Thermo King RD-II MAX Manuals

Thermo King RD-II MAX Manuals

Manuals and User Guides for Thermo King RD-II MAX. We have 1 Thermo King RD-II MAX manual available for free PDF download: Manual

Thermo King RD-II MAX Manual

Thermo King RD-II MAX 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

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