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 EXPRESS WARRANTY. Such terms and conditions are available upon request.
Page 3 CAUTION: Use ONLY Polyol Ester based refrigeration compressor oil (TK P/N 203-413) in R-404A and R-134a units. DO NOT use Polyol Ester based oil in standard Thermo King units. DO NOT mix Polyol Ester and standard synthetic compressor oils. Keep Polyol Ester compressor oil in tightly sealed containers. If Polyol Ester oil becomes contaminated with moisture or standard oils, dispose of properly—DO NOT...
Page 5: Table Of Contents
Table of Contents Safety Precautions ............... . . i Specifications .
Page 6 Table of Contents Refrigeration Maintenance ..............45 Refrigerant Charge .
Page 7 Table of Contents (Continued) Compressor and Clutch Maintenance ............67 Clutch Removal .
Page 9: Safety Precautions
Safety Precautions GENERAL PRACTICES REFRIGERANT ALWAYS WEAR GOGGLES SAFETY Although fluorocarbon refrigerants are classified as safe GLASSES. Refrigerant liquid, refrigeration oil, and refrigerants, certain precautions must be observed when battery acid can permanently damage the eyes (see First handling them or servicing a unit in which they are used. Aid under Refrigeration Oil).
Page 10 Safety Precautions (Rev. 1/99) ELECTRICAL HAZARDS First Aid IMMEDIATE action must be initiated after a person has High Voltage received an electrical shock. Obtain immediate medical assistance if available. When servicing or repairing a refrigeration unit, the possi- bility of serious or even fatal injury from electrical shock The source of shock must be immediately removed by exists.
Page 11: Specifications
Specifications R-134a REFRIGERATION SYSTEM Compressor Zexel DKS-15CH Engine Compressor Oil Charge 11.5 oz (339 ml) Electric Standby Compressor Oil Charge 5.7 oz (168 ml) Compressor Oil Type Polyol Ester P/N 203-413 Refrigerant Type R-134a Hot gas Defrost Method: Truck Engine Operation: CBci 10 MAX Hot gas CBci...
Page 12 Specifications (Rev. 1/99) R-404A REFRIGERATION SYSTEM (continued) Condenser Pressure Fan Switch:Opens 130 ± 10 psi (896 ± 69 kPa) Closes 180 ± 10 psi (1241 ± 69 kPa) Suction Pressure Regulator Setting 18 psi (124 kPa) Defrost Timer: Intuition Interval 4 hours Termination Interval 45 minutes...
Page 13 Specifications (Rev. 1/99) Optional Electric Heaters Power Rating Voltage Watts Current Resistance 230 Vac 3.48 amps 66.1 ohms 380 Vac 2.1 amps 180.5 ohms BELT TENSION (Using Tool P/N 204-427) Field Reset Engine/Compressor Electric Motor/Compressor...
Page 15: Maintenance Inspection Schedule
Maintenance Inspection Schedule First Week Inspection and Maintenance After First Week of operation: • Check the belt tension • Tighten the unit mounting bolts • Check the refrigerant level • Check the compressor oil level Weekly Monthly monthly Annually Inspect/Service These Items ELECTRICAL •...
Page 17: Unit Description
Unit Description The Thermo King CBci truck refrigeration system is a The electric standby compressor is connected in parallel three-piece system consisting of a condenser, an evaporator, with the engine-driven compressor on the Model 20 units. and a compressor. The assemblies are separate, and the con- The engine compressor is driven by a belt from the engine.
Page 18: Oil Separator
Unit Description (Rev. 1/99) the adjacent cavity in the compressor head. When the dis- is also controlled by the condenser fan pressure switch. This charge gas is cooled to 200 ± 5 F (93 ± 3 C), the high tem- normally open switch monitors the compressor discharge perature switch opens, the liquid injection solenoid valve pressure.
Page 19: Operating Modes
Unit Description (Rev. 1/99) does not. The heat relay also energizes the optional water pump and hot water valve, or the optional heater contactor. Defrost The defrost cycle can be initiated any time the evaporator coil temperature is below 42 F (5.6 C). Defrost is initiated automatically by the defrost timer, or manually by pressing the Manual Defrost switch.
Page 20: Unit Features
Unit Description (Rev. 1/99) UNIT FEATURES • Power Cord Warning Light (in Optional Cab Control Box for Model 20 only) • Digital Thermometer • Overload Relay Protection for Electric Standby Motor • Electronic Thermostat (Model 20 only) • Defrost Timer •...
Page 21 Unit Description (Rev. 1/99) AGA321 Electric Motor Reset (Model 20 Only) Master On-Off Switch Control Box Cover Front Curbside View AGA320 Front Roadside View...
Page 22 Unit Description (Rev. 1/99) AGA414 Receiver Outlet Valve Sight Glass Accumulator Condenser Check Valve Drier High Pressure Valve Liquid Injection Solenoid Roadside Components...
Page 23 Unit Description (Rev. 1/99) AGA290 Defrost Timer Fan Relay Defrost Relay Cool Relay Circuit Breakers Heat Relay Terminal Board Power Disconnect Relay Defrost Jumper (Emergency Use Only) Model 10 Control Box Components...
Page 24 Unit Description (Rev. 1/99) AGA336 Defrost Timer Terminal Board Defrost Relay Motor Contactor Circuit Breakers Overload Relay Fan Relay 3-Phase Transformer Model 20 3-Phase Control Box Components...
Page 25 Unit Description (Rev. 1/99) AGA358 Thermometer Sensor Thermostat Sensor Evaporator...
Page 26 Unit Description (Rev. 1/99) AGA359 ORS Fittings Thermostat Sensor Heat Exchanger Thermometer Sensor Expansion Valve Evaporator Coil Defrost Termination Switch Pan Heater Evaporator Components...
Page 27 Unit Description (Rev. 1/99) AGA291 Defrost Termination Switch Heat Exchanger Expansion Valve Thermostat Sensor Fan Motor (Two Used) Pan Heater ORS Fittings Evaporator Coil Exploded View of CBci MAX Evaporator...
Page 28 Unit Description (Rev. 1/99) AGA416 On Light Manual Defrost Switch On-Off Switch Defrost Light Wing Screw Thermometer Remote Control Box...
Page 29 Unit Description (Rev. 1/99) AGA292 Cool Light Inner Dial Heat LED Thermostat Module Thermostat Dial On LED Outer Bezel Inside Remote Control Box...
Page 30 Unit Description (Rev. 1/99) AGA327 Defrost Timer Motor Overload Relay Defrost Relay Chokes Circuit Breakers Clutch Relay Fan Relay 10. Fuse Terminal Board Standby Relay Motor Contractor 12. Single Phase Transformer Model 20 Single Phase Control Box Components...
Page 31 Unit Description (Rev. 1/99) AGA293 LED Display Manual Defrost Switch Setpoint LED On-Off Switch Power Cord LED (Model 20 Only) Setpoint Switch On LED Thermostat Dial Defrost LED Cab Control Box Standard on New Units...
Page 33: Operating Instructions
Operating Instructions UNIT CONTROLS SETPOINT SWITCH. Pushing this switch displays the thermostat setpoint on the LED display and causes the Remote Control Box setpoint LED to light up. ON-OFF SWITCH. The master On-Off switch must be ON-OFF SWITCH. The master On-Off switch must be in the ON position to enable this switch.
Page 34: Unit Protection Devices
Operating Instructions (Rev. 1/99) DEFROST TIMER. This timer automatically places the UNIT PROTECTION DEVICES unit in defrost every 4 hours. The defrost timer also ter- CONTROL SYSTEM CIRCUIT BREAKERS. The minates defrost 45 minutes after it starts if the defrost control system circuit breaker is located in the unit con- termination switch does not open.
Page 35: Unit Operation
Operating Instructions (Rev. 1/99) help the valve reseat and SEAL PROPERLY. The valve ELECTRICAL INSPECTION. The electrical connec- is non-repairable and requires no adjustment. If the tions should be securely fastened. Wires and terminals valve fails to reseat properly, remove the refrigerant should be free of corrosion, cracks or moisture.
Page 36: Adjusting The Thermostat
Operating Instructions (Rev. 1/99) Electric Standby Operation Optional Cab Control Box Connect the external power supply to the power recep- The thermometer reading (sensor temperature) normally tacle. Make sure that the power supply voltage and appears on the LED display while the unit is turned on. phasing is correct for the unit as required by the electri- Pressing the setpoint switch lights the setpoint LED and cal information plate located on the standby motor.
Page 37: Loading Procedure
Operating Instructions (Rev. 1/99) Loading Procedure Post Loading Procedure Make sure that the unit is Off before opening the doors Make sure that all the doors are closed and locked. to minimize frost accumulation on the evaporator coil Adjust the thermostat to the desired temperature set- and heat gain in the trailer.
Page 39: Electrical Maintenance
Electrical Maintenance UNIT WIRING Check Power Make sure the master On-Off switch is ON. Periodically inspect the unit wiring and the wire harnesses for loose, chafed or broken wires to protect against unit mal- Open the remote control box cover. functions due to open or short circuits.
Page 40: Testing The Thermostat
Electrical Maintenance (Rev. 1/99) Check Sensor and Sensor Circuits Thermometer Calibration Test Turn the unit ON (both On-Off switches must be turned Place the sensor in an ice-water bath for a few minutes ON). and allow the sensor temperature to stabilize. Stir the ice-water bath occasionally to keep the temperature sta- Check the power to the thermometer (see Check ble.
Page 41 Electrical Maintenance (Rev. 1/99) Check the power to the thermostat (see Check Power). Disconnect the thermostat sensor harness from the ther- mostat (wires SN4, SN5, and SN6 from terminals T11, Turn the On-Off switch OFF and disconnect the sensor T10, and T9, respectively). wires from the thermostat (wires SN4, SN5, and SN6 from thermostat terminals T11, T10, and T9, respec- Connect the thermostat sensor harness wires to the ther-...
Page 42 Electrical Maintenance (Rev. 1/99) Thermostat Switch Sequence Test Continue to slowly turn the thermostat dial down and lower the thermostat setpoint about 2 F (1.1 C) every The switch sequence test should be performed during 5 seconds. When the thermostat setpoint reaches 2 ± scheduled preventive maintenance operations.
Page 43: Cab Control Box Components (Optional)
Electrical Maintenance (Rev. 1/99) CAB CONTROL BOX COMPONENTS Use a known good thermometer (or a 32 F [0 C] ice- water bath) to check the switch points. The unit should (OPTIONAL) shift from cool to null at 32 F (0 C). Temperature Control Module (TCM) If the unit shifts modes properly and is out of calibra- tion by less than 5 F (2.7 C), recalibrate the thermostat...
Page 44 Electrical Maintenance (Rev. 1/99) Digital Thermometer Blank Display The range for the thermometer is -40 to 199 F (-40 to 93 C). Erratic Display Normally the thermometer reading appears on the LED dis- play. Pressing the Setpoint switch causes the thermostat set- point to appear on the LED display.
Page 45 Electrical Maintenance (Rev. 1/99) Check Power If there are no faults in the SN1, SN2, and SN3 circuits, repeat the Initial TCM Display Test. If the results of the Make sure the master On-Off switch is ON. test have not changed, the TCM is defective and must Disconnect the 14 pin connector (cab control box be replaced.
Page 46: Defrost System
Electrical Maintenance (Rev. 1/99) NOTE: Press the Setpoint switch to display the thermostat The thermostat energizes the cool relay, which shifts setpoint. the unit to cool, by closing internal contacts that con- nect the CR1 circuit to the CR circuit. Start the unit and set the thermostat setpoint 8 to 10 F (4.4 to 5.6 C) below the thermometer reading.
Page 47: Electric Standby Operation (Model 20 Only)
Electrical Maintenance (Rev. 1/99) Manual Defrost Switch To check the defrost cycle, run the unit in cool to drop the evaporator coil to a temperature below 42 F (5.6 C). Press A Manual Defrost switch is located in the remote or cab the manual defrost switch.
Page 48: Testing The Defrost System
Electrical Maintenance (Rev. 1/99) Defrost Termination Switch Bench Test Testing the Defrost System Connect a test light between the screw terminal on the To test the defrost system, run the unit on Cool until the switch and the positive battery terminal. evaporator coil temperature is below 42 F (5.6 C) and press the Manual Defrost switch.
Page 49 To check the three-way valve or the condenser check the terminal board. valve, refer to the procedures described in TK 5984, Diagnosing the Thermo King Refrigeration System. Unit Will Not Terminate Defrost To check the refrigerant charge, refer to Refrigerant NOTE: The defrost timer should automatically terminate Charge in the Refrigeration Maintenance chapter.
Page 50: Defrost Timer
Electrical Maintenance (Rev. 1/99) Temporary Defrost Timer Bypass Procedure Check the operation of the defrost termination switch. If the timer fails and a replacement is not available, bypass- If the unit will not come out of defrost, disconnect the ing the timer will allow the manual defrost switch to pro- 12 wire from the defrost termination switch.
Page 51 Electrical Maintenance (Rev. 1/99) Approximately 1 to 3 minutes after the timer termi- Attach a test lead to the B terminal and to the negative nated defrost, the defrost cycle should reinitiate for terminal of the power source. another brief period of time. This On-Off cycle should Attach a test lead to the 6 terminal and to the negative repeat until the 12 circuit opens.
Page 52: Circuit Breakers
Electrical Maintenance (Rev. 1/99) Attach a test lead to the A terminal and to the positive CONDENSER FAN PRESSURE SWITCH terminal of the power source. (CFPS) Attach a test lead to the 4 terminal and to the positive The CFPS is located in the discharge line. Electrically it is terminal of the power source.
Page 53: Electric Standby Circuits (Model 20 Only)
Electrical Maintenance (Rev. 1/99) ELECTRIC STANDBY CIRCUITS (Model 20 Measure the transformer output voltage (AC) at the ter- minal board. Measure the voltage between wires A and Only) B, between wires B and C, and between wires A and C. Make sure the unit is connected to the proper power source.
Page 54 Electrical Maintenance (Rev. 1/99) 12 Volt System, Single Phase Electric Standby 24 Volt System, Single Phase Electric Standby The DC voltage should be 12 to 15 volts and the current The DC voltage should be 24 to 30 volts and the current through the 2B wire should be less than 35 amps.
Page 55: 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 56 Refrigeration Maintenance (Rev. 1/99) Checking the Refrigerant Charge 15. Close the low side valve on the gauge manifold and operate the unit for 15 minutes. If the unit has an insufficient charge of refrigerant, the evap- orator will be “starved” and the box temperature will rise 16.
Page 57: Checking Compressor Oil Charge
Refrigeration Maintenance (Rev. 1/99) CHECKING COMPRESSOR OIL CHARGE HIGH PRESSURE CUTOUT SWITCH (HPCO) The compressors are furnished with the amount of oil shown in the Specifications chapter. The oil level in the The HPCO is located on the hot gas line (Model 10) or on compressor will change after the compressor is initially run, the check valve assembly (Model 20) inside the condenser making any level measurements inaccurate.
Page 58: System Cleanup
Refrigeration Maintenance (Rev. 1/99) NOTE: Service manifold hoses must have Schrader Place a normal amount of oil in the cleanup compressor valve (tire valve) depressors. before operating. Charge with 6 to 7 lb (2.7 to 3.2 kg) of refrigerant. Set the thermostat well below the box temperature so that the unit will be in cool.
Page 59: Refrigerant Hose Routing
Refrigeration Maintenance (Rev. 1/99) REFRIGERANT HOSE ROUTING To prevent oil trapping, the suction hose must be clamped in a U trap before it goes to the compressor AGA294 Correct Hose Routing Incorrect Hose Routing (Will Cause Oil Trapping) To Condenser Under Cab To Compressor Vertical Lift...
Page 60: Three-Way Valve Condenser Pressure Bypass Check Valve
Refrigeration Maintenance (Rev. 1/99) THREE-WAY VALVE CONDENSER PRESSURE BYPASS CHECK VALVE A three-way valve condenser pressure bypass check valve is used in this unit. This check valve controls the bypass flow of refrigerant gas between the condenser inlet line and the compressor discharge line.
Page 61: 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. COMPRESSOR CONDENSER COIL Removal Removal Remove the refrigerant charge from the system. Remove the refrigerant charge.
Page 62: Evaporator Coil
Refrigeration Service Operations (Rev. 1/99) Installation Solder the suction line to the evaporator coil. Place new O-rings in the ORS fittings on the ends of Connect the hot gas line to the distributor. the drier. Connect the expansion valve to the distributor. Install the new drier and tighten the mounting screws Connect the defrost termination switch wire.
Page 63: Receiver Tank
Refrigeration Service Operations (Rev. 1/99) Clean the suction line to a bright, polished condition. Remove the receiver tank. Install the feeler bulb clamps and the feeler bulb on the Installation side of the suction line in its former position. The feeler bulb must make good contact with the suction line or Position the receiver tank in the unit and install the operation will be faulty.
Page 64 Refrigeration Service Operations (Rev. 1/99) Use a hose cutter to cut the oil return hose to the proper length, and to cut the discharge hose for the installation of the inlet and outlet fitting. Make sure there is no for- eign matter in any of the hoses.
Page 65: Replacing Refrigerant Hoses
Refrigeration Service Operations (Rev. 1/99) REPLACING REFRIGERANT HOSES Lubricate nipple threads and inside of hose with refrigerant oil. Disassembly Refrigerant Hose Installation Remove the refrigerant charge or pump down the low Apply clean compressor oil to the flares to facilitate the side.
Page 66: Liquid Injection Solenoid Valve
Refrigeration Service Operations (Rev. 1/99) Installation Using a wrench, rotate the unit to tighten. Turn the nut the amount shown in the following chart. Fasten the solenoid valve to the mounting bracket. Line Size Rotate No. of Hex Flats Connect refrigerant lines to both sides of the solenoid 2-1/2 valve.
Page 67: Testing The Liquid Injection Solenoid Valve And Metering Orifice
Refrigeration Service Operations (Rev. 1/99) Testing the Liquid Injection Solenoid LOW PRESSURE CUTOUT SWITCH Valve and Metering Orifice Removal Disconnect the LIS wire from the liquid injection sole- Pump down the low side and stop the unit. noid. Disconnect the wires and remove the switch. Install a gauge manifold set on the engine-driven com- pressor.
Page 68: Discharge Check Valve Repair (Model 20 Only)
Refrigeration Service Operations (Rev. 1/99) DISCHARGE CHECK VALVE REPAIR Observe the gauge manifold reading of the engine- driven compressor. If the high side and low side read- (Model 20 Only) ings are not the same, open the gauge manifold valves Testing the Discharge Check Valve and equalize the pressures.
Page 69 Refrigeration Service Operations (Rev. 1/99) Measure the pistons. Replace the piston(s) if the O.D. is greater than 0.998 in. (25.35 mm) or less than 0.995 in. (25.27 mm). Inspect the piston sealing surfaces. Replace the pistons if the sealing surfaces are worn or damaged. Inspect the valve body.
Page 70: Accumulator
Refrigeration Service Operations (Rev. 1/99) Assembly NOTE: A crows foot of this size increases the torque read on the torque wrench by approximately 6%. NOTE: Coat all parts with compressor oil before assembly. Therefore, the reading on the torque wrench should Place the spring in the valve body.
Page 71: Three-Way Valve Repair
Refrigeration Service Operations (Rev. 1/99) Installation Top cap, sealing and support area. Place the accumulator in the unit and tighten the Remove the screen. If any particles drop from the mounting bolts. screen into the discharge line, the discharge line must be removed at the compressor.
Page 72: Three-Way Valve Condenser Pressure Bypass Check Valve Repair
Refrigeration Service Operations (Rev. 1/99) THREE-WAY VALVE CONDENSER PRESSURE BYPASS CHECK VALVE REPAIR Removal Remove the refrigerant charge. Unscrew the condenser pressure bypass check valve cap from the three-way valve. Remove the snap ring. Unscrew the check valve stem by using a screwdriver in the slot provided.
Page 73: Pilot Solenoid
Refrigeration Service Operations (Rev. 1/99) Installation Unbolt the pilot solenoid and remove it from the mounting bracket. Coat the O-ring with compressor oil and install it on the check valve stem. Installation Insert the spring into the hole in the check valve stem Bolt the pilot solenoid to the mounting bracket.
Page 74: In-Line Condenser Check Valve Replacement
NOTE: ORS O-rings are made of a material with a certain hardness. Do not substitute other O-rings. Use Place a heat sink on the check valve. only O-rings from Thermo King service parts. Solder the inlet and outlet connections. Pressurize the refrigeration system and test for leaks.
Page 75: Structural Maintenance
Structural Maintenance UNIT INSPECTION Inspect the unit during the pre-trip inspection and during scheduled maintenance inspections for loose or broken wires or hardware, compressor oil leaks, or other physical damage which might affect the unit performance and require the repair or replacement of parts. EVAPORATOR COIL Clean the evaporator coil during scheduled maintenance inspection by blowing compressed air down through the...
Page 76: Condenser Coil
Structural Maintenance (Rev. 1/99) CONDENSER COIL Clean the condenser coil during scheduled maintenance inspections by blowing compressed air from the back side of the coil out toward the front of the unit (the direction opposite normal air flow). Inspect the coil and fins for dam- age and repair if necessary.
Page 77: Compressor And Clutch Maintenance
CLUTCH REMOVAL NOTE: Make sure the proper tools are available before performing maintenance procedures. Refer to the tool list- ing at the end of this chapter for tools required. Contact Remove Drive Plate your local Thermo King dealer for further information.
Page 78 Compressor and Clutch Maintenance (Rev. 1/99) Remove the snap ring using external snap ring pliers NOTE: To avoid damaging the pulley groove, the (TK 204-808). pulley claws should be hooked into (NOT UNDER) the pulley groove. Remove the cover. Snap Ring Cover Remove Pulley Remove Snap Ring and Cover...
Page 79: Clutch Installation
Compressor and Clutch Maintenance (Rev. 1/99) NOTE: DO NOT hold the coil by the lead wire. Coil Inspect the coil for a loose connector or cracked insula- tion. If the insulation is cracked, replace the coil. Repair or replace the wire or the connector if either is loose or damaged.
Page 80 Compressor and Clutch Maintenance (Rev. 1/99) Install the cover and the snap ring using external ring pliers. NOTE: When installing the snap ring, the chamferred inner edge of the snap ring should face upward. Felt Install Coil Install the pulley assembly using the compressor holder (TK No.
Page 81: Shaft Seal Cover And Shaft Seal: Removal And Installation
Compressor and Clutch Maintenance (Rev. 1/99) After tightening the bolt, ensure that the pulley rotates NOTE: Specified clearance: 0.01 to 0.02 in. (0.3 to smoothly. 0.6 mm). Check Clearance Shims Electrical Connection Install Shims and Drive Plate Connect the lead wire to the electrical circuit. Ensure that the clutch clearance is as specified.
Page 82 Compressor and Clutch Maintenance (Rev. 1/99) Use the seal remover (from the shaft seal kit P/N 204-805) to remove the shaft seal cover. Turn the seal remover to engage the hook on the seal remover with the hook on the shaft seal cover, then slowly pull the shaft seal cover out of the cylinder head.
Page 83 Compressor and Clutch Maintenance (Rev. 1/99) Shaft Seal Installation Place the shaft seal on the seal guide and slide the seal into the cylinder head. Before installing a shaft seal inspect it carefully (see Inspec- tion). Clean the section of the front cylinder head that holds shaft seal.
Page 84: Special Tools
Compressor and Clutch Maintenance (Rev. 1/99) Place the shaft seal cover on the seal guide and slide Special Tools the shaft seal cover into the cylinder head. 8932a Install Shaft Seal Cover Use the seal installer (from the shaft seal kit P/N Clutch Remover P/N 204-806 204-805) to press the shaft seal cover into the cylinder.
Page 85 Compressor and Clutch Maintenance (Rev. 1/99) 8932c 8932e Shaft Seal Kit P/N 204-805 Clutch Installation Kit P/N 204-890 8932d Snap Ring Pliers P/N 204-808...
Page 86: System Compressor And Oil
Compressor and Clutch Maintenance (Rev. 1/99) Each compressor comes with a standard charge of Polyol Ester (POE) oil inside. This quantity of oil is enough to sup- ply the compressor lubrication when it is installed into an already “oil wet” system. New systems require an extra quantity of oil be added to “wet”...
Page 87: Checking The Oil Level
Compressor and Clutch Maintenance (Rev. 1/99) Checking the Oil Level Oil contamination. Dirt in the oil. Drain the Oil Color changed to a varnish color. Presence of foreign substances, metal shavings, etc. in the oil. NOTE: Always replace oil with new fresh oil taken from a sealed container only.
Page 88: Clutch Test
A belt that is too tight causes severe overload on the compressor and motor bearings. Use only approved Thermo King Service Parts replacement belts. They are specially designed for these units.
Page 89: Over-The-Road Mechanical Diagnosis
Over-the-Road Mechanical Diagnosis If the desired box temperature cannot be obtained, any of EXPANSION VALVE LOSES ITS CHARGE. If the the following may be indicated: expansion valve loses its charge, the valve will close causing the system to go into vacuum. Replace the EXCESSIVE HEAT LOAD.
Page 90 Over-the-Road Mechanical Diagnosis (Rev. 1/99) 16. COMPRESSOR LIFE. The following will shorten the • Insufficient oil charge life of a compressor: • Wrong oil or mixed oil • Operating a contaminated system • Lack of compressor lubrication on installation-startup • No oil trap •...
Page 91: Electric Standby Mechanical Diagnosis
Electric Standby Mechanical Diagnosis CONDITION POSSIBLE CAUSE REMEDY Compressor does not run Improperly wired Check wiring against diagram Low line voltage Check line voltage—determine location of voltage drop Relay contacts not closing Check and replace relay if defective Power relay open Check relay, replace if defective Motor wiring defective—open circuit Close power supply start or disconnect switch...
Page 92 Electric Standby Mechanical Diagnosis (Rev. 1/99) CONDITION POSSIBLE CAUSE REMEDY Motor contactor burnout Low line voltage Increase voltage (must be ± 10% of compressor motor rating) Excessive line voltage Reduce voltage (must be ± 10% of compressor motor rating) Unit operates long or Shortage of refrigerant Repair leak and recharge continuously...
Page 93 Electric Standby Mechanical Diagnosis (Rev. 1/99) CONDITION POSSIBLE CAUSE REMEDY Head pressure too high Refrigerant overcharge Remove excess Air in system Evacuate system Dirty condenser Clean Restricted condenser Clean condenser Condenser fan not running Check fan motor Condenser fan rotating backwards Check direction Head pressure too low Refrigerant shortage...
Page 94 Electric Standby Mechanical Diagnosis (Rev. 1/99) CONDITION POSSIBLE CAUSE REMEDY Unit in vacuum. Frost on Ice plugging expansion valve orifice Apply hot wet cloth to expansion expansion valve only valve. Moisture indicated by increase in suction pressure. Replace drier Plugged expansion valve strainer Clean strainer or replace expansion valve Sensor bulb lost charge...
Page 95: 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 (dirty) •...
Page 96 Refrigeration Diagnosis (Rev. 1/99) POSSIBLE CAUSES • • • • Liquid refrigerant entering compressor • • • Restricted line on the low side • • Restricted line on the high side • • • Restricted dehydrator • • Reversed fan rotation •...
Page 97: Wiring And Schematic Diagrams Index
Wiring and Schematic Diagrams Index Refrigeration Mode Schematic Page CBci 10 in Cool CBci 10 in Defrost CBci 20 in Cool CBci 20 in Defrost CBci 10 in Cool (Reference Only for Older Units) CBci 10 in Defrost (Reference Only for Older Units) CBci 20 in Cool (Reference Only for Older Units) CBci 20 in Defrost (Reference Only for Older Units) Dwg No.
Page 99: Cbci 10 In Cool
Wiring and Schematic Diagrams (Rev. 1/99) Condenser Section Evaporator Section AGA674 Truck Engine Section High Pressure Relief Valve 14. Discharge Line High Pressure Cutout Switch 15. High Temperature Switch Three-way Valve 16. Suction Line Oil Separator 17. Compressor Condenser Fan Switch 18.
Page 100: Cbci 10 In Defrost
Wiring and Schematic Diagrams (Rev. 1/99) Evaporator Condenser Section Section AGA675 Truck Engine Section High Pressure Relief Valve 14. Dryer High Pressure Cutout Switch 15. Discharge Line Three-way Valve 16. High Temperature Switch Oil Separator 17. Suction Line Condenser Fan Switch 18.
Page 101: Cbci 20 In Cool
Wiring and Schematic Diagrams (Rev. 1/99) Evaporator Condenser Section Section AGA676 Truck Engine Section Condenser Check Valve 15. Accumulator high Pressure Relief Valve 16. Standby Compressor Pilot Solenoid Valve 17. Suction Line Three-way Valve 18. Discharge Check Valve High Pressure Cutout Switch 19.
Page 102: Cbci 20 In Defrost
Wiring and Schematic Diagrams (Rev. 1/99) Evaporator Condenser Section Section AGA677 Truck Engine Section Condenser Check Valve 15. Accumulator High Pressure Relief Valve 16. Standby Compressor Pilot Solenoid Valve 17. Suction Line Three-way Valve 18. Discharge Check Valve High Pressure Cutout Switch 19.
Page 103: Cbci 10 In Cool (Reference Only For Older Units)
Wiring and Schematic Diagrams (Rev. 1/99) Condenser Section Evaporator Section AGA302 Truck Engine Section High Pressure Relief Valve 14. Discharge Line High Pressure Cutout Switch 15. High Temperature Switch Three-way Valve 16. Suction Line Condenser Fan Switch 17. Compressor Suction Pressure Regulator 18.
Page 104: Cbci 10 In Defrost (Reference Only For Older Units)
Wiring and Schematic Diagrams (Rev. 1/99) Evaporator Condenser Section Section AGA303 Truck Engine Section High Pressure Relief Valve 14. Discharge Line High Pressure Cutout Switch 15. High Temperature Switch Three-way Valve 16. Suction Line Condenser Fan Switch 17. Compressor Suction Pressure Regulator 18.
Page 105: Cbci 20 In Cool (Reference Only For Older Units)
Wiring and Schematic Diagrams (Rev. 1/99) Condenser Section Evaporator Section AGA304 Truck Engine Section Condenser Check Valve 15. Discharge Check Valve High Pressure Relief Valve 16. Oil Separator Pilot Solenoid Valve 17. Discharge Line Three-way Valve 18. Suction Line High Pressure Cutout Switch 19.
Page 106: Cbci 20 In Defrost (Reference Only For Older Units)
Wiring and Schematic Diagrams (Rev. 1/99) Condenser Section Evaporator Section AGA305 Truck Engine Section Condenser Check Valve 15. Discharge Check Valve High Pressure Relief Valve 16. Oil Separator Pilot Solenoid Valve 17. Discharge Line Three-way Valve 18. Suction Line High Pressure Cutout Switch 19.

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Thermo King CBci 10 12V Manual

Table of Contents

Safety Precautions

Specifications

Maintenance Inspection Schedule

Unit Description

Operating Instructions

Electrical Maintenance

Refrigeration Maintenance

Refrigeration Service Operations

Structural Maintenance

Compressor and Clutch Maintenance

Over-The-Road Mechanical Diagnosis

Electric Standby Mechanical Diagnosis

Refrigeration Diagnosis

Wiring and Schematic Diagrams Index

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