Thermo King KD-II SR Manual
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Thermo King KD-II SR Manual

Thermo King KD-II SR Manual

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KD-II SR
TK 41079-1-MM (Rev. 3, 04/03)
Copyright
©
1996 Thermo King Corp., Minneapolis, MN, U.S.A.
Printed in U.S.A.

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Summary of Contents for Thermo King KD-II SR

  • Page 1 KD-II SR TK 41079-1-MM (Rev. 3, 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 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.
  • Page 3 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.

  • Page 5: Table Of Contents

    Defrost Air Switch Checkout and Adjustment ...........49 KD-II SR Units Equipped with a Three-Phase Electric Motor and...
  • Page 6 KD-II SR Idler Pulley Seal Installation ........
  • Page 7 KD-II SR Compressor Pulley Removal and Installation ........

  • Page 9: Safety Precautions

    Make sure gauge manifold hoses are in good condition. Never let them come in contact with a belt, fan motor At Thermo King we recognize the need to preserve the pulley, or any hot surface. environment and limit the potential harm to the ozone layer...
  • Page 10 Safety Precautions (Rev 04/03) ELECTRICAL HAZARDS • SKIN: Flush area with large amounts of lukewarm water. Do not apply heat. Remove contaminated cloth- Microprocessor Service ing and shoes. Wrap burns with dry, sterile, bulky dressing to protect from infection/injury. Get medical Precautions must be taken to prevent electrostatic discharge attention.
  • Page 11 Safety Precautions (Rev 04/03) High Voltage Never use testers consisting of a battery and a light bulb to test circuits on any microprocessor based equipment. When servicing or repairing a temperature control unit, the possibility of serious or even fatal injury from electrical Before connecting or disconnecting the battery, the shock exists.
  • Page 12 IMMEDIATE action must be initiated after a person has Serial number decals, refrigerant type decals and warning received an electrical shock. Obtain immediate medical decals appear on all Thermo King equipment. These decals assistance if available. provide information that may be needed to service or repair the unit.
  • Page 13 Safety Precautions (Rev 04/03) AEA40...
  • Page 14 Safety Precautions (Rev 04/03) AEA38...

  • Page 15: Specifications

    Specifications ENGINE SPECIFICATIONS Engine TK 3.74 Fuel Type No. 2 Diesel fuel under normal conditions Oil Capacity: Crankcase & Oil Filter 9 qt (8.6 liters) w/Bypass Oil Filter 10 qt (9.6 liters) Fill to full mark on dipstick Oil Type API Type CF-4, CG-4 or better API Synthetic Type CF-4, CG-4 or better after first 500 hours...
  • Page 16 Specifications (Rev. 04/03) R-404A REFRIGERATION SYSTEM Compressor Model X214 Refrigerant Charge 7.5 lb. (3.4 kg) R-404A Compressor Oil Charge 66 oz. (1.95 liters)* Compressor Oil Type: R-404A (Solest 35) TK No. 203-413 (Ester base) required Suction Pressure Regulator Setting 18 psig (124 kPa) Special Setting KD-II Single Phase 18 psig (124 kPa) Heat/Defrost Method: Engine Operation...
  • Page 17 Specifications (Rev. 04/03) ELECTRICAL CONTROL SYSTEM Control System Voltage 12.5 Vdc Battery Charging System 12 V 23 amp brush type integral alternator Voltage Regulator Setting 14 V @ 70 F (21.1 C) Alternator/Regulator Capacitor 4.7 mfd 50 Vdc Alternator/Output Capacitor 0.5 mfd 100 Vdc NOTE: Disconnect components from unit circuit to check resistance.
  • Page 18 Specifications (Rev. 04/03) STANDBY POWER REQUIREMENTS Supply Circuit Breaker 30 amp/230 V 20 amp/460 V Extension Cord Size Up to 50 ft—12 gauge 75 ft—10 gauge AIR SWITCH Air Switch Setting 0.7 ±.05 in. (17.78 ± 1.3 mm) H...

  • Page 19: 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 20 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 21: Unit Description

    900 ± 100 rpm on engine operation, con- • KD-II SR 50: Cooling and hot gas heating on engine stantly turning the compressor and fans at both high and low operation and electric standby electric evaporator heat- speed.

  • Page 22: Unit Instruments

    Unit Description (Rev. 04/03) • Engine Tachometer Display RECEIVER TANK SIGHT GLASS. The receiver tank sight glass is used to check the amount of refriger- • Battery Voltage Display ant in the system, and the moisture content of the • Phase Lockout (Model 50) refrigerant.
  • Page 23 Unit Description (Rev. 04/03) FUSE LINK WIRE. The fuse link is located between OIL PRESSURE SENSOR. The oil pressure switch the unit harness and the battery. At a current draw of closes when oil pressure is too low. approximately 50 to 55 amperes, the fusible link will On SR models an oil pressure sensor provides an OPS melt and cut all power to the unit controls.

  • Page 24: Unit Operation

    Unit Description (Rev. 04/03) UNIT OPERATION Starting Unit (Full Unit Self Check) The procedure is used for a complete checkout of the truck, Pre-trip Inspection (Before Starting Unit) unit, and unit control circuits. It should be used when first starting the unit for a trip before the cargo is loaded. A full The following pre-trip inspection should be completed Unit Self Check procedure may take up to 30 minutes and before starting the unit and loading the truck.

  • Page 25: Selection Of Operating Modes On Cycle-Sentry Equipped Units

    FAIL will appear on the display until any key on the SENTRY Equipped Units controller is pressed. Continue as follows: The Thermo King CYCLE-SENTRY system is designed to PASS (Unit running, no alarms) save refrigeration fuel costs. The savings vary with the com- modity, ambient temperatures and trailer insulation.

  • Page 26: Restarting The Unit

    Unit Description (Rev. 04/03) • Dairy products battery is fully charged (optional) and the engine block tem- perature rises to 120 F (49 C on SR models or units without • Candy Preheat). • Chemicals After the unit starts from thermostat demand, defrost initia- •...

  • Page 27: After Start Inspection

    Unit Description (Rev. 04/03) If cooling or heating is required and the engine temperature This provides a good test of the refrigeration system is below approximately 120 F (96 C), but the engine fails to while removing residual heat and the moisture from the start automatically: truck interior to prepare it for a refrigerated load.

  • Page 28: Post Trip Checks

    Unit Description (Rev. 04/03) Post Trip Checks Make sure the setpoint is at the desired setting. One-half hour after loading, defrost the unit by momen- Wash the unit. tarily pressing the manual defrost switch. If the evapo- Check for leaks. rator coil sensor temperature is below 45 F (7.2 C), the unit will defrost.

  • Page 29: Unit Photographs

    Unit Description (Rev. 04/03) Unit Photographs AEA35 Front Curbside View—KD-II SR AEA36 Front Roadside View—KD-II SR...
  • Page 30 Unit Description (Rev. 04/03) aea04 Note: Apply Thread Sealant When Installing High Pressure Cutout Oil Seal (Location Not Shown) Crankshaft Discharge Port Cylinder Head X214 Compressor...
  • Page 31 Unit Description (Rev. 04/03) aea05 Cylinder Head Crankshaft Oil Fill Plug Sight Glass Serial Number Oil Drain Plug Oil Pump Cover Pressure Regulator Assembly Oil Pump Gauge Access 10. Suction Port Suction Valve Adapter X214 Compressor...
  • Page 32 Unit Description (Rev. 04/03) aea37 Engine Air Filter Fuel Filter Throttle Solenoid Oil Drain Tube Oil Filter Access Panel Open (Curbside)—KD-II SR...
  • Page 33 Unit Description (Rev. 04/03) AEA38 Evaporator Access Door Rear View (Curbside)—KD-II SR...
  • Page 34 Unit Description (Rev. 04/03) AEA39 Microprocessor Switch Coil Sensor Location Return Air Sensor Side View (Roadside)
  • Page 35 Unit Description (Rev. 04/03) aea40 Evaporator Electric Motor (Model 50) Suction Pressure Regulator 10. Drier Compressor Condenser Coil Alternator 12. Three-Way Valve Nameplate 13. Expansion Tank High Pressure Relief Valve 14. Fuel Filter Receiver Tank 15. Muffler Air Defrost Switch Top View...
  • Page 36 Unit Description (Rev. 04/03) aea41 Motor Contactor B K9 Relay Motor Contactor A 10. K1 Relay Overload Contactor K3 Relay Overload Reset Solenoid 12. K2 Relay Remote Control Cab Box Harness Connector 13. K5 Relay Preheat Buzzer 14. K6 Relay K8 Relay 15.
  • Page 37 Unit Description (Rev. 04/03) AEA42 Power Receptacle Box—KD-II SR 50...
  • Page 38 Unit Description (Rev. 04/03) AEA43 Keypad LED Display THERMOGUARD™ Remote Control Panel...

  • Page 39: Μp-T System Description

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

  • Page 40: Standard Model 50 Features

    µP-T System Description (Rev. 04/03) CAUTION: The Electric Power Icon will not Optional Model 50 Features appear in the display if electric power is not present The following features are available as options on units (the unit is not plugged in), or if there are electrical volt- equipped with Electric Standby.

  • Page 41: Serial Number Locations

    µP-T System Description (Rev. 04/03) SERIAL NUMBER LOCATIONS Unit: Nameplate on top of the unit frame above the switch panel. Engine: Nameplate on top of the rocker arm cover. Compressor: Stamped on the side below the sight glass. Standby Electric Motor: nameplate on motor housing.
  • Page 42 µP-T System Description (Rev. 04/03) High Voltage Tray High Voltage Tray No Options with Phase Correction...
  • Page 43 µP-T System Description (Rev. 04/03) High Voltage Tray High Voltage Tray with Electric Heat with Phase Correction and Electric Heat...
  • Page 44 µP-T System Description (Rev. 04/03) High Voltage Tray with Single Phase Power and Electric Heater...

  • Page 45: 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 46 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 47 Remote Control Panel Features (Rev. 04/03) ALARM ICON. Appears when an alarm condition has been detected by the microprocessor. ELECTRIC ICON. Appears when the 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 48 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 49 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 Standard Display and the setpoint will return to the old setpoint in about 10 seconds if the Enter key is not pressed.
  • Page 50 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 51 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 52 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 53 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 54: Μp-T Alarms

    Remote Control Panel Features (Rev. 04/03) µP-T ALARMS Types of Alarms There are three types of alarms. They may occur individu- Alarms and Alarm Codes ally or along with other alarms. There can be more than one If an abnormal condition is sensed by the microprocessor, alarm present at one time.

  • Page 55: Alarm Code Definitions

    Remote Control Panel Features (Rev. 04/03) ALARM CODE DEFINITIONS Always record any alarm codes shown. Alarm codes preceded by a dash (-) were detected during a Unit Self Check Stored Check Shutdown Code Description No Fault Microprocessor Power Up Reset Evaporator Coil Sensor Return Air Sensor Discharge Air Sensor...

  • Page 56: Μp-T Unit Self Check Test

    Remote Control Panel Features (Rev. 04/03) ALARM CODE DEFINITIONS Always record any alarm codes shown. Alarm codes preceded by a dash (-) were detected during a Unit Self Check Stored Check Shutdown Code Description Microprocessor Reverted to Default Settings Internal Fault Code, Factory or Dealer Reset Show Programmable Settings µP-T UNIT SELF CHECK TEST All programmable settings will be sequentially displayed.
  • Page 57 Remote Control Panel Features (Rev. 04/03) [CHEC] — Stored or check alarm conditions were detected during the Unit Self Check. These alarms will be preceded by a dash (-) to indicate that they were detected during a Unit Self Check. [FAIL] —...
  • Page 58 Remote Control Panel Features (Rev. 04/03)

  • Page 59: Electrical Maintenance

    Electrical Maintenance Output Terminal Filter Capacitor Sense Terminal EXC Terminal: 8D, 7K, 7KK, F1, or EXC Wire No F1 Terminal (Alternators from F2 Terminal: GRN, BTS, or F2 Wire June 1989 to October 1997) Volt Sense Terminal - Pink Resistance or Excitation Terminal SENSE Wire 8D, 7K, 7KK, F1 or EXC Wire...

  • Page 60: Charging System Diagnostic Procedures

    REGULAR SETTING With the unit switch ON, attach a voltmeter to terminal When a Thermo King unit is installed on a truck, it is often EXC and the alternator chassis. Voltmeter should indi- connected to a truck battery. When both the Thermo King cate battery voltage.

  • Page 61: Unit Wiring

    Electrical Maintenance (Rev. 04/03) PREHEAT BUZZER NOTE: If the battery was discharged enough that a boost was needed, the alternator may not recharge the battery The preheat buzzer module on the circuit board is designed because there may not be adequate current to excite the to indicate preheat is in operation.

  • Page 62: Glow Plugs

    Electrical Maintenance (Rev. 04/03) The flywheel (rpm) sensor may be checked as follows: NOTE: If the voltage is slightly off, the voltage may be increased by turning the sensor in more, and the volt- Install the flywheel (rpm) sensor into the flywheel; age may be lowered by turning the sensor out more.

  • Page 63: Condenser/Evaporator Fan Rotation (Electric Standby Operation)

    Electrical Maintenance (Rev. 04/03) Defrost Air Switch Checkout and Adjustment Before testing or adjusting the air switch, check the clear plastic tubing and black plastic tubing to the evaporator coil. Make sure they are not obstructed or crushed. Check the probes in the evaporator housing to be sure they are in proper position, and make sure they are not obstructed.
  • Page 64 Electrical Maintenance (Rev. 04/03) If the switch is out of calibration, pressurize the hose again until the tester indicates 0.7 in. (17.78 mm) H Adjust the screw clockwise or counterclockwise until the switch closes and the continuity tester indicates a completed circuit with the gauge reading 0.7 in.

  • Page 65: Kd-Ii Sr Units Equipped With A Three-Phase Electric Motor And A Phase Converter That Operates On Single-Phase Power

    5D45076 and 5D48889 diagrams in the back of this manual. • a current relay The KD-II SR units that are ordered with the single-phase • a motor start relay 220 volt electric standby option are equipped with a three- •...
  • Page 66 Electrical Maintenance (Rev. 04/03) First and Second-Phase Connections L1 and L2 supply power directly to the first and second windings in both sets of windings in the motor A branch of T2 passes through the motor contactor to When the motor is starting under a load, the current in T1 become T3.
  • Page 67 Electrical Maintenance (Rev. 04/03) Motor Start Contactor Control Coil Circuit 7EA energizes the motor start contactor through the start relay when the current in T2-T2A exceeds 27 amps A branch of wire 7EA also supplies control voltage to one Wire 7EA supplies control voltage from the unit to the cur- side of the motor start relay contacts.

  • Page 68: Run System

    Electrical Maintenance (Rev. 04/03) Third Phase Connection During a Start L2 supplies power to the third windings in both sets of motor windings through the start second windings in both sets of windings in the motor Run System As the motor approaches normal running speed, the current through T2-T2A drops.
  • Page 69 Electrical Maintenance (Rev. 04/03) Third Phase Connection While Running Normally L1 and L2 supplies power to the third windings in both sets of motor windings through the run transformer and the run capacitors The run transformer, run capacitors, and start capacitors are The primary winding of the run transformer is connected to located in a control box under the motor pedestal.

  • Page 70: Troubleshooting The Phase Conversion System

    Electrical Maintenance (Rev. 04/03) Troubleshooting the Phase Conversion System If the electric motor does not run properly, first check the line voltage, the motor contactor, and the motor overload relay. if these are all acceptable, test the electric motor to narrow down the possible causes for the problem. See the Troubleshooting Chart for the individual component tests.
  • Page 71 Electrical Maintenance (Rev. 04/03) The electric motor has two sets of windings. This test separates the sets. The start current should begin at 40 to 45 amps, and then drop off to approximately 20 amps in 1 to 3 seconds (in wires T2 and T2A).

  • Page 72: Troubleshooting Chart

    Electrical Maintenance (Rev. 04/03) Troubleshooting Chart NOTE: All amperage and voltage measurements should be taken with the unit turned ON and the motor running or attempting to start. Most of the voltage measurements can be taken inside the unit control box, from the components in the high voltage tray and from the test point strip.
  • Page 73 Electrical Maintenance (Rev. 04/03) PROBLEM/PROBABLE CAUSE TEST/SOLUTION Current Relay Check the voltage between T1 and T2 at terminal 1 of the current relay and between T1 and T2A at terminal 3 of the current relay. If there is voltage between T1 and T2, but not T1 and T2A, the control coil is open.
  • Page 74 Electrical Maintenance (Rev. 04/03) PROBLEM/PROBABLE CAUSE TEST/SOLUTION Start Capacitors Voltage Test With line voltage present between T1 and T3C and T1 and T3D at the start capacitors, check the voltage between T1 and T3 and T1 and T3F. Both voltages should be within 10% of line voltage.
  • Page 75 Electrical Maintenance (Rev. 04/03) PROBLEM/PROBABLE CAUSE TEST/SOLUTION Run Capacitors Voltage Test (This test is valid only if the motor is running at normal speed and the motor start contactor is de-energized.) Check the voltage between T3A and T3E and between T3B and T3F at the test point strip.
  • Page 76 2. Check the connections between the electric motor leads and the Thermo King wiring in the connection box on the electric motor. Compare these connections to those indicated in the wiring diagrams and schematics. / Repair the wiring connections as necessary.
  • Page 77 Electrical Maintenance (Rev. 04/03) CAUTION: If the electric motor is being rewound, it must be rewound to the factory specifications because this special application requires the phases to be split. Full Load Current Test—Used to check the overall performance of the phase conversion system. Use an inductive ammeter to check the current in motor leads 1 and 7, 3 and 9, and 2 and 8.

  • Page 78: High Capacity Thermax Heating System

    Electrical Maintenance (Rev. 04/03) ™ Heat/Condenser Evacuation Mode HIGH CAPACITY THERMAX HEATING SYSTEM When the µP-T controller initiates a heat or defrost cycle, both the TherMax™ solenoid and the pilot solenoid ener- ™ The High Capacity TherMax Heating System gize simultaneously. The 26P wire from the interface circuit board supplies a ground to the pilot solenoid and the 26T The high capacity heating system increases the capacity of wire supplies a ground to the TherMax™...

  • Page 79: Engine Maintenance

    Engine Maintenance ENGINE LUBRICATION SYSTEM Oil Filter Change The oil filters should be changed along with the engine oil. The TK 3.74 diesel engine has a pressure lubrication system. Oil is circulated by a trochoid type oil pump driven Spin-on Filters: by the crankshaft timing gear and has several times the Remove the filter.

  • Page 80: 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 81: 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 82: Antifreeze Maintenance Procedure

    Engine Maintenance (Rev. 04/03) Checking the antifreeze Run clear water into the radiator, and allow it to drain out of the block and accumulator until it is clear. Check the solution concentration by using a temperature compensated antifreeze hydrometer or a refractometer Inspect all the hoses for deterioration and the hose designed for testing antifreeze.

  • Page 83: Engine Fuel System

    ENGINE FUEL SYSTEM After filling the radiator, run the unit up to operating tem- The fuel system used on the Thermo King TK 3.74 diesel is perature to check for overheating and coolant level and a high pressure system used in conjunction with a precham- allow the air to be purged for a few minutes.
  • Page 84 Engine Maintenance (Rev. 04/03) Oil Pressure Sensor Pre-Filter Screw In Pump Oil Filter Fuel Pump Bypass Oil Filter (Optional) Mounting Plate Fuel Filter To Fuel Tank Diesel Fuel Heater (Optional) KD-II SR Fuel and Oil System Components...

  • Page 85: Bleeding The Fuel System

    Use the relay board test—see TK 41087. Thermo King recommends that any major injection pump or nozzle repairs be done by a quality diesel injection service NOTE: At initial start-up, open the bleeder screw at specialty shop.

  • Page 86: Fuel Filter Replacement

    Engine Maintenance (Rev. 04/03) Water in the Fuel System Remove the filter, cover and cover gasket. Wash the fil- ter in cleaning solvent and blow out the dirt and clean- Water in the fuel system can damage the injection pump, ing solvent with compressed air.

  • Page 87: Injection Pump Adjustments

    Both rocker arms of the number 1 cylinder will be The KD-II SR has one solenoid to control the high speed loose. Check to see that the number 1 cylinder top dead function.
  • Page 88 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 89 Engine Maintenance (Rev. 04/03) TDC Mark File V-Notch Here Injection Timing Mark 5 Timing Mark Round Notch Timing Marks Timing Individual Cylinder Injection then rotate the engine past number 2 to number 3 and check number 3. Then rotate the engine past number 1 to This procedure should be used when a poor running engine number 2 and check number 2.

  • Page 90: Adjust Engine Valve Clearance

    California service techni- cylinders resulting in burned valves and seats. Exces- cians should see your local Thermo King dealer for recent sive valve clearance will result in noisy valve operation bulletins.

  • Page 91: Engine Mounts For Kd-Ii Sr Unit

    Engine Maintenance (Rev. 04/03) Engine Mounts for KD-II SR Unit The engine mounting system contains three vibration mounts and two snubber mounts. 0.020 Air Gap Between Lower Snubber and Engine Roadside Engine Mount Bracket (91-3202) Bracket When Assembled (Snubbers Only)

  • Page 92: Belt Tensions (Units Manufactured Prior To 1-97)

    WARNING: DO NOT attempt to adjust belts with mature belt and bearing failures. the unit running. Engine Fan Pulley Engine Clutch Compressor Drive Motor (Model 50) Fan Pulley Compressor Idler Water Pump Alternator KD-II SR Belt Arrangement...

  • Page 93: Auto Start/Stop

    Belt tension should allow belt to be deflected 1/2 in. (13 mm) at center of span without any engine move- ment. Over-tensioned belts cause severe overload on the bearings. Use only approved Thermo King Service Parts replacement belts. They are specially designed for the Thermo King units.
  • Page 94 Engine Maintenance (Rev. 04/03) NOTE: Kits are available to upgrade your unit to the sprocket adjusting type idler (90-242 for R-404A and 90-243 for R-134a units). Pulley Adjustment Bolt (91-5146) Idler Mounting Bolt/Plate (91-4976) Belt Tension Stop (91-5194) Spring (91-5140) Belt Tension Adjuster (91-5137) Calibrated Belt Tension Spring Belt Adjustor...

  • Page 95: Idler Assembly

    Special Water—1/2 STL Pulley Assembly Flatwasher—1/2 SS Hex Head Screw—1/2-13 UNC x 4.00 STL Lockwasher—1/2 SS NOTE: Starting first quarter 97 KD-II SR units are manufactured with a different idler assembly. The belt tensioning procedure is described on the following page.
  • Page 96 If not, the reading on The belt tension should be set at a reading of 70 to the torque wrench will not produce the proper belt 80 on the Thermo King Belt Tension Gauge P/N tension. 204-427.
  • Page 97 The compressor/jackshaft (electric motor) belt tension the compressor pulley and check to see that it is cen- should be set at a reading of 64 to 70 on the Thermo King tered in the slot on the left side of the idler bracket. If Belt Tension Gauge P/N 204-427.
  • Page 98 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 99: Kd-Ii Sr Idler Pulley Seal Installation

    INSTALLATION To perform a seal change the following procedure is recom- mended: NOTE: KD-II SR Idler Pulleys use seal assembly P/N 33-1924. The retaining spring is deleted and to prevent Remove idler pulley from the unit. pressure buildup in the pulley assembly, the seals are Remove the two seals and the retaining snap ring installed with the seal lip facing outward.
  • Page 100 Engine Maintenance (Rev. 04/03) Pack bearings with TK P/N 203-386 synthetic grease. Install bearings. (Later pulleys use a slip fit bearing and snap ring.) Install seal assembly P/N 33-1924 with seal lip facing outward. Press pulley side seal until it bottoms on pulley shoulder.

  • Page 101: Kd-Ii Sr Idler Pulley Seal Installation

    INSTALLATION To perform a seal change the following procedure is recom- mended: NOTE: KD-II SR Idler Pulleys use seal assembly P/N 33-1924. The seals are installed with the seal lip facing Remove idler pulley from the unit. outward. See diagram below.

  • Page 102: Integral Fuel Solenoid

    Engine Maintenance (Rev. 04/03) Pack bearings with TK P/N 203-386 synthetic grease. Install bearing seal and “O” in the pulley assembly. Install bearings and snap ring. (Bearings are slip fit.) Reinstall the pulley assembly back into the unit. Install seal assembly P/N 33-1924 with seal lip facing Integral Fuel Solenoid outward.

  • Page 103: Tk 3.74 Engine

    Engine Maintenance (Rev. 04/03) TK 3.74 ENGINE When the fuel solenoid is energized, current is applied to the coil creating an electro-magnetic field, which pulls the Operation of the TK 3.74 engine is controlled by the opera- When in the “pulled-in” position, the plunger releases ten- tion of the fuel solenoid and the throttle (high speed) sole- sion on the governor linkage.

  • Page 104: Fuel Solenoid Diagnostic And Replacement

    Engine Maintenance (Rev. 04/03) Fuel Solenoid Diagnostic and High Speed Adjustment Replacement Start the unit and let it run until the engine is warmed • Refer to the Interface Board diagnostic procedures in the Thermoguard µP-T Controller Operation and Diag- Set the thermostat to make the engine run in high speed nosis Manual TK 41087 sections 3 and 4.

  • Page 105: Refrigeration Maintenance

    Refrigeration Maintenance NOTE: The following procedures involve servicing the refrigeration system. Some of these service procedures are regu- lated by Federal, and in some cases, by State and Local laws. All regulated refrigeration service procedures must be performed by an EPA certified technician, using approved equip- ment and complying with all Federal, State and Local laws.

  • Page 106: 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 107 Refrigeration Maintenance (Rev. 04/03) Calibration Standard Vacuum or Micron Gauge Two Stage Vacuum Pump To 110 Vac Power Thermistor...
  • Page 108 Refrigeration Maintenance (Rev. 04/03) 100 Microns 500 Microns 1000 Microns 2500 Microns 5000 Microns 20,000 Microns Atmospheric Pressure Calibration Adjustment Screw Example: Meter needle shown at calibration position when Calibration Standard specifies 0.15 mm Hg. Vacuum Gauge...

  • Page 109: 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 110: 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 111: 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. utes). Back seat (close) the receiver outlet valve. Back seat 12.
  • Page 112 Refrigeration Maintenance (Rev. 04/03)
  • Page 113 Refrigeration Maintenance (Rev. 04/03) Calibration Standard Vacuum or Micron Gauge Two Stage Vacuum Pump To 110 Vac Power Thermistor...

  • Page 114: Remove Evacuation Hoses

    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 115: Checking Compressor Oil

    Refrigeration Maintenance (Rev. 04/03) As the head pressure is rising, check the receiver tank sight glass. The ball should be floating. If there is no indication of refrigerant in the receiver tank sight glass, the unit is low on refrigerant. NOTE: If the ball floats, there is sufficient refrigerant in the unit for that load at that particular box temper- ature.

  • Page 116: Compound Pressure Gauge (Optional Equipment)

    Refrigeration Maintenance (Rev. 04/03) COMPOUND PRESSURE GAUGE Failure of the HPCO system to stop compressor opera- tion should be investigated first by checking the control (Optional Equipment) circuit operation and secondly by HPCO switch The suction pressure at the compressor is shown on the replacement.

  • Page 117: Low Side Pump Down

    Refrigeration Maintenance (Rev. 04/03) Set the thermostat well below box temperature, and run the unit in cooling mode until temperature is stabilized (at least 5 minutes). Compound Gauge Indicating 20 in. Vacuum WARNING: Any time the discharge valve is front seated, disconnect the unit battery or power source to prevent accidental compressor start-up.

  • Page 118: Three-Way Valve Condenser Pressure Bypass Check Valve

    Refrigeration Maintenance (Rev. 04/03) Prepare to perform service on the low side by equaliz- Using a screwdriver, gently turn the check valve stem ing the high side and low side pressures through the in until the valve is front seated. gauge manifold.
  • Page 119 Refrigeration Maintenance (Rev. 04/03) Check Valve Heating/Defrost Position Cooling Position Three-way Valve Condenser Pressure Bypass Check Valve...

  • Page 121: 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. ACCUMULATOR Front seat the discharge and suction service valves. Release remaining refrigerant pressure from the com- Removal pressor.

  • Page 122: Condenser/Radiator Coil

    Refrigeration Service Operations (Rev. 04/03) Operate the unit at least 30 minutes and then inspect the LIQUID LINE CHECK VALVE oil level in the compressor. Add or remove oil if neces- REPLACEMENT sary. Removal Check the refrigerant charge and add refrigerant if Remove the refrigerant charge.

  • Page 123: Evaporator Coil

    Refrigeration Service Operations (Rev. 04/03) Installation Clean the tubes for soldering. Apply a thin layer of refrigerant oil to new O-rings and Solder the suction line and drain pan hot gas line con- install the inlet and outlet nuts. nections to the evaporator coil. Install the new drier and tighten the mounting bracket Connect the distributor to the expansion valve screws and nuts.

  • Page 124: Heat Exchanger

    Capillary Bulb End View Soldier-in Expansion Valve Screen Location of Expansion Valve Bulb (P/N 66-6047) Solder-in Type (P/N 66-5993) KD-II SR Expansion Valve HEAT EXCHANGER Removal Remove the refrigerant charge. Remove the evaporator top cover. Top View Remove the mounting bolts that hold the heat Completely Wrap Bulb with Tape exchanger on the bulkhead.

  • Page 125: High Pressure Cutout Switch

    Refrigeration Service Operations (Rev. 04/03) HIGH PRESSURE CUTOUT SWITCH Unsolder the remaining outlet suction line and inlet liquid line connections from the condenser side of the Removal bulkhead. Remove putty from around the lines before unsoldering the connections. Pump down the compressor and equalize pressure to slightly positive.

  • Page 126: High Pressure Relief Valve

    Refrigeration Service Operations (Rev. 04/03) HIGH PRESSURE RELIEF VALVE 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 Unscrew and remove the high pressure relief valve.

  • Page 127: Receiver Tank

    Refrigeration Service Operations (Rev. 04/03) RECEIVER TANK Remove the snap ring. Unscrew the check valve stem by using a screwdriver Removal in the slot provided Remove the refrigerant charge. NOTE: Spring and valve are held in by the stem. Unsolder the condenser check valve tube and bypass While removing the stem, use care so the spring and check valve tube from the receiver tank valve are not lost.

  • Page 128: Three-Way Valve Repair

    Refrigeration Service Operations (Rev. 04/03) Coat the entire assembly with compressor oil and CAUTION: Do not force the tool into the brass install the assembly into the check valve seat in the or against the bolts. three-way valve. Unsolder the condenser line from the condenser. CAUTION: The Teflon valve must be inserted Remove the 4 bolts from the valve.
  • Page 129 Refrigeration Service Operations (Rev. 04/03) Install new gaskets on both sides of the valve body. Dip gaskets in compressor oil (use same type of oil that is used in the system) before installing. Install a new O-ring on the piston, then place the Teflon seal over the O-ring.

  • Page 130: Kd-Ii Sr Compressor Pulley Removal And Installation

    Installation vice, anti-seize lubricant should be applied to the outside of KD-II SR units will have an anti-seize lubricant on the the tapered surface on the pulley bushing. Use one of the tapered surfaces of the two-piece compressor pulley. The...

  • Page 131: R-134A And R-404A

    R-134a and R-404A and can be used in low temperature “HFC” may be incorporated in the model designation applications. This oil is available from service parts TK No. on the sides of the unit such as “KD-II SR HFC”. 203-413. Decals will be applied to unit as shown below.
  • Page 132 Refrigeration Service Operations (Rev. 04/03) Bracket Screw O-Ring Inlet Clamp Screw 3/4 OD O-Ring Adapter Compressor Pump O-Ring Elbow 10. Oil Filter Clamp Check Valve O-Ring Outlet Inlet Tube 12. Oil Filter Bracket Compressor Oil Filter (Prior April 1997) Oil Filter Maintenance X214 compressors using R-134a and R-404A are equipped with a bypass oil filter.
  • Page 133 Refrigeration Service Operations (Rev. 04/03) Stabilizer Bracket ORS Adapter Bracket Screw 12. 3/8 O-ring Flatwasher 13. Compressor Inlet Tube Lockwasher 14. Filter Assembly 15. 1/4 O-ring Cylinder Head Stud 16. 3/8 O-ring Bracket Nut 17. Clamp Flatwasher 18. Compressor Outlet Tube Sealing Washer 19.

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

    Refrigeration Service Operations (Rev. 04/03) Compressors Shipped with R-134a Pumps used with other Thermo King refrigerants may be used but extreme care should be taken to prevent contami- The KD-II SR compressors are Thermo King compressors nation of R-134a or R-404A systems with other refrigerants.

  • Page 135: Refrigerant Recovery System-The Collector

    Using a simple purging system allows the Collector to be switched from one unit to the next in just minutes. Thermo King now has available a refrigerant recovery sys- Contact Thermo King Corporation at 612-887-2288 to tem known as The Collector (TK No. 204-884). This new...
  • Page 136 Refrigeration Service Operations (Rev. 04/03) Recovery Complete Light Reset Switch Vapor Recovery Light Power Switch Liquid Valve Vapor Valve Recovery Tank Liquid Hose Valve Recovery Tank Vapor Hose Valve...

  • Page 137: Hilliard Clutch Maintenance (Prior 4-97)

    Hilliard Clutch Maintenance (Prior 4-97) Bushing (Shoe Pivot) Bearings and Spacers Washer Screw Snap Ring Elastic Stop Nuts (6) Link Connector Spring Shoe Hex Head Screws (6) Pulley Housing Clutch Assembly...
  • Page 138 Hilliard Clutch Maintenance (Prior 4-97) (Rev. 04/03) CLUTCH MAINTENANCE Using an inspection mirror, inspect the clutch every 1000 hours of operation or yearly, whichever occurs first. If clutch removal is necessary, 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 139 Hilliard Clutch Maintenance (Prior 4-97) (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 140 Hilliard Clutch Maintenance (Prior 4-97) (Rev. 04/03) 12. Install retaining ring. Torque nuts to 85 to 90 in-lb (9.9 to 10.5 N•m). (Shoes must be held in disengaged position while tightening these 6 bolts and nuts.) Torque to 215 to 220 in-lb (24 to 25 N•m).

  • Page 141: Hilliard Clutch Maintenance (Starting 4-97)

    Hilliard Clutch Maintenance (Starting 4-97) Large Truck Unit Centrifugal Clutch 107-272 has three belt grooves and its engagement speed is 600 ± 100 rpm. When this clutch is installed on a unit Change (P/N 104-272) equipped with a two groove belt, the belt should be placed Beginning in the second quarter of 1997 most large truck in the two grooves nearest to the engine flywheel.
  • Page 142 Hilliard Clutch Maintenance (Starting 4-97) (Rev. 04/03) aea558 (3 belt grooves) Screw Grease Seal Washer Roller Bearing Inner Race Snap-Ring Pulley Housing Ball Bearing Elastic Stop Nuts (6) Large & Small Spacers Connector Link (6) Rolling Bearing Spring (6) Lockwasher (12) Shoe Assembly (3) Bushing (6) Screws (6)
  • Page 143 Hilliard Clutch Maintenance (Starting 4-97) (Rev. 04/03) CLUTCH MAINTENANCE Using an inspection mirror, inspect the clutch with a mirror every 1000 hours of operation or yearly, whichever occurs first. If clutch removal is necessary, clean the shoes and drum, regrease bearings or replace if they are worn. Inspect anchor bushings, shoe lining and springs for wear and replace if necessary.
  • Page 144 Hilliard Clutch Maintenance (Starting 4-97) (Rev. 04/03) Press bushings out of hub. Bushing Removal Remove inner race of roller bearing from the housing shaft. Bushing Insertion NOTE: This race was Loctited and pressed in place, and a puller will be required to remove it. Insert threaded end of screw into bushing.
  • Page 145 Hilliard Clutch Maintenance (Starting 4-97) (Rev. 04/03) Slip large and small spacer into hub I.D. seating against the roller bearing. Apply Mobil #28 grease to roller bearing and fill cavity between large and small spacers. A small amount of grease should also be applied to the seal lip and space between the seal and roller bearing.

  • Page 147: Structural Maintenance

    Check Bolts For Tightness and repair if necessary. KD-II SR Lift Points The KD-II SR unit lifting points are noted below. Note that 3 lift points MUST be used. UNIT INSPECTION Slots in Frame 1-1/2 in. Long 3/4 in. Wide Inspect the unit during unit pre-trip inspection and sched- Hole in Frame 1-1/2 in.

  • Page 148: 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 149: Jackshaft Assembly

    Remove bearing retainer cap from fill plug end of the jackshaft assembly. The KD-II SR 30 does not have electric standby capability, NOTE: There are shims between the bearing retainer therefore, the electric motor is replaced by a jackshaft. The cap and the housing.
  • Page 150 Structural Maintenance (Rev. 04/03) Reassembly Use a tie band or a hose clamp as tool to compress the oil sling retainer enough to fit inside the jackshaft Coat the edges of the oil seals with a gasket sealant. housing. Using a suitable tool, install the seals in the end caps. Install the shaft into the jackshaft housing with oil sling Fill the space between the seal lips with grease.

  • Page 151: Fan Location

    Structural Maintenance (Rev. 04/03) Install the remaining end cap. Torque the bolts to 10 ft-lb (13.6 N•m). 10. Check end play of the shaft with a dial indicator. End play should be between 0.001 to 0.005 in. (0.025 to 0.127 mm). Change shims if necessary. 11.

  • Page 152: Fan Shaft Assembly Overhaul

    Structural Maintenance (Rev. 04/03) Fan Shaft Assembly Overhaul To remove the shaft from the assembly, tap the opposite end of the shaft with a soft hammer. After the shaft has Disassembly been removed, clean all parts in clean solvent. Remove the fan shaft assembly from the unit. Remove both oil plugs and drain the oil from the housing.
  • Page 153 Structural Maintenance (Rev. 04/03) With the roll pin removed, place a pipe over the shaft and drive one bearing down until the opposite bearing and bearing spacer release from the shaft. After removing one bearing and the bearing spacer, turn the shaft upside down and drive the other bearing off, using the pipe.
  • Page 154 Checking End Play After the correct end play is obtained, add grease for the bearings. NOTE: Use ONLY Thermo King special fan shaft grease (P/N 203-278) in this assembly. Lock the assembly in a vise with the vent facing up.
  • Page 155 Structural Maintenance (Rev. 04/03) Oil Plug Screw with O-ring Housing Breather Vent Oil Seal Shaft Sleeve Screw with Flatwasher and Lockwasher Cap and Shims 10. O-ring Roller Bearing 12. Splash Guard Tube Fan Shaft Assembly...

  • Page 157: 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 158 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 159 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 160 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 161 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 163: Electric Standby (Optional) Diagnosis

    Electric Standby (Optional) Diagnosis CONDITION POSSIBLE CAUSE REMEDY Unit switch ON—µP-T does not Battery discharged Charge or replace battery come on Circuit breaker Replace switch if defective Electric motor reset switch tripping Check for short circuit in unit wiring (high voltage) Fuse link blown Replace fuse link Dirty battery terminals...
  • Page 164 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 165: 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 166 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 167: Cool Cycle-Kd-Ii With Thermax™ Heating

    Cool Cycle—KD-II with TherMax™ Heating Compressor Three-way Valve Condenser Coil Pilot Solenoid Heat Solenoid High Pressure Relief Valve Receiver Tank Sight Glass Receiver Outlet Valve 10. Dehydrator Receiver Outlet Check Valve 12. Accumulator Tank 13. Suction Pressure Regulator 14. Heat Exchanger 15.

  • Page 168: Condenser Evacuation Cycle-Kd-Ii With Thermax™ Heating

    Condenser Evacuation Cycle—KD-II with TherMax™ Heating Compressor Three-way Valve Condenser Coil Pilot Solenoid Heat Solenoid High Pressure Relief Valve Receiver Tank Sight Glass Receiver Outlet Valve 10. Dehydrator Receiver Outlet Check Valve 12. Accumulator Tank 13. Suction Pressure Regulator 14. Heat Exchanger 15.

  • Page 169: Heat And Defrost Cycle-Kd-Ii With Thermax™ Heating

    Heat and Defrost Cycle—KD-II with TherMax™ Heating Compressor Three-way Valve Condenser Coil Pilot Solenoid Heat Solenoid High Pressure Relief Valve Receiver Tank Sight Glass Receiver Outlet Valve 10. Dehydrator Receiver Outlet Check Valve 12. Accumulator Tank 13. Suction Pressure Regulator 14.

  • Page 171: Wiring Diagrams And Schematics Index

    Wiring Diagrams and Schematics Index Dwg No. Drawing Title Page 5D45075 KD-II 30 Schematic Diagram 159-160 5D45077 KD-II 30 Wiring Diagram 161-162 5D45076 KD-II 50 Schematic Diagram 163-164 5D45960 KD-II 50 Wiring Diagram 165-166 5D48889 KD-II 50 SR 230/1/60 Wiring Diagram 167-168...
  • Page 173 KD-II 30 Schematic Diagram—Page 1 of 2...
  • Page 174 KD-II 30 Schematic Diagram—Page 2 of 2...
  • Page 175 KD-II 30 Wiring Diagram—Page 1 of 2...
  • Page 176 KD-II 30 Wiring Diagram—Page 2 of 2...
  • Page 177 KD-II 50 Schematic Diagram—Page 1 of 2...
  • Page 178 KD-II 50 Schematic Diagram—Page 2 of 2...
  • Page 179 KD-II 50 Wiring Diagram—Page 1 of 2...
  • Page 180 KD-II 50 Wiring Diagram—Page 2 of 2...
  • Page 181 KD-II 50 SR 230/1/60 Wiring Diagram—Page 1 of 2...
  • Page 182 KD-II 50 SR 230/1/60 Wiring Diagram—Page 2 of 2...

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