Thermo King Whisper Manual
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Thermo King Whisper Manual

Thermo King Whisper Manual

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Whisper
TK 50200-2-MM (Rev. 4, 04/02)
(For units with and without EMI 3000)
©
Copyright
1998 Thermo King Corp., Minneapolis, MN, U.S.A.
Printed in U.S.A.

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  • Page 1 Whisper TK 50200-2-MM (Rev. 4, 04/02) (For units with and without EMI 3000) © Copyright 1998 Thermo King Corp., Minneapolis, MN, U.S.A. Printed in U.S.A.
  • 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

    Table of Contents Safety Precautions ............... . . i Specifications .
  • Page 6 Table of Contents (continued) Bleeding Air from the Cooling System ............35 Engine Thermostat .
  • Page 7 Table of Contents (continued) Suction Vibrasorber ..............75 High Pressure Cutout Switch .

  • Page 9: Safety Precautions

    Safety Precautions GENERAL PRACTICES REFRIGERANT ALWAYS WEAR GOGGLES SAFETY Although fluorocarbon refrigerants are classified as safe GLASSES. Refrigerant liquid and battery acid can per- refrigerants, certain precautions must be observed when manently damage the eyes (see First Aid under Refrig- handling them or servicing a unit in which they are used.

  • Page 11: Specifications

    Specifications ENGINE Model TK 486 Number of Cylinders Cylinder Arrangement In-line vertical, number 1 on flywheel end Firing Order 1-3-4-2 Direction of Rotation Counterclockwise viewed from flywheel end Fuel Type No. 2 diesel fuel under normal conditions No. 1 diesel fuel is acceptable cold weather fuel Oil Capacity: Crankcase 13 qt.
  • Page 12 Tension No. on TK Gauge P/N 204-427 Alternator Belt Lower Fan Belt (Engine to Idler) Upper Fan Belt (Fan to Idler) REFRIGERATION SYSTEM Compressor Thermo King X430 Refrigerant Charge—Type 13 lb (5.9 kg)—R-404A Compressor Oil Charge 4.3 qt (4.1 liters)* Compressor Oil Type...
  • Page 13 Specifications (Rev. 04/02) ELECTRICAL COMPONENTS NOTE: Disconnect components from unit circuit to check resistance. Current Draw (Amps) Resistance—Cold at 12.5 Vdc (Ohms) Fuel Solenoid: Pull-in Coil 35 to 45 0.2 to 0.3 Hold-in Coil 24 to 29 Damper Solenoid High Speed (Throttle) Solenoid Air Heater 0.14 Pilot Solenoid...

  • Page 15: Maintenance Inspection Schedule

    Maintenance Inspection Schedule Every Every Annual/ 1,500 3,000 4,500 Pretrip Hours Hours* Hours Inspect/Service These Items Microprocessor • Run Pretrip Test (refer to Pretrip Test in the Operator’s Manual). Engine • Check fuel supply. • Check engine oil level. • •...
  • Page 16 Maintenance Inspection Schedule (Rev. 04/02) Every Every Annual/ 1,500 3,000 4,500 Pretrip Hours Hours* Hours Inspect/Service These Items Engine (continued) — Change green or blue-green engine coolant every two years. — Change ELC (red) engine coolant every 5 years or 12,000 hours. Units equipped with ELC have an ELC nameplate on the expansion tank (see page 32).

  • Page 17: Unit Description

    Unit Description CYCLE-SENTRY Start-Stop Controls The Whisper is a one-piece, self-contained, diesel powered refrigeration-heating unit. The unit mounts on the front of A CYCLE-SENTRY Start-Stop fuel saving system provides the trailer with the evaporator portion extending into the optimum operating economy. Selecting Continuous or trailer.

  • Page 18: Sequence Of Operation

    Unit Description (Rev. 04/02) Thermo King X430 Compressor Features of the CYCLE-SENTRY system are: The unit is equipped with a Thermo King X430, four- • Offers either CYCLE-SENTRY or Continuous Run operation. cylinder compressor with 30 cu. in. (492 cm ) displacement.

  • Page 19: Operating Modes

    Unit Description (Rev. 04/02) Operating Modes CYCLE-SENTRY Mode, Setpoint at or Above Fresh-Frozen Range The microprocessor uses a complex program to determine Operating mode is controlled by the microprocessor. When which operating mode the unit should be in. Therefore, it is the temperature is within a few degrees of setpoint, the tem- difficult to predict which operating mode the unit should be perature is considered to be in range and the in-range icon...
  • Page 20 Unit Description (Rev. 04/02) CYCLE-SENTRY Mode, Setpoint Below A demand defrost cycle will occur if the difference between Fresh-Frozen Range the return air temperature, discharge air temperature and coil temperature becomes excessive. Operating mode is controlled by the microprocessor. When the temperature is within a few degrees of setpoint, the tem- Two defrost timers are used.

  • Page 21: Design Features

    TK 486 Diesel Engine • X430 Compressor • Compressor Oil Filter • Top Mount Muffler • Thermo King Radiator • Stainless Steel Grille • Stainless Steel Exterior Condenser Hardware • Stainless Steel Evaporator Hardware • Tapered Roller Bearing Fanshaft and Idler •...

  • Page 22: Protection Devices

    Unit Description (Rev. 04/02) Unit Model Whisper (048668) PROTECTION DEVICES • Engine Coolant Temperature Sensor • Engine Low Oil Pressure Switch • Engine Low Oil Level Switch • Evaporator Temperature Sensor • Refrigerant High Pressure Cutout Switch • High Refrigerant Pressure Relief Valve •...

  • Page 23: Serial Number Locations

    Unit Description (Rev. 04/02) SERIAL NUMBER LOCATIONS Unit: Nameplate on the curbside of the unit inside the top service access grille and on the roadside of the unit frame below control panel. Engine: Nameplate on rocker arm cover. Compressor: Stamped on the end above the oil pump. AGA231 Serial Number Location...

  • Page 24: Unit Photos

    Unit Description (Rev. 04/02) Unit Photos AGA231 Front View...
  • Page 25 Unit Description (Rev. 04/02) AEA698 Defrost Damper X430 Compressor TK 486 Engine Back View...
  • Page 26 Unit Description (Rev. 04/02) ara193 Discharge Service Valve 10. Filter Drier Throttling Valve Receiver Tank Sight Glass Suction Service Valve 12. Battery Tray Throttle Solenoid 13. Hand Primer Pump Fuel Solenoid 14. Dipstick Air Restriction Indicator 15. Oil Filter (Standard Blue Filter Shown) Fuel Bleed Screw 16.
  • Page 27 Unit Description (Rev. 04/02) AEA737 Display Keypad Microprocessor Control Panel Switch Panel Control Panel...

  • Page 29: Operating Instructions

    Operating Instructions UNIT CONTROLS Microprocessor On-Off Switch Two sets of controls are used to operate a unit that has a This switch is located in the side of the control box in the THERMOGUARD Microprocessor Temperature Control- engine compartment. It should be placed in the OFF posi- ler.

  • Page 30: Unit Protection Devices

    Operating Instructions (Rev. 04/02) DATA INTERFACE. The Data Interface is a serial port A 40 amp fuse (F9—#2 Circuit) protects the 2AA cir- that can be used to connect the microprocessor to an cuit, which is the main power circuit. ®...

  • Page 31: Unit Operation

    Operating Instructions (Rev. 04/02) LOW OIL LEVEL SWITCH. The low oil level switch CAUTION: Do not add “RED” Extended Life closes if the oil drops below a certain level. If it stays Coolants to cooling systems using “GREEN” or closed for a specified time, the microprocessor will “BLUE-GREEN”...

  • Page 32: Selection Of Operating Modes

    PRE LOAD will appear on the display and the Selection of Operating Modes PRE TRIP test will start. The Thermo King CYCLE-SENTRY system is designed to • PRE AMPS will appear on the display indicat- save refrigeration fuel costs. The savings vary with the com- ing that the amps check is running and the modity, ambient temperatures and trailer insulation.

  • Page 33: Restarting Unit

    Operating Instructions (Rev. 04/02) Your selection of the operating mode for the proper protec- Place the On-Off switch in the ON position. tion of a particular commodity should use the following After a 10 second delay, the unit should preheat and guidelines: start automatically.

  • Page 34: Loading Procedure

    Operating Instructions (Rev. 04/02) COMPRESSOR OIL. The compressor oil level should Load the product so that there is adequate space for air be visible in the sight glass. circulation completely around the load. DO NOT block the evaporator inlet or outlet. REFRIGERANT.

  • Page 35: Electrical Maintenance

    • When testing alternators use accurate equipment such integral regulator is accomplished by installing a as a Thermo King P/N 204-615 (FLUKE 23) digital jumper from terminal F2 to ground. Attempting to multimeter and a Thermo King P/N 204-613 amp full-field the alternator by applying battery voltage clamp or an equivalent.
  • Page 36 Electrical Maintenance (Rev. 04/02) • Make sure the drive belts and pulleys of the charging The B pin is the excitation circuit and should be at system are in good condition and are adjusted properly 10 volts or higher. If not, check the excitation cir- before testing the alternator.
  • Page 37 Electrical Maintenance (Rev. 04/02) The voltage at the B+ terminal should be 13 to 18 volts Connect a jumper wire between the F2 terminal on the and the amperage in the 2A wire should be at least as alternator and a chassis ground, and note the ammeter high as the rated output of the alternator.
  • Page 38 Electrical Maintenance (Rev. 04/02) AEA694 Check Point for 2A Amperage Position for Full Fielding Jumper Full Field Test...

  • Page 39: Battery

    Electrical Maintenance (Rev. 04/02) BATTERY • A 15 amp fuse (F21—#8F Circuit) protects the 8F cir- cuit, which supplies power to various control relays and NOTE: The PROCESSOR On-Off switch must be placed components. in the OFF position before connecting or disconnecting •...

  • Page 40: Air Heater

    Electrical Maintenance (Rev. 04/02) Check the current draw of the heater with a clamp-on ammeter at the H1 wire near the M6 terminal on the front of the heater. Hold the Preheat-Start switch in the PREHEAT position. The current draw should be approximately 89 amps at 12.5 volts and approximately 77 amps at 11 volts.

  • Page 41: Engine Maintenance

    Engine Maintenance EMI 3000 is driven by the crankshaft gear, and is attached to the lower part of the timing gear housing. EMI 3000 is an extended maintenance interval package. It The oil is picked up by a screened inlet near the bottom of was phased in as standard equipment on this unit in the first the oil pan.

  • Page 42: Engine Oil Change

    ELC has been phased into all trailer units equipped with The oil filter should be changed along with the engine oil. TK 486, engines. A nameplate on the coolant expansion Use a genuine Thermo King oil filter. tank identifies units with ELC. Remove the filter.
  • Page 43 ELC cannot be used in older units. The water pump seal bel- The following are the Extended Life Coolants currently lows and O-rings used on older units are not compatible approved by Thermo King for use in ELC units for five with ELC. years or 12,000 hours: To upgrade new production engines for ELC use, all water •...

  • Page 44: Antifreeze Maintenance Procedure

    Engine Maintenance (Rev. 04/02) Antifreeze Maintenance Procedure Do not mix green or blue-green engine coolant with ELC (red) engine coolant. See “ELC (Extended Life Coolant)” As with all equipment containing antifreeze, periodic on page 32 for more information about ELC. inspection on a regular basis is required to verify the condi- The factory recommends the use of a 50/50 antifreeze mix- tion of the antifreeze.

  • Page 45: Bleeding Air From The Cooling System

    Engine Maintenance (Rev. 04/02) Checking the Antifreeze Loosen the water pump belt. Check the water pump bearing for looseness. Check the solution concentration by using a temperature compensated antifreeze hydrometer or a refractometer Inspect the radiator cap. Replace the cap if the gasket (P/N 204-754) designed for testing antifreeze.

  • Page 46: Engine Thermostat

    Engine Maintenance (Rev. 04/02) NOTE: If an engine runs with air trapped in the block, the Injection pump engine may be damaged. The high water temperature Injection nozzles switch may not protect an engine that has air trapped in the block, because the high water temperature switch is The priming pump is used to manually draw fuel from the designed to protect an engine from overheating due to fail- tank up to the fuel pump if the unit should run out of fuel.
  • Page 47 Engine Maintenance (Rev. 04/02) ARA014 Check Valve Fuel Transfer Pump Filter Head Priming Pump Injection Pump Fuel Filter/Water Separator Bleed Screw Engine Fuel System...

  • Page 48: Bleeding The Fuel System

    Engine Maintenance (Rev. 04/02) Bleeding the Fuel System NOTE: The injection nozzles should be tested (and repaired if necessary) at 10,000 hour intervals when used If the engine runs out of fuel, repairs are made to the fuel in normal conditions. Normal conditions are considered to system, or if air gets into the system for any other reason, be the use of clean high quality fuel, no used oil blending, the air must be bled out of the fuel system.

  • Page 49: Draining Water From Fuel Tank

    Engine Maintenance (Rev. 04/02) Start the engine and observe the engine run for a few Let the water and fuel drain into the container until no minutes. If the engine fails to start, or starts but stops in water is visible in the fuel draining from the tank. If the a few minutes, repeat the procedure.

  • Page 50: Engine Speed Adjustments

    Engine Maintenance (Rev. 04/02) High Speed Lubricate the canister seal with clean fuel. Use the Service Test Mode to run the unit in high speed Screw the new canister on hand-tight. Using a strap and check the high speed rpm. It should be 2175 to wrench, tighten another 1/4 turn.
  • Page 51 Engine Maintenance (Rev. 04/02) Remove the round cover (plug) from the timing mark Rotate the engine in the normal direction of rota- access hole on the front of the bell housing. The index tion (clockwise viewed from the water pump end) marks on either side of this hole and the timing marks until the 1-4 timing mark on the flywheel lines up on the flywheel are used to check the injection pump...
  • Page 52 Engine Maintenance (Rev. 04/02) Use the microprocessor keypad to enter the Relay 15. Check position of the timing marks. The injection tim- Board Test Mode. Refer to the appropriate Micropro- ing mark on the flywheel should be aligned with the cessor Operation and Diagnosis Manual for detailed index mark on the side of the timing mark access hole.

  • Page 53: Injection Pump Removal

    Engine Maintenance (Rev. 04/02) Injection Pump Removal Remove the cover plate from the gear case. Remove the nut and lockwasher which secure the gear to the injec- The injection pump drive gear will not fit through the gear tion pump shaft. Use a shop rag to prevent the lock- housing when removing the pump, the gear must be sepa- washer or nut from falling into the gear case.

  • Page 54: Injection Pump Reinstallation

    Engine Maintenance (Rev. 04/02) Thread the long screw supplied with the tool plate into until the 8D circuit is de-energized. The pull-in coil must be the small end of the adapter, also supplied with the tool de-energized after a few seconds to keep it from being dam- plate.
  • Page 55 Engine Maintenance (Rev. 04/02) A fuel solenoid timer is used to control the fuel solenoid When the 8D circuit is energized, it supplies power to the pull-in coil. The fuel solenoid timer consists of a small PC fuel solenoid hold-in coil and to the fuel solenoid relay coil. board that contains some electrical components, a four pin The hold-in coil is energized and remains energized as long wire connector, and one removable relay.
  • Page 56 Engine Maintenance (Rev. 04/02) Troubleshooting the Fuel Solenoid System NOTE: The fuel solenoid pull-in coil will require 35 to 45 amps to turn on the fuel. The unit’s battery must be in good condition. If the battery has enough power to crank the engine over, it has enough power to energize the fuel solenoid pull-in coil.
  • Page 57 Engine Maintenance (Rev. 04/02) If the pull-in coil does not energize, check the If the hold-in coil does function properly, go to resistance of the pull-in coil by placing an ohmme- step 9. ter between the white wire (8DP—pin B) and the Reconnect the fuel solenoid connector and the main black wire (CH—pin C) in the fuel solenoid con- wire harness connector.

  • Page 58: Engine Valve Clearance Adjustment

    Engine Maintenance (Rev. 04/02) 13. Test the relay. Place the On-Off switch in the OFF position after installing the fuel solenoid. Use a jumper to connect the 85 terminal on the relay to the positive battery terminal. Use another jumper to connect the 86 terminal on the relay to a CH circuit.
  • Page 59 Engine Maintenance (Rev. 04/02) If the rocker arms are tight, the engine is at top dead center of the exhaust stroke for the number one cylinder. Rotate the engine 360° to place the engine at top dead center of the compression stroke for the number one cylinder.

  • Page 60: Crankcase Breather

    Engine Maintenance (Rev. 04/02) CRANKCASE BREATHER Hold the adjustment screw in place and tighten the lock nut. The crankcase breather is located on top of the rocker arm cover. The crankcase breather system ducts crankcase gases formed in the crankcase directly to the air intake. Harmful vapors that would otherwise collect in the crankcase and contaminate the oil, or escape to the outside, are drawn back into the engine and burned.

  • Page 61: Engine Air Cleaner (Filter)

    Engine Maintenance (Rev. 04/02) ENGINE AIR CLEANER (Filter) Excessive restriction of the air intake system reduces the flow of air to the engine affecting horsepower output, fuel A heavy duty, dry air cleaner filters all of the air entering the consumption and engine life.

  • Page 62: Emi 3000 Air Cleaner

    “EMI 3000.” It cannot be interchanged with air filters ings. used on previous Thermo King trailer units, however it can Using belt tension gauge, P/N 204-427, is the best method be retrofit on previous units by using the EMI 3000 Air of checking belts for tightness.

  • Page 63: Belt Arrangement

    Engine Maintenance (Rev. 04/02) aea709 Upper Fan Belt Condenser Fan Pulley Condenser Fan (Blower) Condenser Inlet Ring Idler Assembly Belt Guide Lower Fan Belt Engine Pulley Idler Adjusting Arm 10. Alternator Belt Belt Arrangement...

  • Page 64: Fan Belt Removal And Installation

    Engine Maintenance (Rev. 04/02) Upper and Lower Fan Belt Adjustment Installation The upper fan belt should read 74 and the lower fan belt Slip the belt into the groove of the idler pulley. should read 67 on the belt tension gauge. Push the idler adjusting arm back in toward the unit.
  • Page 65 Engine Maintenance (Rev. 04/02) Lift the belt up over the condenser blower wheel and remove it from the unit. Installation Slip the belt over the condenser blower wheel and place it in the condenser fan pulley. Drive the condenser blower wheel out toward the con- denser fan inlet ring using a soft hammer.

  • Page 67: Refrigeration Maintenance

    Testing for an Overcharge The suction pressure should be 13 to 18 psi (90 to 124 kPa). Use the following procedure to identify a Thermo King unit with an excessive refrigerant charge: The discharge pressure should be at least 275 psi (1896 kPa).
  • Page 68 Refrigeration Maintenance (Rev. 04/02) Use the Service Test Mode to run the unit in high speed Connect a refrigerant tank to the gauge manifold cool. Refer to the appropriate Operation and Diagnosis service line and purge the line. Manual for specific information about the Service Test Mid seat the compressor suction service valve.

  • Page 69: Refrigerant Leaks

    Refrigeration Maintenance (Rev. 04/02) AEA672 Floating Ball Colored Ring Moisture Indicating Sight Glass A system has to run for at least 15 minutes to change the color of the indicator ring after the moisture content of the AEA711 system has been changed. For example, evacuating a system Sight Glass to remove the moisture will not change the color of the indi- Checking Compressor Oil...

  • Page 70: High Pressure Cutout Switch (Hpco)

    Refrigeration Maintenance (Rev. 04/02) To add compressor oil pump down the compressor and Failure of the HPCO system to stop compressor operation should be investigated first by checking the control circuit equalize the pressure to slightly positive. Disconnect the operation and secondly by HPCO switch replacement. compressor oil filter return line from the top of the compres- sor and add the oil.
  • Page 71 Refrigeration Maintenance (Rev. 04/02) When the unit is running on defrost or heat, if the condenser To check the operation of the valve: pressure is higher than the discharge pressure, the check Remove the condenser pressure bypass check valve cap valve opens and the condenser pressure is bled off until it from the three-way valve.

  • Page 72: Modulation Valve (Optional)

    Refrigeration Maintenance (Rev. 04/02) MODULATION VALVE (Optional) Refer to the appropriate Microprocessor Operation and Diagnosis Manual for information about testing the modula- The modulation valve is normally open. As a controlled tion valve. See the Refrigeration Service Operations section electrical signal is applied to the coil the armature over- of this manual for removal and installation procedures.

  • Page 73: 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 Place the compressor in position and install the mount- ing bolts.

  • Page 74: Compressor Coupling Installation

    Refrigeration Service Operations (Rev. 04/02) Compressor Coupling Installation To prevent the tool and crankshaft from rotating, use one of the compressor to engine mounting screws to pin In a tapered fit joint the entire twisting load should be han- the tool to the flange. If a nut is used to prevent the bolt dled by the friction fit between the two tapered parts.
  • Page 75 Refrigeration Service Operations (Rev. 04/02) The following procedure requires the key to be fitted after Remove the Keyway Tool and check the fit of the new the tapers are pulled together with 20 ft-lb (27 N•m) torque. key (P/N 55-9024). It should fit into the keyway with a This insures that the key cannot hold the tapers apart when light press fit requiring only a minimum of light tap- the final bolt torque is applied.

  • Page 76: Condenser Coil

    Refrigeration Service Operations (Rev. 04/02) 11. Inspect the compressor side of the coupling to make Remove the condenser coil mounting bolts. Remove sure some Loctite is present at the joint. If not, apply a the mounting clamps from the condenser inlet line. light coating of Loctite to prevent moisture from wick- Unsolder the inlet line and liquid line connections.

  • Page 77: In-Line Condenser Check Valve

    Refrigeration Service Operations (Rev. 04/02) CAUTION: Use a heat sink, P/N 204-584 or Unsolder the lines and remove the check valve. wrap the vibrasorber with wet rags to prevent Installation damaging the vibrasorber. NOTE: A heat sink must be used on the in-line check Pressurize the system and test for leaks.

  • Page 78: Receiver Tank

    Refrigeration Service Operations (Rev. 04/02) Install and tighten the bypass flare nut on the check Pressurize the refrigeration system and check for leaks. valve outlet. Hold the check valve with a back-up If no leaks are found, evacuate the system. wrench on the hex.

  • Page 79: Heat Exchanger

    Refrigeration Service Operations (Rev. 04/02) Disconnect the inlet liquid line and unsolder the distrib- Replace the access panels. utor from the expansion valve. Open the refrigeration valves and place the unit in oper- Remove the expansion valve mounting bolt and remove ation.

  • Page 80: Evaporator Coil

    Refrigeration Service Operations (Rev. 04/02) Solder the liquid inlet and the suction outlet line con- Unsolder the hot gas line and the suction line from the nections on the condenser side of the bulkhead. Seal the evaporator coil. openings through the bulkhead with putty when the Remove the mounting bolts, lift and slide the coil from refrigerant lines have cooled off.

  • Page 81: Three-Way Valve Repair

    Refrigeration Service Operations (Rev. 04/02) Unsolder the inlet and outlet suction lines from the Clean the exterior surface of the valve. accumulator. Remove the line from the three-way valve to the pilot CAUTION: Use a heat sink or wrap vibra- solenoid.
  • Page 82 Refrigeration Service Operations (Rev. 04/02) The following parts will be discarded: Stem assembly. All gaskets. Piston seal. 10. Remove the screen. If any particles drop from the screen into the discharge line, the discharge line must be removed at the compressor. NOTE: The valve body cannot be reconditioned.

  • Page 83: Three-Way Valve Condenser Pressure Bypass Check Valve Repair

    Refrigeration Service Operations (Rev. 04/02) Assembly/Installation Slide the seal onto the tapered tool with the spring side facing away from the piston. After cleaning and inspecting all parts, reassemble the valve. Use the pipe to hand press the seal onto the piston. Install the screen in the bottom cap.

  • Page 84: Pilot Solenoid

    Refrigeration Service Operations (Rev. 04/02) Remove the spring and Teflon check valve. Screw the check valve stem into the three-way valve until the snap ring can be installed. Inspect the check valve seat in the three-way valve. Install the snap ring. If replacement parts are needed, a P/N 60-163 kit must be used which includes the Teflon check valve, spring, Unscrew (back seat) the check valve stem against the...

  • Page 85: Suction Vibrasorber

    Refrigeration Service Operations (Rev. 04/02) SUCTION VIBRASORBER Installation Apply a refrigerant locktite to the threads of the high Removal pressure cutout switch. Pump down the low side and equalize pressure to Install and tighten the high pressure cutout switch and slightly positive.

  • Page 86: Throttling Valve

    Refrigeration Service Operations (Rev. 04/02) THROTTLING VALVE Front seat the discharge and suction service valves. Release the remaining pressure. Removal Remove the suction service valve and line from the Pump down the low side and equalize the pressure to compound gauge. slightly positive.
  • Page 87 Refrigeration Service Operations (Rev. 04/02) Disassembly Inspect all the parts. Remove the piston end cap (round end). Piston and cap for wear (scuff marks). Remove the cotter pin from the castle nut and remove Body for stripped threads. the nut. Bellows end cap for damage in the pilot hole.

  • Page 88: Compressor Oil Filter Change

    Refrigeration Service Operations (Rev. 04/02) Reassembly Installation Install the bellows with the O-ring in the housing. Install the throttling valve using a new O-ring soaked in compressor oil. Bolt the throttling valve to the com- Center the spring on the bellows shoulder. pressor.

  • Page 89: Modulation Valve (Optional)

    Refrigeration Service Operations (Rev. 04/02) Open the service valves, operate the system, and check Unsolder the elbow and tube that connect the modula- the compressor oil filter for leaks. tion valve to the heat exchanger, and remove the modu- lation valve, the elbow and the tube. CAUTION: Use a heat sink or wrap the valve with wet rags to prevent damaging the valve.
  • Page 90 Refrigeration Service Operations (Rev. 04/02) Solder the inlet and outlet connections. After the valve cools, install the coil. Pressurize the refrigeration system and test for leaks. If no leaks are found, evacuate the system. Recharge the unit with proper refrigerant and check the compressor oil.

  • Page 91: Structural Maintenance

    Structural Maintenance UNIT AND ENGINE MOUNTING BOLTS Check and tighten all unit and engine mounting bolts during scheduled maintenance inspections. Torque the unit mount- ing bolts to 60 ft-lb (81 N•m). Torque the engine mounting bolts to 150 ft-lb (203 N•m). UNIT INSPECTION Inspect the unit during pre-trip inspection and scheduled maintenance inspections for loose or broken wires or hard-...

  • Page 92: Defrost Damper

    Structural Maintenance (Rev. 04/02) DEFROST DAMPER To adjust the damper: Remove the damper assembly from the evaporator. Check the damper during scheduled maintenance inspec- tions for shaft wear, end play, and the ability to stop the air Disconnect the damper link from the eye bolt. flow.

  • Page 93: Condenser And Evaporator Fan Location

    Structural Maintenance (Rev. 04/02) Condenser Fan Blower Check Distance A, the distance from the shoulder on the solenoid to the center of the hole in the eye bolt. Loosen the condenser inlet ring (spinning) on the con- Distance A should be 2.75 in. (69.85 mm) with the denser coil bulkhead.

  • Page 94: Fan Shaft Assembly Overhaul

    NOTE: The fan shaft assembly requires a special lubri- Check the radial clearance by passing a wire com- cant, Thermo King P/N 203-278. pletely around the circumference of the inlet rings and the blower wheel. Fan Shaft Assembly Overhaul Torque the blower hub bolts to 18 ft-lb (24 N•m).
  • Page 95 Use the original shims and replace the Shims available from the Service Parts Department: O-ring if needed. 0.020 in. (0.500 mm) Thermo King P/N 99-4231 Install the retainer cap assembly over the shaft, then 0.007 in. (0.177 mm) Thermo King P/N 99-2902 install the bolts.

  • Page 96: Idler Assembly

    Structural Maintenance (Rev. 04/02) After correct end-play is obtained, add oil for the bear- To remove the shaft from the assembly, tap the opposite ings. end of the shaft with a soft hammer. After the shaft has been removed, clean all the parts in clean solvent. Lock the assembly in a vise with the vent facing up.
  • Page 97 Place the assembly on the workbench with the vent up. Rotate the shaft by hand. The shaft should be free 0.020 in. (0.500 mm) Thermo King P/N 99-4231 enough to rotate without having to hold the housing. 0.007 in. (0.177 mm)

  • Page 99: Mechanical Diagnosis

    Mechanical Diagnosis CONDITION POSSIBLE CAUSE REMEDY Engine will not crank Electrical problem Check and repair electrical system Defective starter solenoid Replace solenoid Defective starter Repair starter Water in cylinders Check for hydrostatic lock. Remove injectors and turn engine slowly Starter motor turns but engine Starter clutch defective Replace does not crank...
  • Page 100 Mechanical Diagnosis (Rev. 04/02) CONDITION POSSIBLE CAUSE REMEDY Engine does not develop full Air intake system clogged Clean air intake system power Fuel tank vent clogged Unclog vent Clogged fuel tank or fuel lines Clean fuel tank and fuel lines Speed adjustment wrong Adjust speed Insufficient fuel volume leaving filter Check for dirty filter or air in system...
  • Page 101 Mechanical Diagnosis (Rev. 04/02) CONDITION POSSIBLE CAUSE REMEDY Engine runs hot Dirty radiator Wash radiator Coolant level is low Add coolant Cooling system heavily scaled Cleaning cooling system Cylinder head gasket leaks Replace cylinder head gasket. Use correct gasket Faulty thermostat Check or replace thermostat Loose or worn water pump belt Replace belt...
  • Page 102 Mechanical Diagnosis (Rev. 04/02) ENGINE EMITS EXCESSIVE SMOKE WHITE SMOKE BLACK SMOKE BLUE SMOKE Fuel is not burning Excessive Fuel to Air Ratio Oil Consumption • Air or water in fuel • Type of fuel used • Poor compression • Incorrect timing •...

  • Page 103: 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 104 Refrigeration Diagnosis (Rev. 04/02) POSSIBLE CAUSES • • Expansion valve closed too much • • Expansion valve needle eroded or leaking • • • Expansion valve partially closed by ice, dirt or wax • • • Liquid refrigerant entering compressor •...

  • Page 105: Refrigeration Diagrams

    Cool Cycle Compressor Discharge Service Valve Discharge Vibrasorber Discharge Line Three-way Valve Three-way Valve Bypass Check Valve Condenser Coil Condenser Check Valve High Pressure Relief Valve Receiver Tank Sight Glass Receiver Outlet Valve Liquid Line Drier Heat Exchanger Expansion Valve Feeler Bulb Equalizer Line Distributor...
  • Page 106 Defrost and Heating Cycle Compressor Discharge Service Valve Discharge Vibrasorber Discharge Line Three-way Valve Three-way Valve Bypass Check Valve Condenser Coil Condenser Check Valve High Pressure Relief Valve Receiver Tank Sight Glass Receiver Outlet Valve Liquid Line Drier Heat Exchanger Expansion Valve Feeler Bulb Equalizer Line...
  • Page 107 Cool Cycle With Modulation 1. Compressor 2. Discharge Service Valve 3. Discharge Vibrasorber 4. Discharge Line 5. Three-way Valve 6. Three-way Valve Bypass Check Valve 7. Condenser Coil 8. Condenser Check Valve 9. High Pressure Relief Valve 10. Receiver Tank 11.
  • Page 108 Defrost and Heating Cycle With Modulation 1. Compressor 2. Discharge Service Valve 3. Discharge Vibrasorber 4. Discharge Line 5. Three-way Valve 6. Three-way Valve Bypass Check Valve 7. Condenser Coil 8. Condenser Check Valve 9. High Pressure Relief Valve 10. Receiver Tank 11.

  • Page 109: Wiring Diagram Index

    Wiring Diagram Index Drawing No. Drawing Title Page 5D49314 Early Model (Coiled Wire Fuse Link) Wiring Schematic 5D49313 Early Model (Coiled Wire Fuse Link) Wiring Diagram 102-105 5D52378 Late Model (Fuse Link in Battery Cable) Wiring Schematic 5D54669 Late Model (Fuse Link in Battery Cable) Wiring Diagram 107-110...
  • Page 111 Early Model (Coiled Wire Fuse Link) Wiring Schematic...
  • Page 112 Early Model (Coiled Wire Fuse Link) Wiring Diagram—Page 1 of 4...
  • Page 113 Early Model (Coiled Wire Fuse Link) Wiring Diagram—Page 2 of 4...
  • Page 114 Early Model (Coiled Wire Fuse Link) Wiring Diagram—Page 3 of 4...
  • Page 115 Early Model (Coiled Wire Fuse Link) Wiring Diagram—Page 4 of 4...
  • Page 116 Late Model (Fuse Link in Battery Cable) Wiring Schematic...
  • Page 117 Late Model (Fuse Link in Battery Cable) Wiring Diagram—Page 1 of 4...
  • Page 118 Late Model (Fuse Link in Battery Cable) Wiring Diagram—Page 2 of 4...
  • Page 119 Late Model (Fuse Link in Battery Cable) Wiring Diagram—Page 3 of 4...
  • Page 120 Late Model (Fuse Link in Battery Cable) Wiring Diagram—Page 4 of 4...

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