Maintenance Manual: Thermo King Corp., Minneapolis, MN, U.S.A

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Maintenance Manual

C-290
R-134a

Thermo King Corp., Minneapolis, MN, U.S.A.


The information on maintenance included in this section applies to models of the units using R-134a:

C-290 part number 918266

For further information, refer to the general section in this manual.

The purpose of the information given in this section is to help owners, operators, and maintenance
personnel to keep Thermo King units in good condition and to maintain them properly. For detailed
information on Thermo King refrigeration systems, refer to the Maintenance Manual for Thermo King
refrigeration systems.

This manual is published for informational purposes only and the information so provided should not be considered as all-
inclusive or covering all contingencies. 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.
Thermo King’s warranty will not be apply to any equipment which has been “so repaired or altered outside the
manufacturer’s plants as, in the manufacturer’s judgement, to affect its stability”.
No warranties, express or implied, including warranties of fitness for a particular purpose or merchantability, or warranties
arising from course of dealing or usage of trade, are made regarding the information, recommendations and descriptions
contained herein. Manufacturer is not responsible and will not be held liable in contract ot tort (including negligence) for
any special, indirect or consequential damages, including injury or damage caused to vehicles, contents or persons, by
reason of the installation of any Thermo King product or its mechanical failure.
RECOVER REFRIGERANT
At Thermo King we recognise the need to preserve the environment and limit the
potential harm tothe 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.
In addition, service personnel must be aware of Federal regulations concerning the use
of refrigerants and the certification of technicians. For additional information on
regulations and technician certification programmes, contact your local THERMO KING
dealer.

Caution
The units are dispatched with a reserve charge of dry nitrogen at low pressure.
This reserve load can be safely exposed to the atmosphere.
If the unit is operated before completing installation of the system, SERIOUS
DAMAGE TO THE COMPRESSOR will be sustained. This installation includes:
installing the components, connecting the refrigeration lines and wires,
checking that the system does not have leaks, evacuating, cleaning and
charging the system.
TK 51493-1-MM (01/02 E)
Table of Contents

1 Safety Precautions......................................................................................................... 1-1


1.1 General Precautions ........................................................................................................ 1-1
1.2 Refrigerant ....................................................................................................................... 1-1
1.2.1 First Aid ............................................................................................................... 1-1
1.3 Refrigerant Oil .................................................................................................................. 1-1
1.3.1 First Aid ............................................................................................................... 1-1
1.4 Electrical Hazards ............................................................................................................ 1-2
1.4.1 High Voltage........................................................................................................ 1-2
1.4.2 Low Voltage ........................................................................................................ 1-2
2 Technical Specifications ............................................................................................... 2-1
2.1 Technical Specifications................................................................................................... 2-1
2.1.1 Refrigeration System Technical Specifications ................................................... 2-1
2.1.2 Electrical System................................................................................................. 2-2
3 Unit Description ............................................................................................................. 3-1
3.1 Unit Features.................................................................................................................... 3-1
3.2 M-15 In-Cab Box Controls................................................................................................ 3-2
3.3 Protection Devices ........................................................................................................... 3-2
3.4 Serial number Location .................................................................................................... 3-2
4 Inspection and Maintenance Schedule ........................................................................ 4-1
5 Operation ........................................................................................................................ 5-1
5.1 General ............................................................................................................................ 5-1
5.2 Operating Modes.............................................................................................................. 5-1
5.3 Unit Operation .................................................................................................................. 5-1
5.3.1 Weekly Pre-Trip Inspection ................................................................................. 5-1
5.3.2 Starting the Unit .................................................................................................. 5-1
5.3.3 Post-Start Inspection........................................................................................... 5-1
5.3.4 Loading Procedure.............................................................................................. 5-1
5.3.5 Procedure After Loading ..................................................................................... 5-1
5.3.6 Weekly Post-Trip Inspections.............................................................................. 5-1
5.4 M-15 In-Cab Control Installation Instructions ................................................................... 5-2
6 Electrical Maintenance .................................................................................................. 6-1
6.1 Troubleshooting for M-15 In-Cab Control......................................................................... 6-1
7 Refrigeration Maintenance............................................................................................ 7-1
7.1 Refrigerant Charge........................................................................................................... 7-1
7.2 Checking Compressor Oil Charge ................................................................................... 7-1
7.3 High Pressure Cutout Switch (HPCO) ............................................................................. 7-2
7.4 Low Pressure Cutout Switch (LPCO)............................................................................... 7-2
7.5 Cleaning Procedure for Small Truck Units ....................................................................... 7-3
8 Refrigeration System Service Operations ................................................................... 8-1
8.1 Condenser Coil ................................................................................................................ 8-1
8.1.1 Removal .............................................................................................................. 8-1
8.1.2 Installation ........................................................................................................... 8-1
8.2 Drier ................................................................................................................................. 8-1
8.2.1 Removal .............................................................................................................. 8-1
8.2.2 Installation ........................................................................................................... 8-1
iv

8.3 High Pressure Cutout Switch ........................................................................................... 8-2


8.3.1. Removal .............................................................................................................. 8-2
8.3.2 Installation ........................................................................................................... 8-2
8.4 Low Pressure Cutout Switch ............................................................................................ 8-2
8.4.1 Removal .............................................................................................................. 8-2
8.4.2 Installation ........................................................................................................... 8-2
8.5 Expansion Valve Assembly .............................................................................................. 8-3
8.5.1 Removal .............................................................................................................. 8-3
8.5.2 Installation ........................................................................................................... 8-3
8.6 Replacing Refrigerant Hoses (Speedy Clip System)........................................................ 8-3
8.6.1 Disassembly ........................................................................................................ 8-3
8.6.2 Assembly ............................................................................................................. 8-3
9 Structural Maintenance ................................................................................................. 9.1
9.1 Unit Inspection.................................................................................................................. 9-1
9.2 Condenser Coil................................................................................................................. 9-1
9.3 Evaporator Coil................................................................................................................. 9-1
9.4 Unit Mounting Bolts .......................................................................................................... 9-1
10 Clutch and Compressor Maintenance ......................................................................... 10-1
10.1 Operation.......................................................................................................................... 10-1
10.2 Clutch Removal ................................................................................................................ 10-1
10.2.1 Clutch Installation ................................................................................................ 10-3
10.3 Shaft Seal Cover and Shaft Seal: Removal and Installation ............................................ 10-5
10.3.1. Special Tools ....................................................................................................... 10-7
10.4 System Compressor and Oil ............................................................................................ 10-8
10.4.1 Compressor Installation....................................................................................... 10-8
10.4.2 Adding Extra Oil to the System............................................................................ 10-9
10.4.3 Checking Oil Level............................................................................................... 10-9
10.4.4 Oil Contamination ................................................................................................ 10-9
10.4.5 Electrical Connection........................................................................................... 10-10
10.4.6 Checking the clutch ............................................................................................. 10-10
10.5 Belt Tensions.................................................................................................................... 10-10
10.5.1 Compressor/Engine Belt and Pulleys .................................................................. 10-10
11 Troubleshooting............................................................................................................. 11-1
12 Refrigeration Diagnostics ............................................................................................. 12-1
13 C-290 Unit Diagrams...................................................................................................... 13-1
1 SAFETY PRECAUTIONS
1.1 GENERAL PRECAUTIONS 1.2 REFRIGERANT
1. ALWAYS WEAR GOGGLES OR SAFETY GLASSES. Although fluorocarbon refrigerants are classified as safe
Refrigerant and battery acid can permanently damage the refrigerants when the correct tools and procedures are used,
eyes. certain precautions should be taken when handling them or when
2. Never close the compressor discharge service valve with the carrying out maintenance work in units where they are used.
unit running. Never operate the unit with the discharge When released into the atmosphere in the liquid state,
service valve closed. fluorocarbon refrigerants evaporate rapidly and freeze anything
3. Keep hands, clothing and tools clear of fans and belts when they come into contact with.
the unit is running.
4. Be sure gauge manifold hoses are in good condition. Never 1.2.1 First Aid
let them come in contact with belts, fans, pulleys or hot In the event of freezing, the main objective of first aid is to
surfaces. protect the affected area and prevent it from deteriorating, as well
5. Never apply heat to a sealed refrigeration system or as to rapidly warm the affected area and maintain respiration.
container.
• EYES: In the case of contact with the liquid, flush the eyes
6. Fluorocarbon refrigerants in the presence of an open flame
immediately with large amounts of water and seek urgent
produce toxic gases. These gases are severe respiratory
medical attention.
irritants capable of causing death.
• SKIN: Flush affected area with large amounts of lukewarm
7. Be sure all mounting bolts are the correct length for the
water. Do not apply heat. Remove contaminated clothing and
application and are securely tightened.
shoes. Cover burns with dry, sterile, padded dressings to
8. Use extreme caution when drilling holes in the unit. Holes protect from infection or injury. Seek medical attention. Wash
may weaken structural components. Holes drilled in wiring contaminated clothing before it is reused.
can cause fire or explosion. Holes drilled into the
• INHALATION: Move the patient to a well-ventilated area
refrigeration system will release refrigerant.
and carry out cardio-pulmonary resuscitation if necessary.
9. Use caution when working around exposed coil fins. The fins Remain with the patient until the emergency medical team
can cause painful lacerations. arrives.
10. Use caution when working with refrigerant in a closed or
confined area with a limited air supply such as a trailer, 1.3 REFRIGERATION OIL
container or hold of a ship. Refrigerant tends to displace air
and can cause oxygen depletion which may result in Avoid allowing refrigeration oil to come into contact with the
unconsciousness or death due to suffocation. eyes. Avoid prolonged or repeated contact of refrigeration oil
with skin or clothing. To avoid irritation, wash after handling
refrigeration oil.

1.3.1 First Aid


In the case of contact with the eyes, immediately flush with
plenty of water for at least 15 minutes. SEEK MEDICAL
ATTENTION. Wash skin with soap and water.

TK 51493-1-MM (01/02 E)
1-2 Safety Precautions

1.4 ELECTRICAL HAZARDS First aid


Immediate action must be taken after a person has received an
1.4.1 High Voltage electrical shock. Medical attention should be summoned as soon as
possible.
When servicing or repairing a refrigeration unit, the possibility of
serious or even fatal injury from electrical shock exists. Extreme The source of electricity must be immediately removed, either by
care must be used when working with an operating refrigeration shutting down the power or removing the victim from the source. If
unit. Lethal voltage potentials can exists on connections in the high the victim must be removed from a live circuit, pull the victim off
voltage tray of the control box. with a non-conductive material. Use the victim's clothing, a rope,
wood or your belt. After separating the victim from the power
Precautions source, immediately check for pulse and respiration. If a pulse is
not present, start CPR (Cardiopulmonary Resuscitation)
1. When working on the high voltage circuits, do not make any immediately. If a pulse is present, respiration may be restored by
rapid movements. Unplanned movements can cause contact mouth to mouth resuscitation. Obtain emergency medical
with high voltage. assistance as soon as possible.
2. Use tools with insulated handles that are in good condition.
Never hold metal tools in your hand if exposed high voltage If it is necessary to remove the victim from an exposed circuit, use
conductors are within reach. a non-conductive material. To release the patient from the exposed
circuit, use a jacket, rope or a piece of wood, or wrap a belt around
3. Treat all wires as high voltage wires.
the patient’s arm or leg. DO NOT TOUCH the patient, as you may
4. Never work alone on high voltage circuits. Another person receive a shock from the current flowing from the patient’s body.
should be nearby in case of accident.
After removing the victim from the source, immediately check the
5. Have insulating gloves, wire cutters and safety glasses to hand
pulse and breathing. If there is no pulse, carry out cardio-
in case of accident.
pulmonary resuscitation and call the emergency medical services.
If there is a pulse, breathing may be re-established by means of
mouth-to-mouth resuscitation, although the emergency services
should always be called.

1.4.2 Low Voltage


Control circuits are 12 volt dc. This voltage potential is not
considered dangerous, but the large amount of current available
can cause severe burns if shorted to ground.
Do not wear jewelry, watches or rings when working on the unit. If
these items contact an electrical circuit severe burns may result.

TK 51493-1-MM (01/02 E)
2 TECHNICAL SPECIFICATIONS
2.1 TECHNICAL SPECIFICATIONS

2.1.1 Refrigeration System Technical


Specifications

Compressor: SELTEC TM 15-XD

Compressor oil capacity: Main: 150 cc

Type of compressor oil: Polyolester, part no. 203-413

Capacity and type of refrigerant: 3.08 lb/1.4 kg, R-134a

High pressure cutout: Opens 2,068 ±70 kPa (300 ±10 psi)

Closes 1,379 ±70 kPa (200 ±10 psi)

Low pressure cutout: Opens From 5 to 11 inches of vacuum

Closes From 27.6 to 48.3 kPa (from 4 to 7 psi)

CAUTION!
CAUTION!
When draining compressor oil, note the level of oil so the same level can be maintained in the compressor when
replaced.

Polyolester compressor oil should be used in conventional Thermo King units. Mineral oils and PAG type oil should
not be added to systems that use R-134a.

TK 51493-1-MM (01/02 E)
2-2 Technical Specifications

2.1.2 Electrical System


Condenser and evaporator fan motors

Full Load
Unit Number Voltage Power Rating in W Full Load r.p.m. Current

Condenser 1 13 V 100 2,800 9.2 A


Condenser 1 26 V 100 2,800 4.1 A
Evaporator (SLE) 2 13 V 100 2,800 6.2 A
Evaporator (SLE) 2 26 V 100 2,800 3.7 A

Fuses (located in M-15 in-cab control)

Condenser
Evaporator fans fans HPCO/LPCO/CLU
Voltage Fuse 1 Fuse 2 Fuse 3 Fuse 4

12 V 1A 20 A 15 A 10 A
24 V 1A 20 A 15 A 10 A

Relays (located in M15 in-cab control)


1K: Thermostat relay.
When activated, the battery voltage starts up the condenser fan motor. It also activates the compressor clutch through high
and low pressure cutouts.
EFR: Evaporator Fan Relay.
When activated, the battery voltage starts up the evaporator fan motors.

TK 51493-1-MM (01/02 E)
3 UNIT DESCRIPTION
Thermo King C-290 units are refrigeration systems equipped with The in-cab control comprises an on/off switch, a thermometer, a
compressors powered by the vehicle engine and designed for thermostat, internal thermostat adjustment and indicator lights.
refrigeration applications for small trucks and vans. These are
two-piece units mounted on the front/roof of the truck. The
compressor is mounted in the engine compartment of the truck
3.1 UNIT FEATURES
and is powered by the vehicle engine via a belt. The thermostat • In-cab controller: M-15
controls compressor operation, by activating the clutch. The unit
• Digital thermometer
is connected to the compressor by refrigeration hoses and lines.
• Electronic thermostat - adjustable:
The control circuits run on 12 V or 24 VDC supplied by the
— -0ºC +10ºC
truck’s batteries. The refrigeration system is protected by a high
pressure cutout and a low pressure cutout. • Main compressor TM 15-XD

C-290 condenser

1 Condenser coil 3 Drier


2 High pressure cutout switch 4 Liquid sight glass

ES300C evaporator

1 Temperature sensor 3 Expansion valve


2 Low pressure cutout switch

TK 51493-1-MM (01/02 E)
3-2 UNIT Description

3.2 M-15 IN-CAB CONTROLS


1. On/off key
This is used to start/stop the unit.

2. Temperature indicator
The temperature of the return air will be displayed
automatically in degrees Celsius.

3. Unit operating indicator light (when it is ON)


Indicates that the unit is in refrigeration mode.
When the thermostat, the HPCO, or the LPCO stops the
unit, the unit operating indicator light should be “OFF” and
the ON indicator light should remain “ON”.

4. ON indicator light
Indicates that the unit has been started by pressing the on/off
ASA124 key.

3.3 PROTECTION DEVICES


• High Pressure Cutout Switch
The high pressure cutout switch is a pressure-sensitive switch in the discharge line. If the discharge pressure increases beyond 2,068
kPa (300 psi), the switch opens the circuit disconnecting the clutch from the compressor to stop the unit. When the discharge pressure
falls below 1,379 kPa (200 psi), the switch closes and restarts the operation of the unit.
• Low Pressure Cutout Switch
The low pressure cutout switch is a pressure-sensitive switch in the suction line. If the pressure falls below between 5 and 11 inches of
vacuum, the switch opens the circuit, disconnecting the compressor clutch to stop the unit.
• Fuses
Fuse 1: Protects the in-cab control from possible overloads.
Fuse 2: Protects the evaporator fans (EF1-EF2) from possible overloads.
Fuse 3: Protects the condenser fan (CF) from possible overloads.
Fuse 4: Protects the compressor’s clutch coil (CLU), through the high pressure cutout switch (HPCO) and the low pressure cutout
switch (LPCO), from possible overloads.

3.4 SERIAL NUMBER LOCATION


CONDENSER: Inside the condenser chassis
EVAPORATOR: In the evaporator chassis
ON-THE-ROAD COMPRESSOR: On the identification plate located on the compressor body

TK 51493-1-MM (01/02 E)
4 INSPECTION AND MAINTENANCE
SCHEDULE
Inspection and maintenance after the first week
AFTER THE FIRST WEEK of operation:
• Check the belt tension
• Tighten unit and bracket mounting bolts

Every six
Weekly Monthly Annual Inspect/repair the following items
months

Electrical system

• • Check the operation of the protection circuits.

• • Check the thermostat and thermometer calibration(ice bath).

• • Check for damaged cables or connections in the wiring.

Refrigeration

• • Visually inspect the units and cooling hoses for leaking liquid.

• • Check the refrigerant level.

• Replace the dehydrator.

Structure

• • • • Visually inspect the unit for damaged, loose, or broken parts.


Clean the entire unit including the evaporator and condenser
• • •
coils.
• • Check the mounting bolts, brackets, tubes, hoses, etc.

Drive Kit

• • Visually inspect the drive kit.

• • Check that all the screws in the drive kit are properly tightened.

• • Check that there are no abnormal vibrations.

• Replace the belt.

TK 51493-1-MM (01/02 E)
TK 51493-1-MM (01/02 E)
5 OPERATION
5.1 GENERAL Mounting bracket. Check that the bolts are properly tightened.

In these units, REFRIGERATION and NULL cycles alternate to Electrical system. The electrical connections should be securely
maintain the temperature of the compartment at the thermostat made. The wires and terminals should show no signs of corrosion,
setpoint. The operating modes are: refrigeration and Null mode. cracks, or dampness.

The thermostat controls the operation of the unit by activating Drain circuit. Check the hose and the drain circuit connections to
and de-activating the 1K thermostat relay. ensure that they are open. Check the lower part of the drain hose
to ensure that it is not obstructed or crushed.
The evaporator fans operate when the unit starts up.
Structure. Check for noticeable physical damage.

5.2 OPERATING MODES Sight glass. Check that the level of coolant is correct.

Refrigeration 5.3.2 Starting the Unit


The thermostat activates the lK thermostat relay when the 1. Start the truck engine.
temperature of the compartment is 3°C greater than the 2. Press the ON/OFF switch located in the in-cab control, the
temperature setpoint and keeps it activated while the temperature ON/OFF indicator light should come ON.
in the compartment remains above the temperature setpoint. The
1K thermostat relay starts up the condenser fan and engages the
5.3.3 Post-Start Inspection
compressor clutch, and makes the unit cool.
Pre-cooling. With the thermostat set to the desired temperature,
Null Mode run the unit for between half-an-hour and one hour (or longer if
The thermostat deactivates the 1K thermostat relay when the possible) before loading the truck. Pre-cooling eliminates residual
temperature of the compartment is below the temperature setpoint heat and humidity from inside the compartment and serves as a
and keeps it deactivated while the temperature of the good test of the refrigeration system.
compartment remains more than 3°C below the temperature
setpoint. When the 1K thermostat relay is deactivated, the 5.3.4 Loading Procedure
compressor and the condenser fan do not operate.
1. To minimize frost accumulation in the evaporator coil and a
heat increase inside the unit box, ensure that the unit is OFF
Increase in before opening the doors. (The unit may remain in operation
Decrease in
temperature while the truck is being loaded from a store with the doors
temperature REFR. closed.)
3ºC above the 2. Carefully check and record the cargo temperature when
setpoint loading the truck. Check whether any products are out of
temperature.
Temperature 3. Load the cargo in such a way that there is sufficient space for
Setpoint the air to circulate throughout the load. DO NOT block the
evaporator inlet or outlet.
4. The cargo should be pre-cooled before loading. Thermo King
NULL AUA0044 units are designed to maintain the cargo at the temperature at
which it is loaded. The refrigeration units for transport are not
designed to reduce the temperature of the cargo.
5.3 UNIT OPERATION
5.3.5 Procedure after loading
5.3.1 Weekly Pre-trip Inspection
1. Ensure that all doors are closed and locked.
The following weekly pre-trip inspection should be carried out 2. Start the unit.
before loading the truck. The weekly inspection does not replace
the regular maintenance inspections (refer to the section on the 5.3.6 Weekly Post-trip Inspections
maintenance inspection schedule); however, it is an important
part of the preventative maintenance program which is designed 1. Wash the unit.
to prevent operating problems before they occur. 2. Check for leaks.
Leaks. Check for coolant leaks or leaks from worn refrigeration 3. Check for loose or lost hardware.
lines. 4. Check for physical damage to the unit.
Belts. Check that there are no cracks or worn areas and that the
belt tension is correct.

TK 51493-1-MM (01/02 E)
5-2 Operation

5.4 M-15 IN-CAB CONTROL INSTALLATION


INSTRUCTIONS

1. Place selector (A) in position SP to read the temperature


setpoint.
2. Using the potentiometer (B) adjust the temperature setpoint.
This can be adjusted between +10ºC and 0ºC (temperature pre-
set in the factory: +3ºC).
3. Place selector (A) in position TH to read the compartment
temperature.

ASA125

TK 51493-1-MM (01/02 E)
6 ELECTRICAL MAINTENANCE
6.1 TROUBLESHOOTING FOR M-15 IN-CAB CONTROL
Before troubleshooting, check that the in-cab control 12/24 V selector is in the correct position and check the ground circuit through pin 9
of connector C-11.

ASA126

IMPORTANT: This troubleshooting guide applies solely to the functions of the M-15 in-cab control and should not be considered as
exhaustive or applicable in all electrical eventualities; in these cases the wiring should be compared to the diagram.

Symptoms Solution

Blank screen when the ON/OFF switch is 1. Check that the voltage at pin 6 of connector C-9 is positive (12V or 24V
pressed. depending on the unit).
2. Check fuse 1, located inside the in-cab control.
3. If the fault persists, replace the in-cab control.
Unit does not refrigerate when 1. Check that the voltage at pin 3 of connector C-9 is positive (12V or 24V
temperature of the compartment is greater depending on the unit).
than the temperature setpoint. 2. Check fuse 4, located inside the in-cab control.
3. If the fault persists, replace the in-cab control.
Unit operating indicator light is OFF when 1. Check that the voltage at pin 1 of connector C-9 is positive (12V or 24V
unit is refrigerating. depending on the unit).
2. Check fuse 3, located inside the in-cab control.
3. If the fault persists, replace the in-cab control.
The condenser fan does not operate in 1. Check that the voltage at pin 1 of connector C-9 is positive (12V or 24V
cool mode. depending on the unit).
2. Check fuse 3, located inside the in-cab control.
3. If the fault persists, replace the in-cab control.
Evaporator fan does not operate 1. Check that the voltage at pin 7 of connector C-9 is positive (12V or 24V
depending on the unit).
2. Check fuse 2, located inside the in-cab control.
3. If the fault persists, replace the in-cab control.
Temperature displayed on screen is out of 1. Check that the in-cab control 12/24V selector is in the correct position.
range. 2. Check the thermostat sensor.
3. If the fault persists, replace the in-cab control.

TK 51493-1-MM (01/02 E)
6-2 Electrical Maintenance

TK 51493-1-MM (01/02 E)
7 REFRIGERATION MAINTENANCE
7.1 REFRIGERANT CHARGE 7.2 CHECKING COMPRESSOR OIL
1. Connect the gauge manifold to the suction and discharge line
CHARGE
connections of the on-the-road compressor. Compressors are supplied complete with the oil-charge indicated
2. Connect the refrigerant bottle to the gauge manifold and in the chapter on Technical Specifications. The level of
place it on a scale. compressor oil will vary once the compressor has been started up,
3. Open the valve on the refrigerant bottle and purge the rendering the oil level measurements incorrect.
manometer connecting hose.
To ensure that the oil supply is sufficient, the following procedure
4. Keep the low pressure side valve of the gauge manifold should always be followed when refrigerant is lost or removed
closed. Open the high pressure side valve.
from the unit:
1. Install a compressor which has a supply of residual oil and a
automatic lubricating system, like, for example, a TK 214
model. Connect an oil separator to the discharge or suction
line to recover and drain the circulating oil.
NOTE: An improvised oil separator can be made up with the
suction tube by installing a reversed suction filter in the suction
tube, near the compressor. Close both access holes and use the
lower one to drain the accumulated oil.

2. Add a normal amount of oil to the flushing compressor before


starting up the unit.
3. Charge the unit until it reaches 3.08 lb/1.4 kg of R-134a .
4. Run the unit at low speed (from 600 to 800 r.p.m.) for 2 hours
or until the oil level in the compressor reaches the necessary
minimum level, whichever comes first. Drain the collected
oil from the oil separator as the oil separator fills up, taking
care that the recovered oil does not recirculate.
5. Prepare the original compressor removed from the unit (or a
spare) draining all the oil and replacing it with the amount of
oil indicated in the chapter on Technical Specifications.
6. Install the original compressor (or the spare) and carry out the
manual refrigerant draining and re-charging procedure.
Charge the compressor until it reaches 3.08 lb/1.4 kg. of
R-134a.
5. Add refrigerant until it reaches 3.08 lb/1.4 kg of R-134a.
6. Close the refrigerant bottle valve and the high pressure side
valve of the gauge manifold.
7. Start the vehicle engine and run at 1,000 r.p.m. and connect
the unit.
8. Set the unit thermostat to 32ºF/0ºC (see operating manual).
9. Run the unit until it reaches a temperature close to that
indicated, and a pressure in the high pressure circuit of
12.5 bar, with R-134a. Partially close the air intake to the
condenser if necessary.
10. Open the low-pressure side valve of the gauge manifold and
the refrigerant bottle valve, and add refrigerant slowly until
no bubbles can be seen in the liquid sight glass.
11. Close the refrigerant bottle and gauge manifold valves.
12. Let the unit running for 15 minutes.

TK 51493-1-MM (01/02 E)
7-2 Refrigeration Maintenance

7.3 HIGH PRESSURE CUTOUT SWITCH 7.4 LOW PRESSURE CUTOUT SWITCH
(HPCO) (LPCO)
The HPCO switch is located in the discharge line inside the The low pressure cutout switch is located in the suction line. If the
condenser unit. If the discharge pressure rises above 300 psi suction pressure falls below between 5 and 11 in. Hg of vacuum
(2,068 kPa), the HPCO switch opens the 7A circuit, which (between -17 and -37 kPa), this opens the circuit to the clutch so as
deactivates the power supply relay. to stop the compressor. To check the low pressure cutout:
To test the HPCO, adapt a manifold as indicated in the illustration 1. Install a manifold on the compressor.
of the high pressure cutout manifold. 2. Close the accumulator tank outlet valve and run the unit in
refrigeration mode.
3. When the suction pressure falls below between 5 and 11 pulg.
Hg of vacuum (between -17 and -37 kPa), the LPCO should
open and the compressor should stop.

1. Relief valve (66-7392)


2. O-ring (33-1015)
3. Adapter Tee Weather Head (No 552X3)
High pressure cutout manifold

1. Connect the manifold to the compressor discharge service


valve.
NOTE: The service manifold hoses should have Schrader valve
(pneumatic valve) depressors.

2. Adjust the thermostat below the temperature of the


compartment so that the unit remains in refrigeration mode.
3. First, increase the compressor discharge pressure by blocking
the airflow to the condenser coil.
NOTE: The discharge pressure should never exceed 400 psi (2
758 kPa) when using R-134a.

4. In the event of the high pressure cutout system not being able
to stop the compressor, it will be necessary to check the
operation of the control circuit and replace the HPCO.

TK 51493-1-MM (01/02 E)
Refrigeration Maintenance 7-3

7.5 CLEANING PROCEDURE FOR SMALL Replacing the unit


TRUCK UNITS 1. Install a new drier.
2. Install a new expansion valve.
3. Install compressor and lines.
4. Use dry nitrogen to pressurize the system to 150 psi
(1,034 kPa).
5. Use a foaming solution to check for leaks.
6. Add the correct quantity of oil.
7. If there are no leaks, drain the unit. A dry unit with no leaks
will maintain a vacuum of 1,000 microns for five minutes or
longer.
8. Charge the unit with the correct quantity of refrigerant.
9. Start up the unit and check for correct operation.
10. After two weeks’ operation, change the drier.

Necessary tools:
• “Flushing compressor” TK 214 (4)
• Suction line filter (P/N 204-498, and filter P/N 66-2988) (3)

Cleaning Procedure
1. Ensure that all the hose routing is correct.
2. Ensure that the oil trap is correctly installed.
3. Recover the contaminated refrigerant from the system.
4. Remove the compressor lines.
5. Clean the compressor using the flushing compressor and a
HFC refrigerant. (Always recover the refrigerant before
disconnecting the flushing compressor.)
6. Remove the internal pieces from the expansion valve (1).
7. Remove the filter-drier (2) and connect the hose directly to the
condenser battery.
8. Install a temporary suction line filter (3) (P/N 204-498, and P/
N 66-2988) in the suction line.
9. Connect the flushing compressor (4) to the suction line and to
the compressor discharge line (see illustration).
10. Drain the system and check for leaks. Continue draining the
system to extract humidity and air.
11. Install HFC refrigerant and clean the system. Solid
contaminants will collect in the suction line filter. Oil from the
system and from the flushing compressor will drain from the
suction line filter. (Add oil to the compressor as necessary.)
Refrigerant oil from the flushing compressor will absorb the
acids in the system.
12. Examine the compressor oil to check for acid contamination.
13. Continue cleaning the compressor until the compressor oil is
clean.

TK 51493-1-MM (01/02 E)
7-4 Refrigeration Maintenance

TK 51493-1-MM (01/02 E)
8 REFRIGERATION SYSTEM SERVICE
OPERATIONS
NOTE: It is considered good practice to replace the filter-drier 8.2 DRIER
whenever the high pressure side is opened or when the low
pressure side is opened for a long period. 8.2.1 Removal
1. Create a vacuum in the refrigeration system and equalize the
8.1 CONDENSER COIL pressure to a slightly positive level.
2. Disconnect the ORS nuts at the ends of the drier.
8.1.1 Removal 3. Loosen the mounting screws and remove the filter-drier.
1. Drain the refrigerant charge.
2. Remove the condenser cover. 8.2.2 Installation
3. Unsolder the inlet and the liquid tubes. 1. Position new O-rings in the ORS fittings at the ends of the
4. Remove the assembly rivets. drier.
5. Remove the coil from the condenser. 2. Install the new drier and tighten the mounting screws and
nuts.
3. Install and tighten the ORS inlet nut. Hold the drier immobile
8.1.2 Installation with a back-up spanner applied to the hexagon located behind
the ORS.
1. Clean the tubes for soldering. 4. Release a small amount of refrigerant to purge the air through
2. Place the coil in the unit and install the assembly rivets. the drier and then tighten the ORS outlet nut.
3. Solder the inlet and liquid line connections. 5. Pressurize the system and check for leaks. If there are no
4. Pressurize the system and check for leaks. leaks, open the refrigeration valves and start up the unit.
5. Drain the system.
6. Recharge the unit.
7. Reinstall the cover.

C-290 Condenser

1
1. Condenser coil 3. Drier
2. High pressure cutout switch 4. Liquid sight glass

TK 51493-1-MM (01/02 E)
8-2 Refrigeration System Service Operations

8.3 HIGH PRESSURE CUTOUT SWITCH 8.3.2 Installation


1. Apply Loctite for refrigerant to the thread of the cutout.
8.3.1 Removal 2. Install and tighten the switch and reconnect the cables.
1. Drain the refrigerant charge. 3. Pressurize the refrigeration system and check for leaks.
2. Disconnect the cables and remove the switch. 4. If there are no leaks, charge the system.

ES300C Evaporator

1 Temperature sensor 3 Expansion valve


2 Low pressure cutout switch

8.4 LOW PRESSURE CUTOUT SWITCH 8.4.2 Installation


1. Apply Loctite for refrigerant to the thread of the cutout.
8.4.1 Removal 2. Install and tighten the cutout switch and reconnect the cables.
1. Drain the low pressure side and stop the unit. 3. Pressurize the refrigeration system and check for leaks.
2. Disconnect the cables and remove the cutout switch. 4. If there are no leaks, drain the low pressure side.
5. Open the accumulator tank outlet valve, start up the unit, and
check the refrigerant charge.

TK 51493-1-MM (01/02 E)
Refrigeration System Service Operations 8-3

8.5 EXPANSION VALVE ASSEMBLY 8.6 REPLACING REFRIGERANT HOSES


(SPEEDY CLIP SYSTEM)
8.5.1 Removal
1. Evacuate the low pressure side and equalize the pressure to a
8.6.1 Disassembly
slightly positive level. 1. Drain the refrigerant charge or drain the low pressure side.
2. Remove the feeler bulb and the coil sensor from the suction 2. Use two spanners to loosen the hose fittings.
line clamps. Note the position of the feeler bulb on the suction 3. Remove the hose and the hose connectors.
line.
3. Disconnect the equaliser line from the expansion valve.
8.6.2 Assembly
4. Disconnect the liquid line and the distributor from the
expansion valve. 1. Cut the hose to the desired length. Use the recommended
5. Remove the expansion valve from the unit. hose-cutting tool. Do not use saws, knives, or similar tools.

8.5.2 Installation
1. Install the expansion valve assembly in the unit.
2. Connect the liquid line and the distributor to the expansion
valve.
3. Connect the equaliser line to the expansion valve.
4. Clean the suction line until it is polished and shining. Install
the feeler bulb clamps and the feeler bulb and the coil sensor
on the side of the suction line in their previous positions. The
feeler bulb and the sensor must be in contact with the suction
line or they will not function correctly. Wrap the bulb and the Cutting the hose
sensor with insulating tape. 2. Fit two clips of appropriate diameter over the hose. Only one
View from clip for hose #4.
one end
Coil sensor

Suction line
AJA244
ASA127
Location of the expansion valve bulb and the coil sensor

Fitting the clips


3. Lubricate the cylinder of the fitting to be inserted in the hose
using Thermo King refrigerant oil.

ASA128

Lubricating the cylinder of the fitting


Wrap the bulb and the sensor completely with tape
1. Pressurize the low pressure side and check for leaks. If there
are no leaks, drain the low pressure side.

TK 51493-1-MM (01/02 E)
8-4 Refrigeration System Service Operations

4. Manually insert the fitting into the hose. The hose should touch
the projecting part of the fitting without rising over it. Clean
off excess oil.

ASA129

Manually Inserting the fitting


5. Place the clamp for the clips into the fitting slot. The clamp is
properly positioned when it can rotate in the slot.

Positioning the clamp


6. Fit the clips in the clamp arm seat.

Fitting the clips


7. Tighten up both clips using recommended pliers. Check that
the clips are properly positioned and tightened.

Tightening both clips

TK 51493-1-MM (01/02 E)
9 STRUCTURAL MAINTENANCE
9.1 UNIT INSPECTION
Check the unit during the pre-trip inspection and the scheduled
maintenance inspections and look for loose or broken cables or
screws, as well as oil leaks in the compressor or any other
physical defect that may impair the performance of the unit and
may require repair or replacement of parts.

9.2 CONDENSER COIL


Clean the condenser coil during the scheduled maintenance
inspections by blowing compressed air from the back of the coil
to the front of the unit (opposite direction to normal airflow).
Check the coil and the fins for defects and repair them if
necessary.

9.3 EVAPORATOR COIL


Clean the evaporator coil during the scheduled maintenance
inspections by blowing compressed air from the back of the coil
towards the box (opposite direction to normal airflow). Check the
coil and the fins for defects and repair them if necessary (to do
this it will be necessary to remove the evaporator fan and the front
cover).

CAUTION!
Air pressure should not be too high so as to avoid
damaging the coil fins.

9.4 UNIT MOUNTING BOLTS


Periodically check the mounting bolts and tighten them to 81 Nm
(60 ft lb).

TK 51493-1-MM (01/02 E)
9-2 Structural Maintenance

TK 51493-1-MM (01/02 E)
10 CLUTCH AND COMPRESSOR
MAINTENANCE
10.1 OPERATION Removal

The stationary field coil is mounted on the compressor body 1. Remove the central screw using the arbor puller
concentrically to the shaft. The pulley assembly, composed of a (TK 204-804) to prevent the drive plate from rotating.
pulley, a disc, and a wheelhub, is mounted on the compressor
shaft. The wheelhub and the disc are connected loosely by flat
springs which keep the disc slightly separated from the pulley
lattice (friction surface) when they are disengaged.
A magnetic field is created when current runs through the coil.
The magnetic field pulls the disc against the pulley lattice and
compresses the flat springs. This causes the wheelhub and the
disc to rotate together with the pulley.

CAUTION! 4

5
1. Holder
Removing the central bolt

2. Remove the drive plate using the shaft seal kit (TK 204-805).
1 Then remove the washers from the drive shaft or from the
drive plate.
AJA245

1. Wheelhub 4. Disc
2. Stationary field coil 5. Flat springs
3. Pulley
Compressor clutch assembly

10.2 CLUTCH REMOVAL


NOTE: Ensure that suitable tools are available before carrying
out these maintenance procedures. Refer to the tools list at the
end of this chapter to find out which tools will be needed. For
more information contact your local Thermo King dealer.

Removing the drive plate

TK 51493-1-MM (01/02 E)
10-2 Clutch and Compressor Maintenance

3. Remove the snap ring using the external snap ring pliers NOTE: DO NOT hold the coil by the main cable.
(TK 204-808).
4. Remove the cover.

Removing the coil

Inspection
1. Snap ring
1. Drive plate
2. Cover
If the contact surface is burnt, the drive plate and the pulley
Removing the snap ring and the cover should be replaced.
2. Pulley assembly
5. Remove the pulley assembly using the clutch remover (TK P/
N 204-806), and the spacer located in the wheelhub at the Inspect the appearance of the pulley assembly. If the pulley
cylinder head. contact surface is excessively scored as a result of slippage, the
pulley and drive plate should be replaced. Moreover, there
NOTE: To avoid damaging the pulley groove, the pulley hooks
should be no foreign substance, such as oil or abrasive grit,
should be connected to at the level of the pulley groove (NEVER lodged between the clutch plate and the pulley. Clean these
BELOW THIS POINT). contact surfaces and the drive plate thoroughly.

Removing the Pulley


6. Remove the main coil cable from the holder coil at the top of
the compressor.
7. Remove the three screws that secure the coil to the compressor
and remove the coil.

TK 51493-1-MM (01/02 E)
Clutch and Compressor Maintenance 10-3

3. Coil NOTE: Correct torque: 2.9 to 4.3 ft lb (0.4 to 0.6 kg).


Check the coil for loose connectors or cracks in the insulation.
3. Fit the main cable in the compressor cable holder.
If cracks are found in the insulation, replace the coil. Repair or
replace the wire or the connector if either of these is loose or
damaged.

1. Drive plate
2. Pulley assembly
3. Coil
Checking the components

10.2.1 Clutch Installation


1. Felt
NOTE: Before carrying out the installation, refer to the Installing the coil
procedures set out in the “Inspection” section above.
4. Fit the pulley assembly using the compressor holder (TK P/N
1. Ensure that the felt is installed at the front of the cylinder head.
204-807) and a hand press.
2. Fit the coil on top of the compressor (with the main cable on
top). At this point ensure that the concave part of the coil is
aligned with the felt and then tighten the mounting screws to
the torque indicated.

Installing the pulley


5. Fit the cover and the snap ring using the external snap ring
pliers.

TK 51493-1-MM (01/02 E)
10-4 Clutch and Compressor Maintenance

NOTE: When fitting the snap ring, its grooved inner edge should NOTE: Correct torque: 8..7 to 10.1 ft lb (1.2 to 1.4 kg).
face upwards.
After tightening the stud, ensure that the pulley rotates
smoothly.

1. Snap ring
1. Shims
2. Cover
Installing the shims and the drive plate
Installing the cover and the snap ring
8. Ensure that the clutch gap is as indicated. If necessary adjust
6. Fit the drive plate in the drive shaft using the original
the space using the adjusting shims.
washer(s). Hand tighten the drive plate.
Shims are available in the following thicknesses:
7. Tighten the stud to the indicated torque setting using the arbor
puller (TK P/N 204-804) to prevent the drive plate from TK code for shims Thickness in in. (mm)
rotating.
TK 11-8031 0.0039 in. (0.1 mm)
TK 11-8032 0.0118 in. (0.3 mm)
TK 11-8033 0.0197 in. (0.5 mm)

NOTE: Correct gap: 0.01 to 0.02 in.(0.3 to 0.6 mm).

Checking the gap

TK 51493-1-MM (01/02 E)
Clutch and Compressor Maintenance 10-5

Electrical connection
1. Connect the main cable to the electrical circuit.
NOTE: The stationary field is factory grounded, therefore only
the positive (main) cable needs to be connected.

2. Engage and disengage the clutch several times to check that it


engages correctly. The disc should engage firmly against the
pulley.

10.3 SHAFT SEAL COVER AND SHAFT


SEAL: REMOVAL AND INSTALLATION

Removal
1. Remove the magnetic clutch assembly as instructed in the
“Removal of magnetic clutch” section in this manual.
2. Remove the felt pad. 1. Shaft seal
3. Use the seal puller (from the shaft seal kit, P/N 204-805) to Removing the shaft seal
remove the shaft seal cover. Rotate the seal puller to engage
the seal puller hook with the shaft seal cover hook. Then Inspection
slowly remove the shaft seal cover from the cylinder head.
Do not re-use the shaft seal. Always use a new shaft seal when
NOTE: The shaft seal cover MUST NOT be reused. Always use a reassembling a compressor. Exercise care to ensure that the lip of
new shaft seal cover when reassembling a compressor. the shaft seal being installed does not get scratched or damaged in
any way. Ensure that the shaft seal is not contaminated with lint or
dirt that could damage the surface of the shaft seal.

Inspecting the shaft seal

1. Shaft seal cover


2. Felt pad
Removing the shaft seal cover

4. Use the seal puller (from the shaft seal kit, P/N 204-805) to
remove the shaft seal. Rotate the seal puller to engage the seal
puller hook with the shaft seal hook. Then slowly remove the
shaft seal from the head of the cylinder.

TK 51493-1-MM (01/02 E)
10-6 Clutch and Compressor Maintenance

Installing the shaft seal


Carefully inspect the shaft seal before installation (see Inspection).
1. Clean the front part of the cylinder head which secures the
shaft seal.
2. Apply clean compressor oil to the new shaft seal and to the
front of the cylinder head. If the sliding surfaces are dirty,
clean them with solvents, dry the clean surfaces and apply
clean compressor oil.
3. Place the seal guide (from the shaft seal kit P/N 204-805) on
the end of the shaft.

Pressing the seal into the cylinder head


7. Place the seal guide (from the shaft seal kit, P/N 204-805) on
the shaft end.
8. Place the shaft seal cover on the seal guide and slide the seal
cover inside the cylinder head.

1. Seal guide
Placing the guide on the shaft

4. Place the shaft seal on the seal guide and slide the seal inside
the cylinder head.

Installing the shaft seal cover


9. Use the seal puller (from the shaft seal kit P/N 204-805) to
press the shaft seal cover inside the cylinder.
10. Remove the seal guide from the shaft.

1. Seal guide
2. Shaft seal
Placing the shaft seal on the guide

5. Use the seal installer (from the shaft seal kit, P/N 204-805) to
press the shaft seal as far into the cylinder head as possible.
6. Remove the seal guide from the shaft.

TK 51493-1-MM (01/02 E)
Clutch and Compressor Maintenance 10-7

NOTE: Fit the shaft seal cover as shown in the illustration.


When replacing the shaft seal, the felt pad should also be
replaced with a new one.

Correct fitting of the shaft seal cover

10.3.1 Special Tools

8932c
Clutch installation kit, P/N 204-890

8932a

Clutch remover, P/ N204-806

8932d

Snap ring pliers, P/N 204-808

8932b

Compressor holder, P/N 204-807

TK 51493-1-MM (01/02 E)
10-8 Clutch and Compressor Maintenance

8932e 8932f

Shaft seal kit, P/N 204-805 Pulley shaft, P/N 204-804

10.4 SYSTEM COMPRESSOR AND OIL

10.4.1 Compressor Installation


All compressors come with a standard charge of polyolester oil
(POE) inside. This quantity of oil is sufficient to lubricate the
compressor in a system that is already “oil soaked”. New systems
require the addition of an extra quantity of oil to “soak” all the
system’s interior surfaces.
During normal operation, there is always a certain quantity of oil
that moves from one side to another inside the system. This oil
lubricates all the components, returns to the compressor for a time
then continues to flow through the system.

TK 51493-1-MM (01/02 E)
Clutch and Compressor Maintenance 10-9

10.4.2 Adding Extra Oil to the System Remove the compressor from the engine compartment and drain
the oil from the compressor drain plug and from all other holes.
The original oil charge in a new system depends on the size of the Rotate the clutch manually (so as to rotate the internal parts of the
system and on the quantity of oil, which remains in the compressor compressor) and drain the oil again. Repeat this operation until
during operation. there is no oil left in the compressor. Measure the oil in liquid
The correct oil to use is polyolester oil (POE) (TK P/N 203-413). ounces. Check the oil for signs of contamination.
All additional or replacement oil should be added to the system
through the suction system.

CAUTION!
All oil containers should be kept completely airtight. Oil
tends to absorb the humidity from the air and can
become contaminated if their containers are left open. If
contaminated oil is added to the system it can damage
the system’s components.

Major loss of refrigerant


In the event of major loss of refrigerant, it should be assumed that
some of the system’s oil has also been lost. The oil level should be
checked using the “Checking the Oil Level” method set out in this
manual.

10.4.3 Checking Oil Level


10.4.4 Oil Contamination
Draining the oil 1. Dirt in oil.
2. A change in color to a varnish color.
3. Presence of foreign substances, metal filings, or other elements
in the oil.
NOTE: Always replace oil with fresh oil taken only from a sealed
receptacle.

NOTE: Replace the system filter-drier whenever the system is


opened for checking.

When the system is contaminated


If the compressor oil is black, the system is very contaminated. If
this occurs, it will be necessary to clean the entire system. If
cleaning is necessary, use the correct industrial materials.
Whenever this occurs the extent of the contamination should be
determined. Do this by removing the filter-drier and determining
whether there is also dark oil in this part of the system. If this is the
Draining the oil case, cleaning of the system is recommended.
If the oil in the filter-drier is clean, install a new filter-drier and
replace the compressor oil with clean oil. For more information,
refer to the section on checking and draining the oil.

CAUTION!
All extra or replacement oil should be added to the
system through the accumulator tank filler cap.

TK 51493-1-MM (01/02 E)
10-10 Clutch and Compressor Maintenance

10.4.5 Electrical Connection 10.5 BELT TENSIONS


1. Connect the main cable to the electrical circuit.
NOTE: The stationary field is grounded in the factory, therefore
10.5.1 Compressor/Engine Belt and Pulleys
only the positive (main) cable needs to be connected. A cable with Correct alignment of the pulley and correct belt tension are very
a “CH” sticker is also connected to one of the compressor’s important factors in the installation of the compressor. The
mounting studs. compressor clutch should be perfectly aligned with the engine
pulley and with any other auxiliary pulley or any of the adjusting
2. Engage and disengage the clutch several times to check that it components of the belt. When installing the clutch, ensure that the
engages properly. The disc should engage firmly against the shaft transmission key is in position and that the shaft stud is
pulley. correctly tightened. Check the alignment of the pulley by firmly
holding a rod of 24 to 35 in. (60 to 90 cm) in length and 0.5 in. (13
10.4.6 Checking the clutch mm) in diameter into the V-groove of the clutch pulley and
ensuring that the rod aligns perfectly with the V-groove of the
1. If the coil wire is broken, replace the coil. engine drive pulley. Check again ensuring that the belt goes from
2. Check the amperage and the voltage. The amperage should be pulley to pulley in perfect alignment with no signs of bending to
between 3.6 and 4.2 A at 12 V. Check for the following one side.
symptoms and conditions:
Adjust the belt tension from 58 to 60 in the TK manometer,
a. A very high current reading: a short-circuit in the coil.
PN204-427. Check the belt tension again 36 to 48 hours after
b. No current reading: an open circuit in the armature. initial operation of the unit, as the belt may stretch during the initial
hours of use. Remember, good alignment and correct belt tension
c. An intermittent or bad ground in the system results in a
guarantee long life for your belt.
lower voltage at the clutch. Check that the coil snap ring or
the coil securing screws are tightened hard for good
grounding.
d. Replace the coil if there is an open circuit or a short-
circuit.
3. Correct gap. An incorrect gap may result in failure to engage
or disengage and/or noises in the clutch. Check that the gap is
correct using a feeler gauge (from 0.01 to 0.02 in. [from 0.3 to
0.6 mm]). Make the adjustment following the guidelines in the
chapter on installing the clutch.

TK 51493-1-MM (01/02 E)
11 TROUBLESHOOTING
Use the following information to troubleshoot the unit. If you 11. DIRTY OR WET DRIER. If the drier outlet line is colder
cannot achieve the correct compartment temperature, one of the than the inlet line, the drier is dirty or saturated and should be
following problems may have occurred: replaced.
1. EXCESSIVE HEAT. Constant or excessively long stops 12. DIRT IN THE EXPANSION VALVE FILTER. Recover the
where the doors are opened can generate excessive heat in the refrigerant charge, remove the filter and clean. If there is
system. Excessive heat may also be generated by loose doors dampness in the refrigeration system, this will collect in the
or body panels, warm loads or poor insulation. expansion valve and will freeze. Abnormally low suction
pressure is a sign of this. Clean the system, replace the drier,
2. DIRTY ON COILS. Accumulated dirt in the condenser or
drain the system, pressurize it, and check for leaks. If there
evaporator coils acts as an insulator, reducing the capacity of
are no leaks, charge the system.
the unit.
13. AIR FLOW. Do not load product directly in front of the air
3. INCORRECT BELT TENSION. If the drive belt is not
return or outlet. Ensure that the fan is positioned correctly in
correctly tensioned the compressor will not be driven at the
the opening to achieve maximum airflow.
correct speed, and the efficiency of the unit will be reduced.
Conversely, excessive tensioning will put an additional load 14. COMPRESSOR LIFE. Compressor life will be shortened if
on the bearings, causing rapid wear. one of the following occurs:
4. LOW LEVEL OF REFRIGERANT. Shortage of refrigerant • The system is run while contaminated
reduces the capacity of the unit. Find and solve the reason for • There is no oil trap
the low level and recharge the system. DO NOT operate the • The oil level is inadequate
unit if the refrigerant charge is low. • The oil used is mixed or incorrect
5. FAULTY SETTING OF EXPANSION VALVE. High heat • The compressor is insufficiently lubricated at initial
settings will prevent correct supply to the evaporator, installation
resulting in low suction pressure. Low heat settings will
• The compressor speed is excessive (the recommended
overload the coil, resulting in high suction pressure. ONLY
working speed is between 2,000 and 3,000 r.p.m.)
an experienced refrigeration service in refrigeration should
adjust the heat settings.
6. EXCESS OIL. An excess of compressor oil in the system can
result in a lower than normal suction pressure, and therefore a
reduced capacity.
7. HUMIDITY IN THE SYSTEM. Symptom: Frozen
expansion valve - will not refrigerate. This can usually be
checked by warming the expansion valve with a hand or with
warm cloths to see whether the valve will open. Drain the
system in the same way as during the installation. Install a
new drier.
8. EXPANSION VALVE LOSES ITS CHARGE. If the
expansion valve loses its loading, the valve will close, thus
causing the system to empty. Replace the valve.
9. AIR IN THE SYSTEM. The air cannot condense. Its
presence in the system increases the discharge pressure.
When the compressor stops, the air will collect at the high
point of the high pressure side. Drain the system.
10. LIQUID LINE TEMPERATURE. During normal operation,
the liquid line will be slightly warmer than the air
surrounding it. An extremely warm line indicates a shortage
of refrigerant. A cold line indicates that there is a blockage
and this results in pulsing which can be seen in the liquid line
sight glass.

TK 51493-1-MM (01/02 E)
11-2 Troubleshooting

AJA247 *
A
B
C*

Technical specifications of the main compressor

Model Displ. Dimensions (see previous diagram)

MAX R.P.M. (Metrics) A B C1 D

TM 15 XD 9.0 cubic inches 3.28 in. 4.41 in. 8.55 in. 4.09 in.
4,000 r.p.m. (147 cc) (83.3 mm) (112 mm) (217.3 mm) (104 mm)

1. Add 2.5 cm (1 in.) to the dimensions of the screw-fitted tubing.

Compressor r.p.m. formula

Drive pulley Clutch pulley Maximum compressor


diameter ³ diameter X High engine r.p.m. = r.p.m.

6.5 in. ÷ 5.25 in. x 2,500 = 3,095

TK 51493-1-MM (01/02 E)
12 REFRIGERATION DIAGNOSTICS

The suction line has frost on it

The unit does not refrigerate


High discharge pressure
Low discharge pressure

Unit running in vacuum


No discharge pressure
High suction pressure
Low suction pressure
No suction pressure

Noisy compressor
Empty sight glass
Rapid cycle

Symptom
Possible causes

• • Excessive usage of refrigerant

• • • • • • Shortage of refrigerant

• • • • • • • No refrigerant

• Air through the condenser is too hot (ambient temperature)

• Airflow through the condenser restricted (dirty)

• • Air through the condenser is too cold (ambient temperature)

• • • Air in the refrigeration system

• Bent or broken condenser fan blades

• Short air cycles around the evaporator coil

• • • • Airflow through the evaporator restricted

• • Broken compressor belt

• • • Excessive compressor oil in the system

• Loose compressor pulley

• Loose or burnt compressor bearing

• • • • Broken compressor valve plate

The power element of the expansion valve has lost its


• • • • charge

The expansion valve feeler bulb has been incorrectly


• • • assembled

TK 51493-1-MM (01/02 E)
12-2 Refrigeration Diagnostics

The suction line has frost on it

The unit does not refrigerate


High discharge pressure
Low discharge pressure

Unit running in vacuum


No discharge pressure
High suction pressure
Low suction pressure
No suction pressure

Noisy compressor
Empty sight glass
Rapid cycle

Symptom
Possible causes

• • • The expansion valve feeler bulb makes poor contact

• • • • The expansion valve is too open

• • The expansion valve is too closed

• • • Expansion valve needle eroded or leaking

• • • Expansion valve partially blocked by ice, dirt, or wax

• • • • Liquid refrigerant leaking into the compressor

• • • Tubing on the low-pressure side blocked

• • Tubing on the high-pressure side blocked

• • • Dehydrator blocked

• • Reverse fan rotation

• • • • Manometer out of calibration

• The condenser fan motor is not working

• • • • • The evaporator fan motor is not working

• Loose belts

TK 51493-1-MM (01/02 E)
13 C-290 UNIT DIAGRAMS
d

Illustration
Number Illustration Title Rev. Page

3B18476 C-290 unit Installation Diagram A 13-3 to 13-5

3B18477 ES300C unit Installation Diagram A 13-6 to 13-7

3B16228 C-290 unit Refrigeration Diagram B 13-8

3B16143 C-290 unit Wiring Diagram C 13-9

3B16144 C-290 unit Schematic Diagram C 13-10

TK 51493-1-MM (01/02 E)
13-2 C-290 Unit Diagrams

TK 51493-1-MM (01/02 E)
C290 Unit Installation Diagram - Page 1 of 3

13-3
C-290 Unit Installation Diagram - Page 2 of 3

13-4
C-290 Unit Installation Diagram - Page 3 of 3

13-5
ES300C Installation Diagram - Page 1 of 2

13-6
ES300C Installation Diagram - Page 2 of 2

13-7
C-290 Unit Refrigeration Diagram

13-8
C-290 Unit Wiring Diagram

13-9
C290 Unit Schematic Diagram

13-10

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