x214 PDF

Overhaul Manual
X214,SB-210+
X418, X426 &
toCompressor
Additional text information
X430 be placed here
TK 6875-8-OM (Rev. 9, 02/14)
TK 5XXXX-X-PL
Ingersoll Rand’s Climate Solutions sector delivers energy-efficient HVACR solutions for
customers globally. Its world class brands include Thermo King, the leader in transport
temperature control and Trane, a provider of energy efficient heating, ventilating and air
conditioning systems, building and contracting services, parts support and advanced controls
for commercial buildings and homes.
Distributed by:
Thermo King Corporate

314 West 90th Street
Minneapolis, MN 55420
Direct (952) 887-2200
TK 6875-8-OM
©1998 Ingersoll Rand Company

Printed in U.S.A.
Overhaul Manual
X214, X418,
X426 & X430
Compressor
TK 6875-8-OM (Rev. 9, 02/14)
Copyright© 1998 Thermo King Corp., Minneapolis, MN, U.S.A. Printed in

U.S.A.
Revision History
Rev. 9 – TK 6875-8-OM (Rev. 9, 02/14) Update for Oil Collection Container, Pressurized Seal
Cavity, and Internal Oil Filter.
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 apply to any
equipment which has been “so repaired or altered outside the manufacturer’s plants as,
in the manufacturer’s judgment, to effect 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
or in 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.
2
Recover Refrigerant
At Thermo King, we recognize the need to preserve the environment
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.
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
programs, contact your local Thermo King dealer.
3
CHANGES, COMMENTS and SUGGESTIONS
You are invited to comment on this manual so it can be updated and improved to better meet you
needs. Any corrections, comments or suggestions are welcome. Please complete the following
information:
Manual Form Number _____________________________________________________
Section and Page # _______________________________________________________
Your Name ______________________________________________________________
Company Name __________________________________________________________
Phone Number ___________________________________________________________
Corrections, Comments and Suggestions _____________________________________
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Return to:
NORTH AMERICA EUROPEAN SERVED AREA
THERMO KING CORPORATION THERMO KING CORPORATION

314 West 90th Street Ingersoll Rand Climate Control Technologies
Mail Stop 38 Monivea Road
Minneapolis, MN 55420 Mervue, Galway, Ireland
Attn: Service Department Attn: Service Department
4
Table of Contents
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
General Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Battery Installation and Cable Routing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Battery Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Refrigerant Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Refrigerant Oil Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Electrical Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
High Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Low Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
First Aid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
First Aid, Refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
First Aid, Refrigerant Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
First Aid, Engine Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
First Aid, Electrical Shock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Compressor Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Compressor Model Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Two Cylinder Compressors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Four Cylinder Compressors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Oil Collection Container . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
General Compressor Repair Techniques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Dirt and Moisture can Easily Ruin Compressors! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Compressor Oil Indications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Compressor Oil Color Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Disassembly and Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Disassembly Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Reassembly Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Fastener Torque Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Cleaning Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Drive Coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Discharge Valve Plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Two-piece Compressor Seal Plate and Mounting Flange Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Seal Plate Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Installation of Spring Loaded Neoprene Bellows Type Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Installation of Metal Bellows Seal With Set Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Installation of Metal Bellows Seal With Drive Tangs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Installation of Metal Bellows Seal With Hex Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Oil Sump and Oil Pickup Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
5
Table of Contents
Internal Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Pre-Lubrication of Oil Pump Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Connecting Rod, Piston and Sleeve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Compressor Crankshaft Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Removal and Installing Crankshaft Counterweights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Compressor Body Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Check Valve Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Unloader Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Check Out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Leak Testing, Storage, and Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Leak Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Compressor History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Compressor History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Released . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Two-piece Compressor Seal Plate and Mounting Flange Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Metal Bellows Crankshaft Seal with Set Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Polyol Ester (POE) Compressor Oil for HFC Refrigerants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Groove Top Pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Teflon Seal Type Drive End Ball Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
New Coupling Mounting Washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Large Shaft Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Metal Bellows Crankshaft Seal with Drive Tangs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
8 Pin Coupling and Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Fins Eliminated from Crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Seven Quart Oil Sump on Four Cylinder Compressors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Deep Oil Sump on Two Cylinder Compressors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Increase Bronze Bearing Bore Diameter in Oil Pump Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Improve Heat Treating on Oil Pump Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
HPCO Switch with Straight Threads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
C5 Crankshaft Drive End Bearing and Cast Iron Oil Pump Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Oil Collection Container . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Check Valve in Oil Collection Container . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Pressurized Seal Cavity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Internal Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
6
Safety Precautions
Thermo King recommends that all service be
DANGER: Avoid engine operation in
performed by a Thermo King dealer. However,
confined spaces and areas or
you should be aware of several general safety
circumstances where fumes from the
practices:
engine could become trapped and cause
serious injury or death.
The symbol appears next to a point that is
particularly important WARNING: Make sure your gauge
manifold hoses are in good condition
DANGER: Denotes the possibility of before using them. Never let them come in
serious injury or death. contact with moving belts, fans, pulleys or
hot surfaces. Defective gauge equipment
WARNING: Denotes the possibility of can damage components or cause serious
serious equipment damage or serious injury.
personal injury.
WARNING: Always wear goggles or safety
CAUTION: Denotes the possibility of glasses when working on a unit.
minor to severe equipment damage or Refrigerant liquid, oil and battery acid can
personal injury. permanently damage your eyes. See “First
Aid” on page 10.
General Practices
WARNING: Use extreme caution when
DANGER: Do not operate the compressor drilling holes in a unit. Holes might
with the discharge service valve closed. weaken structural components. Holes
This condition increases internal pressure, drilled into electrical wiring can cause a
which can cause an explosion. fire or explosion.
DANGER: Never apply heat to a sealed WARNING: Exposed coil fins can cause
refrigeration system or container. Heat lacerations. Service work on the
increases internal pressure, which might evaporator or condenser coils is best left to
cause an explosion. a certified Thermo King technician.
DANGER: Refrigerant in the presence of WARNING: Do not apply heat to a closed

an open flame, spark or electrical short cooling system. Before applying heat to a
produces toxic gases that are severe cooling system, drain it. Then flush it with
respiratory irritants. water and drain the water. Antifreeze
contains water and ethylene glycol. The
DANGER: Keep your hands, clothing and ethylene glycol is flammable and can
tools clear of fans when working on a unit ignite if the antifreeze is heated enough to
that is running. Loose clothing might boil off the water.
entangle moving pulleys or belts, causing
serious injury or possible death. WARNING: Be careful when using
ladders or scaffolding to install or service
DANGER: Do not inhale refrigerant. Use a unit. Observe the manufacture’s safety
caution when working with refrigerant or labels and warnings.
a refrigeration system in any confined
area with a limited air supply, such as a CAUTION: Make sure all mounting bolts
cargo area or garage. Refrigerant are tight and are the correct length for
displaces air and can cause oxygen their applications. Improper torque and
depletion, resulting in suffocation and incorrect bolt lengths can damage
possible death. equipment.
7
Safety Precautions
NOTE: In the USA, EPA Section 608

CAUTION: Always cover battery
Certification is required to work on refrigeration
terminals to prevent them from making
systems.
contact with metal components during
battery installation. Battery terminals
Battery Installation and Cable grounding against metal could cause the
Routing battery to explode.
WARNING: Improperly installed battery
could result in a fire or explosion! A Battery Removal
Thermo King approved battery must be DANGER: Disconnect the negative
installed and properly secured to the battery terminal (-) first when removing a
battery tray. battery. Connect the positive terminal (+)
first when installing a battery.
WARNING: Improperly installed battery
cables could result in fire or explosion! This order is important because the frame is
Battery cables must be installed, routed grounded to the negative battery terminal. If the
and secured properly to prevent them from negative terminal is still connected, a complete
rubbing, chaffing or making contact with circuit exists from the positive terminal of the
hot, sharp or rotating components. battery to the frame. Metal objects contacting the
positive side and the frame simultaneously will
WARNING: Do not attach fuel lines or cause sparks or arcing. If there are sufficient
any additional wiring harnesses to the hydrogen gases emitted from the battery, an
battery cables as this could cause an explosion might occur, causing equipment
electrical fire! damage, serious injury, even death.
CAUTION: Do not connect other

manufacturer’s equipment or accessories
Refrigerant Hazards
to the Thermo King unit. This could result DANGER: Do not use a Halide torch.
in severe damage to equipment and void When a flame comes in contact with
the warranty! refrigerant, toxic gases are produced.
These gases can cause suffocation, even
CAUTION: Set all unit electrical controls death.
to the OFF position before connecting
battery cables to the battery to prevent unit DANGER: Store refrigerant in proper
from starting unexpectedly and causing containers, out of direct sunlight and away
personal injury. from intense heat. Heat increases pressure
inside storage containers, which can cause
CAUTION: Always wear protective them to burst.
clothing, gloves and eye wear when
handling and installing batteries. Battery DANGER: Do not use oxygen (O2 ) or
acid can cause serious burns when compressed air for leak testing. Oxygen
exposed to eyes or skin. If battery acid mixed with refrigerant is combustible.
contacts skin or clothing, wash
immediately with soap and water. If acid WARNING: Wear butyl lined gloves when
enters your eye, immediately flood it with handling refrigerant to help prevent
running cold water for at least twenty frostbite.
minutes and get medical attention
immediately.
8
Safety Precautions
CAUTION: Refrigerant in a liquid state Electrical Hazards

evaporates rapidly when exposed to the
atmosphere, freezing anything it contacts. High Voltage
Be careful when handling refrigerant to DANGER: Lethal amounts of voltage are
protect your skin from frostbite. present in some electrical circuits. Use
extreme care when working on an
CAUTION: When being transferred,
operating refrigeration unit.
refrigerant must be in liquid state to avoid
possible equipment damage. WARNING: Do not make rapid moves
when working on high voltage circuits in
CAUTION: When transferring refrigeration units. Do not grab for falling
refrigerant, use a process that prevents or
tools because you might accidentally touch
greatly restricts refrigerant from escaping
a high voltage source.
into the atmosphere. Refrigerant damages
the earth’s upper ozone layer. WARNING: Use tools with well insulated
handles. Never hold uninsulated metal
Refrigerant Oil Hazards tools near exposed, energized conductors.
WARNING: Protect your eyes from WARNING: Treat all wires and
contact with refrigerant oil. The oil can connections as if they were high voltage
cause serious eye injuries. Avoid until a meter and wiring diagram indicate
prolonged or repeated contact with otherwise.
refrigerant oil. To prevent irritation, wash
your hands and clothing thoroughly after WARNING: Never work alone on high
handling the oil. voltage circuits in the refrigeration unit.
Another person should be nearby to shut
CAUTION: Use the correct oil in Thermo off the unit and provide aid in the event of
King systems to avoid damaging an accident.
equipment and invalidating its warranty.
WARNING: Safety glasses, rubber-
CAUTION: Do not mix refrigerant oils insulated gloves and cable cutters should
because that can cause system damage. be near your work area, in the event of an
electrical accident.
CAUTION: Use dedicated equipment to
prevent contaminating systems with the WARNING: Use caution when working
wrong type of oil. with electrical circuits that contain
capacitors. Some capacitors hold a
CAUTION: Store refrigerant oil in an significant charge that might cause burns
approved sealed container to avoid or shocks if accidentally discharged. Make
moisture contamination. sure capacitors are discharged before
working on electrical circuits.
CAUTION: Do not expose the refrigerant
oil to the air any longer than necessary. Low Voltage
The oil will absorb moisture, which results
in much longer evacuation times and WARNING: Control circuits used in
possible system contamination. refrigeration units are low voltage (12 to
24 volts dc). This voltage is not dangerous,
CAUTION: Wipe up spills immediately. but the large amount of amperage
Refrigerant oil can damage paints and available from the alternator can cause
rubber materials. severe burns if accidentally shorted to
ground with metal objects, such as tools.
9
Safety Precautions
WARNING: Do not wear jewelry, watches First Aid, Electrical Shock

or rings because they increase the risk of Take IMMEDIATE action after a person has
shorting out electrical circuits and received an electrical shock. Get quick medical
damaging equipment or causing severe assistance, if possible.
burns.
The source of the shock must be quickly stopped,
by either shutting off the power or removing the
First Aid victim. If the power cannot be shut off, the wire
should be cut with an non-conductive tool, such as
First Aid, Refrigerant a wood-handle axe or thickly insulated cable
In the event of frostbite, protect the frozen area cutters. Rescuers should wear insulated gloves
from further injury, warm the area rapidly and and safety glasses, and avoid looking at wires
maintain respiration. being cut. The ensuing flash can cause burns and
blindness.
EYES : For contact with liquid, immediately flush
eyes with large amounts of water. CALL A If the victim must be removed from a live circuit,
PHYSICIAN. pull the victim away with a non-conductive
material. Use wood, rope, a belt or coat to pull or
SKIN: Flush area with large amounts of warm
push the victim away from the current. DO NOT
water. Do not apply heat. Remove contaminated
TOUCH the victim. You will receive a shock from
clothing and shoes. Wrap burns with dry, sterile,
current flowing through the victim’s body. After
bulky dressing to protect from infection. CALL A
separating the victim from power source,
PHYSICIAN. Wash contaminated clothing before
immediately check for signs of a pulse and
reuse.
respiration. If no pulse is present, start CPR
INHALATION: Move victim to fresh air and use (cardio pulmonary resuscitation). If a pulse is
CPR (cardio pulmonary resuscitation) or present, respiration might be restored by using
mouth-to-mouth resuscitation to restore breathing, mouth-to-mouth resuscitation. Call for emergency
if necessary. Stay with victim until emergency medical assistance.
personnel arrive.
First Aid, Refrigerant Oil

EYES : Immediately flush with water for at least
15 minutes. CALL A PHYSICIAN. Wash skin
with soap and water.
INGESTION: Do not induce vomiting.
Immediately contact local poison control center or
physician.
First Aid, Engine Coolant

EYES : Immediately flush with water for at least
15 minutes. CALL A PHYSICIAN. Wash skin
with soap and water.
INGESTION: Do not induce vomiting.
Immediately contact local poison control center or
physician.
10
Compressor Description
General Description NOTE: When replacement parts are required,

we recommend using only Factory Approved
The most significant part of the refrigeration Thermo King Replacement Parts. Only Genuine
system is the compressor. Its function is to pump Thermo King Replacement Parts deliver the
low pressure gas out of the evaporator so that a reliability, productivity, quality, and performance
rapid and continuous boiling action is maintained you’ve come to expect from Thermo King.
in the evaporator coil. The low pressure gas is
compressed and forced into the condenser coil NOTE: Most of the overhaul procedures for the
where it is cooled by air passing through the coil. compressors covered in this manual are the
The high pressure and reduced temperature causes same. Photographs of an X426 compressor are
it to liquefy (condense). used in this manual as examples. Other
illustrations are provided in cases where the
The compressors covered by this manual are photograph is not applicable.
reciprocating piston type pumps, constructed
mainly of cast aluminum. The aluminum alloy
pistons and cast iron sleeves are machined to close Compressor Model
tolerances to that no rings are needed to seal the Identification
piston to the cylinder wall. The compressor is There are a number of compressor models. The
equipped with a high nickel alloy ductile iron following information is provided to help identify
crankshaft. To prevent leakage around the the different compressor models. Refer to the
crankshaft, the compressor is fitted with a rotary appropriate Parts Manual to order the correct
type refrigeration seal. parts.
Pressurized lubrication is provided to the
connecting rods and bearings by a gerotor oil Two Cylinder Compressors
pump in the compressor body. The oil level in the The one basic model of the two cylinder
compressor can be inspected through the oil level compressor is the X214. There are some minor
sight glass in the body. Since the refrigeration variations such as fittings and oil sumps, but
system is sealed, it should be necessary to add oil otherwise all X214 compressors are basically the
only if there has been a large refrigeration leak in same.
the system, or if a major item in the refrigeration
system, such as an evaporator coil or a condenser Four Cylinder Compressors
coil has been replaced.
There are four major differences in the four
A spring loaded discharge valve and spring loaded cylinder compressors:
valve cage provide pressure relief if liquid
refrigerant enters the compressor. The entire cage • The crankshaft drive shaft diameter is either
lifts and prevents breaking or deforming of the 1.0 in. (small shaft), or 1.187 in. (large shaft).
valves. • The crankshaft drive end bearing is either a C3
When any repairs or replacements are to be made bearing, or a C5 bearing.
on the compressor, it is very important that the • A pressurized seal cavity was phased into use
parts used are clean and not nicked or scratched. on large shaft compressors starting in the first
During disassembly, parts should be cleaned and quarter of 2014.
inspected; and if they are to be used in
reassembly, they should be wrapped in a clean • An internal oil filter were phased into use on
cloth to prevent marring the surfaces. Oil all parts large and small shaft compressors in truck and
with compressor oil during assembly, and be sure trailer units that typically use compressors
they are installed in the same position they were with an external oil filter starting in the first
in before disassembly. quarter of 2014.
11
These differences combine to make five basic The compressor model is marked on the four
types. cylinder compressor body as shown below in
Figure 1.
• The small shaft compressor with a C3
crankshaft drive end bearing. This type
includes the X418, X426, and X430. 1
• The small shaft compressor with a C5
includes the X418C5, X426C5, and X430C5.
NOTE: Some small shaft compressors with a
C5 crankshaft drive end bearing used in
truck units also have an internal oil filter.
• The large shaft compressor with a C3
includes the X426LS, and X430LS.
includes the X426LSC5, and X430LSC5.
crankshaft drive end bearing, a pressurized
seal cavity, and an internal oil filter. This type
also includes the X426P, and X430P.
The following table shows the four cylinder
1. Compressor Model Marked Here
compressor models according to the shaft size and
the crankshaft drive end bearing used. Figure 1: Typical Compressor Model Location
Compressor Model by Shaft Size

and Bearing Type
C3 Bearing C5 Bearing
X418 X418C5
Small Shaft X426 X426C5
X430 X430C5
X426LS X426LSC5
Large Shaft
X430LS X430LSC5
Large Shaft with X426P
Pressurized Seal X430P
Cavity
12
Compressors that have a C5 crankshaft drive end Compressors that have a pressurized seal cavity
bearing also have a cast iron oil pump housing, have a “P” on the seal cover. Therefore, a
which is painted black. Therefore, a compressor compressor with a pressurized seal cavity can be
with a C5 bearing can be identified by the black identified by the “P” on the seal cover as shown in
oil pump housing as shown in Figure 2. Figure 3.
ARA2163
1. “P” Indicates Pressurized Seal Cavity

Figure 3: Seal Cover for Compressor with
1. Black Oil Pump Housing Pressurized Seal Cavity
Figure 2: Compressor with C5 Bearing
13
Oil Collection Container container. It is a very tight fit between the check
valve and the grommet in the oil collection
The oil collection container was added to trailer container.
units starting in the first quarter of 2010. The oil
collection container collects the compressor shaft NOTE: The check valve is no longer required on
seal seepage to keep the unit clean. This seepage Pressurized Seal Cavity Compressors.
is normal and is necessary for shaft seal durability.
1
The oil collection container is mounted on the
body of the compressor. A tube connects the oil
collection container to the compressor shaft seal
cover. The oil that seeps from the seal will travel
through the tube and collect in the container.
Empty the container once per year during oil
changes, or during annual services. The container
has a drain spout with a cap. Remove cap and
drain the oil into a cup (not provided) and discard
the oil properly. Retighten the cap snugly by hand.
2
NOTE: The oil collection bottle is not used in 3
Europe.
4
5
1. Seal Cover Drain Barb

2. Tube from Seal Cover to Oil Collection
Container
3. Grommet
4. Check Valve (Starting in November 2012)
5. Oil Collection Container
Figure 5: Oil Collection Container Showing Check
Valve
1
2 If maintenance in the area requires removal of the
oil collection container or the tube, caution should
3 be observed to prevent damage to the check valve.
Although the check valve was glued to the tube at
4
production, pulling the check valve back through
1. Tube to Compressor Shaft Seal Cover the grommet may cause the Valve to fall off or be
2. Compressor Mounting Flange damaged.
(Sectioned to Show Detail) Several options are available:
3. Oil Collection Container
1. If possible, disconnect the tube at the seal
4. Cap (Remove to Drain Oil)
cover drain barb and leave the tube in the oil
Figure 4: Oil Collection Container Components collection container.
The check valve was added in November 2012 to 2. The grommet can be pried off the bottle with
improve the shaft seal reliability by ensuring oil the tube still inserted, allowing the tube and
stays on the shaft seal when the suction pressure is check valve to be easily removed from the
in a vacuum. It is made of silicone rubber, a container.
material that can be damaged easily. The check
valve is located on the end of the tube inside the
14
3. If option 1 or 2 are not feasible and it is

necessary to pull the check valve back through
the grommet, gently twist as pulling back.
If the check valve does come off the tube, install a
new check valve from stock.
15
ARC018
Figure 6: Two Cylinder Compressor
16
1. Compressor Body 45. Oil Pump Shaft Key

2. Cylinder Head Gasket 46. Oil Pump Housing
3. Cylinder Head 47. Oil Pump Assembly
4. O-ring 48. Oil Pump Cover O-ring
5. Sealing Washer 49. O-ring
6. Bolt (3/8-16 x 2) 50. Oil Pump Cover Plate
7. Bolt (3/8-16 x 2-5/8) 51. Bolt (5/16-18 x 1-1/8)
8. Discharge Valve Assembly Bolt (3/8-16 x 2-1/4)
12. Stud 52. Flatwasher
20. Valve Plate O-ring 53. Oil Pressure Regulator Assembly
21. Cylinder Sleeve 54. Regulator O-ring
22. Adapter Gasket 55. Plug
23. Suction Port Screen 56. Plug O-ring
25. Piston Assembly 57. Oil Line Fitting or Valve
26. Piston Pin 58. Oil Sump
27. Piston Pin Retaining Ring 59. Oil Sump Gasket
31. Connecting Rod Assembly 60. Bolt
32. Connecting Rod Bolt 61. Bolt
33. Connecting Rod Nut 62. Copper Washer
34. Bearing Set (Standard) 63. Oil Sump Screen
Bearing Set (0.005) 64. Oil Pickup O-ring
Bearing Set (0.010) 65. Bolt
Bearing Set (0.020) 66. Lockwasher
Bearing Set (0.030) 67. Flatwasher
35. Pump Shaft O-ring 68. Check Valve Assembly
36. Crankshaft Pump End Bearing 69. Oil Fill Screw
37. Plug 70. Oil Fill O-ring
38. Dowel Pin 71. Crankshaft Seal
39. Crankshaft 72. Crankshaft Seal Plate
40. Metering Plug 73. Bolt
41. Key 74. Lip Seal
42. Crankshaft Drive End Bearing 75. Seal Plate O-ring
43. Housing Gasket 76. Sight Glass
44. Oil Pump Shaft 77. Sight Glass O-ring
Two Cylinder Compressor (for Figure 6)
17
ARC019
Figure 7: Early Style Four Cylinder Compressor
NOTE: The early style compressor had a spring loaded shaft seal,
and the seal plate and mounting flange were made in one piece.
18
1. Compressor Body 33. Check Valve Assembly

2. Connecting Rod Nut 34. Pump End Gasket
3. Connecting Rod Bolt 35. Oil Pump Housing
4. Connecting Rod Assembly 36. O-ring
5. Bearing Set (Standard) 37. O-ring
Bearing Set (0.005) 38. Oil Pump Cover Plug and Copper Washer
Bearing Set (0.010) 39. Oil Pump Cover
Bearing Set (0.020) 40. Oil Pump Cover Bolt and Washer
7. Piston Pin 42. Regulator O-ring
8. Piston Assembly 43. Oil Pressure Regulator
9. Retaining Ring 44. Regulator Spring
10. Key 45. Plunger
11. Crankshaft Drive End Bearing 46. Regulator Retaining Ring
12. Metering Plug 47. Oil Line Fitting or Valve
13. Crankshaft 48. Oil Pump Assembly
14. Crankshaft Oil Pump End Bearing 49. O-ring
15. Dowel Pin 50. Oil Pump Shaft
16. Suction O-ring and Screen 51. Oil Pump Drive Key
17. Copper Washer and Bolt 52. Seal Plate/Mounting Flange
18. Cylinder Sleeve 53. Screw and Washer
19. O-ring 54. O-ring
20. Discharge Valve Plate Assembly 55. Oil Sump Gasket
21. Sight Glass O-ring 56. Oil Sump
22. Sight Glass 57. Oil Sump Bolt and Washer
23. Cylinder Head Gasket 58. Check Valve Assembly
24. Cylinder Head 59. Check Valve Assembly
25. Cylinder Head Bolt and Flat Washer 60. O-ring
26. Cylinder Head Bolt and Flat Washer 61. Oil Suction Screen Assembly
27. Manifold Gasket 62. Mounting Screen Hardware
28. Manifold 63. Screen Bracket
29. Pipe Plug 64. Mounting Bracket Bolt and Washer
30. Manifold Mounting Bolt 65. Crankshaft Seal Assembly
31. Flatwasher 66. Seal Plate Gasket
32. Magnetic Plug and Copper Washer 67. Rotation Nameplate
Early Style Four Cylinder Compressor (for Figure 7)
19
ARC020
Figure 8: Late Style Four Cylinder Compressor
NOTE: The late style compressor has a metal bellows type shaft seal.
Because of the various types of mounting required on different installations,
the mounting flange and seal plate are made as separate parts.
20
1. Compressor Body 33. Check Valve Assembly

2. Connecting Rod Nut 34. Pump End Gasket
3. Connecting Rod Bolt 35. Oil Pump Housing
4. Connecting Rod Assembly 36. O-ring
5. Bearing Set (Standard) 37. O-ring
Bearing Set (0.005) 38. Oil Pump Cover Plug and O-ring
Bearing Set (0.010) 39. Oil Pump Cover
7. Piston Pin 42. Regulator O-ring
8. Piston Assembly 43. Oil Pressure Regulator
9. Retaining Ring 44. Seal Plate Gasket
11. Crankshaft Drive End Bearing 45. Oil Pickup Tube and Screen
12. Metering Plug 46. Oil Pickup Tube Clamp and Hardware
13. Crankshaft 47. Oil Pickup Tube Mounting Bracket
14. Crankshaft Oil Pump End Bearing 48. Bolt and Lockwasher
15. Dowel Pin 49. Oil Line Fitting or Valve
16. Suction O-ring and Screen 50. Oil Pump Assembly
17. Oil Fill Plug and O-ring 51. O-ring
18. Cylinder Sleeve 52. Oil Pump Drive Shaft
19. O-ring 53. Oil Pump Drive Key
20. Discharge Valve Plate Assembly 54. Seal Plate Mounting Bolt
21. Sight Glass O-ring 55. Oil Sump Gasket
22. Sight Glass 56. Oil Sump
23. Head Gasket 57. Oil Sump Bolt
24. Cylinder Head 58. Check Valve Assembly
25. Cylinder Head Bolt Assembly 59. Check Valve Assembly
26. Cylinder Head Bolt Assembly 60. O-ring
27. Manifold Gasket 61. Crankshaft Seal
28. Manifold 62. Bolt
32. Magnetic Plug and O-ring 63. Seal Plate
Late Style Four Cylinder Compressor (for Figure 8)
21
Specifications
X214 Compressor
No. Cylinder Two
Bore/Stroke 2.25 in. (57 mm)/1.75 in. (45 mm)
Cubic Inch Displacement 13.92 cu. in. (228 cm3)
Weight 45 lbs (20 kg)
X418 Compressor
No. Cylinder Four
Cubic Inch Displacement* 18 cu. in. (295 cm3)
X426 Compressor
No. Cylinder Four
Cubic Inch Displacement* 25.84 cu. in. (424 cm3)
X430 Compressor
No. Cylinder Four
Cubic Inch Displacement 29.82 cu. in. (489 cm3)
Operating Clearances
Inches Millimeters
Crankshaft End Play @ 70 F (21 C)
C3 Bearing locked in bore 0.0070 to 0.0125 0.1778 to 0.3175
C3 Bearing unlocked in bore 0.0070 to 0.0470 0.1778 to 1.1938
C5 Bearing locked in bore 0 to 0.010 Maximum 0 to 0.254 Maximum
Connecting Rod Bearing To 0.0008 to 0.0024 0.0203 to 0.0610
Crankshaft Rod Journal
Oil Pump Cover Clearance 0.0010 to 0.0040 0.0254 to 0.1016
(distance below housing)
Piston to Sleeve 0.0018 to 0.0027 0.0457 to 0.0686
Piston Wrist Pin to Bushing 0.0001 to 0.0006 0.0025 to 0.0152
Unloader Check Valve to Bore 0.0020 to 0.0040 0.0508 to 0.1016
Unloader Piston to Bore 0.0020 to 0.0040 0.0508 to 0.1016
*The X418 and X426 compressors have the same bore/stroke but differ in cubic inch displacement. This
is accomplished by using different port locations in the cylinder sleeve. The closer the ports are to the
top of the cylinder sleeve, the smaller the total displacement.
22
Specifications
Part Dimensions
Inches Millimeters
Connecting Rod Bearing Insert—Standard I.D. 1.3755 to 1.3766 34.9377 to 34.9656
Crankshaft Rod Journal—Standard O.D. 1.3742 to 1.3747 34.9047 to 34.9174
Compressor Body Main Bearing Bore I.D.
Two Cylinder 2.8330 to 2.8345 71.9582 to 71.9963
Four Cylinder with C3 Bearing 3.9355 to 3.9370 99.9617 to 99.9998
Crankshaft Main Journal—Drive End O.D. 1.7715 to 1.7719 44.9961 to 45.0063
Crankshaft Main Journal—Oil Pump End O.D. 1.5746 to 1.5750 39.9948 to 40.0050
Cylinder Sleeve I.D. 2.2495 to 2.2500 57.1373 to 57.1500
Piston O.D. 2.2473 to 2.2477 57.0814 to 57.0916
Connecting Rod Wrist Pin Bushing—Standard I.D. 0.6255 to 0.6258 15.8877 to 15.8953
Piston Wrist Pin—Standard O.D. 0.6250 to 0.6252 15.8750 to 15.8801
Oil Pump Gerotor Assembly Thickness 0.3430 to 0.3440 8.7122 to 8.7376
Oil Pump Housing Main Bearing Bore I.D.
Two Cylinder 2.8339 to 2.8345 71.9811 to 71.9963
Oil Pump Inner Wear Plate Thickness 0.1867 to 0.1873 4.7422 to 4.7574
Oil Pump Outer Wear Plate Thickness 0.1867 to 0.1873 4.7422 to 4.7574
Check Valve—Unloader Head O.D. 1.1240 to 1.1250 28.5496 to 28.5750
Piston—Unloader Head O.D. 0.9970 to 0.9980 25.3238 to 25.3492
Bore in Unloader Head—Check Valve I.D. 1.1270 to 1.1280 8.6258 to 28.6512
Bore in Unloader Head—Piston I.D. 1.0000 to 1.0010 25.4000 to 25.4254
23
Specifications
Torque Values
Thread Size Torque
Location of Screw
or Component Dia. Length Part
Pitch in-lb ft-lb kgm N•m Req.
in. in. No.
Cylinder Head 3/8 16 2-5/8 275 22.9 3.17 31.1 55-6806 8
Cylinder Head 3/8 16 2 275 22.9 3.17 31.1 55-6805 12
Cylinder Head w/Unloaders 3/8 16 1-1/8 275 22.9 3.17 31.1 55-9106 1
Center Screw in Large Check 1/4 28 - 25 2.1 0.29 2.8 55-4281 1
Valve Assembly
Check Valve 1-1/4 18 - 336 28.0 3.87 38.0 22-787 1
Assembly—Large NEF
Check Valve 1/4 - - 300 25.0 3.46 33.9 22-653 2
Assembly—Upper NPT
Check Valve 1/4 - - 120 10.0 1.38 13.6 22-568 2
Assembly—Lower NPT
Connecting Rod Nut 5/16 24 - 300 25.0 3.46 33.9 55-1681 A/R
One Piece Seal Plate and 3/8 16 1-5/8 335 28.0 3.86 37.9 55-2306 9
Mounting Flange—Early
Style Four Cylinder
Mounting Flange—Late Style 3/8 16 1-5/8 335 28.0 3.86 37.9 55-2306 6
Four Cylinder
Seal Plate—Late Style 3/8 16 1-1/8 335 28.0 3.86 37.9 55-9106 3
Four Cylinder
Seal Plate—Four Cylinder 3/8 16 1-1/8 335 27.9 3.86 37.9 55-9106 9
without Mounting Flange
Seal Plate—Two Cylinder 5/16 18 1-1/4 150 12.5 1.73 17.0 55-172 6
Sight Glass - - - 600 50 6.91 67.8 22-350 A/R
Manifold 3/8 16 1-3/4 335 28.0 3.86 37.9 55-3641 4
Manifold 3/8 16 2-3/8 335 28.0 3.86 37.9 55-6822 4
Oil Drain Plug 5/8 18 - 450 37.5 5.18 50.9 55-6751 A/R
Oil Fill Plug 1/2 13 1 450 37.5 5.18 50.9 55-6750 1
Oil Pickup Tube Bracket 1/4 20 1/2 120 10.0 1.38 13.6 55-165 2
Oil Pickup Plug 5/8 18 - 450 37.5 5.18 50.9 55-6751 1
Oil Pressure Regulator 9/16 18 - 225 18.8 2.59 25.4 22-784 1
Oil Pump Cover/Housing 3/8 16 2-1/4 275 22.9 3.17 31.1 55-183 8
Oil Pump Cover 5/16 18 1-3/8 150 12.5 1.73 17.0 55-681 2
Oil Sump 3/8 16 3 335 27.9 3.86 37.9 55-1417 16
Oil Sump 3/8 16 1-1/4 335 27.9 3.86 37.9 55-129 16
Piston Head Nut, FlexLoc 5/16 24 - 160 13.3 1.85 1.80 - A/R
Type without Oil
Piston Head Nut, Flangenut 5/16 24 - 130 10.8 1.50 14.7 55-318 A/R
Type with Oil
Throttling Valve Body 3/8 16 1-1/8 275 22.9 3.17 31.1 55-9106 4
24
Specifications
Torque Values (Continued)

Thread Size Torque
Location of Screw
or Component Dia. Length Part
Pitch in-lb ft-lb kgm N•m Req.
in. in. No.
All Other Bolts 5/16 18 - 150 12.5 1.73 17.0 - A/R
All Other Bolts 3/8 16 - 275 22.9 3.17 31.1 - A/R
NOTE: Torque (in-lb) x 0.08333 = torque (ft-lb)

Torque (in-lb) x 0.01152 = torque (kgm)
Torque (in-lb) x 0.1130 = torque (N•m)
Special Tools
The following special tools for all versions of X214, X418, X426, and X430 compressors are available
from the Thermo King Service Parts Department. Refer to the Tool Catalog (TK 5955).
Description Part Number
Drive Coupling Puller 204-139

Wrench - Sight Glass 204-244
Check Valve Removal Tool 204-464
Tool - Puller Plate 204-483
Adapter - Gauge Fitting 204-626
Puller - Pump Bearing Plate (Slide Hammer) 204-638
Replacement Parts:
Plate 204-639
Adapter 1/2-20 x 5/16-18 204-640
Adapter - Gauge Fitting 90 Degree 204-853
Seal Installer 204-953
Keyway Tool 204-972
Coupling Removal Tool 204-991
Compressor Seal Installer 204-995
Compressor Bearing Puller 204-1000
Tool - Compressor Installation (Set of 2) 204-1087
Bearing Removal Tool 204-1153
25
General Compressor Repair Techniques
Because of the various refrigeration unit models a • Only use chemical solvents that leave no oily
given compressor may be used on, no attempt is residue, such as naphtha, lacquer thinner, or
being made in this manual to show a removal brake cleaner to clean compressor
procedure. This manual assumes that the components. The solvents must be
compressor has been removed properly in nonchlorinated. Do Not Bead Blast
accordance to the maintenance manual for the compressor components clean.
appropriate model.
• If the job must be interrupted, cover the
This manual does cover the drive coupling compressor. A fresh, clean piece of plastic
removal and reinstallation. The illustrations used sheeting wrapped tightly around the
are typical, your installation may vary from what compressor is best. Cloth should not be used
is shown. as it does not block moisture.
• Be sure to use the correct oil to prevent
Dirt and Moisture can Easily contamination of the system.
Ruin Compressors! • Always keep your refrigeration oil capped. A
Compressors are assembled at the factory in few minutes with the cap off can ruin it!
special clean rooms with filtered, conditioned air.
• Do not dip seal parts in oil. Containers of oil
Field conditions will not always allow factory
used for dipping parts sit open and collect
clean repair areas but every effort should be taken
moisture, dirt and dust. Instead, use a small,
to keep the compressor work area as clean as
clean oil can dedicated for use only with the
possible. Follow these rules to protect
correct oil for the compressor you are
compressors from dirt and moisture.
repairing.
• Pump down the system and recover the
• Discard all the old O-rings and gaskets that are
refrigerant in compliance with Federal, State
exposed while working on the compressor.
and local regulations.
O-rings and gaskets should not be reused.
• Use dry nitrogen to break the vacuum. This Replace them with new ones.
prevents dirt and moisture from getting into
the compressor. Compressor Oil Indications
• Use cap plugs or tape instead of rags to cover Discoloration of the oil is an indication of a
compressor openings as soon as vibrasorbers contaminated system and future problems. Refer
or service valves are removed. Poloyol ester to the following compressor Oil Color Code to
oil draws in moisture like a sponge and rags diagnose the conditions and correct it.
will not stop moisture from entering the
compressor.
Compressor Oil Color Code
• Remove all dirt and debris from the
compressor prior to disassembly. COLORLESS or LIGHT YELLOW. Indicates
good compressor oil.
• Work in a clean, closed area. Stay away from
open doors or windows that allow dirt to blow BLACK OIL. Indicates carbonization caused by
in parts cleaning areas, grinding areas and air in the system or the presence of wear particles
bead blasting machines. that contain iron. Change the compressor oil and
oil filter.
• Keep your tools and workbench spotless.
Keep your hands as clean as possible. LIGHT BROWN OIL. Use an acid test kit to test
the acidity of a sample of the compressor oil. For
• Once the compressor is opened to the alkyl benzine oil use acid test kit P/N 203-346.
atmosphere, get the job done quickly. Plan For polyol ester oil use acid test kit P/N 203-518.
ahead. Have your parts and tools ready. Change the compressor oil if the test indicates the
oil is acidic.
26
General Compressor Repair Techniques
BROWN OIL. Indicates copper plating caused by A contaminated system will cause a failure if left
moisture in the system. Air in the system or high uncorrected. The contaminate in the system will
compressor temperatures can cause oxidation break down the refrigerant oil, causing excessive
which will turn the oil brown. Change the bearing wear and scoring of parts within the
compressor oil if the test indicates the oil is acidic compressor. Copper plating and moisture will
affect the valve plate rings and break down the
GRAY OR METALLIC OIL. Indicates the
refrigerant and affects the capacity of the unit.
presence of wear particles that contain aluminum.
This is usually caused by bearing wear or piston Particles and bearing scale traveling with the
scoring. The compressor should be disassembled refrigerant will plug the driers and expansion
and inspected for worn or damaged components. valves, causing erratic operation until the
The oil and oil filter should be changed. condition is corrected. Flushing with refrigerant
or the use of suction filters and liquid line driers is
GREEN OIL. Green compressor oil indicates
recommended whenever a contaminated system is
there is water in the system and copper plating
found. In some cases, the contaminated condition
may have occurred. The compressor should be
can be corrected by changing oil, refrigerant and
disassembled and the shaft seal, bearings, gears,
drier. Use a recommended evacuation process
and rotors should be inspected. Parts with
before the unit is placed in service. See TK 40229
significant copper plating should be replaced, the
“Clean-up of Refrigeration Systems with Thermo
oil separator should be replaced, and the oil and
King Compressors.”
oil filter should be changed.
27
Disassembly and Reassembly
The following are suggested sequences for a full 10. Install drive coupling.
disassembly and reassembly of the compressor.
CAUTION: When servicing compressors, Fastener Torque Procedure
make sure all parts are reinstalled in their Use the following procedure when specific steps
original locations. Carefully mark similar are not provided.
components, and pay special attention to
fastener length to ensure they are 1. Carefully remove any remaining gasket
reinstalled correctly. material and clean both gasket surfaces
thoroughly.
Disassembly Sequence 2. Always use a new gasket and coat the gasket
with clean compressor oil just prior to
1. Remove drive coupling. assembly.
2. Drain residual oil. 3. Install all bolts (and washers) and pre-tighten
3. Remove manifold (four cylinder compressors to 70% of the recommended torque, following
only). a criss-cross pattern.
4. Remove head, or heads from compressor 4. Use a hand torque wrench and the same
body. criss-cross pattern to bring all bolts to final
torque. Hold bolts “On Torque” for a few
5. Remove discharge valve plates from seconds.
cylinders.
6. Remove seal plate/mounting flange and Cleaning Components
crankshaft seal.
CAUTION: Do not bead blast compressor
7. Remove oil sump, internal oil filter (if so components clean. The abrasive media
equipped), and oil pickup screen. can become embedded in castings, free
8. Remove connecting rods, pistons and sleeves. itself during compressor operation, and
damage the compressor. Only use
9. Remove oil pump. chemical solvents that leave no oily
10. Remove crankshaft. residue, such as naphtha, lacquer thinner,
or brake cleaner to clean compressor
11. Remove check valves. components. The solvents must be
nonchlorinated. Crocus cloth may be used
Reassembly Sequence to remove rust or oxidation from external
compressor components.
1. Install check valves.
2. Install crankshaft. Drive Coupling
3. Install oil pump.
Removal
4. Install connecting rods, pistons and sleeves.
There are several different types of drive
5. Install oil pickup screen and internal oil filter couplings and clutches used on the four cylinder
(if so equipped). compressors in units manufactured by Thermo
6. Install oil sump. King, but they are all held on by a single bolt
threaded into the end of the compressor
7. Install discharge valve plates. crankshaft. Once this bolt is removed, the
8. Install head, or heads and manifold. coupling or clutch can be removed from the shaft.
Remove the bolt and then use a puller to remove
9. Install crankshaft seal and seal plate/mounting the coupling or clutch.
flange.
28
NOTE: Do not sand or lap the tapered area as

CAUTION: Use a puller to remove the
component fracture may result.
drive coupling or pulley from the
crankshaft. Puller (P/N 204-139) or puller 3. Using no lubricants, set the coupling on the
with handle (P/N 204-991) are available crankshaft and align the keyway using the
for use on compressor couplings with Keyway Tool (P/N 204-972). Insert the
threaded holes. DO NOT use a hammer to tapered end of the tool into the keyway and
pound the coupling or pulley off. This will gently move the coupling on the shaft while
damage the compressor. pressing the tool into the keyway. This will
align the keyway in the crankshaft with the
Installation keyway in the coupler.
Thermo King employs a tapered joint to secure
the drive coupling or drive pulley to the
compressor shaft. This has two advantages: first it
prevents any looseness that might occur as when
using a sliding fit on a shaft. The second
advantage is that when torqued properly the
friction between the two tapers can be used to
AGA333
drive the compressor under most loads.
Figure 9: Keyway Tool P/N 204-972
A key is used in the tapered joint to guarantee
proper positioning of the coupler to the CAUTION: If you are assembling a used
compressor, and to the engine or drive pulley. coupler or crankshaft and the tool does
Using a key can also prevent slippage between the not fit easily there is a problem with one of
taper surfaces in case of extreme shock loads. If the keyways! Do not remove the coupler
the tapers are allowed to slip, galling of the and place the key in the crankshaft keyway
surfaces occurs. Galled surfaces make and then drop the coupler on. If the tool
disassembly difficult, and reassembling galled does not fit, the key will not fit, and it will
parts will not assure proper alignment. hold the taper in the coupling off the taper
Keyways are cut with a tool which leaves a radius on the shaft. Check both keyways for burrs
at the end of the keyway. If the key being installed or corrosion. A key can be coated with fine
is pushed onto the radius at the end of the keyway, lapping compound and used as a lapping
the taper will not seat properly and the coupling tool to clean the keyways. Clean the key
will wobble. This causes stress to be put on the and keyway with solvent before final
crankshaft and reduces its life. Make sure keys are installation.
of the correct length to fit entirely in their 4. Remove the Keyway Tool and check the fit of
respective keyway prior to installation. the new key. It should fit into the keyway with
The following procedure should be used to install a light press fit requiring only a minimum of
a compressor coupling onto the compressor shaft. light tapping. If the key does not fit properly,
remove the coupling and inspect the keyways
1. Clean the compressor shaft and taper and the and key for burrs or other problems. Recheck
tapered bore of the coupling with a solvent the fit as shown above.
that leaves no oily residue, such as naphtha,
lacquer thinner, brake cleaner or the like. The 5. When the key fits properly, remove the
solvent must be nonchlorinated. coupling from the crankshaft and apply a very
thin even coating of blue Loctite 242 to the
2. Inspect both mating surfaces for burrs, back one third of the taper for the 1.0 in.
oxidation and other surface imperfections. diameter crankshaft. Do not use Loctite on the
Dress with crocus cloth if necessary and taper for the 1.187 in. diameter crankshaft
reclean as required. taper because it makes it very difficult to
remove the coupling later.
29
10. Spray a corrosion inhibitor on the exposed

part of the crankshaft after tightening the
coupling bolt.
AGA334 Coupling and Clutch Mounting Bolt

Torque Specifications
1
The couplings and clutches used on Thermo King
1. Coat area shown with Blue Loctite 242. four cylinder compressors are described in the
Figure 10: Compressor Shaft following tables and figures. Depending on when
they were manufactured, they may have either 6
6. Re-install the coupling and align the keyways
pins or 8 pins.
with the Keyway Tool.
7. Do not install the key at this time. Install the Coupling Mounting Bolt Torque Specifications
flatwasher and bolt and pre-torque to 20 ft-lb The following table below shows the torque
(27 N•m). Remove the bolt and washer. specifications for the socket-head mounting bolts
8. Install the key in the keyway. It should fit with used with compressor couplings.
a light press fit requiring only a minimum of
Crankshaft Diameter
light tapping. Do not install the key into the
keyway beyond the front face of the coupling. 1.0 in. 1.187 in.
If tapped in further, it may cause the coupler to Mounting Bolt M12 X 1.75
3/8-16 in.
move off center on the crankshaft. Dimensions Metric
Type and Color
Thick Silver* Thick Silver
of Washer
1
Washer P/N 77-2498 77-2505
2
3 Torque 54 ft-lb 90 ft-lb
Specifications (73 N•m) (122 N•m)
*If a black washer is found when the coupling is

removed from a compressor with 1.0 in. diameter
crankshaft, the washer should be replaced with a
silver washer P/N 77-2498. Torque to 54 ft-lb (73
N•m).
1
5 4
AGA1254
1. Coupling or Clutch
Key tapped flush with outside of coupling. 2
2.
Do not tap key any farther into keyway.
3
3. Bolt
4. Washer
Spray this area with corrosion inhibitor after
5. AGA522
assembling.
Figure 11: Compressor Coupling Installation
1. 1.0 in. Diameter Crankshaft
9. Install the bolt and washer and torque the bolt 2. 0.23 in. Thick Silver Washer P/N 77-2498
as shown in “Coupling and Clutch Mounting 3. 3/8-16 in. Bolt—Torque to 54 ft-lb (73 N•m)
Bolt Torque Specifications” below.
Figure 12: Small Crankshaft Coupling Installation
30
1
1
2
2
3
3
AGA524
AGA523
1. 1.0 in. or 1.187 in. Diameter Crankshaft

1. 1.187 in. Diameter Crankshaft
Thin Washer
2. 0.23 in. Thick Silver Washer P/N 77-2505
2. P/N 55-4002 for 1.0 in. Crankshaft
M12 X 1.75 Metric Bolt—Torque to 90 ft-lb P/N 55-9232 for 1.187 in. Crankshaft
3.
(122 N•m)
3/8-16 in. Bolt—Torque to 45 ft-lb (61 N•m)
Figure 13: Large Crankshaft Coupling Installation for 1.0 in. Crankshaft
3.
M12 X 1.75 Metric Bolt—Torque to 90 ft-lb
Clutch Mounting Bolt Torque Specifications (122 N•m) for 1.187 in. Crankshaft
The following table below shows the torque Figure 14: Clutch Installation
specifications for the mounting bolts used with
compressor clutches. NWE MAX-II Coupling Mounting Bolt Torque
Specifications
Crankshaft Diameter
The NWE MAX-II unit uses a different mounting
1.0 in. 1.187 in.
bolt than other units with X430 compressors. The
Mounting Bolt M12 X 1.75 NWE MAX-II mounting bolt is a hex cap head,
3/8-16 in.
Dimensions Metric
instead of the standard socket-head. Its
Type and Color characteristics are specified in the following table:
Thin Silver Thin Silver
of Washer
Washer P/N 55-4002 55-9232 NWE MAX-II Mounting Bolt P/N 51-721
Torque 45 ft-lb 90 ft-lb Grade Specification ISO Class 10.9
Specifications (61 N•m) (122 N•m) Dimensions M12 X 1.75 Metric
Washer (Spacer) P/N 77-2505
75 to 80 ft-lb
Torque Specifications
(101 to 108 N•m)
31
Cylinder Head
1
Removal
1. Four Cylinder Only—Remove the manifold
bolts and manifold.
2. Remove all head bolts.
3. Tap the head with a soft hammer or a soft
punch to loosen the head. Remove the head.
2
1
AGA539
1. Inspect Surface
2. Check Threads
Figure 16: Inspection of Cylinder Head
Installation
1. Apply clean refrigerant oil to the gaskets.
AGA538 2. Two Cylinder Only—Install the cylinder head
gasket and head with all the bolts assembled
1. Soft Punch loosely. Tighten the bolts in a criss-cross
Figure 15: Cylinder Head Removal pattern to 70% of recommended torque. See
“Torque Values” on page 24. Use a hand
CAUTION: Do not pry on head or wedge torque wrench to tighten the head bolts to final
any object between head and block. torque.
4. Carefully remove any gasket material from the
crankcase or cylinder head.
Repair
1. Check all gasket surfaces for cracks, deep
scratches, pitting, or anything that may
prevent proper sealing.
2. Check head for warping with straight edge.
The maximum allowable warpage is 0.0005
in. over any 2 in. span, or a total of 0.002 in.
over the entire head. To maintain critical
alignment of assembled components, Thermo
King does not recommend resurfacing
cylinder heads.
3. Inspect all thread holes for striped threads. Do
not use threaded inserts (Helicoils) to repair
damaged threads.
32
3. Four Cylinder Only—Install the gaskets, 3. When the valve plate is free, turn it by hand
cylinder heads, and discharge manifold with and lift it straight out of the compressor body.
all bolts assembled loosely. Tighten the The discharge valve assembly can skew and
discharge manifold bolts in a criss-cross wedge itself into the compressor body during
pattern to 70% of final torque. See “Torque removal. If this happens, gently tap the
Values” on page 24. Tighten the cylinder head assembly back into the cylinder and start over.
bolts in a criss-cross pattern to 70% of
recommended torque. See “Torque Values” on
page 24. Use a hand torque wrench to tighten
the cylinder head bolts to final torque. Use a
hand torque wrench to tighten the discharge
manifold bolts to final torque.
AGA541
Figure 19: Valve Plate Removal or Installation

AGA521
4. Remove and discard the O-rings.
Figure 17: Cylinder Head Torque Sequence
Discharge Valve Plates

Removal
1. Remove the cylinder head. See “Cylinder
Head” on page 32.
2. After removing the head and gasket, remove
the discharge valve plates. It may be necessary
to turn the valve plate slightly clockwise to
loosen it.
AGA542
Figure 20: O-ring Location
AGA540
Figure 18: Valve Plate Removal
33
Repair
1
NOTE: Valve plates must seal completely or the
2 compressor will lose capacity.
1. Inspect the cage, ring valve, valve spring, and
3 retainer for wear or damage.
2. Valve plates may be tested by pouring clean
5 fluid (Stodard solvent, which must be
nonchlorinated) into the depression of the
valve plate. The solvent should not leak
6
through. If the valve plate assembly is worn,
damaged or leaks, replace it with a new
assembly. Remove all traces of solvent before
installing the valve plate assembly.
7
8
1
10
AGA543
11
1. Solvent
ARC021 Figure 22: Testing Valve Plate Assembly
for Leakage
1. Bolt 7. Wave Washer Installation

2. Spring 8. Ring Valve 1. Apply clean refrigerant oil to the new O-rings
3. Sleeve 9. Support and install them in the compressor body above
5. Hex Nut 10. Plate the cylinder sleeve. See “Figure 20: O-ring
6. Cage 11. Support Screw Location” on page 33.
Figure 21: Valve Plate 2. Apply clean refrigerant oil to the valve plate
NOTE: Parts shown for reference only. Valve assembly and install the valve plate assembly.
plate is sold only as assembled unit. Turn it slightly to prevent binding. See
“Figure 19: Valve Plate Removal or
Installation” on page 33.
3. Install the cylinder heads. See “Installation”
on page 32.
34
Two-piece Compressor Seal • Spring Loaded Neoprene Bellows Type—Two

Plate and Mounting Flange Cylinder Compressors
Assembly • Metal Bellows Type With Set Screws—Four
In the third quarter 1988 the compressor seal Cylinder Compressors with 1.0 in. diameter
crankshafts
plate/mounting flange was changed to a two-piece
assembly. This change allows removal of the NOTE: Early four cylinder compressors with
mounting flange without losing the refrigeration 1.0 in. diameter crankshafts used a neoprene
charge. The two-piece assembly uses nine bolts, bellows seal. These seals should be replaced
six mount the flange, and three mount the seal with a metal bellows type if using R404A,
plate. R407C, R134A, or R22 refrigerants.
1
• Metal Bellows Type With Drive Tangs—Four
Cylinder Compressors with 1.187 in. diameter
3 crankshafts
• Metal Bellows Type With Hex Drive—Four
2 Cylinder Compressors with 1.187 in. diameter
crankshafts and pressurized seal cavity
Removal
1. Remove the Seal Plate/Mounting Flange.
3
3 Two-Piece Seal Plate/Mounting Flange Only
a. Remove the six mounting flange bolts and
4 remove the mounting flange.
b. Remove the three seal plate bolts and use a
slide hammer to remove the seal plate.
5
NOTE: Use slide hammer P/N 204-638 and
adapter P/N 204-640 to obtain the 5/16-18
male thread needed to fit the seal plate.
AGA583
1. Dust Seal (Lip Seal)

2. Seal Plate 1
3. Three Seal Plate Mounting Holes
4. Mounting Flange
5. Six Mounting Flange Holes
2
Figure 23: Two-Piece Seal Plate/Mounting Flange
AGA588
Seal Plate Assembly

1. Slide Hammer
Over the past several years the following four
2. Adapter P/N 204-640
types of seals have been used to seal the drive end
of the crankshaft from leaking refrigerant. Figure 24: Two-Piece Seal Plate Removal
35
One-Piece Seal Plate/Mounting Flange Only 3. Metal Bellows Type Seal With Set Screws
Only (Small Shaft Bus Applications)—
a. Remove the seal plate bolts. Tap the seal
Loosen the set screws that fasten the seal to
plate with a soft hammer or soft punch to
the crankshaft.
remove the seal plate.
1
AGA580
AGA544 Figure 27: Set Screw Location
1. Tap Lightly NOTE: A modified (shortened) 3mm or 1/8

Figure 25: One-Piece Seal Plate Removal inch Allen wrench is needed to loosen the set
screws. New seals are shipped with a
2. Place the seal plate gasket side down on a
modified 1/8 inch Allen wrench. Make sure
work bench and push the hard ring out of the
the wrench fits squarely into the bottom of
seal plate.
the socket hole before attempting to loosen
the set screws.
1
AGA578
Figure 28: Special Allen Wrench
4. Remove the bellows assembly from the shaft

by prying evenly on each side with small pry
bar.
AGA546
2
1. Punch
2. Hard Ring
Figure 26: Hard Ring Removal
NOTE: Provide a clean soft surface for hard
ring to fall onto when pushed out of the seal
plate.
AGA545
Figure 29: Seal Removal
5. Discard all seal parts.
36
Repair 1 2
1. Clean all parts thoroughly to remove all oil
and gaskets.
2. Polish the crankshaft with crocus cloth if it is
rusted or dirty. Do not allow abrasives to
contaminate the compressor.
3. Inspect each side of the crankshaft for flatness
with a straight edge. No light should be visible
between the shaft and the straight edge
AGA547
(especially in the bearing contact areas).
1. This Side Toward Seal Plate
Installation of Spring Loaded 2. This Side Toward Compressor
Neoprene Bellows Type Seal
Figure 31: Hard Ring Positions
1. Install the lip seal in the seal plate with the lip
side facing out and the flat side facing toward
1
the compressor.
2
3
1 4
2 ARC010
ARC022
1. Lip Side Facing Out 1. Seal Plate

2. Flat Side Toward Compressor 2. O-ring
Figure 30: Lip Seal Installation Neoprene Seal—Install with Polished
3.
Surface Toward Compressor
NOTE: Some early style seal plates do not
use the lip seal. 4. Installation Tool P/N 204-953
Figure 32: Hard Ring Installation
2. Install a new O-ring onto the new neoprene
seal and apply clean compressor oil to the seal CAUTION: Do not touch the hard ring or
assembly. Ensure that the installation tool the carbon ring surface (bronze seal for
(P/N 204-953) is clean. Use the installation 0.875” shaft compressors) with your
tool to push the seal (with the polished surface hands, hold them by the edges.
toward the installation tool) fully into the seal
plate.
If the insertion tool is not available, use the
pad in the new seal packaging to protect the
polished surface of the seal during assembly.
37
4. Apply refrigerant oil to the primary ring and

1
place it in the bellows. Make sure to align the
3 notches.
1
2
ARC023
1. Centering Washer
2. Bellows Assembly
3. Primary Ring
Figure 33: Spring Loaded Neoprene bellows Type
Seal AGA550
NOTE: Steps 3 through 6 must be performed 1. Notch Must Line Up

within 30 seconds to keep the neoprene
Figure 35: Align Primary Ring
inside the bellows assembly from bonding to
the crankshaft. 5. Apply refrigerant oil to the front gasket and
place it on the compressor body.
3. Apply refrigerant oil to the bellows assembly
and install the centering washer, the spring,
and the bellows assembly.
1
1
AGA549 1. Gasket Must Seal Here
1. Centering Washer Figure 36: Gasket Positioning
Figure 34: Seal Assembly Installation 6. Install the seal plate on the compressor. Hold
the seal plate against the spring tension of the
bellows until bolts are snug.
7. Torque the seal plate bolts in two steps using a
criss-cross pattern. See “Torque Values” on
page 24.
38
Installation of Metal Bellows Seal If the installation tool is not available, use the
With Set Screws pad in the new seal packaging to protect the
polished surface of the hard ring during
In May of 1992 Thermo King Corporation
assembly.
introduced a new metal bellows crankshaft seal.
The current service part number is 22-1100. The 1
current replacement procedure follows:
1. Install the new lip seal in the seal plate with 2
the lip side facing out and the flat side facing 3
toward the compressor. 4
1
ARC011
1. Seal Plate
2. O-ring
2 ARC010
Hard Ring—Install with Polished Surface
3.
Toward Compressor
1. Lip Side Facing Out
4. Hard Ring Installation Tool P/N 204-953
2. Flat Side Toward Compressor
Figure 37: Lip Seal Installation
2. Apply clean compressor oil to the new O-ring CAUTION: Do NOT touch or damage the
and install it in the seal plate. Apply clean polished seal face surfaces.
compressor oil to the new hard ring. Ensure
that the hard ring installation tool 3. Back out the set screws from the new seal and
(P/N 204-953) is clean. Use the hard ring apply a small amount of removable thread
installation tool to push the hard ring (with the locking compound (Loctite 242-31-blue P/N
polished surface toward the installation tool) 203-400) to the set screw threads.
fully into the seal plate. Do not pinch the
CAUTION: Keep the orange protective
O-ring.
cap in position until final assembly.
1 2
ARC024
AGA576
2
2. This Side Toward Compressor 1. Clamp Ring
Figure 38: Hard Ring Positions 2. Orange Protective Cap
Figure 40: Cross Section of Set
Screw Type Bellows Seal
39
6. Tighten the set screws to approximately 45

1
in-lb (5.0 N•m) with the Allen wrench
provided.
2
AGA577
5
3
4
1. Set Screw
AGA580
2. Seal Faces
3. Hard Ring Figure 43: Set Screw Location
4. O-ring 7. Remove the seal installation tool.
5. Bellows
8. Remove the orange protective cap. Clean the
Figure 41: Set Screw Type Bellows Seal hard ring and the primary ring (bronze ring)
4. Apply clean compressor oil to the O-ring with the alcohol wipes found in package
inside the bellows and place the bellows on labeled “1”. Then clean the polished mating
the crankshaft. Leave the orange protective surfaces of both rings with the lint free dry
cap on the bellows. wipes from package number “2”. Apply clean
compressor oil to the polished surfaces of the
5. Use seal installation tool P/N 204-995 to seal, the lip seal, and the seal plate gasket
install the bellows squarely on the crankshaft. from package number “3” before assembling.
Clean the seal installation tool and place it on
the crankshaft. Turn the knob until the tool CAUTION: Oil applied to the seal faces
bottoms out. must be absolutely clean.
1 9. Install the seal plate and gasket to the
2 compressor body. Do not bump the seal hard
ring on the end of the crankshaft during
3 assembly.
10. Install the seal plate mounting bolts and
washers. Torque the seal plate bolts in two
steps using a criss-cross pattern. See “Torque
Values” on page 24.
AGA1256
1. Crankshaft
2. Bellows
3. Seal Installation Tool P/N 204-995
Figure 42: Bellows Installation
with Tool P/N 204-995
40
Installation of Metal Bellows Seal 1 2

With Drive Tangs
In August of 1998 Thermo King introduced a new
crankshaft with a larger input shaft which
afforded more surface area on the coupling taper.
At the same time a new method of attaching the
bellows to the crankshaft was implemented. The
new crankshaft is machined with two flat surfaces
and the new bellows has two tangs which slide
over these surfaces. The current replacement ARC025
procedure follows:
1. Install the new lip seal in the seal plate with
2. This Side Toward Compressor
the lip side facing out and the flat side facing
toward the compressor. Figure 45: Hard Ring Positions
3. If the installation tool is not available, use the
1 assembly.
2
2 ARC010
3
1. Lip Side Facing Out 4

2. Apply clean compressor oil to the new O-ring
and install it in the seal plate. Apply clean ARC011
that the hard ring installation tool 1. Seal Plate
(P/N 204-953) is clean. Use the hard ring 2. O-ring
installation tool to push the hard ring (with the Hard Ring—Install with Polished Surface
3.
polished surface toward the installation tool) Toward Compressor
fully into the seal plate. Do not pinch the 4. Hard Ring Installation Tool P/N 204-953
O-ring. Figure 46: Hard Ring Installation
CAUTION: DO NOT touch or damage the

polished seal face surfaces. Keep the
protective cap in position until final
assembly.
41
4. Apply clean compressor oil to the O-ring 5. Remove the yellow protective cap. Clean the
inside the bellows. Slide the bellows on the hard ring and the primary ring (bronze ring)
crankshaft, align the drive tangs with the drive with the alcohol wipes found in package
flats, and then push the bellows firmly against labeled “1”. Then clean the polished mating
the crankshaft shoulder. surfaces of both rings with the lint free dry
wipes from package number “2”. Apply clean
1 compressor oil to the polished surfaces of the
seal, the lip seal, and the seal plate gasket
from the package number “3” before
assembling.
CAUTION: Oil applied to the seal faces
AGA579
must be absolutely clean.
6. Install the seal plate and gasket to the

2 compressor body. Do not bump the seal hard
1. Yellow Protective Cap
assembly.
2. Drive Tang
Figure 47: Cross Section of
Drive Tang Type Bellows washers. Torque the seal plate bolts in two
1 Values” on page 24.
2
Installation of Metal Bellows Seal
3 4 With Hex Drive
In the first quarter of 2014 a pressurized seal
cavity was phased into use on large shaft
compressors. The pressurized seal cavity uses a
new seal with a hex drive and a new crankshaft
with a hex drive collar. The replacement
procedure follows:
5
1. Install the new lip seal in the seal plate with
the lip side facing out and the flat side facing
AGA581
toward the compressor.
1. Drive Tang
2. Seal Faces
3. Hard Ring
1
4. O-ring
5. Bellows
Figure 48: Drive Tang Type Bellows Seal
2 ARC010
1. Lip Side Facing Out

42
2. Apply clean compressor oil to the new O-ring

CAUTION: DO NOT touch or damage the
and install it in the seal plate. Apply clean
polished seal face surfaces. Keep the
protective cap in position until final
that the hard ring installation tool
assembly.
(P/N 204-953) is clean. Use the hard ring
installation tool to push the hard ring (with the NOTE: Do not replace the internal lip seal
polished surface toward the installation tool) unless it is damaged. To replace it, pry the old
fully into the seal plate. Do not pinch the one out and press the new one into place with
O-ring. the lip facing into the seal plate. Make sure
the lip seal is pressed all the way down into
1 2 the seal plate. Oil the lip seal.
ARC025

2. This Side Toward Compressor
Figure 50: Hard Ring Positions
3. If the installation tool is not available, use the 1
assembly.
1 ARA2172
2
3 1. Lip Facing Into Seal Plate
4 Figure 52: Internal Lip Seal Installation

4. Apply clean compressor oil to the O-ring
inside the bellows. Slide the bellows on the
5 crankshaft, align the hex drive on the bellows
with the hex drive collar, and then push the
bellows firmly against the hex drive collar.
1. Seal Plate Leave the protective cap in place during
2. O-ring installation. If the hex drive does not slide on
Hard Ring—Install with Polished Surface easily, rotate the assembly 30 degrees.
3.
Toward Compressor
4. Hard Ring Installation Tool P/N 204-953
5. Internal Lip Seal
43
1 CAUTION: Oil applied to the seal faces

must be absolutely clean.
2
6. Install the seal plate and gasket to the
compressor body. Do not bump the seal hard
assembly.
washers. Torque the seal plate bolts in two
Values” on page 24.
1. Hex Drive Collar Oil Sump and Oil Pickup

2. Hex Drive Screen
Figure 53: Hex Drive Bellows Installation
(Shown Without Protective Cap) Removal
1. Remove all the bolts from the oil sump.
1 2
1
3
4
5
2
AGA552
ARA2166
1. Mounting Bracket
1. O-ring (Inside Bellows) 2. Oil Intake Hole
2. Hex Drive
Figure 55: Pickup Screen and O-ring
3. Seal Faces
2. Tap the sump with a soft hammer or punch to
4. Hard Ring
loosen the gasket.
5. O-ring (In Seal Plate)
6. Bellows CAUTION: Do not pry or drive any object
Figure 54: Hex Drive Type Bellows Seal
between the sump and the compressor
body.
5. Remove the yellow protective cap. Clean the
hard ring and the primary ring (bronze ring) 3. Remove bolts from the mounting bracket and
with the alcohol wipes found in package remove the oil pickup screen.
labeled “1”. Then clean the polished mating 4. Remove the O-ring from the oil intake hole.
surfaces of both rings with the lint free dry
wipes from package number “2”. Apply clean Repair
compressor oil to the polished surfaces of the
seal, the lip seals, and the seal plate gasket 1. Remove all old gasket material from the sump
from the package number “3” before and the compressor body.
assembling. 2. Clean the oil pickup screen.
44
Installation
1. Early style compressor body with groove for
1
oil pickup tube O-ring in the oil intake hole— 2
Apply refrigerant oil to the O-ring and place it
in this groove. Insert the pickup tube.
1
AGA553
2 1. Mounting Bracket
ARC012
2. Oil Pickup Tube
1. Oil Pickup Tube Figure 58: Pickup Tube Installation
2. O-ring
3. Apply refrigerant oil to the sump gasket and
Figure 56: Early Style Pickup Tube Installation place it on the compressor body. The gasket
1. Later style compressor body with groove for fits properly in only one position.
oil pickup tube O-ring in the oil intake hole— 4. Install the oil sump. Install the oil sump bolts
Apply refrigerant oil to the O-ring and place it and washers. Torque the oil sump bolts in two
on the pickup tube. Push the pickup tube into steps using a criss-cross pattern. See “Torque
the oil intake hole in the compressor body Values” on page 24.
until it bottoms out. The flange on the pickup
tube will force the O-ring into the oil intake
hole.
1 2
3
ARC013
1. Oil Pickup Tube

2. Flange
3. O-ring
Figure 57: Later Style Pickup Tube Installation
2. Hold the mounting bracket in place and install
and torque the mounting bracket bolts. See
“Torque Values” on page 24.
45
Internal Oil Filter

In the first quarter of 2014 four cylinder
compressors with an internal oil filter were phased
into truck and trailer units that typically use
compressors with external oil filters. The internal
oil filter is located in the compressor sump near
the oil pickup tube.
3 1. Stud On Oil Pickup Tube Bracket

Figure 60: Remove Nut from Stud
5 6 1
1. Oil Discharge Tube

2. O-Ring
2
3. Internal Oil Filter
4. Pressure Relief Valve
5. Oil Pickup Tube
6. Stud On Oil Pickup Tube Bracket
Figure 59: Internal Oil Filter 1. Internal Oil Filter
2. Oil Discharge Tube
Removal Figure 61: Remove Internal Oil Filter from Oil
1. Remove the oil sump if necessary (see “Oil Discharge Tube
Sump and Oil Pickup Screen” on page 44).
Installation
2. Remove the nut that fastens the internal oil
filter to the stud on the oil pickup tube bracket. 1. Place the internal oil filter on the oil discharge
tube and the stud on the oil pickup tube
3. Remove the internal oil filter from the oil bracket. Be careful to avoid damaging the
discharge tube. O-ring in the oil filter.
2. Install and tighten the nut that fastens the
internal oil filter to the stud on the oil pickup
tube bracket.
3. Install the oil sump (see “Oil Sump and Oil
Pickup Screen” on page 44).
46
Oil Pump 1 2 3 4 5
Removal
CAUTION: The oil pump assembly is a
precision device with close clearances. All
parts must be kept clean, the work area
must be kept clean, and oil applied to the 1. Regulator
pump must be clean. Contamination by 2. O-ring
dirt, debris, chips, or burrs could cause the 3. Spring
oil pump to fail prematurely. Parts must be 4. Plunger
protected from nicks and scratches. 5. Snap Ring
1. Remove the oil pressure regulator and oil Figure 63: Disassemble View of
pickup plug. Oil Pressure Regulator
2. Check the operation of the oil pressure d. Coat the parts using clean refrigeration oil
regulator by pressing on the plunger and and reassemble.
checking the movement. The plunger should
5. Install oil pressure regulator.
move free and smooth. You should feel
constant resistance from the plunger spring a. Replace the o-ring seal.
throughout the entire stroke of the plunger.
b. Apply clean refrigeration oil to the valve
3. Remove the oil pump cover. by coating or dipping.
c. Screw the regulator into the housing.
d. Tighten to 23 ft-lb (31 N•m).
6. Remove the outer wear plate and the gerotor
assembly. See “Figure 64: Oil Pump
Components” on page 48.
1
NOTE: Because of the close fit of the oil
pump assembly, the wear plates must be
removed very carefully or they will bind in
2 AGA556
the housing. If they bind, square them up by
tapping very lightly and attempt to remove
1. Oil Pressure Regulator again.
2. Oil Pickup Plug
Figure 62: Oil Pump Cover
4. Remove the oil pressure regulator. Use a 3/4
in. wrench to remove the regulator from the
pump cover.
Cleaning
a. Examine the valve for any dirt, chips or
other accumulation.
b. If it becomes necessary to disassemble the
valve, remove the spring clip using snap
ring pliers.
c. Clean the parts using approved solvent.
The solvent must be nonchlorinated.
47
2
Repair
1 3
1. Inspect the oil pump cover and housing for
damage and nicks.
4
2. Inspect the oil pump cover and housing for
dirt, debris, chips, and burrs. Carefully remove
any contamination. Use a clean shop wipe and
solvent (clean Stodard solvent or clean
mineral spirits) and wipe the oil pump housing
and pump cover clean.
NOTE: Pay particular attention to the lower
inner groove in the oil pump housing. Debris
6 AGA557 5 often collects in this area.
1. Y Spring
2. Notch Toward Cover
3. Eccentric Ring
4. Outer Wear Plate
5. Gerotor 1
6. Inner Wear Plate
Figure 64: Oil Pump Components
7. Remove the inner wear plate.
8. Remove and discard the square key See
“Figure 65: Square Key Removal” on
page 48.
Check for Debris in This
1 1.
Area of the Inner Groove
Figure 66: Checking Pump Housing
3. Check the condition of the oil pump drive pin.
In most cases the drive pin will remain in the
crankshaft after the oil pump is removed. It is
not necessary to remove the drive pin from the
crankshaft for inspection.
4. Discard the old O-rings, square key, and Y
spring.
NOTE: It is strongly recommended you discard
AGA555 all of the oil pump components and replace them
with Oil Pump Kit P/N 22-1160 during rebuild.
1. Square Key
Figure 65: Square Key Removal
NOTE: If you choose to reinstall existing oil
pump components, make sure all components
9. Remove the oil pump shaft. Protect the oil are not worn or damaged. Accurately check the
pump shaft with cloth and use pliers to pull it gerotor gears, inner wear plate, and outer wear
straight out. plate to make sure they are within thickness
NOTE: It is not necessary to remove the oil specifications (see “Part Dimensions” on page
pump housing to service the oil pump. Use puller 23).
plate P/N 204-483 or slide hammer P/N 204-638
to remove the oil pump housing if necessary.
48
Pre-Lubrication of Oil Pump Parts 1

The oil pump parts must be completely immersed
2
in clean refrigerant oil to lubricate the pump
assembly thoroughly. Do not smear oil on with
your fingers! It cannot be stressed enough that
the oil must be absolutely clean and that it
thoroughly covers the part. Compressor oil and an
oil cup for holding clean compressor oil are
provided in Oil Pump Kit P/N 22-1160. If a
number of pumps are going to be done in quick
succession, the oil may be used for three or four
pumps if it is kept covered and checked frequently
for contamination. ARC015
CAUTION: Do not save oil from one day 1. Outer Gerotor Gear
to the next. 2. Inner Gerotor Gear
Figure 67: Install Gerotor Gears
Installation 7. Immerse the eccentric ring and roll it into
1. Install a new O-ring on the oil pump shaft. pump. The ring should be positioned so that
the pin in the pump cover will align with the
2. Immerse the O-ring and shaft in oil and then slot in the eccentric ring.
install the pump shaft into the crankshaft.
8. Install the Y spring. Roll the pump so it ends
3. Immerse the inner wear plate in oil and install up in the 12:00 o'clock position.
it in the pump housing. Make sure it lines up
with the pin in the bottom of the housing.
Check the plate for proper seating against the
housing, it should not wobble.
NOTE: Both of the pump wear plates and the
gerotor gears can be installed with either
face in or out.
NOTE: The new oil pump gerotor and wear
plates must be kept clean. If the parts pick up
any debris, they must be wiped clean. Parts AGA582
must be handled carefully to prevent damage
or contamination. Figure 68: Install Y Spring
4. Install the key into the keyway on the shaft. 9. Immerse the outer wear plate in oil and install
it in the pump housing. Install the outer wear
5. Immerse the inner gerotor gear in oil and plate with the notch aligned with the eccentric
carefully slide it on the shaft. Make sure the ring.
key stays in place.
6. Immerse the outer gerotor gear in oil and
install it.
49
11. Immerse new pump cover O-rings in oil and

1 install them in the pump cover.
12. Install the pump cover. Make sure the
alignment pin in the cover fits into the outer
wear plate alignment hole.
ARC016
1. Outer Wear Plate

4
2
Figure 69: Install Outer Wear Plate
10. Using a calibrated depth micrometer, measure
the oil pump cover clearance (see “Operating 3
Clearances” on page 22). Check this clearance
in multiple locations. If the depth is below
AGA554
specification, recheck the pump cavity for
debris or part damage. If the depth is above 1. Bypass Hole
specification, replace the pump assembly or Outer Wear Plate Alignment
pump housing. 2.
Hole
CAUTION: The oil pump cover clearance 3. Alignment Pin

is critical. Even when new parts are 4. Oil Pickup Hole
machined correctly, a small piece of debris Figure 71: Install Oil Pump Cover
may not allow the pump to seat in the
NOTE: The pump cover and outer wear plate
housing correctly. The resulting
must be clean and free of debris.
interference and reduced lubrication on
initial start-up can cause premature pump 13. Install the oil pump cover bolts and washers.
failure. Torque the oil pump cover/housing bolts in
two steps using a criss-cross pattern (see
NOTE: A depth micrometer must be used to
“Torque Values” on page 24).
measure the pump cover clearance. The
micrometer calibration must be checked 14. Immerse new O-rings in oil and install them
before use. Place the micrometer on flat on the oil pressure regulator and the oil pickup
machined surface and measure the depth (a plug.
used compressor seal hard ring can be used).
15. Install the oil pressure relief valve and the oil
The micrometer should read exactly zero
pickup plug (see “Torque Values” on page 24).
inches or it must be adjusted.
16. Install any additional oil fittings that may have
been removed.
CAUTION: After a compressor is rebuilt
and/or stored for any amount of time, a
startup procedure must be done when the
compressor is installed or the oil pump
could fail (see “Startup” on page 65).
AGA560
Figure 70: Measure Oil Pump Cover Clearance
50
Connecting Rod, Piston and 4. Measure piston and the sleeve. If the piston or
Sleeve sleeve are worn beyond the maximum
allowable operating clearance shown in
Removal “Operating Clearances” on page 22, they
should be replaced.
1. Remove the cylinder heads (see “Cylinder
Head” on page 32), the discharge valve plates
(see “Discharge Valve Plates” on page 33) and
the oil sump and the oil pickup screen (see
“Oil Sump and Oil Pickup Screen” on page 1
44).
2. Remove the connecting rod nuts.
3. Tap the connection rod cap lightly with a soft
hammer to loosen it from the rod.
AGA562
4. Remove the piston, rod and sleeve as an
1 1
assembly from the cylinder and keep them in 1
sets. This will aid in the evaluation of the
components.
CAUTION: There are no marks on the
rods and caps that identify them as sets,
but they must be kept in matched sets. It is
helpful to mark them as such.
AGA563
1
1. Check for Damage and Wear

Figure 73: Inspecting Pistons and Sleeve
5. Remove the snap rings from the piston.
AGA561
Figure 72: Piston and Sleeve Removal
Repair
1. Remove the piston and rod from the sleeve.
2. Inspect the sleeve for scoring, damage or
AGA564
cracks near the ports. The cross hatching or
Figure 74: Removal of Snap Ring from Piston
honing marks should still be visible in the
sleeve. There should be no large scratches in
the sleeve.
3. Inspect the piston for wear and damage.
Check for large scratches in the piston
surfaces.
51
6. Remove the wrist pin from the piston and rod. 11. Inspect large end of connecting rod for wear
The wrist pin is a float fit so you should be or damage.
able to press it out by hand.
3
2
1
4
AGA566
1 2
5 ARC014 1. Check Bearing Fit

2. Check Bolt for Damage
1. Piston 4. Piston Head
Figure 76: Inspect Connecting Rod
2. Wrist Pin 5. Ring Valve
3. Snap Ring NOTE: Thermo King does not recommend
reinstalling used connecting rod bearings.
Figure 75: Piston Components
Use new bearings for inspecting the
7. Remove the piston from the rod. connecting rod and the crankshaft.
8. Inspect the piston, piston head, and ring valve 12. Place the bearing in the rod. It should fit into
for wear or damage. Replace the complete the machined radius snugly when pushed with
piston assembly if the ring valve is worn, the thumb. When the bearing is bottomed out,
cracked, broken or missing, if excessive both ends of the bearing should be flush with
grooves are worn into the ring valve from the the mating surfaces of the rod. The bearing
piston grooves, or if the piston grooves are should fit into the rod cap in the same manner.
worn flat from the ring valve.
NOTE: Be sure to align the tabs in the
NOTE: The grooved piston supersedes the bearings with the notches in the mating
flat top piston. The grooved piston has small parts.
concentric grooves on the top of the piston
under the ring valve. These grooves reduce
the stiction between the top of the piston and 2
the ring valve. The grooved and flat top
pistons are interchangeable, but the piston
components are not. Do Not Use Flat Top
Pistons.
9. Inspect the wrist pin for wear or damage. AGA567 1
Measure the wrist pin if it shows signs of 2
wear. If the outside diameter of the wrist pin is
less than 0.6250 in. (15.8750 mm), replace the 1. Check Bearing Fit
piston assembly. 2. Check Bolt Holes for Damage
10. Inspect the wrist pin bushing in the small end Figure 77: Inspect Connecting Rod Cap
of the connecting rod for wear or damage.
Measure the wrist pin bushing. Replace the
wrist pin bushing if its inside diameter is more
than 0.6258 in. (15.8953 mm).
52
13. Use plastigauge to check the clearance 4. Place the piston and sleeve in the compressor
between the connecting rod bearings and the body. Take care to prevent damage to
corresponding crankshaft rod journal. crankshaft from the rod bolts. Install the rods
so the index marks face the other rod on the
a. Place a piece of plastigauge on the
same rod journal. See “Figure 79: Connecting
crankshaft rod journal.
Rod and Cap Installation” on page 53.
b. Install the bearings in connecting rod and
5. Install the connecting rod cap. Make sure the
rod cap.
index mark on the cap is aligned next to the
c. Install the connecting rod and rod cap with index mark on the connecting rod as shown.
the index marks aligned as shown in Index marks may point toward the front or
“Figure 79: Connecting Rod and Cap rear of the compressor.
Installation” on page 53.
1
d. Install the connecting rod nuts and torque
them to 25.0 ft-lb (33.9 N•m). Do not
allow the connecting rod to rotate on the
crankshaft rod journal.
e. Remove the rod cap and check the
plastigauge to determine the clearance of
the connecting rod bearing. The
recommended rod bearing clearance is
0.0008 to 0.0024 in. (0.0203 to 0.0610
mm).
AGA569
1
1. Index Marks
Figure 79: Connecting Rod and Cap Installation
6. Install the connecting rod nuts and torque
them to 25.0 Ft-lb (33.9 N•m). Rotate the
crankshaft after each rod assembly is torqued
AGA93 to check that the components move freely.
Figure 78: Check Plastigauge
14. If the rod bearing clearance is too large, use

undersize bearings and have a competent
machine shop grind the crankshaft to fit the
undersize bearings.
Assembly
1. Place the piston on the connecting rod and
AGA570
install the wrist pin and the snap rings.
2. Install the bearings in connecting rod and rod
cap. Figure 80: Torque Rod Bolts
3. Apply apply refrigerant oil to the piston and
place it in the sleeve.
53
Crankshaft 3. Use one of the following procedures to

remove the crankshaft.
WARNING: The removal and installation
of the crankshaft requires that the Old Design Compressor with Aluminium
compressor body be heated. Make sure to Oil Pump Housing and C3 Bearing - Set the
wear heat resistant gloves and eye compressor on the oil pump end with the seal
protection when preforming these end up. Use an oxy-acetylene torch with a
procedures. It is also recommended that large rosebud tip to carefully and uniformly
an assistant be available to help with these heat the area around the seal end bearing and
procedures. monitor the temperature with a noncontact
thermometer P/N 204-1059 (or similar). The
crankshaft and bearing will typically slip out
Removal
of the compressor body before the temperature
1. Remove the cylinder heads (see “Cylinder reaches 200 F (93 C). If not, use Bearing
Head” on page 32), the discharge valve plates Removal Tool P/N 204-1153 to remove the
(see “Discharge Valve Plates” on page 33), the crankshaft and bearing (see the following
seal plate (see “Seal Plate Assembly” on page procedure). Do not heat the area around the
35), the oil sump and the oil pickup screen seal end bearing above 350 F (177 C). Do not
(see “Oil Sump and Oil Pickup Screen” on attempt to drive the bearing out of the
page 44), the oil pump (see “Oil Pump” on compressor body without heating or it will
page 47) and the connecting rods, pistons and damage the compressor body.
sleeves (see “Connecting Rod, Piston and
NOTE: If required, Bearing Removal Tool
Sleeve” on page 51).
P/N 204-1153 can be used to remove a
2. If needed, use slide hammer P/N 204-638 to crankshaft with a C3 bearing. See the
remove the oil pump housing. Attach the slide following procedure.
hammer to the oil pump housing with two
New Design Compressor with Cast Iron
5/16 in. bolts. Use caution to prevent damage
to the oil pump housing. (Black Paint Color) Oil Pump Housing and
C5 Bearing - Use the following procedure:
a. Set the compressor on the oil pump end
with the seal end up.
b. Install the Bearing Removal Tool P/N
204-1153 on the seal end of the
compressor as shown in Figure 82 and
Figure 83. Position the two vertical tubes
on the tool to the top and bottom of the
compressor body as shown in Figure 83.
This positions the slots in the tool to
provide the best access for heating the area
around the seal end bearing.
AGA571
Figure 81: Remove Oil Pump Housing
54
Figure 82: Bearing Removal Tool P/N 204-1153
1. Heat Through Both Slots In Tool

Figure 84: Heat Area Around Bearing Through Tool
Figure 83: Install Bearing Removal Tool Figure 85: Heat Area Around Bearing
From Inside Compressor Body
c. Use an oxy-acetylene torch with a large
rosebud tip to carefully and uniformly heat
the area around the seal end bearing and
monitor the temperature with a noncontact
thermometer P/N 204-1059 (or similar).
Heat the area around the seal end bearing
to 325 to 350 F (163 to 177 C). Do not
heat the area around seal end bearing
above 350 F (177 C).
Figure 86: Check Temperature

Of Area Around Bearing
55
d. Use an impact wrench to tighten the large 1. Check the condition of main bearings by
top bolt on the bearing removal tool and pressing on the bearing while turning it.
push the bearing and crankshaft out of the
NOTE: Thermo King recommends replacing
compressor body. Do not attempt to push
all main bearings during compressor repairs
the bearing and crankshaft out of the
that involve removing the crankshaft.
compressor body without heating or it will
damage the compressor body and the 2. If necessary use the bearing puller tool P/N
bearing. 204-1000 to remove the ball bearings from the
compressor crankshaft.
3. Place the crankshaft in the tool so that two
vertical bars support the inner race of the ball
bearing.
4. Place the included spindle on the pump end of
the crankshaft and press off the bearing.
2
1
Figure 87: Removing Crankshaft
Repair
IMPORTANT: Crankshafts for compressors
with the pressurized seal cavity and the hex drive AGA773
seal are not repairable and must be replaced as
an assembly. These crankshafts have a hex drive 1. Vertical Bars Support Inner Race
collar pressed on in front of the drive end 2. Spindle for Oil Pump End
bearing as shown below.
Figure 89: Pressing Bearing Off Oil Pump End
5. Rotate the crankshaft 180 degrees and press

off the other bearing. DO NOT use the
1 spindle because it could jam on the taper of
the crankshaft nose.
1. Hex Drive Collar

Figure 88: Pressurized Seal Cavity Crankshaft
56
Installation
1. Inspect the crankshaft to be certain it is
1 completely assembled before installing it.
Make sure that the plugs and the metering jet
(if used) are installed in the oil passageways,
and that oil pump drive pin and the bearings
have been installed. See steps 8, 9, and 10
above.
2. Position the compressor body with the seal
end down and support it to allow clearance for
the drive end of the crankshaft.
NOTE: Figure 92 on page 57 shows a
compressor support fabricated from 1/4 in. (6
mm) sheet metal. It is 10 in. (250 mm) wide,
13 in. (330 mm) long, and 4 in. (100 mm)
high. The hole has a diameter of 6 in. (150
mm).
AGA774
1. DO NOT Use Spindle

Figure 90: Pressing Bearing Off Drive End
6. Use a micrometer to measure the rod journals.
If the outside diameter of a rod journal is less
than 1.3742 in. (34.9047 mm), replace the
crankshaft or have a competent machine shop
grind the crankshaft to use undersize bearings.
7. Remove the plugs and the metering jet from
the oil passageways. Clean the passageways Figure 92: Compressor Support
thoroughly. 3. Use an oxy-acetylene torch with a large
8. Reinstall all the plugs and the front seal rosebud tip to carefully and uniformly heat the
metering jet. Torque to 60 in-lb (6.8 N•m). compressor body in the area around the seal
end bearing and monitor the temperature with
9. Install the oil pump drive pin in the rear main a noncontact thermometer P/N 204-1059 (or
journal before installing the ball bearings. similar). Ensure the heat is applied and the
10. Press the ball bearings onto the crankshaft. required temperature established in the areas
Press on the inner race of the bearing and with thicker material at the sides and top of
support the crankshaft under main journal the bearing bore location, shown as item “1”
while performing this operation. in Figure 94. Heat the area around the seal end
bearing to approximately 250 F (121 C). Do
not heat the area around seal end bearing
above 350 F (177 C).
AGA572
Figure 91: Install Bearings
57
Figure 93: Heat Compressor Body
Figure 95: Installing Crankshaft
1 1
1. Check Temperature In These Three Places

Figure 94: Check Temperature
Of Area Around Bearing
4. Place the crankshaft (at room temperature or
cooler) in the compressor body. Carefully line
up the crankshaft assembly but without the
cool crankshaft assembly making contact with
the hot body as shown in Figure 95. Then
quickly position the cool crankshaft assembly Figure 96: Crankshaft Installed
into contact with the shoulder in the bearing With Bearing Fully Seated
bore of the hot compressor body. Leave a few
moments and the heat will exchange between
the compressor body and crankshaft, and the
bearing will become thermally fixed in the
bearing bore.
58
5. Apply refrigerant oil to the oil pump housing

CAUTION: Do not use an excessive
gasket and place it on the compressor body.
amount of Loctite. Use care in application
Align the oil holes in oil pump housing gasket
and assembly to prevent contamination of
with oil holes in compressor body.
the bearing or internal area of the
6. Place the oil pump housing in position and tap compressor or refrigeration system with
it lightly with a soft face hammer till it Loctite.
contacts the compressor body. Use a soft face
hammer to avoid damaging the O-ring sealing Compressor Crankshaft
surfaces. Precautions
7. Place two 3/8-16 X 1-1/4 in. bolts and two 3/8 1. Alignment of the compressor to the engine
in. washers in mounting holes on opposite flywheel is controlled by the position of the
sides of the oil pump housing. Snug the bolts engine flywheel housing. Two checks should
down and turn the crankshaft to make sure it be made to assure that alignment is correct.
rotates freely. After checking that the Refer to the appropriate Engine Overhaul
crankshaft rotates freely, remove these bolts to Manual to correct an alignment problem.
install the oil pump.
a. Use a dial indicator to check the radial run
out, which is the concentricity of the
C3 Bearing Only—Using Loctite RD/620 to
flywheel to the flywheel housing.
Fasten Seal End Main Bearing In
Maximum total indicated radial run out is
Compressor Body
0.004 in. (0.10 mm).
1. Remove the crankshaft from the compressor
body.
2. Clean the outer race of the seal end main
bearing and the bore in the compressor body
with a nonchlorinated solvent to remove all
oils.
3. Apply a thin coating of Loctite RC/620 to
both the outer race of the bearing and the bore
in the compressor body.
4. Seat the crankshaft assembly fully into the
bore on the seal end of compressor body. Be
sure the crankshaft assembly in seated as far
as possible into the compressor body. Figure 97: Checking Radial Run Out
5. Place the oil pump housing in position and tap b. The flywheel housing should fit tightly
it lightly till it contacts the compressor body. against the engine block. Nicks, burrs and
debris between the block and flywheel
6. Place two 3/8-16 X 1-1/4 in. bolts and two 3/8
housing can cause misalignment and result
in. washers in mounting holes on opposite
in a loosely mounted flywheel housing.
sides of the oil pump housing and snug the
Use a dial indicator to check the axial run
bolts down.
out, which is measured from the flywheel
7. Allow 15 minutes for the Loctite to fix the to end surface of the flywheel housing.
parts. Full cure of the Loctite requires 12 Maximum total indicated axial run out is
hours at room temperature or 30 minutes at 0.010 in. (0.25 mm). See “Figure 98:
250 F (121 C). Checking Axial Run Out” on page 60.
59
Removal and Installing Crankshaft

Counterweights
Long stroke compressors have two add-on
counterweights riveted to the integral
counterweight portion of the cast crankshaft.
When regrinding crankpin journals, it is necessary
to remove the add-on counterweights which must
be plainly marked so they may be replaced exactly
as they were removed.
There have been some cases where a crankshaft
from a long stroke compressor was reground and
then installed without the add-on counterweights
Figure 98: Checking Axial Run Out being reinstalled. The result can be cracked
refrigerant lines, cracked frames and loose screws
CAUTION: Misalignment of the flywheel due to an unbalanced condition.
housing to the engine will cause
To properly regrind a long stroke crankshaft, the
crankshaft fracture as indicated below:
following procedure must be adhered to:
1. Mark the add-on counterweights, so they will
1 be reinstalled on the same integral
counterweight.
2. Drill off rivet head and drive out rivet with a
AGA517 punch.
2 3. Regrind the crankshaft shaft to the new

undersized diameter. Bearing sets are
1. Misalignment Fractures Occur Here
available in 0.005 in. (0.127 mm), 0.010 in.
(0.254 mm), 0.020 in. (0.508 mm) and 0.030
2. Coupling Problem Fractures Occur Here
in. (0.762 mm) undersize. The standard
Figure 99: Crankshaft Fractures diameter of connecting rod journal is 1.3742
2. Fitting the drive coupling to the crankshaft of to 1.3747 in. (34.9047 to 34.9174 mm). The
the compressor is a critical operation when clearance for the connecting rod bearing to the
installing a compressor. When the coupling is crankshaft rod journal is 0.0008 to 0.0024 in.
removed, inspect the crankshaft taper and the (0.0203 to 0.0610 mm).
coupling for rust and pitting. A crankshaft or 4. Tap holes in the integral counterweight with a
coupling that has significant pitting on the 5/16-18 UNC tap.
taper should be replaced. Crankshaft failures
in the taper area generally are the result of 5. Countersink the holes in the add-on
improper fit between the coupling and the counterweight with an 82 degree tool to accept
crankshaft. Refer to “Drive Coupling” on 5/16 flat head screws. This must be done
page 28 for the proper removal and because the original countersink is 90 degrees.
installation procedures. 6. Reinstall the add-on counterweights with
5/16-18 UNC flat head screws. Be sure to
install them on same integral counterweight
from which they were removed. Cut off the
excess screw length if required. Stake the
screws with a centerpunch to prevent screw
from backing out.
60
7. Thoroughly clean the crankshaft to remove all 2. If necessary, remove all the check valves.
metal chips and coat with compressor oil.
a. The two lower check valves are located in
1 the front seal area.
b. The two upper check valves are located in
the sump area.
2
c. The large check valve is located in the
passageway between the suction cavity
and the sump. Use tool P/N 204-464 to
remove the large check valve.
3
AGA573
1 2 1
6
AGA776
1. Upper Check Valves
1. Remove Rivets 2. Large Check Valve
2. Integral Counterweight Figure 101: Check Valve Locations
3. Mark Counterweights NOTE: In order to remove the large check
4. Add-On Counterweight valve from four cylinder compressors built
5. Counter Sink 82° after April 1987, it will be necessary to apply
6. Tap with 5/16-18 UNC Threads heat to soften the factory-applied Loctite.
Figure 100: Installing Counterweights
Compressor Body Repair

Removal 1
1. Remove the cylinder heads (see “Cylinder
Head” on page 32), the discharge valve plates
(see “Discharge Valve Plates” on page 33), the
seal plate (see “Seal Plate Assembly” on page
35), the oil sump and the oil pickup screen
(see “Oil Sump and Oil Pickup Screen” on
AGA574
page 44), the oil pump (see “Oil Pump” on
page 47), the connecting rods, pistons and 1. Tool P/N 204-464
sleeves (see “Connecting Rod, Piston and Figure 102: Removing Large Check Valve
Sleeve” on page 51) and the crankshaft (see
“Crankshaft” on page 54).
61
Inspection
1. Inspect all passageways for plugging or
damage.
2. Inspect all threads for damage.
3. Inspect all gasket surfaces for flatness.
4. Scrape all gasket material off, and clean the
compressor body thoroughly.
Check Valve Installation

1. Install the lower check valves. Torque to 10.0
ft-lb (13.6 N•m).
2. Install the upper check valves. Torque to 25.0
ft-lb (33.9 N•m).
3. Clean the threads of the large check valve.
Apply four drops of Loctite 277 equally
spaced on the threads. Do not use an excessive
amount of Loctite.
4. Install the large check valve with tool P/N
204-464. Torque to 28.0 ft-lb (38.0 N•m).
62
Unloader Head
Operation
1 3
During normal operation, the unloader head 2
allows refrigerant to pass from the discharge valve
plates through the check valve located in the head. 4
The solenoid valve is de-energized in this 5
position. Discharge pressure passes from Port “A”
through the solenoid valve to the center port, Port
6
“C”, which forces the unloader piston down and
seals up the discharge hole to the suction cavity. 7
16
During the unload operation, the unloader 15
solenoid is energized, the pressure passes from
Port “B” to Port “C”. This allows the refrigerant
to pass from the suction chamber to the top of the 14
unloader. This reduction in pressure and the 13 8
11
spring in the unloader piston allows the valve to 12
9
lift. This will cause the refrigerant to pass back
into the suction cavity of the compressor at the
10
same time the check valve located in the head
seats and prevents the discharge pressure from AGA516
short cycling in the compressor. This continues
until the solenoid de-energizes. At this time the 1. Unloader Valve Cover
discharge pressure builds up, seals off the port to 2. Retaining Clip
the suction cavity and the system pumps with four 3. Check Valve Cover
cylinders. 4. Unloader Spring
5. Check Valve Spring
CAUTION: Unloader heads are used on
special compressor bodies that have a 6. Check Valve Piston
return gas passage. Do not use unloader 7. Unloader Cylinder Head
heads on compressor bodies that do not 8. Port “A”
have the return gas passage. 9. Solenoid
10. Port “B”
Check Out 11. Port “C”
12. Normal Flow
1. With unloader de-energized, compressor 13. Unload Flow
should pump down normally 15 to 20 in. Hg
14. Gasket
vacuum (-51 to -68 kPa) and should hold a 15
15. Unloader Spring Sleeve
in. Hg vacuum (-51 kPa) for three minutes.
16. Unloader Piston
2. Using an auxiliary battery, energize and Figure 103: Unloader Head Components
de-energize unloader solenoid on compressor
cylinder head while the compressor is
running. An audible noise will be made when
unloading, as well as a pressure change in
both suction and discharge.
63
Unloader Head
Disassembly 4. With valve energized, flow will be from B to

C and A to C closed.
1. Remove cylinder head from body same as
standard head. NOTE: The valve is non-repairable.
2. Remove solenoid valve. 5. Inspect check valve for wear on sides. If wear
is present, valve must be replaced.
3. Remove check valve.
6. Inspect unloader valve.
4. Remove unloader valve.
NOTE: It may be necessary to disassemble
NOTE: It may be necessary to tap valves slightly valve assembly to check spring and clean
to loosen from head. internal portion of piston. To disassemble
piston from cover, depress piston and remove
Repair roll pin. Compress spring and remove
retaining ring.
1. Inspect solenoid valve for physical change.
a. Inspect piston sides for wear.
2. Measure resistance of coil or check for
amperage. b. Remove ring, insert into bore, check end
gap clearance. Gap must not exceed 0.016
3. With valve de-energized, flow will be from
in. (0.406 mm).
Port A to C and none from B to C.
c. Inspect spring ends, cover and unloader
piston and sleeve for wear.
To reassemble, reverse the disassembly
procedure.
AGA777
1 2 3 1 2 3
1. Port A
2. Port C
3. Port B
Figure 104: Solenoid Valve Ports
64
Leak Testing, Storage, and Startup
Leak Testing Startup

Leak test the compressor with refrigerant gas such The following procedure must be followed for any
as R-134a at approximately 70 psi (483 kPa). compressor that has had an oil pump installed
and/or has been stored for any length of time.
Storage CAUTION: If a non factory
Thermo King compressors rebuilt in the field remanufactured compressor is rebuilt and
should be properly sealed, leak checked, stored for any amount of time, a startup
evacuated and charged with 20 ± 5 psi (138 ± 34 procedure is recommended.
kPa) dry nitrogen to ensure that they do not
1. Once the compressor is installed in the unit,
become contaminated if they are to be stored for attach a suitable gauge on the compressor oil
any length of time after overhauling. Cover plates filter pressure access port (if equipped). You
are available for all compressors for this purpose. can also use the oil pressure fitting on the oil
pump cover.
2. Install a suction gauge below the throttling
valve.
3. Disconnect the wires to the fuel solenoid.
1 2 3 4
4 5
5 3
AGA587
AGA586
1. Schrader Valve Assembly

2. Suction Cover Plate
3. Suction Cover Plate Gasket
4. Discharge Cover Plate
5. Discharge Cover Plate Gasket
Figure 105: Cover Plates
65
Leak Testing, Storage, and Startup
4. Turn the unit on and crank it for 20 seconds.

5. Check the suction and oil pressure gauges
while cranking. Oil pressure is determined by
subtracting suction pressure from the pressure
on the gauge at the oil pressure port.
CAUTION: Do not crank the unit for
more than 20 seconds or damage to the
starter motor may occur.
6. If at least ten pounds of oil pressure is not
developed in the first thirty seconds, allow the
starter to cool for a few minutes and crank
again for 20 seconds. If oil pressure still does
not develop, check the compressor oil level. If
the level is above the oil pickup screen, the oil
pump or relief valve will need to be
rechecked.
7. As soon as oil pressure is developed,
reconnect the fuel solenoid.
66
Compressor History
Compressor History Large Shaft Compressor

The following describe changes made to the In August of 1998 the large shaft compressor was
X214, X418, X426, and X430 compressors. introduced. The large shaft compressors,
(X426LS and X430LS) have a crankshaft drive
Released shaft diameter of 1.187 in. These compressors are
used in trailer units for improved reliability. The
Four cylinder compressors with the gerotor oil large shaft compressors use a metric M12 X 1.75
pump were released in 1983. Two cylinder coupling/clutch mounting bolt.
compressors with the gerotor oil pump were
released in 1993. The original four cylinder compressors have a
crankshaft drive shaft diameter of 1.0 in. and are
Two-piece Compressor Seal Plate often called small shaft compressors. They
and Mounting Flange Assembly typically use a 3/8-16 in. coupling/clutch
mounting bolt.
In the third quarter 1988 the compressor seal
plate/mounting flange was changed to a two-piece
Metal Bellows Crankshaft Seal with
assembly on four cylinder compressors used in
Drive Tangs
trailer units.
In August of 1998 a new metal bellows crankshaft
Metal Bellows Crankshaft Seal with seal with drive tangs was introduced for use with
Set Screws large shaft compressors.
In May of 1992 a new metal bellows crankshaft
8 Pin Coupling and Clutch
seal with set screws was introduced for four
cylinder compressors. In the fourth quarter of 1998 the 6 pin coupling
and clutch were replaced with an 8 pin coupling
Polyol Ester (POE) Compressor Oil and clutch in trailer units.
for HFC Refrigerants
Fins Eliminated from Crankcase
In 1994 the use of Polyol Ester (POE) compressor
oil for HFC refrigerants was implemented. In 2002 the fins on crankcase castings were
eliminated.
Groove Top Pistons
Seven Quart Oil Sump on Four
In 1994 the pistons were changed from flat top to
Cylinder Compressors
groove top pistons. A groove top piston has small
concentric grooves on the top of the piston under In the first quarter of 2003 the seven quart oil
the ring valve. These grooves reduce the stiction sump on four cylinder compressors used in
between the top of the piston and the ring valve. multi-temp trailer units was introduced.
Teflon Seal Type Drive End Ball Deep Oil Sump on Two Cylinder
Bearing Compressors
In 1996 the drive end ball bearing was changed to In the first quarter of 2003 the deep oil sump on
a Teflon seal type ball bearing. two cylinder compressors used in certain truck
units was introduced.
New Coupling Mounting Washer
In the first quarter of 1998 the black coupling
washer was changed to a 0.23 in. thick silver
washer (P/N 77-2498).
67
Compressor History
Increase Bronze Bearing Bore Check Valve in Oil Collection

Diameter in Oil Pump Housing Container
In the first quarter of 2005 the bronze bearing A check valve was added Oil Collection
bore diameter in oil pump housings was increased Container in November 2012 to improve the shaft
to 0.7502 to 0.7507 in. (19.0551 to 19.0678 mm). seal reliability by ensuring oil stays on the shaft
Before that the bronze bearing bore diameter was seal when the suction pressure is in a vacuum. See
0.7497 to 0.7502 (19.0424 to 19.0551 mm). “Oil Collection Container” on page 14 for more
information.
Improve Heat Treating on Oil Pump NOTE: The check valve is no longer required on
Shaft Pressurized Seal Cavity Compressors.
In the first quarter of 2005 an improved process to
heat treat the oil pump shafts was implemented. Pressurized Seal Cavity
Starting in the first quarter of 2014 a pressurized
HPCO Switch with Straight Threads seal cavity was phased into use on large shaft four
In the second quarter of 2006 an HPCO switch cylinder compressors. Compressors with a
with straight threads and a copper sealing washer pressurized seal cavity can be identified by the
was introduced in Super II units. “P” on the seal cover. See “Compressor Model
Identification” on page 11 for more information
The HPCO with straight threads is P/N 41-6356.
about identifying compressor models.
The copper sealing washer is P/N 33-4277.
NOTE: The HPCO with straight threads is not Internal Oil Filter
interchangeable with the HPCO with 1/8 in. Starting in the first quarter of 2014 four cylinder
NPT (P/N 41-3669). Make sure to use the correct compressors with an internal oil filter were phased
type when replacing an HPCO. into truck and trailer units that typically use
compressors with external oil filters.
C5 Crankshaft Drive End Bearing
and Cast Iron Oil Pump Housing
In the second quarter of 2007 the use of a C5
crankshaft drive end bearing and cast iron oil
pump housing is being implemented. The cast
iron oil pump housing is painted black. Therefore,
a compressor with a C5 bearing can be identified
by the black oil pump housing. See “Compressor
Model Identification” on page 11 for more
information about identifying compressor models.
A compressor with a C5 bearing and a cast iron
oil pump housing requires special tools and
procedures to remove and install the crankshaft.
See “Crankshaft” on page 54.
Oil Collection Container

The oil collection container was added to trailer
units starting in the first quarter of 2010. The oil
collection container collects the compressor shaft
seal seepage to keep the unit clean. See “Oil
Collection Container” on page 14 for more
information.
68
Index
C startup 65
check valve installation 62 storage 65
cleaning components 28
compressor T
general description 11 two-piece compressor seal plate and mounting flange
history 67 assembly 35
model identification 11
compressor body repair 61 U
connecting rod, piston and sleeve 51 unloader head 63
crankshaft 54
crankshaft counterweights, removal and installing 60
crankshaft precautions 59
cylinder head 32
D
disassembly sequence 28
discharge valve plates 33
drive coupling 28
F
first aid 10
electrical shock 10
engine coolant 10
refrigerant 10
refrigerant oil 10
I
internal oil filter 46
M
metal bellows seal with drive tangs, installation 41
metal bellows seal with hex drive, installation 42
metal bellows seal with set screws, installation 39
O
oil collection container 14
oil pump 47
oil sump and oil pickup screen 44
R
reassembly sequence 28
S
safety precautions 7
battery installation and cable routing 8
battery removal 8
electrical hazards 9
general practices 7
refrigerant hazards 8
refrigerant oil hazards 9
seal plate 35
special tools 25
specifications 22
operating clearances 22
part dimensions 23
spring loaded neoprene bellows type seal, installation
37
69
Overhaul Manual
X214,SB-210+
X418, X426 &
toCompressor
Additional text information
X430 be placed here
TK 6875-8-OM (Rev. 9, 02/14)
TK 5XXXX-X-PL
Ingersoll Rand’s Climate Solutions sector delivers energy-efficient HVACR solutions for
customers globally. Its world class brands include Thermo King, the leader in transport
temperature control and Trane, a provider of energy efficient heating, ventilating and air
conditioning systems, building and contracting services, parts support and advanced controls
for commercial buildings and homes.
Distributed by:
Thermo King Corporate

314 West 90th Street
Minneapolis, MN 55420
Direct (952) 887-2200
TK 6875-8-OM
©1998 Ingersoll Rand Company

Printed in U.S.A.

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Overhaul Manual

Thermo King Corporate

©1998 Ingersoll Rand Company

Copyright© 1998 Thermo King Corp., Minneapolis, MN, U.S.A. Printed in

No warranties, express or implied, including warranties of fitness for a particular

We strictly adhere to a policy that promotes the recovery and limits

In addition, service personnel must be aware of Federal regulations

Manual Form Number _____________________________________________________

Section and Page # _______________________________________________________

Your Name ______________________________________________________________

Company Name __________________________________________________________

Phone Number ___________________________________________________________

Corrections, Comments and Suggestions _____________________________________

NORTH AMERICA EUROPEAN SERVED AREA

THERMO KING CORPORATION THERMO KING CORPORATION

Internal Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

DANGER: Refrigerant in the presence of WARNING: Do not apply heat to a closed

NOTE: In the USA, EPA Section 608

CAUTION: Do not connect other

CAUTION: Refrigerant in a liquid state Electrical Hazards

WARNING: Do not wear jewelry, watches First Aid, Electrical Shock

First Aid, Refrigerant Oil

First Aid, Engine Coolant

General Description NOTE: When replacement parts are required,

Compressor Model by Shaft Size

1. “P” Indicates Pressurized Seal Cavity

1. Seal Cover Drain Barb

3. If option 1 or 2 are not feasible and it is

Figure 6: Two Cylinder Compressor

1. Compressor Body 45. Oil Pump Shaft Key

Figure 7: Early Style Four Cylinder Compressor

1. Compressor Body 33. Check Valve Assembly

Figure 8: Late Style Four Cylinder Compressor

1. Compressor Body 33. Check Valve Assembly

Torque Values (Continued)

NOTE: Torque (in-lb) x 0.08333 = torque (ft-lb)

Description Part Number

Drive Coupling Puller 204-139

NOTE: Do not sand or lap the tapered area as

10. Spray a corrosion inhibitor on the exposed

AGA334 Coupling and Clutch Mounting Bolt

*If a black washer is found when the coupling is

1. 1.0 in. or 1.187 in. Diameter Crankshaft

Figure 19: Valve Plate Removal or Installation

Discharge Valve Plates

Figure 20: O-ring Location

Figure 18: Valve Plate Removal

1. Bolt 7. Wave Washer Installation

Two-piece Compressor Seal • Spring Loaded Neoprene Bellows Type—Two

1. Dust Seal (Lip Seal)

Seal Plate Assembly

AGA544 Figure 27: Set Screw Location

1. Tap Lightly NOTE: A modified (shortened) 3mm or 1/8

Figure 28: Special Allen Wrench

4. Remove the bellows assembly from the shaft

Figure 29: Seal Removal

5. Discard all seal parts.

1. Lip Side Facing Out 1. Seal Plate

4. Apply refrigerant oil to the primary ring and