ring can be installed. Unscrew the check valve stem by using a screwdriver in the slot provided. Install the snap ring. NOTE: Spring and valve are held in by the stem.
  • Page 94 Refrigeration Service Operations (Rev. 04/03) Remove the spring clip. Observe the slot in the spool Install the piston on the stem and attach with spring shaft and slide piston away from this slot. clip. Remove the piston. NOTE: The Teflon seal will stretch when it is installed.

  • Page 95: R-134A And R-404A

    (30), 50 and 125 containers are available. When purchasing R-134a in 30 pound or 50 pound containers, specify indus- trial containers with 1/4 inch flare fittings to receiver con- tainers with 1/4 inch flare fittings for use with Thermo King truck unit applications. Three-way Valve Assembly...

  • Page 96: Equipment Recommendations For Use With R-134A And R-404A

    Compressor Oil When evacuating, a two stage three or five CFM pump is As of January 1, 1993, Thermo King Corporation has cho- recommended. It is also recommended that dry nitrogen be sen to use a compressor oil called Polyol Ester (POE)—also used first.
  • Page 97 Dangerous contamination will result if other refrigerants or standard oils are introduced to R-134a or R-404A systems. NOTE: For additional information on parts and supplies, consult your local Thermo King dealer and Thermo King Tool Catalog TK No. 5955. Refrigerant Recovery...
  • Page 98 Refrigeration Service Operations (Rev. 04/03) Compressor Oil Filter Oil Filter Maintenance X426 compressors using R-134a and R-404A are equipped with a bypass oil filter. To ensure the system stays clean, the oil filter and filter-drier MUST be changed every two (2) years or whenever a major service procedure has been per- formed.

  • Page 99: Refrigerant Recovery System-The Collector

    COLLECTOR tem exceeds a 10 in. Hg. vacuum. Thermo King now has available a refrigerant recovery sys- • Uses an automatic precooling technology to keep the tem known as The Collector (TK No. 204-884). This new...

  • Page 100: Throttling Valve

    Refrigeration Service Operations (Rev. 04/03) THROTTLING VALVE Removal Pump down the low side and equalize pressure to slightly positive. Front seat the discharge and suction service valves. Release remaining pressure. Remove the suction valve and line from compound gauge. Unbolt and remove the throttling valve from the unit. Repair DISASSEMBLY Remove the piston end cap (round end).
  • Page 101 Refrigeration Service Operations (Rev. 04/03) Installation Install the throttling valve using new O-ring soaked in compressor oil (same type of oil that is used in the sys- tem). Bolt the throttling valve to the compressor. Connect the suction hose from the throttling valve to the accumulator tank.
  • Page 102 Refrigeration Service Operations (Rev. 04/03) SCREW — plate 10. TEE FLATWASHER GASKET — piston housing PLATE — bellows end 12. PISTON GASKET — end plate 13. SPRING — piston WASHER — adjusting 14. NUT — adjusting SPRING — bellows 15. PIN — cotter BELLOWS &...

  • Page 103: Hilliard Clutch Maintenance

    Hilliard Clutch Maintenance Clutch Assembly...
  • Page 104 Hilliard Clutch Maintenance (Rev. 04/03) CLUTCH MAINTENANCE Inspect the clutch every 1000 hours of operation or yearly, whichever occurs first. Remove the clutch, clean the shoes and drum, regrease bearings or replace if they are worn. Inspect shoe anchor bushings, shoe lining and springs for wear and replace if necessary.
  • Page 105 Hilliard Clutch Maintenance (Rev. 04/03) Install spacers and fill cavity with Mobil 28 grease (TK No. 203-394). Press second bearing in—seal side up. Place Elatomer bushing and metal bushings in shoes and hub. Position shoes in a circle on a flat surface and install springs on shoes.
  • Page 106 Hilliard Clutch Maintenance (Rev. 04/03) 12. Install retaining ring. Clutch Torque Values...

  • Page 107: Structural Maintenance

    Structural Maintenance UNIT AND ENGINE MOUNTING BOLTS CONDENSER COIL Periodically check and tighten all unit and engine mounting Clean the condenser coil during scheduled maintenance bolts. Torque the unit mounting bolts to 60 ft-lb inspections by blowing compressed air from the back side (81.3 N•m).

  • Page 108: Defrost Damper

    Structural Maintenance (Rev. 04/03) DEFROST DAMPER If the damper blade does not seal evenly along full width of blade: Check the damper during scheduled maintenance inspec- Loosen the damper bearing blocks. tions for shaft wear, end play and sealing against air flow. Manually close the damper so the blade makes Position the damper so that the air flow is stopped top and contact at the top and bottom of the funnel, the full...

  • Page 109: Jackshaft Assembly

    Structural Maintenance (Rev. 04/03) Jackshaft Assembly Use a bearing splitter or similar tool to remove the bearing cones from the shaft. JACKSHAFT ASSEMBLY Clean all parts in clean solvent and then examine the Model 30 units are not equipped with an electric motor. The bearing cups and cones for damage.

  • Page 110: Fanshaft Assembly

    Structural Maintenance (Rev. 04/03) Check end play with a dial indicator. Add or remove After draining the oil from the housing, remove the shims until end play is between .001 to .005 in. (0.025 four retaining bolts from the bearing retainer cap. to 0.127 mm).
  • Page 111 Structural Maintenance (Rev. 04/03) After all the parts are cleaned, inspect the bearings and bearing races for wear or damage. To replace the bearings, first remove the roll pin that is in the center of the shaft. Installing Bearings When replacing the bearing race on the evaporator end Removing Roll Pin of the assembly, the splash guard will come out with the race.
  • Page 112 Structural Maintenance (Rev. 04/03) Torquing Retainer Plate Bolts Lock the assembly in a vise and set up a dial indicator to read the end play. To measure the end play, rotate the Installing Oil Seal shaft while pushing in one direction, and set the dial Place the shaft in the housing.
  • Page 113 Checking End Play After the correct end play is obtained, add grease for Oil Plug Screw with O-ring the bearings. Housing NOTE: Use ONLY Thermo King special fanshaft Breather Vent grease (P/N 203-278) in this assembly. Oil Seal Shaft Lock the assembly in a vise with the vent facing up.

  • Page 114: Rd-Ii Sr Idler Pulley Seal Installation

    Structural Maintenance (Rev. 04/03) RD-II SR IDLER PULLEY SEAL Installation Procedure INSTALLATION To perform a seal change the following procedure is recom- mended: NOTE: RD-II SR Idler Pulleys use seal assembly P/N 33- 1924. The retaining snap rings are deleted and to prevent Remove idler pulley from the unit.
  • Page 115 Structural Maintenance (Rev. 04/03) Pack bearings with TK P/N 203-386 synthetic grease. Install seal assembly P/N 33-1924 with seal lip facing outward. Press pulley side seal until it bottoms on pulley shoulder. Press the opposite seal until it is flush with the pulley edge.

  • Page 116: Mechanical Diagnosis

    Mechanical Diagnosis CONDITION POSSIBLE CAUSE REMEDY Unit switch ON—nothing happens Dead battery Recharge or replace battery Remote switch off (optional) Turn on Circuit breaker open Replace or reset Corroded battery connections Clean and tighten Fusible link blown Check for shorted main harness and replace fusible link Unit switch ON—indicator lights Battery low...
  • Page 117 Mechanical Diagnosis (Rev. 04/03) CONDITION POSSIBLE CAUSE REMEDY Engine cranks but FAILS to start Electric fuel pump not operating Check pump for running and 8 to 10 (continued) psig (55 to 69 kPa). Repair or replace fuel pump Injection pump incorrectly timed Adjust timing Faulty injeciton nozzle(s) Repair injection nozzle or replace it...
  • Page 118 Mechanical Diagnosis (Rev. 04/03) CONDITION POSSIBLE CAUSE REMEDY Engine does not reach full power Leaking injection nozzle or irregular Clean and repair nozzle (continued) injection caused by fouling Insufficient compression pressure Check cylinder with compression due to faulty piston or valves tester.
  • Page 119 Mechanical Diagnosis (Rev. 04/03) CONDITION POSSIBLE CAUSE REMEDY Engine knocks Insufficient air Clean air filter Air in fuel system Bleed fuel system Engine is cold Warm up Fuel return line plugged Remove restriction Injection pump not timed Retime injection pump Injection nozzle fouled or opening Clean, repair or replace injection pressure too low...
  • Page 120 Mechanical Diagnosis (Rev. 04/03) CONDITION POSSIBLE CAUSE REMEDY Oil pressure too low or drops Worn oil pump, camshaft, main or Repair engine suddenly (continued) connecting rod bearings, loose oil gallery plug, oil in water through crack High oil consumption Oil leakage Check and eliminate possible causes Clogged air cleaner...

  • Page 121: Electric Standby (Optional) Diagnosis

    Electric Standby (Optional) Diagnosis CONDITION POSSIBLE CAUSE REMEDY Unit switch ON—indicator lights Battery discharged Charge or replace battery do not come on Circuit breaker open Reset alarm code Electric motor reset switch tripping Check for short circuit in unit wiring (high voltage) Fuse link blown Replace fuse link...
  • Page 122 Electric Standby (Optional) Diagnosis (Rev. 04/03) CONDITION POSSIBLE CAUSE REMEDY Contact chatter Low battery voltage Check voltage condition. Check momentary voltage dip during starting—low voltage prevents magnet sealing Defective or incorrect coil Replace coil Poor contact in control circuit Check auxiliary switch contacts and overload relay contacts.

  • Page 123: Refrigeration Diagnosis

    Refrigeration Diagnosis POSSIBLE CAUSES • • • • Overcharge of refrigerant • • • • • • Shortage of refrigerant • • • • • No refrigerant • Air through condenser too hot (ambient) • Air flow through condenser restricted •...
  • Page 124 Refrigeration Diagnosis (Rev. 04/03) POSSIBLE CAUSES • • • Expansion valve feeler bulb making poor contact • • Expansion valve open too much • • Expansion valve closed too much • • Expansion valve needle eroded or leaking • • •...

  • Page 125: Cool Cycle-Rd-Ii Sr With Thermax™ Heating

    Cool Cycle—RD-II SR with TherMax™ Heating...

  • Page 126: Condenser Cycle-Rd-Ii Sr With Thermax™ Heating

    Condenser Cycle—RD-II SR with TherMax™ Heating...

  • Page 127: Heat And Defrost Cycle-Rd-Ii Sr With Thermax™ Heating

    Heat and Defrost Cycle—RD-II SR with TherMax™ Heating...

  • Page 128: Index

    Index Drawing Title Dwg No. Rev. Page Wiring Diagram RD-II 30 5D45077 Schematic Diagram RD-II 30 5D45075 Wiring Diagram RD-II 50 5D45960 Schematic Diagram RD-II 50 5D45076...

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Rd-ii sr 50 230/3/60 eecRd-ii sr 50 230/3/60Rd-ii sr 50 220/3/50 eecRd-ii sr 50 380-460/3/50-6Rd-ii sr 50 380/3/50 eecRd-ii sr 30 eec ... Show all

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