Thermo King 914972 Manuals

Manuals and User Guides for Thermo King 914972. We have 1 Thermo King 914972 manual available for free PDF download: Manual

Thermo King 914972 Manual

Thermo King 914972 Manual (186 pages)

Brand: Thermo King | Category: Refrigerator | Size: 5 MB

Table of Contents

Table of Contents

5
- List of Figures
  
  11
- Safety Precautions
  
  13
  - General Practices
    13
  - Auto Start/Stop
    13
  - Refrigerant
    13
    
    First Aid
    13
  - Refrigeration Oil
    14
    
    First Aid
    14
  - Electrical Hazards
    14
    
    Microprocessor Service
    14
    
    Welding of Units or Truck Bodies
    15
    
    High Voltage
    15
    
    Low Voltage
    16
- Specifications
  
  17
  - Engine-TK 3.95
    17
  - R-134A Refrigeration System
    18
  - R-404A Refrigeration System
    18
  - Engine Clutch
    18
  - Air Switch
    19
  - Belt Tension
    19
  - Electrical Control System
    19
  - Electrical Components
    19
  - Thermostat
    20
  - Electrical Standby Compressor Motors
    20
  - Standby Power Requirements
    20
- Maintenance Inspection Schedule
  
  21
- Unit Description
  
  23
  - General Description
    23
  - X426 Compressor
    23
  - Microprocessor Controller TG-V
    23
  - Operating Modes
    24
    
    Engine Operation
    24
    
    Electric Operation (Model 50 Units)
    24
    
    Defrost Operation
    25
  - Serial Number Locations
    25
  - Unit Features
    25
  - Unit Options
    25
  - Protection Devices
    26
  - Unit Photographs
    27
  - Figure 1: Roadside View
    27
  - Figure 2: Curbside View
    27
  - Figure 3: Top View
    28
  - Figure 4: TG-V Control Panel
    29
  - Figure 5: TG-V In-Cab Controller
    30
- Operating Instructions
  
  31
  - Unit Controls
    31
    
    TG-V Unit Control Box
    31
    
    Thermoguard V Microprocessor Controller (TG-V)
    32
    
    Remote Control Box Outside (Optional)
    33
  - Other Controls
    33
  - Unit Indicators
    34
  - Unit Protection Devices
    34
- Operating Instructions (Continued)
  
  34
- Electronic Controls
  
  41
  - TG-V Thermostat
    41
  - Figure 7: TG-V Thermostat
    41
  - Single Temp In-Cab TG-V Controller (Optional)
    42
  - Display Symbols and Control Keys
    43
    
    Display Symbols
    43
    
    Control Keys
    45
  - General Display Information
    46
  - Displaying Operating Data
    48
  - Entering the Setpoint
    50
  - Displaying and Clearing Alarm Codes
    51
  - Additional Operating Information
    53
    
    Sensor Failure
    53
    
    Temperatures Outside of Display Range
    53
  - Guarded Access Mode
    54
    
    Programming
    54
    
    Figure 8: In-Range Temperature Differential Setting
    71
  - Testing the TG-V Thermostat
    72
    
    TG-V Calibration
    72
    
    Ice-Water Bath Preparation
    72
    
    Sensor Test
    72
    
    Preparing TG-V Module for Bench Test
    73
    
    TG-V Module Bench Test
    75
    
    TG-V Terminal Voltage Chart
    77
    
    TG-V Terminal Identification
    78
    
    TG-V Terminal Identification
    79
    
    TG-V Terminal Identification
    80
    
    Sensor Test
    81
    
    Figure 9: Sensor
    81
- Electrical Maintenance
  
  83
  - Alternator (Prestolite)
    83
  - Figure 10: Prestolite Terminal Locations
    83
  - Excessive Voltage Output
    84
  - Battery
    85
  - Unit Wiring
    85
  - Electrical Contacts
    85
  - Charging System (12 VDC)
    85
  - Preheat Buzzer
    85
  - RPM Sensor
    85
  - Figure 11: Flywheel (RPM) Sensor
    85
  - Glow Plugs
    86
  - Figure 12: RPM+ and RPM- Wires
    86
  - Figure 13: Glow Plug Test
    86
  - Engine Reset Switch
    87
  - Low Oil Pressure Switch (LOP)
    87
  - Defrost Air Switch Checkout and Adjustment
    87
  - High Capacity Thermax TM Heating System
    88
  - Figure 14: Testing Air Switch
    88
  - Figure 15: Air Switch
    88
    
    Cool Mode
    89
    
    Heat/Condenser Evacuation Mode
    89
    
    Defrost Mode
    89
    
    Start up Mode
    89
  - In-Cab TG-V Controller
    89
  - Figure 16: Single Temperature In-Cab TG-V Controller
    89
    
    Field Test Procedure for Single Temperature In-Cab TG-V Controllers
    90
    
    Figure 17: Connecting Tester to Controller
    90
    
    Connector Pins for Single Temperature In-Cab TG-V
    91
    
    Figure 18: Connector on Back of Single Temperature In-Cab TG-V
    91
- Engine Maintenance
  
  93
  - Engine Lubrication System
    93
    
    Engine Oil Change
    93
    
    Oil Filter Change
    94
  - Crankcase Breather
    94
  - Engine Air Cleaner
    94
    
    Oil Bath Type
    94
    
    Figure 19: Oil Filter Parts
    94
    
    Figure 20: Oil Bath Air Cleaner
    94
    
    Dry Type (Optional)
    95
    
    Figure 21: Dry Air Cleaner (Optional)
    95
    
    Figure 22: Air Restriction Indicator
    95
  - Engine Cooling System
    96
  - Figure 23: Engine Cooling System Components
    96
    
    Antifreeze Maintenance Procedures
    97
    
    Figure 24: Accumulator Tank Drain
    97
  - Engine Fuel System
    98
  - Figure 25: Thermostat
    98
  - Figure 26: Fuel System
    99
    
    Bleeding the Fuel System
    100
    
    Water in the Fuel System
    100
    
    Fuel Filter Replacement
    100
    
    Electric Fuel Pump
    101
    
    Figure 27: Electric Fuel Pump
    101
  - Fuel Solenoid System
    102
  - Figure 28: Fuel Solenoid Timer
    102
  - Figure 29: Fuel Solenoid Location
    102
    
    Fuel Solenoid Timer Operation
    103
    
    Figure 30: Simplified Schematic Diagram of Fuel Solenoid System
    103
    
    Troubleshooting the Fuel Solenoid System
    104
    
    Figure 31: Main Wire Harness Connector Pin
    104
    
    Figure 32: Fuel Solenoid Connector Pin
    104
    
    Figure 33: Relay Socket Terminal Identification
    105
    
    Fuel Solenoid Replacement
    106
  - Engine Speed Adjustments
    106
    
    Low Speed Adjustment
    106
    
    High Speed Adjustment
    106
    
    Figure 34: Fuel Solenoid Components
    106
  - Injection Pump
    107
    
    Injection Pump Removal
    107
    
    Figure 35: Engine Speed Adjustments
    107
    
    Injection Pump Installation
    108
    
    Timing the Injection Pump to the Engine
    108
    
    Figure 36: Timing Marks
    109
    
    Timing Individual Cylinder Injection
    110
    
    Fuel Limit Screw and Maximum Speed Stop Screw
    110
  - Engine Valve Clearance Adjustment
    110
  - Figure 37: Individual Cylinder Timing and Firing Order
    110
  - Belts
    111
  - Figure 38: Adjusting the Valve Clearance
    111
    
    Engine-Compressor Belt Adjustment
    112
    
    Figure 39: Engine-Compressor Belt Adjustment
    112
    
    Figure 40: Belt Arrangement
    113
    
    Compressor-Alternator Belt Adjustment
    114
    
    Compressor-Electric Motor Belt Adjustment
    114
    
    Water Pump Belt
    114
    
    Figure 41: Alternator Belt Adjustment
    114
- Refrigeration Maintenance
  
  115
  - Evacuation
    115
  - Figure 42: Evacuation Station
    116
  - Figure 43: Vacuum Gauge
    117
    
    Set up and Test of Evacuation Equipment
    118
    
    Figure 44: Leak
    118
    
    Figure 45: Moisture
    118
    
    Unit Evacuation
    119
    
    Refrigerant Leaks
    119
    
    Unit Charging
    119
  - Refrigerant Charge
    120
    
    Testing the Refrigerant Charge with an Empty Box
    120
    
    Testing the Refrigerant Charge with a Loaded Box
    120
  - Checking Compressor Oil
    120
  - Figure 46: X426 Compressor
    120
  - High Pressure Cutout (HPCO)
    121
  - Compressor Pump down and Checkout
    121
  - Figure 47: High Pressure Cutout Manifold
    121
  - Three-Way Valve Condenser Pressure Bypass Check Valve
    122
  - Figure 48: Compound Gauge Indicating 20 In. Vacuum
    122
  - Figure 49: Three-Way Valve Condenser Pressure Bypass Check Valve
    122
- Refrigeration Service Operations
  
  125
  - Commissioning Unit
    125
  - Low Side Pump down
    125
  - Accumulator
    125
    
    Removal
    125
    
    Installation
    125
  - Compressor
    126
    
    Removal
    126
    
    Installation
    126
- Refrigeration Service Operations (Continued)
  
  126
  - Condenser/Radiator Coil
    126
  - Liquid Line Check Valve
    127
    
    Removal
    127
    
    Installation
    127
  - Dehydrator (Filter-Drier)
    127
  - Evaporator Coil
    127
  - Expansion Valve Assembly
    127
    
    Installation
    128
    
    Cleaning In-Line Screen
    128
    
    Figure 50: Location of Expansion Valve Bulb
    128
    
    Figure 51: Completely Wrap Bulb with Tape
    128
    
    Figure 52: Expansion Valve
    128
  - Heat Exchanger
    129
    
    Removal
    129
    
    Installation
    129
  - High Pressure Cutout Switch
    129
  - High Pressure Relief Valve
    129
  - Pilot Solenoid
    130
    
    Removal
    130
    
    Installation
    130
  - Pressure Regulator Valve
    130
  - Receiver Tank
    130
  - Three-Way Valve Condenser Pressure Bypass Check Valve Repair
    130
    
    Installation
    131
  - Three-Way Valve Repair
    131
    
    Removal
    131
    
    Figure 53: Condenser Pressure Bypass Check Valve
    131
    
    Figure 54: Three-Way Valve Assembly
    132
    
    Installation
    133
  - Compressors Shipped with R-134A
    133
  - Equipment Recommendations for Use with R-404A
    133
    
    Dedicated Equipment
    133
    
    Vacuum Pumps
    133
    
    Gauge Manifold Sets
    134
    
    System Clean-Up
    134
    
    Refrigerant Recovery
    134
- Hilliard Clutch Maintenance
  
  135
  - Large Truck Unit Centrifugal Clutch Change
    135
  - Figure 55: Front View and Cross Section
    135
  - Figure 56: Hilliard Centrifugal Clutch
    136
  - Clutch Maintenance
    137
    
    Tools Required
    137
    
    Grease
    137
    
    Disassembly Procedure
    137
    
    Figure 57: Housing Removal
    137
    
    Figure 58: Bearing Removal
    137
    
    Assembly Procedure (Using New Bearings and Seal)
    138
    
    Figure 59: Bushing Removal
    138
    
    Figure 60: Bushing Insertion
    138
    
    Figure 61: Clutch
    139
- Structural Maintenance
  
  141
  - Unit and Engine Mounting Bolts
    141
  - Lift Points
    141
  - Unit Inspection
    141
  - Evaporator Coil
    141
  - Condenser Coil
    141
  - Defrost Damper
    141
  - Figure 62: Check Bolts for Tightness
    141
  - Figure 63: Lift Points
    141
  - Jackshaft Assembly
    142
    
    Disassembly
    142
    
    Figure 64: Defrost Damper Adjustment
    142
    
    Figure 65: Jackshaft Assembly
    142
    
    Reassembly
    143
    
    Figure 66: Installing Oil Sling Retainer
    143
  - Fanshaft Assembly
    144
    
    Disassembly
    144
    
    Figure 67: Removing Bearing Retainer Bolts
    144
    
    Figure 68: Removing Shaft
    144
    
    Figure 69: Removing Oil Seal
    144
    
    Reassembly
    145
    
    Figure 70: Removing Roll Pin
    145
    
    Figure 71: Installing Bearings
    145
    
    Figure 72: Installing Splash Guard
    145
    
    Figure 73: Installing Oil Seal
    145
    
    Figure 74: Shims and O-Ring
    145
    
    Figure 75: Torquing Retainer Plate Bolts
    146
    
    Figure 76: Checking End Play
    146
    
    Figure 77: Fan Shaft Assembly
    146
- Mechanical Diagnosis
  
  147
- CYCLE-SENTRY Diagnosis
  
  151
- Electric Standby (Optional) Diagnosis
  
  153
- Refrigeration Diagnosis
  
  155
- Refrigeration Diagrams
  
  157
- Index
  
  161
Wiring and Schematic Diagrams Index

165

Advertisement

Advertisement

Related Products

Thermo King Categories

Refrigerator

Refrigerator Automobile Accessories

Air Conditioner

Air Conditioner Portable Generator Heat Pump

More Thermo King Manuals