LRT-HP (900273)

LRT-HP (900273)
TK 54264-3-MM (Rev. 0, 01/09)
Copyright 2009 Thermo King Corp., Minneapolis, MN, USA.

Printed in USA.
The maintenance information in this manual covers unit models:

LRT-HP System Number (900273)
For further information, refer to:
LRT-HP (900273) Parts Manual
TK 53863
X426, X430 Compressor Overhaul for Bus Air Conditioning
TK 6075
Silver Brazing & Soft Soldering
TK 7949
Tool Catalog
TK 5955
IntelligAIRE II Diagnostic Manual
TK 51535
IntelligAIRE II Operator Manual
TK 52076
IntelligAIRE II Pocket Guide
TK 51712
Electrostatic Discharge Training Guide
TK 40282
Thermo King Bus A/C Preventive Maintenance Forms
TK 40809
Diagnosing Thermo King Bus Air Conditioning Systems
TK 51066
The information in this manual is provided to assist owners, operators and service people in the proper
upkeep and maintenance of Thermo King units. The above manuals may be purchased from your local
Thermo King dealer.
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 Kings terms and conditions
including, but not limited to, the Thermo King Limited Express Warranty. Such terms and
conditions are available upon request. Thermo Kings warranty will not apply to any
equipment which has been so repaired or altered outside the manufacturers plants as,
in the manufacturers 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.
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 and State
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.
About This Manual
About This Manual

Purpose
The purpose of this manual is to provide general maintenance information necessary to maintain the
climate control unit at peak operating standards. This includes safety information, unit information such
as bills of material and kit numbers, general unit information, maintenance procedures and related
information (such as wiring and schematic diagrams), and some diagnostic and troubleshooting
information.
NOTE: This manual may cover more than one unit. Therefore, it may contain information not
applicable to your unit.
Contents
This manual is organized into the following chapters:
Chapter
Purpose
Safety Precautions
Provides detailed safety information. You should be familiar with the

safety precautions before working on any unit.
Model Systems and Update

Matrices or About this Unit
(sometimes called Model and Kit
Numbers or something similar)
These tables list the bills of material and kit options that make up your
unit. Use them for the following purposes:
Specifications
Lists unit specifications.
General Description
Gives an overview description of your unit including standard and

optional features, illustrations, and general a/c theory.
Unit Controls and Operation
Gives more detailed descriptions of the features specific to your unit.
Controller(s)
Provides description of controller, operating procedures, and circuit board

maintenance procedures. (May be more than one chapter because some
units have more than one controller option.)
Maintenance Inspection Schedule
Table of routine maintenance procedures.
Maintenance Chapters
Provides detailed maintenance procedures required for your unit.

(Electrical, Refrigeration, Compressor1, Structural, Clutch, Batteryless
Alternator1, Power Pack1)
Air Conditioning Diagnosis and

Analysis, Refrigeration Diagrams
Provides troubleshooting information for diagnosing problems.
1. To determine if you have the right manual for your unit: the bill of
material (B/M) number on your unit serial plate should match one of
the bill of material numbers listed in this section. (If this is not the case,
you may not necessarily have the wrong manual. Your unit may be a
custom order or the manual may be outdated. If you cannot find your
unit in the matrix, call TK Service for more information.)
2. To communicate with TK Service Department: If you need to call TK
Service, you must know your model number(s) in order for the service
representative to help you.
3. To order options and kits: Options and kits listed can be ordered using
the bill of material number (sometimes called the system number) in
the leftmost column of the charts. Call your Thermo King Service
Representative for more information.
About This Manual
Chapter
Purpose
Temperature-Pressure Charts
Provides general Temperature-Pressure information for refrigerants.
Wiring and Schematic Diagrams
Wiring and Schematic diagrams applicable to the unit.
1
Optional. If your book does not have this chapter then this is not an option for your unit. Some OEMs supply their own
compressor. If so, this manual will not contain compressor information.
About This Manual
Contacting Thermo King Service

Before you call Thermo King Service, have the following information on hand:
Bill of Material (usually located on the condenser/evaporator serial plates)
Unit Type
Bus Manufacturer
Who to call: Your Thermo King Service Representative.
Blank Pages
This manual may contain blank pages at the end of chapters. This is normal. There is no information
missing from the manual.
Roadside/Curbside Terminology
Roadside/Curbside terminology: These terms can be confusing because of differences between North
America and Europe. Please note:
Curbside:
The side of the bus to the drivers right when the driver is in his seat and facing forward.
Roadside:
The side of the bus to the drivers left when the driver is in his seat and facing forward.
Using the Model Tables in Model Systems and Update Matrices

The model tables in this section (called About this Unit, Model Systems and Update Matrices, or
something similar) list important unit information that you will need to communicate with the Thermo
King Service Department. See the table on the previous page for a description of how to use these tables.
About This Manual
Table of Contents
About This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Contacting Thermo King Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Blank Pages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Roadside/Curbside Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Using the Model Tables in Model Systems and Update Matrices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
List of Figures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
General Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Battery Removal Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Engine Coolant Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Electrical Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Refrigerant Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Refrigerant Oil Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
First Aid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Engine Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Refrigerant Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Battery Acid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
System Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Electrical Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Refrigerant Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
X430 Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Compressor Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Low Pressure Cutout Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
High Pressure Cutout Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Solder Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Unit Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Thermo King IntelligAIRE II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
X430 Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Serial Number Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Photos and Illustrations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Unit Controls and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Driver Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Mode Switch (MSW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Fan Switch (FSW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Unit Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
IntelligAIRE II Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Ambient Temperature Sensor (ATS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Return Air Temperature Sensor (RTS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Coil Temperature Sensor (CTS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Water (Coolant) Temperature Sensor (WTS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Evaporator Pressure Regulator (EPR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
System Controlled Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Liquid Line Solenoid Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Coolant Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Boost Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Evaporator Blower Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Condenser Fan Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Compressor Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Table of Contents
Unit Controls and Operation (continued)
Unit Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Liquid Line Sight Glass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Compressor Oil Sight Glass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Unit Protection Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
High Pressure Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Low Pressure Cutout Switch (LPCO) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
High Pressure Cutout Switch (HPCO) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Compressor Discharge Sensor (CDS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Circuit Breakers and Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
IntelligAIRE II Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
IntelligAIRE II Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
IntelligAIRE II Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
IntelligAIRE II RS-232 PC Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
IntelligAIRE II Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Display Module Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Modes of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Auto Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Cool Mode (Reheat) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Cool Mode (Cycling Clutch) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Vent Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Heat Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Operating Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Selecting Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Viewing and Changing Setpoints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Selecting Operating Modes (Deluxe Display Module Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Selecting Fan Speed (Deluxe Display Module Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Selecting Damper Settings (Deluxe Display Module Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
IntelligAIRE II Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Setup Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Calibration Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Service Test Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Hourmeter and Real Time Clock Display Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Alarm Code Display Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Maintenance Inspection Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Refrigeration/Heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Structural . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
X430 Compressor Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Electrical Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Maintenance Inspection Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Wiring and Harness Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
High Pressure Cutout Switch (HPCO) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
HPCO Test Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
HPCO Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Low Pressure Cutout Switch (LPCO) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
LPCO Test Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
LPCO Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Condenser Pressure Switch (CPS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
CPS Test Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
CPS Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Boost Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Coolant Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Coil Burnout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Failure to Open (Normally Closed Types) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Failure to Close . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Coolant Valve Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
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Table of Contents
Electrical Maintenance (continued)
Condenser Axial Fan Motors (Brush) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Motor Test Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Motor Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Evaporator Blower Motor (Brush) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Motor Test Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Evaporator Blower Motor Removal and Installation (Brush) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Fresh Air Damper Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Fresh Air Damper Operation Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Actuator Motor Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Actuator Motor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Actuator Motor Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Refrigeration Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Maintenance Inspection Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Refrigerant Service Safety Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
General Refrigerant Handling Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Polyolester Oil Handling Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Accessing Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
HVAC Service Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Service Valve Positions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Gauge Manifold Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Before You Proceed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Gauge Manifold Positions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Gauge Connections: Balancing Pressure, Removing Refrigerant, and Charging System . . . . . . . . . . . . . . 70
Attachment and Purging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Removing the Gauge Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Compressor Pumpdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Low Side Pumpdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Refrigerant Recovery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Recovery from a Working Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Recovery from a Working Unit with an Orit 10 EPR Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Recovery from a Non-functioning Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Removing Air from Recovered Refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Refrigerant Evacuation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
When Evacuation Is Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Problems Caused by Poor Evacuation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Evacuation Stations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Evacuation Time Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Evacuation Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Refrigerant Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Checking the Refrigerant Charge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Charging an Evacuated Unit by Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Charging from a Partially Charged State . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Leak Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Testing a Pressurized System for Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Testing an Empty System for Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Using Pressurized Nitrogen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Contaminants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Types of Contaminants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Removing Air: Unit Contaminated for a Short Period . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Removing Air: Unit Contaminated for a Long Period . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Removing Moisture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Replacing a Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Ice Bath Test for Air and Other Non-Condensables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
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Table of Contents
Refrigeration Maintenance (continued)
Compressor Oil Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Checking the Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Adding Compressor Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Removing Excess Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Checking Compressor Oil Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Compressor Efficiency Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Compressor Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Operating Compressor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Non-Operating Compressor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Compressor Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Compressor Crankshaft Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Set Screw Type Metal Bellows Crankshaft Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Installation of Set Screw Type Metal Bellows Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Brass Sealing Washers Used In Discharge Line Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
SAE J639 Service Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
O-Ring Seal Fitting Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Refrigeration Hose Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Suction and Discharge Hose Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Service Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Suction Service Valve Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Discharge Service Valve Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Service Valve Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
High Pressure Relief Valve Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Condenser Coil Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Receiver Tank Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Filter-Drier Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Evaporator/Heater Coil Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Expansion Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Cleaning In-line Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Sensor Bulb Contact . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Superheat: Measurement and Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
EPR Valve Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Evaporator Pressure Regulator (EPR) Valve (Pilot Type) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Procedure for Checking and Adjusting the EPR Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
EPR Valve Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
EPR Valve Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Structural Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Maintenance Inspection Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Unit Compressor and Electric Motor Mounting Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Unit Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Evaporator, Heater and Condenser Coil Inspection and Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Drain Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Coolant Antifreeze in Heating Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Evaporator Coil Return Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Internal Return Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
12
Table of Contents
Air Conditioning Diagnosis and Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
Analysis Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
Diagnosis Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
Typical Operating Pressures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
System Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
Troubleshooting Compressor Suction and Discharge Pressures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
Temperature-Pressure Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
Refrigeration Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
Wiring and Schematic Diagrams Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
13
Table of Contents
14
List of Figures
Figure 1: Typical Roof Mount Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Figure 2: Typical Air Circulation Diagram (with EPR Valve Shown) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Figure 3: Curbside/Roadside . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Figure 4: Electrical Control Panel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Figure 5: Circuit Breakers and Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Figure 6: Standard Display Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Figure 7: Deluxe Display Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Figure 8: High Pressure Cutout Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Figure 9: Test Light Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Figure 10: Sporlan Coolant Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Figure 11: Axial Fan Motor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Figure 12: Test Terminals on Resistor Block and Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Figure 13: Evaporator Blower Motor Assembly (Brush) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Figure 14: Actuator Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Figure 15: Actuator Connector Plug Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Figure 16: Actuator Motor/Mounting Plate Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Figure 17: Plate Assembly on Actuator Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Figure 18: Fresh Air Actuator Motor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Figure 19: Valve Fully Counterclockwise (Back-seated) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Figure 20: Valve Fully Clockwise (Front-seated) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Figure 21: Valve Turned Half Way In (Open to Service Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Figure 22: Quick Disconnect Access Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Figure 23: Hand Valves Open to Center Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Figure 24: Hand Valves Closed to Center Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Figure 25: Balancing Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Figure 26: Removing Refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Figure 27: Charging the System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Figure 28: Connecting Gauge Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Figure 29: Compound Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Figure 30: Thermo King Evacuation Station TK No. 204-725 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Figure 31: Leak . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Figure 32: Moisture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Figure 33: Testing for Refrigerant Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Figure 34: Typical Pressurized Gas Bottle with Pressure Regulator and Gauges . . . . . . . . . . . . . . . . . . . . . . . 81
Figure 35: Contaminants in a System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Figure 36: Suction Filter Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Figure 37: Ice Bath Sample Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Figure 38: Compressor Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Figure 39: Balance SystemBoth Valves Front Seated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Figure 40: Adding Compressor Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Figure 41: Checking Oil Pump Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Figure 42: Compressor Front Drive Plate TK No. 22-790 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Figure 43: Stainless Steel Bellows Crankshaft Seal TK No. 22-751 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Figure 44: Compressor Front Drive Plate TK No. 22-754 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Figure 45: Stainless Steel Bellows Crankshaft Seal TK No. 22-1100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Figure 46: Special Allen Wrench . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Figure 47: Cross Section of Set Screw Type Bellows Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Figure 48: Set Screw Type Bellows Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Figure 49: Bellows Installation with Tool TK No. 204-995 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Figure 50: Seal Installation Tool Placed on Compressor Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Figure 51: Seal Installation Tool Secured To Crankshaft and Tightening Set Screws . . . . . . . . . . . . . . . . . . . . 97
Figure 52: Seal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Figure 53: Installation of Mating Ring (Hard Ring) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Figure 54: Installation of Seal Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Figure 55: Fitting and Brass Sealing Washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Figure 56: Suction Adapter with or without Depressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Figure 57: Discharge Adapter with or without Depressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Figure 58: JIC Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
15
List of Figures
Figure 59: O-ring Face Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Figure 60: Hose Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Figure 61: Typical Suction and Discharge Hose Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Figure 62: Hose Routing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Figure 63: Ideal Hose Routing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Figure 64: Correct and Incorrect Hose Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Figure 67: Service Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Figure 68: Expansion Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Figure 69: Sensor Bulb Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Figure 70: Pilot Type EPR Valve with Pilot Line Shutoff Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Figure 71: Pilot Type EPR Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Figure 72: Tetraseal Size for ORIT-15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
Figure 73: Pilot Type EPR Valve Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Figure 74: Cutaway View of ORIT 15 Pilot Type EPR Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
Figure 75: Return Air Filter (Internal) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
Figure 76: Typical Refrigeration Diagram with Description of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
16
Safety Precautions
Safety Precautions
NOTE: EPA Section 608 Certification is
required to work on refrigeration systems.
Thermo King recommends that all services be
performed by a Thermo King dealer. However,
you should be aware of several general safety
practices:
The
symbol appears next to a point that is
particularly important.
DANGER: Denotes the possibility of
serious injury or death.
WARNING: Denotes the possibility of
serious equipment damage or serious
personal injury.
CAUTION: Denotes the possibility of
minor to severe equipment damage or
personal injury.
General Practices
DANGER: Do not operate the compressor
with the discharge valve closed. This
condition increases internal pressure,
which can cause an explosion.
DANGER: Never apply heat to a sealed
refrigeration system or container. Heat
increases internal pressure, which might
cause an explosion.
DANGER: Refrigerant in the presence of
an open flame, spark or electrical short
produces toxic gases that are severe
respiratory irritants.
DANGER: Keep your hands, clothing and
tools clear of fans, pulleys, or belts when
working on a unit that is running. Loose
clothing might entangle moving fans,
pulleys, or belts, causing serious injury or
possible death.
DANGER: Do not inhale refrigerant. Use

caution when working with refrigerant or
a refrigeration system in any confined
area with a limited air supply, such as a
bus or garage. Refrigerant displaces air
and can cause oxygen depletion, resulting
in suffocation and possible death.
WARNING: Make sure your gauge
manifold hoses are in good condition
before using them. Never let them come in
contact with moving belts, motors, engine
pulleys or hot surfaces. Defective gauge
equipment can damage components or
cause serious injury.
WARNING: Wear goggles or safety
glasses when working around air
conditioning systems or batteries.
Refrigerant liquid, oil and battery acid can
permanently damage your eyes.
WARNING: Use extreme caution when
drilling holes in the unit. Holes might
weaken structural components. Holes
drilled into electrical wiring can cause a
fire or explosion.
WARNING: Exposed coil fins can cause
lacerations. Service work on the
evaporator or condenser coils is best left to
a certified Thermo King technician.
WARNING: Be careful when using
ladders or scaffolding to install or service
air conditioning systems. A work platform
is recommended for servicing rooftop
units. Follow the manufactures
instructions, safety labels and warnings.
CAUTION: Make sure all mounting bolts
are tight and are the correct length for
their applications. Improper torque and
incorrect bolt lengths can damage
equipment.
17
Safety Precautions
CAUTION: If soldering is required, use

dry nitrogen to purge the system during
any solder operations. Refer to Using
Pressurized Nitrogen at the end of the
Refrigeration Maintenance chapter.
Battery Removal Hazards

DANGER: Disconnect the negative
terminal (-) first when removing a battery.
Connect the positive terminal (+) first
when installing a battery.
This order is important because the frame is
grounded to the negative battery terminal. If the
negative terminal is still connected, a complete
circuit exists from the positive terminal of the
battery to the frame. Metal objects contacting the
positive side and the frame simultaneously will
cause sparks or arcing. If there are sufficient
hydrogen gases emitted from the battery, an
explosion might occur, causing equipment
damage, serious injury, even death.
CAUTION: Use recommended
procedures when servicing equipment.
Improper procedures might damage
equipment.
Engine Coolant Hazards

CAUTION: Do not use coolant boosters
or anti-corrosion additives in older
Thermo King units (five to seven years
old) as it will deteriorate the
rubber/neoprene parts/hoses. Contact
your local Thermo King dealer for
additional information.
CAUTION: Use a mixture of 50 percent
antifreeze and 50 percent water in Thermo
King bus air conditioning and heating
units manufactured with heating coils.
This blend prevents coil freezing and
assists in preventing corrosion buildup.
18
Electrical Hazards
WARNING: Control circuits used by bus
air conditioners are low voltage (12 or 24
volts dc). This voltage is not dangerous,
but the large amount of amperage
available from the alternator can cause
severe burns if accidentally shorted to
ground with metal objects, such as tools.
WARNING: Do not wear jewelry, watches
or rings because they increase the risk of
shorting out electrical circuits and
damaging equipment or causing severe
burns.
WARNING: Use caution when working
with electrical circuits that have
capacitors. Some capacitors hold a
significant charge that might cause burns
or shocks if accidentally discharged. Make
sure capacitors are discharged before
working on electrical circuits.
CAUTION: When working with electrical
circuits that contain microprocessors,
always wear an ESD wrist strap (TK No.
204-622) and connect the opposite end to
the chassis ground or CH terminal. This
precaution will prevent electrostatic
discharge from damaging circuits.
CAUTION: Certain service procedures on
bus air conditioning equipment require
that the system be de-energized. When this
precaution is necessary, ensure the
batterys master switch or service switch is
turned off. Confirm that power has been
removed before servicing. Equipment that
is connected to power is dangerous to
service.
Refrigerant Hazards
DANGER: Do not use a Halide torch.
When a flame comes in contact with
refrigerant, toxic gases are produced that
might cause suffocation, even death.
Safety Precautions
DANGER: Store refrigerant in proper

containers, out of direct sunlight and away
from intense heat. Heat increases pressure
inside storage containers, which can cause
them to burst.
DANGER: Do not use oxygen (O2) or
compressed air for leak testing systems.
Oxygen mixed with refrigerant is
combustible.
WARNING: Wear protective garments and
goggles or safety glasses when working
with refrigerant to prevent frostbite and
eye injuries.
WARNING: Wear butyl lined gloves when
handling refrigerant to help prevent
frostbite.
CAUTION: All charging using the newer
refrigerants (Azeotropic blends) must be
done in liquid state. Failure to do this will
decrease system operating efficiency.
Refer to the charging procedures found in
this manual for your unit.
CAUTION: When recovering or
transferring refrigerant, use a process
that prevents refrigerant from escaping
into the atmosphere. Refrigerant damages
the earths upper ozone layer.
CAUTION: Refrigerant in a liquid state
evaporates rapidly when exposed to the
atmosphere, freezing anything it contacts.
Be careful when handling refrigerant to
protect your skin from frostbite.
Refrigerant Oil Hazards

WARNING: Protect your eyes from
contact with refrigerant oil. The oil can
cause serious eye injuries. Avoid
prolonged or repeated contact with
refrigerant oil. To prevent irritation, wash
your hands and clothing thoroughly after
handling the oil.
CAUTION: Do not mix refrigerant oils

because that can cause system damage.
CAUTION: Use dedicated equipment to
prevent contaminating the system with the
wrong type of oil or refrigerant.
CAUTION: Thermo King uses a variety of
compressor oils. Oil used in the system
must be verified. Check ID label or
Specification chapter in this manual for
correct oil. Using incorrect oil will
invalidate the warranty.
CAUTION: When servicing TK units, do
not use equipment that might be
contaminated with PAG oils.
CAUTION: Store refrigerant oil in an
approved sealed container to avoid
moisture contamination.
CAUTION: Do not expose refrigerant oil
to the air any longer than necessary. The
oil will absorb moisture, which results in
much longer evacuation times and
possible system contamination.
CAUTION: Wipe up spills immediately.
Refrigerant oil can damage paints and
rubber materials.
First Aid
Engine Coolant
Eyes: In case of eye contact, 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.
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.
19
Safety Precautions
Refrigerant
In the event of frostbite, protect the frozen area
from further injury, warm the area rapidly and
maintain respiration.
Eyes: Immediately
flush eyes with large amounts

of water. CALL A PHYSICIAN.
Skin: Flush area with large amounts of warm
water. Do not apply heat. Remove contaminated
clothing and shoes. Wrap burns with dry, sterile,
bulky dressing to protect from infection. CALL A
PHYSICIAN. Wash contaminated clothing before
reuse.
Inhalation: Move
victim to fresh air and use CPR

(cardio pulmonary resuscitation) or
mouth-to-mouth resuscitation to restore breathing,
if necessary. Stay with victim until emergency
personnel arrives.
Battery Acid
Eyes: Immediately flush with water for at least 15
minutes. CALL A PHYSICIAN. Wash skin with
soap and water.
20
System Kits
LRT-HP (900273) Systems
System
Name
System
Number
Unit Fan
Motors
Control
Voltage
Refrigeration
Wiring
Diagrams
LRTHP-M6 1000
900273
Spal
27 Vdc
R-22
1E11954
1E11955
LRT-HP (900273) System Kits

System
Name
Evaporator/
Condenser
Compressor Kit
Install Kit
Driver Display Kit
LRTHP-M6 1000
006955/
099916
X430700153
880240
700427
NOTE: When calling the dealer or factory for information or parts please have the Bill of Material
number for your particular unit handy.
21
System Kits
22
Specifications
Electrical Controls
Software Version
P4.0
Software Application File
2C40104H04
Software Configuration Fil
2C40105H44
Starter Solenoids (2 Used)

Type
Solenoid Actuated Contactor (SPNO)Ground on

Base
Voltage
24 Vdc
Current
100 amps
Duty
Continuous
Resistance
51.054.0 10% ohms @ 77 F (25 C)
Control Panel Relays (9 used)

Type
Double Pole Single Throw (DPST)
Voltage: Maximum Vdc @ 85 C
30.0 Vdc
Voltage: Pull-In
14.4 Vdc
Coil Operating Current

Contact Rating Resistive: (Normally Open-NO)
40 A @ 14 Vdc
Resistance
272 10 ohms
Solenoid (Coolant) Valve

Type
Normally closed
Voltage
27 Vdc
Resistance
38.4 10 percent ohms @ 77 F (25 C)
Motors
Condenser Fan Motor Assemblies (3)
Model
Long Life Brush
Type
Encased Axial Fan
Horsepower
0.273 hp
Voltage
27 Vdc
Current DrawFull Load
10 amps
RPMFull Load
3300 rpm
Evaporator Blower Motor Assemblies (3)

Model
Long Life Brush
Type
Forward curved blower
Horsepower
0.360 hp
Voltage
27 Vdc
Current DrawFull Load
10 amps
RPMFull Load
3800 rpm
Fresh Air Damper Motor (Units with Fresh Air option only)
Voltage
27 Vdc
23
Specifications
Refrigerant
Type
R22
Refrigerant Charge (System)
Refer to unit charging procedures found in the

Refrigeration Maintenance chapter.
Refrigerant Controls
Condenser Pressure Switch)
Opens 200 20 psig (1379 138 kPa)
Closes 300 +25/-0 psig (2068 +172/-0 kPa)
Expansion Valves (2 Used)
Type
External equalizer with Strainer
Superheat Setting
10 to 15 F (6 to 9 C)
Connection
Solder
Evaporator Pressure Regulator (EPR) (Orit 15)

Type
Pilot operatedAdjustable
Adjusted Minimum Pressure
50 1 psig (345 7 kPa)
High Pressure Relief Valve

Opens 500 + 75/15 psig (3447 + 517/103 kPa)
Closes 400 psig (2758 kPa)
24
Specifications
X430 Compressor
Model
X430
Displacement
30 cid (492 cm3)
Cylinders
Recommended Operating Range
800 to 3000 RPM
Oil Charge (System)
119 oz (3.52 liters)
*Oil Type for R22
Synthetic SSU Viscosity
Oil Pump Operating Pressure Range
15 to 45 psig (103 to 310 kPa, 1 to 3 bar, Kg/cm2)
Weight with Service Valves
115 lbs. (52 kg)
*Consult your parts catalog for oil part number.
CAUTION: Failure to use correct Thermo King recommended oil will invalidate your
warranty.
Compressor Clutch
Type
Electromagnetic
Voltage
27 Vdc
*Resistance
12 ohms @ 100 F (38 C)

11.6 ohms @ 75 F (24 C)
11.2 ohms @ 50 F (10 C)
Air Gap
0.045 0.005 in. (1.143 1.127 mm)
Bearing Grease
Exxon Unirex N2
Rotation
Clockwise
Pulley Diameter
8.90 OD
Pulley Groove
5V/3V
*For additional information, refer to the Clutch Coil Electrical Check in the Clutch Maintenance chapter
in this manual.
Low Pressure Cutout Switch

Opens 5-17 in. Hg Vacuum
Closes 1 to 7 psig (7 to 49 kPa)
High Pressure Cutout Switch

Opens 470 7 psig (3240 49 kPa)
Closes 375 38 psig (2590 262 kPa)
25
Specifications
Solder Applications
Components
Used for:
Details
Copper to copper or copper to

brass
General refrigeration
tubing connections
Joint Clearances: 0.003 to 0.005 in. (0.076 to 0.127 mm)
Copper to stainless steel or

brass to stainless steel
Refrigeration tubing
connections of
dissimilar metals
Components
Used for:
Details
Copper to copper or copper to

brass
Hot water tubing

connections
Copper to stainless steel or

brass to stainless steel
Hot water tubing

connections of
dissimilar metals
Use: Solder Type 15% Silver TK No. 203-364 Use: Flux

Type TK No. 203-365

Type TK No. 203-365
Use: Solder Type 95% Tin and 5% antimony

TK No. 204-167 Use: Flux Type TK No. 204-417

Type TK No. 203-365
NOTE: Some units may be equipped with an evaporator pressure regulating valve (EPR). To reduce the
chance of overheating the EPR valve, 95-5 solder or equivalent may be used.
Use 95-5 TK No. 204-167
Use Flux TK No. 204-417
26
General Description
Unit Overview
Serial Number Locations
The LRT-HP M6 1000 is a roof-mounted air

conditioning unit with a low, aerodynamic profile
designed for inner city and tour buses.
Motors: Located on back of motor housing

assembly.
Thermo King IntelligAIRE II

The IntelligAIRE IITM microprocessor controls
temperatures in up to three zones. It has a base
module, an optional display module, and up to
four expansion modules. It has an RS232 interface
for downloading data to a PC. For more
information, see the IntelligAIRE II chapter in
this manual.
Compressor: Stamped
on plate attached to
compressor body above clutch.
Unit Evaporator: Nameplate
is located inside of
unit below the sight glass.

Unit Condenser: Nameplate is located on the
curbside mounting channel under the cover.
X430 Compressor
The X430 is a 30 cid (491.6 cm3), four-cylinder,
V-type, reciprocating compressor. Maximum
operating speed is 3000 RPM. The compressor is
belt-driven by the bus engine through the electric
clutch. Large grease cavities provide bearing
lubrication. A grease fitting in the front seal
allows lubrication without disassembly.
Cutout switches provide protection from high and
low refrigerant pressures. Suction and discharge
service valves with gauge manifold ports provide
easy servicing.
27
General Description
Photos and Illustrations
1.
2.
3.
4.
5.
6.
Roof Skin
Duct Extension
Evaporator Blower
Hot Water Coil
Evaporator Coil
Return Air
7.
8.
9.
10.
11.
12.
Supply Air
Air Outlet
Luggage Rack
Main Duct
Gasket Seal Blower Opening
Gasket Seal Return Air Opening
Figure 1: Typical Roof Mount Unit
28
General Description
1.
EPR Valve (Where provided): Maintains a controlled back pressure in the evaporator to keep the
coil at the desired temperature thus preventing evaporator coil freeze up.
2.
Expansion Valve Bulb: Measures the temperature at evaporator outlet.
3.
Evaporator Coil: Picks up heat from the load.
4.
Expansion Valve: Meters amount of refrigerant to the evaporator coil.
5.
Filter-Drier (Dehydrator): Removes moisture from the system.
6.
Condenser Coil: Removes heat from refrigerant.
7.
Receiver Tank: Storage device for refrigerant.
8.
Compressor: Moves refrigerant.

Figure 2: Typical Air Circulation Diagram (with EPR Valve Shown)
29
General Description
FRONT
ROADSIDE
CURBSIDE
1.
Condenser Fans (5)
2.
Evaporator Serial Name Plate
3.
Filter Drier
4.
Receiver Tank
5.
Electrical Control Panel Assembly

Figure 3: Curbside/Roadside
30
General Description
8
6
5
2
34
10
6.
F1-F6 (Protects Evaporator Blower

Motors
F14 ((Protects Control Circuit
7.
CB1 (Evaporator Circuit Breaker)
3.
F13 (Protects Boost Pump Circuit
8.
Relays (9)
4.
F12 (Protects Clutch Circuit
9.
CB2 (Condenser Circuit Breaker)
5.
F7-F11 (Protects Condenser Fan

Motors
10.
High Current Solenoids (2)
1.
IntelligAIRE II Base Module
2.
Figure 4: Electrical Control Panel Assembly
31
General Description
32

Driver Controls
Return Air Temperature Sensor

(RTS)
Mode Switch (MSW)
The RTS is located in the evaporator section. It

monitors the return air temperature from inside
the bus and sends a signal to the controller
through the J1939 network, regulating the
compartment air temperature and humidity.
(Bus OEM Supplied)

When this switch is provided by the OEM, its
function is to allow the driver to select the mode
of operation for the HVAC system. Available
modes include, Cool, Vent, Heat, and Automatic.
When not provided, IntelligAIRE II control
system will operate the HVAC system in the
Automatic mode.
For buses equipped with the Programmable Logic
Controller (PLC), the PLC uses the input from the
mode switch and then energizes the appropriate
circuit into the microprocessor controller system
so the HVAC system will function in the desired
mode.
NOTE: Refer to bus OEM maintenance manuals
for information on PLC and associated control
logic.
Fan Switch (FSW)

(OEM Supplied)
This switch controls blower speed in Heat or Vent
mode. Two switch settings are provided, High
speed and Low speed.
Unit Controls
IntelligAIRE II Control System
Coil Temperature Sensor (CTS)

The CTS monitors the evaporator coil temperature
and sends a signal to the controller. If the coil
temperature drops too low, the controller stops the
compressor to prevent the evaporator coil from
freezing. The controller starts the compressor
after the coil temperature rises enough to keep the
evaporator coil from freezing.
Water (Coolant) Temperature

Sensor (WTS)
The WTS is a standard sensor on IntelligAIRE II
systems that prevents the blowers from operating
until the coolant is warm enough to heat the bus
interior.
Condenser Pressure Switch (CPS)

The condenser pressure switch monitors the
discharge (condenser) pressure. When the
discharge pressure reaches the switch setpoint, it
changes the condenser fan speed.
Evaporator Pressure Regulator

(EPR)
This unit uses the IntelligAIRE II microprocessor

controller. The IntelligAIRE II interface allows
you to easily download alarm codes for
troubleshooting, and to easily upload programs
for new configurations. It has a completely sealed
control panel for maximum safety and durability,
and can be used to control up to three temperature
zones. See the microprocessor controller chapter
in this manual for more information.
The EPR valve is installed on the suction line and

controls the pressure in the evaporator coil to
prevent the coil from icing. See Specifications
for the EPR pressure setting.
Ambient Temperature Sensor (ATS)
This solenoid valve is used in split A/C systems

using small automotive compressors. It promotes
pressure equalization within the unit and prevents
liquid from flowing into the evaporator.
The ATS monitors outside air temperature and

sends a signal to the controller through the J1939
network, enabling the controller to select Cool or
Heat mode, when running in Auto mode
operation.
System Controlled
Components
Liquid Line Solenoid Valve
33
Coolant Valve
Unit Protection Devices
This coolant valve controls the flow of engine

coolant to the evaporator heater coils.
Boost Pump
A high pressure relief valve is installed in the

refrigerant tubing system to vent excessive
pressure buildup if necessary.
(OEM Supplied)
The boost pump increases the flow of engine
coolant to the heating coil or driver defrost heater.
Evaporator Blower Motors

These motors turn the blower wheels that pull the
compartment air through the filters and
evaporator/heater coils to provide conditioned air
to the passenger compartment.
Low Pressure Cutout Switch (LPCO)

The LPCO switch is a pressure sensitive switch
located in the suction line or the suction manifold.
If the suction pressure drops below the switch
setpoint, the switch will open to stop the
compressor. If the switch stays open for more than
60 seconds, the IntelligAIRE I or IntelligAIRE II
controller shuts down the compressor and logs
Alarm Code 11.
Condenser Fan Motors

These motors turn the fans that draw air through
the condenser coils. As this airflow passes
through the condenser coils, it cools and
condenses the refrigerant inside the condenser
coils.
Compressor Clutch
The compressor clutch is an electromagnetic
device that engages the belt-driven pulley to the
engine belt-driven compressor.
Unit Indicators
Liquid Line Sight Glass
The liquid line sight glass shows the flow of
liquid refrigerant leaving the drier. A clear sight
glass with an occasional bubble indicates normal
flow. A stream of bubbles indicates a low
refrigerant charge, or an obstruction in the system.
The moisture indicator (dry eye) in the liquid line
sight glass shows the level of moisture in the
system by changing color. Check the color of the
indicator against the color decal on the sight glass.
The dry eye in the sight glass is GREEN when the
system is dry and YELLOW when the system is
wet (contains excessive moisture).
Compressor Oil Sight Glass

The compressor oil sight glass indicates the level
of compressor oil in the compressor sump.
34

(HPCO)
The HPCO switch is a pressure sensitive switch
located in the compressor head or discharge
manifold. If the discharge pressure exceeds the
switch setpoint, the switch will open to stop the
compressor. If the switch stays open for more than
2 seconds, the IntelligAIRE I or IntelligAIRE II
controller shuts down the compressor and logs
Alarm Code 10.
Compressor Discharge Sensor

(CDS)
The IntelligAIRE controller monitors the
compressor discharge temperature through the
CDS. If the compressor discharge temperature
exceeds 300 F (149 C) for 30 minutes, the
controller logs Alarm Code 08. If the compressor
discharge temperature exceeds 320 F (160 C) for
one minute, the controller shuts down the
compressor and logs Alarm Code 12.
Circuit Breakers and Fuses

For more details, see the schematic diagram in
this manual.
Name
Amps
Protects
Fuse (not
numbered)
150
Battery circuit
(OEM Supplied)
CB1
85
Evaporator Fan Motors
F1, F3, F5
30
F2, F4, F6
20
CB2
85
F7-F11
15
F12
10
Clutch Circuit
F13
15
Boost Pump Circuit
F14
10
Control Circuits
Figure 5: Circuit Breakers and Fuses
35
36
IntelligAIRE II Controller
IntelligAIRE II Overview
IntelligAIRE II Components
The Thermo King IntelligAIRE II is a

microprocessor-based controller for bus HVAC
systems. It can have a standard display, a deluxe
display, or no display, and can control
temperatures in up to three zones.
The IntelligAIRE II is a component-based system

that allows expansion of features and temperature
control zones. The IntelligAIRE II consists of the
following components:
IntelligAIRE II Features
IntelligAIRE II features include:
Temperature setpoints for three zones

(standard and deluxe display)
Return air and ambient temperature display in

three zones (standard and deluxe display)
Cool, heat, and vent mode operation in three

zones (deluxe display only)
Internal air flow control in three zones (deluxe

display only)
Fresh air damper control in three zones

(deluxe display only)
Driver control of heat, cool, defrost, vent, and

blower speed (deluxe display only).
Base Module: The base module contains the main

system controller. It communicates with the
display module and expansion modules (if
applicable) via an SAE J1939 CAN bus.
Expansion Modules: Based on application, a unit
can have up to 4 expansion modules that can
support additional passenger zones, floor heat
zones, or provide expanded driver control.
Display Module (Optional): The
display module
provides a user interface. It is available in
standard and deluxe versions. See the next section
for the display panel description.
IntelligAIRE II RS-232 PC Interface

The IntelligAIRE II has an RS-232 interface to a
computer for use by service technicians. This
diagnostic interface:
Displays and saves alarm codes
Stores, accesses, and tracks alarm code history
Accesses hourmeter readings for the

compressor, evaporator, and unit run hours
Tests the system by manually or automatically

cycling system outputs
Displays and monitors system inputs
Installs software upgrades by flash load rather

than by changing a software EPROM.
37
Display Module Description

Display modules are available in a standard
version (shown in Figure 6 below) and a deluxe
version (shown in Figure 7 on page 39). The
display module consists of touch keys, an LED

display, and display indicators. Keys and indicator
lights are as follows:
1.
Passenger Zone 1 Return Air Temperature

Indicator
8.
ON/OFF Key
2.
Passenger Zone 2 Return Air Temperature

Indicator
9.
Setpoint Indicator
3.
Drivers Zone Return Air Temperature

Indicator
10.
DOWN ARROW Key
4.
Ambient Air Temperature Indicator
11.
Percent Indicator
5.
DISPLAY SELECT Key
12.
UP ARROW KEY
6.
THERMO KING LOGO Key
13.
LED Display
7.
Warning Indicator
Figure 6: Standard Display Module
38
15. DAMPER SELECT Key
1.
Auto Mode Indicator
2.
Cool Mode Indicator
16. Passenger Zone 1 Return Air Temperature Indicator
3.
Heat Mode Indicator
17. Passenger Zone 2 Return Air Temperature Indicator
4.
Vent Mode Indicator
18. Drivers Zone Return Air Temperature Indicator
5.
OPERATING MODE SELECt Key
19. Ambient Air Indicator
6.
Auto Fan Speed Indicator
20. DISPLAY SELECT Key
7.
High Fan Speed Indicator
21. THERMO KING LOGO Key
8.
Medium Fan Speed Indicator
22. Warning Indicator
9.
Low Fan Speed Indicator
23. ON/OFF Key
10.
FAN SPEED SELECT Key
24. Setpoint Indicator
11.
Auto Damper Indicator
25. DOWN ARROW Key
12.
Recirculate Mode Indicator
26. Percent Indicator
13.
Drivers Panel Air Indicator
27. UP ARROW Key
14.
Defrost Indicator
28. LED Display

Figure 7: Deluxe Display Module
39
On/Off Key: Turns
the controller on and

off. (If the bus has an OEM-supplied
switch, this button is ignored.)
NOTE: The controller does a self-check when

turned on. Display functions are not available
until after the engine is running.
Operating Mode Select Key: On a
deluxe
display module, selects operating mode:
Auto, Cool, Heat, or Vent. The default
mode is Auto. Press this key to select other
modes. On a standard display module, the bus
OEM may provide a mode selection switch.
Fan Speed Select Key: Selects evaporator
fan speed: Auto, High, Medium, or Low.

The default mode is Auto. Press this key
to select other fan speeds. Available speeds
depend on configuration.
Damper Select Key: Selects damper
position. The default mode is Auto. In

Auto mode, the passenger zone damper
opens when the inside temperature is within a few
degrees of setpoint. The passenger zone damper
has two modes: Auto and Recirculate. The driver
zone has up to four modes, depending on the
number of damper actuators installed. Select the
following modes with the DAMPER SELECT key:
Auto: Fresh air damper is controlled
automatically. Panel air and defrost dampers are
closed.
Recirculate: Fresh
air damper, panel air damper,

and defrost damper are closed.
Panel: Fresh air damper and panel air
damper are
opened. Defrost damper is closed.

Defrost: Fresh air damper and defrost damper are
opened. Panel air damper is closed.
Display Select Key: Selects the
display
temperature shown on the display:
Passenger Zone 1 Return Air
Temperature, Passenger Zone 2 Return Air
Temperature, Driver Zone Return Air
Temperature, or ambient air temperature. The
standard default display is Passenger Zone 1
Return Air Temperature. Press the DISPLAY SELECT
key to view other temperatures.
NOTE: The ambient temperature can alert the
driver to possible icing on some road surfaces.
40
Up and
Down Arrow Keys: Increase
and decrease the setpoint temperature for the

selected zone. In the Standard Display of return
air temperature, pressing the UP or DOWN key
displays the setpoint for the selected zone.
Subsequent key presses increase or decrease the
setpoint.
Warning Indicator Display: If
a warning
light stays on after the system has powered up,

there is a malfunction occurring. A yellow
warning indicates a Check or Log alarm. The
system is operable, but should be investigated. A
red warning indicates a Shutdown alarm. The unit
will not run and should be checked immediately.
See Alarm Code Display Mode on page 45 for
more information.
Modes of Operation
Auto Mode
NOTE: For more information on the thermostat
sequence, see the schematic diagram at the end
of this manual
In Auto mode, the controller selects Cool or Heat
mode based on the ambient temperature, return air
temperature, and setpoint.
If the ambient temperature is below 55 F (12.7 C),
the unit operates in Heat Mode. The unit stays in
Heat Mode as long as the return air temperature is
between 4.5 F (2.5 C) degrees above setpoint and
2.5 F (1.4 C) degrees below setpoint. If the return
air temperature goes 4.5 F (2.5 C) degrees above
the setpoint for more than ten minutes, the unit
switches to Cool Mode.
If the ambient temperature is above 60 F (15.6 C),
the unit operates in Cool Mode. The unit stays in
Cool Mode if the return air temperature is
between 2.5 F (1.4 C) above setpoint and 4.0 F
(2.2 C) below setpoint. If the return air
temperature goes below 4.0 F (2.2 C) for more
than ten minutes, the unit switches to Heat Mode.
Cool Mode (Reheat)
Viewing and Changing Setpoints
In Cool mode with Reheat, the compressor runs

continuously. Setpoint is maintained by passing
hot engine coolant through the heater coil. The
evaporator fan speed is controlled automatically
by the microprocessor or manually by the driver.
To view and change setpoints:
Cool Mode (Cycling Clutch)

In Cool mode with Cycling Clutch, the
compressor cycles on and off to maintain setpoint.
A timer prevents the compressor from rapid
cycling by setting a minimum off time (60
seconds). The evaporator fan speed is controlled
automatically by the microprocessor or manually
by the driver.
Vent Mode
In Vent mode, the evaporator blowers run at the
speed determined automatically by the
microprocessor or manually by the driver. The
compressor, boost pump, and coolant valve are
off.
Heat Mode
In Heat mode, setpoint is maintained by passing
hot engine coolant through the heater coil. The
evaporator blowers remain off until the engine
coolant temperature rises to 105 F (41 C), as
measured by the WTS (water temperature sensor)
located on the inlet coolant tube. The evaporator
fan speed is controlled automatically by the
microprocessor or manually by the driver.
Operating Procedures
Selecting Displays
The Standard Display of Passenger Zone 1 Return
Air Temperature displays when the unit is turned
on.
To select other displays:
Press the DISPLAY SELECT key. The indicator

above the DISPLAY SELECT key lights, indicating
which temperature is displayed: Passenger
Zone 1, Passenger Zone 2, Driver Zone, or
Ambient.
1. Press the DISPLAY SELECT key to select the

desired zone. The indicator above the DISPLAY
SELECT key lights, indicating which
temperature is displayed: Passenger Zone 1,
Passenger Zone 2, Driver Zone, or Ambient.
2. To view the setpoint for the selected zone,
press the UP or DOWN ARROW key once. The
setpoint indicator flashes, indicating that
setpoint is displayed.
3. Press the UP key to raise the setpoint. Press the
DOWN key to lower the setpoint. When the
desired setpoint displays, wait approximately
5 seconds. The display returns to the
temperature for the selected zone, indicating
that the setpoint has changed.
Selecting Operating Modes (Deluxe

Display Module Only)
The default operating mode is Auto. To select a
different mode, press the OPERATING MODE SELECT
key. The indicator above the OPERATING MODE
SELECT key lights, indicating which mode is
selected: Auto, Cool, Heat, or Vent.
Selecting Fan Speed (Deluxe

The default fan speed is Auto. To select a different
fan speed, press the FAN SPEED SELECT key. The
indicator above the FAN SPEED SELECT key lights,
indicating which mode is selected: Auto, High,
Medium, or Low.
Selecting Damper Settings (Deluxe

The default damper setting is Auto for the
passenger zones and Fresh Air for the driver zone.
To select a different damper setting, press the
DAMPER SELECT key. The indicators above the
DAMPER SELECT key indicate which modes are
selected. Auto and Recirculate are available for
the passenger zones. Fresh Air, Recirculate, Panel
Air, Defrost, and Normal are available for the
driver zone.
41
IntelligAIRE II Diagnostics
Setup Mode
When accessed through the display module, Setup
mode is view-only. To change settings, you must
use a PC with SMART-Pac software.
1. To enter the Setup Mode, press and hold both
the UP and DOWN ARROW keys down for
approximately 5 seconds. [Un] appears,
indicating the unit is in Setup Mode. Normal
operation stops when the unit is in Setup
Mode.
2. To scroll through the Setup Mode features,
press the DISPLAY SELECT key. The features
appear in the order shown here:
Programmable Features (Setup Mode)
Display
Programmable Feature
Un
Units of Measure (F = Fahrenheit or

C = Celsius)
CC
Clutch Control (rh or Cy)
HC
High Cool Setpoint Limit
LC
Low Cool Setpoint Limit
HH
High Heat Setpoint Limit
LH
Low Heat Setpoint Limit
HA
High Auto Mode Setpoint Limit
LA
Low Auto Mode Setpoint Limit
3. When the desired feature displays, press the

UP or DOWN ARROW key to display the current
value.
4. To return to Standard Display mode, press the
TK LOGO key.
Calibration Mode
When accessed through the display panel, the
Calibrate Mode is view-only. To change settings,
you must use a PC with SMART-Pac software.
Consult the unit schematic diagram to determine
which input is being displayed. For example, on
the schematic diagram, Analog Input 13 is the
ATS. When [A13] is displayed in Calibration
mode, it is the current reading of the ATS.
1. To enter Calibration Mode, press and hold the
UP ARROW key and the TK LOGO key for
approximately 5 seconds. [Axx] appears,
42
indicating the unit is in Calibration Mode.

Normal unit operation stops when the unit is
in Calibration Mode.
2. To scroll through the Calibration Mode
features, press the DISPLAY SELECT key. The
display shows [Axx] for analog inputs, [Uxx]
for analog outputs, and [Pxx] for
potentiometers on the servo actuators.
3. When the desired feature displays, press the
UP or DOWN ARROW key to view its value.
The analog input reading on the display is
converted to the units associated with the
analog input. If an input is not adjustable, it
will display ---.
The analog output reading on the display is
the percentage of full-scale output voltage 0.0
to 5.0 Vdc. You can measure output voltage
with a voltmeter.
TK LOGO key.
Service Test Mode

Service test mode allows a service technician to
verify the operation of relays, contactors, motor
controllers, coolant valves, and modulating
valves.
1. To enter Service Test Mode, press and hold the
DOWN ARROW key and the DISPLAY SELECT key
for approximately 5 seconds. [Pt] appears,
indicating the unit is in Service Test Mode.
in Service Test Mode.
2. To scroll through the Service Test Mode
options, press the DISPLAY SELECT key. The test
options appear in the order shown below.
3. When the desired test displays, press the UP or
DOWN ARROW key to select the test.
If an output or function is not enabled in the
configuration, the test for that feature is
skipped.
4. To exit Service Test Mode and return to the
Standard Display, press the TK LOGO key.
Service Tests (Service Test Mode)

Display
Service Tests
Pt
Pretrip Test
rt
Relay Test
Ft
Functional Test
EFx
Variable Evaporator x Fan Speed Control

Test
CF
Variable Condenser Fan Speed Control

Test
CUx
Variable Coolant Valve x Control Test
dPx
Variable Damper Position x Control Test
Pretrip Test
To initiate the Pretrip Test, press either the UP or
DOWN ARROW key when [Pt] is shown in the
display. The test stops if any alarm codes are
generated. At the end of the test, the display
shows [PAS] (pass) or [FAL] (fail). Pretrip tests
are as follows:
1. Relay Test: Sequentially cycles each enabled
output on for 5 seconds.
2. Variable Output Tests (CF, EFx, CUx, dPx):
Sequentially increment each enabled output
from 0 to 100 percent in 10 seconds.
If the compressor has not been enabled in the
configuration, the test will jump to step 4.
3. Cool High Test: The temperature delta for
each enabled zone must be at least a preset
amount in a preset time period. If discharge air
temperature sensors are not installed, the
return air temperature for each enabled zone
drops at least a preset amount in a preset time
period.
If the boost pump is not enabled in the
configuration, the test jumps to step 5.

TK LOGO key.
Relay Test
The Relay Test manually energizes each relay
output one at a time, allowing relays to be latched
on for diagnosis by a technician.
1. To initiate the Relay Test, press either the UP
or DOWN ARROW key when [rt] appears in the
display. When initiated, the Relay Test turns
on the first relay.
2. To scroll through the relay tests, press either
the UP or DOWN ARROW key. The output on the
digital display is turned on and all other
outputs are turned off. Consult the unit
schematic diagram to determine what
component is controlled by each output. The
controller has time limits for outputs that can
cause damage if left on too long.
3. To exit the Relay Test at any time, press the
DISPLAY SELECT key.
Functional Test
These tests allow the technician to force the unit
into a particular operating mode, regardless of
setpoint or return air temperature sensor readings.
1. To initiate the Functional Test, press either the
UP or DOWN ARROW key when [Ft] appears in
the display.
2. To scroll through the Functional tests, press
either the UP and DOWN ARROW key. The
Functional Test Features appear in the order
shown in the table below.
3. To exit the Functional Test at any time, press
the DISPLAY SELECT key.
4. Heat High Test: The temperature delta for

each enabled zone must be at least a preset
amount in a preset time period. If discharge air
temperature sensors are not installed, the
return air temperature for each enabled zone
rises at least a preset amount in a preset time
period.
5. Test Complete: The display shows [PAS]
(pass) or [FAL] (fail).
43
Functional Test Features

Display
Total Unit Hour Format
Auto Test Feature
Un
Hr
XX
YY
ZZ
CH
Cool High
Cn
Cool Medium
CL
Cool Low
EP1
Hr
XX
YY
ZZ
HH
Heat High
EP2
Hr
XX
YY
ZZ
Hn
Heat Medium
EP3
Hr
XX
YY
ZZ
HL
Heat Low
UH
Vent High
Un
Vent Medium
UL
Vent Low
Variable Output Tests

The Variable Output test energizes the device
connected to the selected output with a 0 percent
drive signal or position signal. [00] appears in the
display.
1. To initiate the Variable Output Test, press
either the UP or DOWN ARROW key when [EFx],
[CF], [Cux], or [dPx] appears in the display.
2. Press the UP or DOWN ARROW keys to increase
or decrease the drive signal or position signal
for the selected output. Each key press
changes the signal and the reading in the
display by 1 percent.
3. To exit the Variable Output Test at any time.
press the DISPLAY SELECT key.
Hourmeter and Real Time Clock

Display Mode
1. To enter Hourmeter Display Mode, press and
hold the DISPLAY SELECT key for approximately
5 seconds. [Un] appears, indicating the unit
has entered the Hourmeter Display Mode.
in Hourmeter Display Mode.
2. Release the DISPLAY SELECT key to view the
hourmeter readings. The controller
automatically scrolls through the displays.
Each record is displayed in several parts, with
each part being displayed for 1 second. Each
part is described below.
Evaporator Hour Format
Compressor Hour Format

CP
Hr
XX
YY
ZZ
The underlined symbols display as shown.

The non-underlined symbols are replaced with
numbers according to the following legend:
Digit Legend
XX
Most significant two digits of hour total
YY
Middle two digits of hour total
ZZ
Least significant two digits of hour total
For example, a Total Unit Hours reading of

187 hours would appear as:
Example of 187 Total Unit Hours
Un
Hr
00
01
87
When all hourmeters have displayed, the

Display Module scrolls through the time and
date for the real time clock:
Real Time Clock Format
rtc
Hr
XX
Hour24 Hour Format
UtE
XX
Minute
nth
XX
Month
dAy
XX
Day of Month
yr
XX
Year
3. To modify time or date parameters:

a. Press the UP or DOWN ARROW key while the
parameters are displayed. The display
blinks, indicating the Modify mode.
b. Press the DISPLAY SELECT key to scroll
through each selection for the clock.
c. To modify the displayed selection, press
the UP or DOWN ARROW key. After scrolling
through all the parameters, the system will
44
return to Standard Display Mode. If more

than 5 seconds pass between key presses
during the modify mode, the system
returns to Standard Display Mode and the
real time clock settings will not change.
4. To exit the Hourmeter Display Mode, press
the TK LOGO key.
Alarm Code Display Mode

Displaying Alarm Codes
1. To enter the Alarm Code Display Mode, press
and hold the THERMO KING LOGO key for 5
seconds. The display changes to the most
recent alarm code.
2. To scroll through the alarm codes, press the
DISPLAY SELECT key.
3. To clear the displayed alarm code, press the UP
or DOWN ARROW key. Two dashes (- -) display,
indicating the alarm is cleared. See the table
Alarm Codes on page 46 for alarm code
descriptions.
4. To exit Alarm Code Display Mode, press the
TK LOGO key.
Types of Alarm Codes
Log: Indicates a service timer has expired. The
alarm code reappears until the timer is reset.
Check: Indicates
a system fault that requires

attention but is not serious enough to shut the unit
down. You can clear a Check Alarm only after the
alarm condition no longer exists.
Shutdown: Indicates a
serious system fault that

causes the unit to shut down. You can clear a
Shutdown Alarm at any time, but the alarm will
re-occur if the alarm condition is not corrected.
45
Alarm Codes
Code
Type
00
Description
No Alarm Codes Present
01
Check
Coolant Temperature Sensor (WTS) - reading out-of-range
02
Check
Evaporator Coil Temperature Sensor (CTS) - reading out-of-range
03
Check
Return Air Temperature Sensor (RTS) - reading out-of-range
04
Check
Discharge Air Temperature Sensor (DTS) - reading out-of-range
05
Check
Ambient Air Temperature Sensor (ATS) - reading out-of-range
06
Check
Compressor Discharge Temperature Sensor (CDS) - reading out-of-range
07
Check
Low Heating Capacity
08
Check
Compressor Discharge Temperature Warning
09
Check
Low Cooling Capacity
10
Shutdown
High Pressure Shutdown
11
Shutdown
Low Pressure Shutdown
12
Shutdown
Compressor Discharge Temperature Shutdown
13
Shutdown
Condenser Fan Motor Drive - drive fault
14
Shutdown
Evaporator Fan Motor Drive - drive fault
15
Check
Compressor Clutch - output fault
16
Check
Boost Pump (BP) - output fault
17
Check
Condenser High Speed - output fault
18
Check
Condenser Low Speed - output fault
19
Check
Condenser Variable Speed - output fault
20
Check
Loader/Unloader Solenoid 1 (LV1/US1) - output fault
21
Check
Loader/Unloader Solenoid 2 (LV2/US2) - output fault
22
Check
Condenser Pressure Transducer (CPT) - reading out-of-range
25
Check
Evaporator High Speed - output fault
26
Check
Evaporator Medium Speed - output fault
27
Check
Evaporator Low Speed - output fault
28
Check
Evaporator Variable Speed - output fault
29
Check
Liquid Valve (LLV)- output fault
30
Check
Modulating Liquid Valve (MLV) - output fault
31
Check
Coolant Valve (CV) - output fault
32
Check
Variable Coolant Valve - feedback fault
33
Check
Floor Coolant Valve - output fault
34
Check
Floor Variable Coolant Valve - feedback fault
35
Check
Fresh Air Damper - output fault
36
Check
Variable Fresh Air Damper - feedback fault
40
Check
Base Module (ECM) - internal fault
41
Check
Base Module (ECM) Battery Power - input fault
42
Check
Base Module (ECM) Control Power - input fault
43
Check
Base Module Compressor Power - input fault
44
Check
Base Module Boost Pump (BP) Power - input fault
50
Check
Expansion Module 1 (EPM) - internal fault
51
Check
Expansion Module 1 (EPM) Battery Power - input fault
46
Alarm Codes (Continued)

Code
Type
Description
52
Check
Expansion Module 1 (EPM) Control Power - input fault
60
Check
61
Check
62
Check
70
Check
71
Check
72
Check
80
Check
81
Check
82
Check
90
Log
Condenser/Compressor Service Timer - has expired
91
Log
Evaporator 1 Service Timer - has expired
92
Log
93
Log
95
Check
Display Module (DDM) - not responding
96
Check
Expansion Module 1 (EPM) - not responding
97
Check
98
Check
99
Check
102
Check
Passenger Zone 1 Evaporator Coil Temperature Sensor (CTS1) - reading out-of-range
103
Check
Passenger Zone 1 Return Air Temperature Sensor (RTS1) - reading out-of-range
104
Check
Passenger Zone 1 Discharge Air Temperature Sensor (DTS1) - reading out-of-range
107
Check
Passenger Zone 1 Low Heating Capacity
109
Check
Passenger Zone 1 Low Cooling Capacity
114
Check
Passenger Zone 1 Evaporator Inverter - drive fault
125
Check
Passenger Zone 1 Evaporator High Speed - output fault
126
Check
Passenger Zone 1 Evaporator Medium Speed - output fault
127
Check
Passenger Zone 1 Evaporator Low Speed - output fault
128
Check
Passenger Zone 1 Evaporator Variable Speed - output fault
129
Check
Passenger Zone 1 Liquid Valve (LLV1) - output fault
130
Check
Passenger Zone 1 Modulating Liquid Valve (MLV1) - output fault
131
Check
Passenger Zone 1 Coolant Valve - output fault
132
Check
Passenger Zone 1 Variable Coolant Valve - feedback fault
133
Check
Passenger Zone 1 Floor Coolant Valve - output fault
134
Check
Passenger Zone 1 Floor Variable Coolant Valve - feedback fault
135
Check
Passenger Zone 1 Fresh Air Damper - output fault
136
Check
Passenger Zone 1 Variable Fresh Air Damper - feedback fault
202
Check
Passenger Zone 2 Evaporator Coil Temperature Sensor (CTS2) - reading out-of-range
203
Check
Passenger Zone 2 Return Air Temperature Sensor (RTS2) - reading out-of-range
204
Check
Passenger Zone 2 Discharge Air Temperature Sensor (DTS2) - reading out-of-range
207
Check
Passenger Zone 2 Low Heating Capacity
209
Check
Passenger Zone 2 Low Cooling Capacity
47
Alarm Codes (Continued)

Code
Type
Description
214
Check
Passenger Zone 2 Evaporator Inverter - drive fault
225
Check
Passenger Zone 2 Evaporator High Speed - output fault
226
Check
Passenger Zone 2 Evaporator Medium Speed - output fault
227
Check
Passenger Zone 2 Evaporator Low Speed - output fault
228
Check
Passenger Zone 2 Evaporator Variable Speed - output fault
229
Check
Passenger Zone 2 Liquid Valve (LLV2) - output fault
230
Check
Passenger Zone 2 Modulating Liquid Valve (MLV2) - output fault
231
Check
Passenger Zone 2 Coolant Valve - output fault
232
Check
Passenger Zone 2 Variable Coolant Valve - feedback fault
233
Check
Passenger Zone 2 Floor Coolant Valve - output fault
234
Check
Passenger Zone 2 Floor Variable Coolant Valve - feedback fault
235
Check
Passenger Zone 2 Fresh Air Damper - output fault
236
Check
Passenger Zone 2 Variable Fresh Air Damper - feedback fault
302
Check
Driver Zone Evaporator Coil Temperature Sensor (CTS3) - reading out-of-range
303
Check
Driver Zone Return Air Temperature Sensor (RTS3) - reading out-of-range
304
Check
Driver Zone Discharge Air Temperature Sensor (DTS3) - reading out-of-range
307
Check
Driver Zone Low Heating Capacity
309
Check
Driver Zone Low Cooling Capacity
314
Check
Driver Zone Evaporator Inverter - drive fault
325
Check
Driver Zone Evaporator High Speed - output fault
326
Check
Driver Zone Evaporator Medium Speed - output fault
327
Check
Driver Zone Evaporator Low Speed - output fault
328
Check
Driver Zone Evaporator Variable Speed - output fault
329
Check
Driver Zone Liquid Valve (LLV3) - output fault
331
Check
Driver Zone Coolant Valve - output fault
332
Check
Driver Zone Variable Coolant Valve - feedback fault
333
Check
Driver Zone Floor Coolant Valve - output fault
334
Check
Driver Zone Floor Variable Coolant Valve -feedback fault
335.
Check
Driver Zone Fresh Air Damper - output fault
336
Check
Driver Zone Variable Fresh Air Damper - feedback fault
337
Check
Driver Zone Panel Air Damper - output fault
338
Check
Driver Zone Variable Panel Air Damper - feedback fault
339
Check
Driver Zone Defrost Air Damper - output fault
340
Check
Driver Zone Variable Defrost Air Damper - feedback fault
48

Coordinate the maintenance inspection schedule
with the Bus Preventive Maintenance Schedule.
See Thermo King Bus A/C Preventive
Maintenance forms TK 40809 for more
information.
NOTE: See the appropriate chapter in this

maintenance manual for instructions on how to
correctly perform required maintenance.
NOTE: Thermo King reserves the right to deny

warranty coverage on claims due to lack of
maintenance or neglect. Claims in question must
be supported by maintenance records.
Off Season Operation Of Bus Air Conditioning System

In order for the A/C system to be ready for operation, normal preventive maintenance is
necessary. Operate all systems periodically, especially during the off season. By operating
the system weekly for short intervals (5 to 10 minutes) year round, the internal parts of the
compressor will remain lubricated. Off-season operation also helps reduce compressor shaft
seal leakage and allows early detection of refrigerant loss.
Prior to operating the compressor during winter months, you must warm up the coach
interior to normal operating temperature (60 to 76 F [15 to 21 C]). Unless this precaution is
taken, liquid refrigerant might be forced into the compressor, causing severe damage.
49
Electrical
Monthly
6,000 Miles
(10000 km)
50
Quarterly
18,000
Miles
(30000 km)
Annually
Check condition of or service the following:
Semi-annually
Check evaporator blower motors speed, voltage, amperes (all

motors).
Semi-annually
Check condenser fan motor speed, voltage amperes (all motors).
Check thermostat cycle sequence on all modes (e.g., Cool/Reheat,

vent/heat).
Visually inspect alternator drive belts for excessive wear, tension

and alignment.
Clean alternator, check for signs of corrosion, and check wire

connections.
Clean control panel area and return air sensor with compressed air.
NOTE: These may need to be cleaned more frequently.
Check boost pump (OEM supplied) motor operation, and inspect

brushes (when equipped).
Inspect wires and terminals for damage or corrosion. If corrosion is

present, clean terminals with electrical contact cleaner.
Check condenser pressure switch/condenser motor high and low

speed operation.
Check high pressure cutout and low pressure cutout switches.
Refrigeration/Heating
Monthly
6,000 Miles
(10000 km)
Quarterly
18,000
Miles
(30000 km)
Annually
Check refrigerant charge. Make sure discharge pressure is 250 psig

(1724 kPa) on R-22 systems. The ball in the top receiver tank sight
glass should be floating and the liquid line sight glass (if equipped)
should be full and clearno bubbles.
Charge: OK _______, Needs charging _______
Inspect condition of refrigerant hoses and tubing.
Inspect for leaks of refrigerant and oil.
Check dry eye in the liquid line sight glass for moisture content.
Check compressor oil level and color (1/4 to 3/4 way up on the sight
glass after 30 minutes of operationX430 compressor).
Install service gauge manifold set and check system operating

pressures, temperatures and suction line conditions.
Check compressor oil for acidity.
Check compressor efficiency.
Check compressor oil pump pressure.
Replace filter-drier (liquid line dehydrator). NOTE: The filter-drier

should be changed anytime the system is opened.
Check hot water control valve operation.
51
Structural
Monthly
6,000 Miles
(10000 km)
Quarterly
18,000
Miles
(30000 km)
Visually inspect unit for loose, damaged, or broken parts.
Clean or replace return air filter (more frequently if necessary).
Annually

Inspect condenser coil for cleanliness.
Inspect evaporator coil for cleanliness.
Semi-annually
Lubricate evaporator fanshaft bearings (Shell Alvania EP2).
Clean condenser and evaporator drains. Make sure the evaporator

drain hose check valves (kazoos) are in place and in good condition.
Visually inspect engine coolant hose and hose clamp condition on

heater coil system.
Clean condenser and evaporator coils.
Check engine coolant for antifreeze protection down to 30 F

(34 C) to prevent heater coil freeze up.
Tighten compressor, unit, and fan motor mounting bolts and

brackets (more frequently if necessary).
Check condenser air seals.
X430 Compressor Clutch

Monthly
6,000 Miles
(10000 km)
Quarterly
18,000
Miles
(30000 km)
Annually
Inspect clutch armature for wear and overheating caused by

slippage.
Inspect compressor drive belts for excessive wear, tension and

alignment (refer to bus manufacturer and/or belt supplier for proper
tension).
Check clutch air gap 0.045 0.005 in. (1.143 0.127 mm) and
surface flatnessX430 compressor.
Steam clean compressor and clutch.
Check clutch coil resistance and voltage.
Lubricate X430 compressor clutch bearing (Exxon Unirex N2).
52
Electrical Maintenance
Procedures
Monthly
6,000 Miles
(10000 km)
Quarterly
18,000 Miles
(30000 km)
Inspect evaporator blower motor bearings, speed, voltage, and

amperage.
See Specifications chapter for normal readings.
Bearings: OK _______, Replace ______
Speed _______RPM,
Voltage _______ Vdc,
Amperage _______ amps
Semi-Annually
Inspect condenser fan motor bearings, speed, voltage, and

amperage.
See Specifications chapter for normal readings.
Bearings: OK _______, Replace ______, Brushes______
Speed _______ RPM,
Voltage _______ Vdc,
Amperage _______ amps
Semi-Annually
Annually
Check thermostat cycle sequence on all modes (e.g., Cool/Vent,

Cool/Reheat, and Vent/Heat).
OK _______ Diagnose thermostat/unit_______
Visually check alternator belt wear, alignment and tension.

Condition: OK _______, Replace ______
Alignment: OK _______, Adjusted ______
Tension: OK _______, Adjusted ______
Clean alternator, check for signs of corrosion, and check wire

connections.
Clean control panel area and return air sensor.
Check boost pump motor (OEM supplied) operation, voltage, and

inspect brushes.
Voltage _______Vdc
Brushes: OK _______, Replace ______
Operation: OK _______, Replace motor______
Inspect all wires and terminals for damage or corrosion.
Check condenser pressure switch (CPS)/condenser fan motor high

and low speed operation. See Specifications chapter for normal
readings.
CPS opens at _______ psig
CPS closes at _______ psig
Check low pressure cutout and high pressure cutout.
53
WARNING: Take precautions to ensure

the unit and the bus will not accidentally
start while you are servicing the system.
Wiring and Harness Inspection

Inspect the unit wiring and wire harness during
scheduled maintenance intervals as follows:
4
3
1. Monitor the voltage available and test for

voltage drops. More than a 0.2 volt drop
across any of the wiring or connections
indicates a problem. Repair or replace the
component.
2. Spray contacts and terminals with an electrical
cleaner. A good grade of cleaner also provides
waterproofing that helps prevent voltage
leaks.

(HPCO)
The high pressure cutout (HPCO) switch is
located on the compressor cylinder head or
discharge manifold. If the discharge pressure rises
above switch setpoint, the switch opens the clutch
circuit, stopping the compressor. When the
discharge pressure drops below switch setpoint,
the switch closes. To test the switch, rework a
gauge manifold per Figure 8.
1.
Suction Gauge
2.
Relief Valve
3.
O-ring
4.
Adapter Tee (Edelmann PN 22-7200)
5.
Discharge Gauge
Figure 8: High Pressure Cutout Manifold
HPCO Test Procedure

Refer to the Specifications chapter for the
HPCO specifications.
1. Connect the modified gauge set as seen in
Figure 8 to the compressor discharge service
valve with a heavy duty, black-jacketed, thick
wall #HCA 144 hose with a 900 psig (6205
kPa) working pressure rating.
2. Adjust the temperature setpoint well below the
ambient temperature so that the unit will go
into the Cool mode.
3. Start the unit and let it run for a few minutes.
4. Raise the discharge pressure by blocking the
condenser coil air inlet. Observe the discharge
pressure reading on the gauge the instant the
compressor stops. If the gauge reading
exceeds the switch specification (see
Specifications chapter), replace the switch.
54
WARNING: If the HPCO fails to stop the

compressor when pressure reaches the
switch specification, immediately stop the
unit. Pressure in excess of this amount
can damage the unit.
CAUTION: If the HPCO fails, excess
pressure may build up, causing the high
pressure relief valve to open.
5. To investigate the failure of the HPCO to stop
compressor operation, first check the control
circuit operation, then replace the HPCO
switch. To check the control circuit operation,
disconnect the electrical leads to the HPCO
switch. The compressor should immediately
stop, indicating the HPCO switch is defective
and must be replaced.
HPCO Removal and Installation

Removal
1. Jumper the low pressure cutout (LPCO)
switch to prevent automatic unit shutdown.
2. Attach a gauge manifold to the compressor.
See Gauge Manifold Attachment, Purging,
and Removal.
3. Run the unit and close the suction service
valve to pump the compressor down to a
15 in. vacuum (51 kPa).
CAUTION: Refrigerant pressure in the

manifold is high.
8. Bleed the refrigerant from high side to low
side through the gauge manifold. Reclaim any
refrigerant left in the high side.
9. Disconnect the wires and remove the switch
Installation
NOTE: Install the new switch immediately to
minimize the amount of air entering the system.
1. Install the new switch and connect the wires.
2. Pressurize the compressor and test for leaks.
3. If no leaks are found, evacuate the
compressor. Then open the suction and
discharge service valves and place the unit in
operation.
Low Pressure Cutout Switch

(LPCO)
The low pressure cutout (LPCO) switch is located
on the suction manifold of the compressor. If the
suction pressure drops below the switch setpoint,
the switch opens the clutch circuit, stopping the
compressor.
LPCO Test Procedure
4. Stop the unit.
Refer to the Specifications chapter for the

LPCO specifications.
5. If the compound gauge rises out of the 15 in.

vacuum (51 kPa), run the unit again. Repeat
this process until the reading remains at a
15 in. vacuum (51 kPa).

and Removal.
6. With the unit stopped and the compound

gauge reading remaining at a 15 in. vacuum
(-51 kPa), close (i.e., front seat) the discharge
service valve.
CAUTION: Whenever the discharge
service valve is front seated, secure the
unit and the bus so they cannot run.
7. Have a new switch ready to install. Apply
refrigeration LoctiteTM to the threads of the
new switch.
2. Adjust the thermostat setpoint well below the

ambient temperature so the unit goes into
Cool mode.
4. Close the receiver tank outlet valve or liquid
line shutoff valve to pump down the low side.
Observe the suction pressure reading on the
compound gauge at the instant the compressor
stops. The switch should open to stop the
compressor within the switch specifications.
5. To test switch closing, connect the switch to a
test light using the following procedure:
55
a. Disconnect the switch leads.

b. Jumper one side of the switch to ground.
c. Connect the other side of the switch to a
test light, as shown in Figure 9.
LPCO Removal and Installation

Removal
and Removal.
2. Jumper the low pressure cutout (LPCO)
switch to prevent automatic unit shutdown.
4. Pump down the low side and equalize the
pressure in the low side to slightly positive
(see Low Side Pumpdown).
5. Have new switch ready to install onto the
1/4 in. MFL fitting. Before installing, check
the switch. The Schrader valve depressor must
be functional. Ensure depressor is not bent or
plugged with dirt.
6. Disconnect the wires and remove the switch.
1.
2.
3.
4.
5.
Ground
LPCO Switch
Test Light
Voltage Source (12 or 24 V)
Compressor
Figure 9: Test Light Connections
d. Connect the other end of the test light to a

voltage source (12 or 24 volts).
e. Slowly open the tank outlet valve or liquid
line shutoff valve to allow the suction
pressure to rise. Observe the suction
pressure reading on the compound gauge
at the instant the test light comes on. The
reading should be within the switch
specifications.
6. To investigate the failure of the LPCO to stop
the compressor, first check the control circuit
operation, then replace the LPCO. To check
control circuit operation, disconnect the
electrical leads to the LPCO. The compressor
should immediately stop, indicating the LPCO
switch is defective and must be replaced.
Installation
NOTE: Install the new switch immediately to
minimize the amount of air entering the system.
1. Install the new switch and connect the wires.
2. Pressurize the low side and check for leaks.
3. If no leaks are found, evacuate the low side.
Open the receiver tank outlet valve or liquid
line shutoff valve and place the unit in
operation.
Condenser Pressure Switch

(CPS)
This pressure sensitive switch is located in a
fitting on the high pressure inlet line to the
receiver tank in the evaporator section. The CPS
monitors the discharge pressure. When pressure
reaches the switch setpoint, it changes the
condenser fan speed.
CPS Test Procedure

Refer to the Specifications chapter for the CPS
specifications.
and Removal.
56
2. Adjust thermostat setpoint well below the

ambient temperature so that the unit will be in
Cool mode.
Boost Pump
Consult the bus OEM manual for information

concerning diagnosis and repair procedures.
4. Raise the discharge pressure by covering the

condenser coil air inlets. Observe the
discharge pressure reading on gauge when the
condenser fans go from low speed to high
speed.
5. Lower the discharge pressure by removing the
covers from the condenser coil air inlets.
Observe the discharge pressure reading on
gauge when the condenser fans go from high
speed to low speed.
6. Failure of the CPS to change the condenser
fan speeds should be investigated first by
checking the control circuit operation, and
secondly by replacing the CPS switch. To
check control circuit operation, disconnect the
electrical connector to the CPS switch. The
condenser fans should run in high speed. Place
a jumper between the CPS and CH circuits in
the evaporator control harness. The condenser
fans should go to low speed. If the condenser
fans go from high speed to low speed when
the jumper is placed between the CPS and CH
circuits, the CPS switch is defective and must
be replaced.
CPS Removal and Installation
(OEM Supplied)
Coolant Valve
The coolant valve controls the flow of engine
coolant to the heater coil. The coolant valve
requires no maintenance. However, deposits of
dirt, scale, or sludge can accumulate in the valve,
causing the valve coil to hum. You can eliminate
this by cleaning or flushing the valve and engine
coolant system. To assist in preventing corrosion
buildup and freezing, Thermo King specifies that
all heating coils be operated with a mixture of 50
percent ethylene glycol and 50 percent water.
Service of the valve includes replacement of the
coil; the diaphragm, plunger, and seal; or the
entire valve.
There are three possible valve malfunctions: coil
burnout, failure to open and failure to close. Each
is described below.
Coil Burnout
Coil burnout is caused by:
Improper voltage
Continuous over-voltage of more than 10%
Incomplete magnetic circuit due to the

omission of parts such as coil housing or
plunger
Mechanical interference with movement of

plunger which can be caused by a deformed
enclosing tube.
Removal
1. Recover the refrigerant charge.
2. Disconnect the wires and remove the switch.
Installation
1. Before installing the new switch, apply a
refrigerant loctite to the threads of the new
switch.
Failure to Open (Normally Closed

Types)
2. Install and tighten the new switch.
Failure to open on normally closed coolant valves

is caused by:
3. Pressurize the system and leak test the system.
Coil burned out or an open circuit to coil

connections
Improper voltage
Deformed valve body or enclosing tube
4. If no leaks are found, evacuate the system.

5. Recharge the unit with the proper refrigerant
and check the compressor oil.
57
Failure to Close
Failure to close is caused by:
Torn diaphragm
Deformed valve body or enclosing tube
Foreign material (dirt, scale, etc.) in seat.
pipe sealing compound to the threads of the

fittings to avoid deposits that might interfere
with the operation of the valve.
Coolant Valve Repair

1. Turn the power switch off. Disconnect the
electrical connections to the coolant valve.
2. Close the engine coolant return shutoff valve
above the engine. Remove the heater coil inlet
hose connection. Drain the coolant.
3. Disconnect the lead wires.
4. Remove the locknut on the coolant valve coil
and remove the coil.
NOTE: In most cases, only the coil needs
replacement.
5. Sporlan valve disassembly and assembly.
a. Remove the four enclosing tube mounting
bolts. Disassemble the enclosing tube and
the internal valve parts.
b. Assemble the new diaphragm, plunger and
gasket seal on the valve base. Install the
enclosing tube and the mounting bolts.
6. Install the coil assembly and tighten the
locknut.
7. Connect the coolant lines. Fill the heating
system with coolant and bleed air from the
system.
8. Connect the electrical connections to the
coolant valve and place the unit back in
service.
NOTE: When installing the valve, observe
the In and Outlet positions stamped on the
valve for proper connections. Failure to
connect the valve properly will cause a
malfunction.
9. When replacing the entire coolant valve,
remove the coolant connections and fittings
from the valve body. You can install the new
valve without disassembly. Carefully apply
58
1.
Locknut
5.
Plunger
2.
Coil
6.
Diaphragm
3.
Mounting Bolt (4)
7.
Gasket
4.
Enclosing Tube
8.
Body
Figure 10: Sporlan Coolant Valve
Condenser Axial Fan Motors

(Brush)
The axial fan motor is a non-repairable motor. If
this motor malfunctions, it must be replaced.
Motor Test Procedure

Refer to the Specifications chapter for fan
motor specifications.
To test the motor:
1. Disconnect the motor power plug from the

unit wire harness.
3. Lift the panel and disconnect the motor power

plug from the unit wire harness.
2. Apply 24 Vdc to the red wire and ground to

the black wire. The motor should run at full
speed. If it does not, then the motor is not
operable and must be replaced.
4. Remove the four (4) mounting bolts that

attach the axial fan motor assembly and the
fan guard to the orifice panel.
3. Disconnect the black wire from ground and

the motor should stop. If the motor fails this
test, it must be replaced.
5. Remove the axial fan motor assembly from

the unit.
Installation
1. Attach the axial fan motor assembly and the
fan guard to the orifice panel. Securely tighten
the mounting bolts.
2. Reconnect the power plug.
3. Replace the condenser fan orifice panel and
securely tighten the mounting bolts.
4. Start the unit and check the fan motor
operation.
5. If the unit is operating properly, return the bus
to service.
Evaporator Blower Motor

(Brush)
Bottom View
Motor Test Procedure

NOTE: Refer to the Specifications chapter for
fan motor specifications.
To test the motor:
1. If the unit does not have a battery, start the
bus. (The unit does not have to be running, but
must have power to the motors.)
Side View
Figure 11: Axial Fan Motor Assembly
Motor Removal and Installation

Removal
1. Disconnect power to the unit. Make sure you
cannot start the unit or serious injury could
result.
2. Remove the bolts that attach the center
condenser orifice panel to the condenser.
NOTE: The motors are attached to the
orifice access panel frame.
2. Disconnect the wires from the 2+, 3+, and 4+

terminals on the resistor block. Note which
wires go to which terminals.
3. Use a jumper wire to apply +24 V to the
terminals on the resistor block.
a. Apply +24 V to the 2+ terminal. The
motor should run at low speed.
b. Apply +24 V to the 3+ terminal. The
motor should run at medium speed.
c. Apply +24 V to the 4+ terminal. The
motor should run at high speed.
If the motor fails to run at any of the test
points, replace it.
59
1.
Resistor Block Terminals.

2.
Note which wires go to which terminals.
Orange Wire Connected to Positive (+)

Motor Terminal
Figure 12: Test Terminals on Resistor Block and Motor
60
Evaporator Blower Motor Removal

and Installation (Brush)
5. Unscrew the six (6) screws attaching the

motor housing to the evaporator frame and
remove the housing from the unit.
Removal
NOTE: The motor and housing are replaced as a
unit. No repair is possible to the motor itself.
Motor assembly removal and installation is the
same for each unit.
1. Turn the unit off.
2. Unfasten and carefully remove the evaporator
cover from the unit.
3. Remove evaporator drain pan.
4. Disconnect the power plug from the motor(s).
IMPORTANT: Verify that the rotation of the
motor/blower wheel is correct.
Installation
1. Install the motor assembly into the frame.
2. Align and replace the motor assembly
mounting screws in the frame. Securely
tighten all the mounting screws.
3. Connect the power plug to the motor.
4. Return power to the unit and run the motor(s).
5. If the unit runs properly, replace the
evaporator cover and secure fasteners.
6. Reinstall evaporator drain pan.
7. Restore the unit to service.
1
AJA3000
1.
Mounting Screws
Figure 13: Evaporator Blower Motor Assembly (Brush)
61
Fresh Air Damper Actuator

NOTE: The actuator motor, TK 41-3255, is a
non-repairable, DC motor used for fresh air
damper applications in bus A/C units. Use the
following tests to diagnose a fresh air damper
that does not operate correctly.
CAUTION: Incorrect installation and
alignment will cause binding, which
might damage the unit.
NOTE: The fresh air damper actuator motor
unit is located underneath the fresh air cowl.
This cowl must be removed to access the
actuator motor.
2
period, the digital readout shall display Pt to

indicate the unit has entered Service Test
Mode.
NOTE: Normal unit operation shall cease
when the Display Module is in Service Test
Mode.
2. Press the ZONE SELECT key to scroll through the
test options. The test options shall appear in
the order shown in the following table.
Service Tests (Service Test Mode)
Digital
Service Tests
Display
Pt
Pretrip Test
rt
Relay Test
Ft
Functional Test
EFx
Variable Evaporator x Fan Speed Control

Test
CF
Variable Condenser Fan Speed Control

Test
CUx
Variable Coolant Valve x Control Test
dPx
Variable Damper Position x Control Test
3. Select dP1 (passengers Fresh Air Damper) or

dP3 (Drivers Fresh Air Damper).
1.
Connector Plug
2.
Mounting Screw Locations (3)
3.
Actuator Shaft
Figure 14: Actuator Motor
CAUTION: Ensure the unit and bus can

not be run while you are servicing the
system.
Fresh Air Damper Operation Test

The following test uses the Service Test Mode
feature in IntelligAIRE II Diagnostics. For
additional information refer to the Service Test
Mode procedure in the IntelligAIRE II
Diagnostics chapter in this manual.
1. Press and hold both the DOWN ARROW key and
the ZONE SELECT key for at least 5 seconds. This
places the unit into the Service Test Mode.
After these keys have been held for this
62
4. After dP1 or dP3) is selected, press the UP or

DOWN ARROW key. This initiates the Variable
Output Test.
When initiated, the Variable Output Test shall
energize the device connected to the selected
output with a 0 percent drive signal or position
signal, and the digital display shall display
00.
5. Press either the UP ARROW or DOWN ARROW key.
For each press of the UP ARROW or DOWN ARROW
key, the drive signal or position signal for the
output and the digital display is incremented
or decremented by 1 percent.
6. If the fresh air damper being tested, does not
operate properly, repair as required.
7. After the fresh air damper has been tested, exit
the Variable Output Test by pressing the ZONE
SELECT key.
8. Press the TK LOGO (hidden key) to return to the
standard display mode.
Actuator Motor Test

The following testing procedures refers to Figure
15. For additional information, refer to drawing
2C36452.
7. If actuator fails these tests, it must be

replaced.
Actuator Motor Removal

1. Remove the fresh air cowl. See Fresh Air
Cowl Removal and Installation earlier in this
chapter.
2. Remove the cable tie that secures the cable to
the connector plug.
3. Disconnect the power connector.
NOTE: Normally the motor actuator can be
removed without disassembling the linkage. See
Figure 16 below.
2
Figure 15: Actuator Connector

Plug Wiring Diagram
Test Voltages
CW
1
4
CCW
+ON 4
+ON 6
- ON 6
- ON 4
Rotation Test
1. Apply + 24 Vdc on Pin 6 and ground Pin 4.

The actuator shaft should turn counter
clockwise.

The actuator shaft should turn clockwise.
Ohmmeter Test
1. Place an ohmmeter between pins 1 and 3.
2. The ohmmeter should read 4.7 K ohms
20 percent.
3. Place the ohmmeter test leads between pins 1
and 2. Apply + 24 Vdc on Pin 6 and ground
Pin 4. The actuator shaft should turn counter
clockwise.
4. The ohmmeter should read less than
1 K ohms.
the actuator shaft should turn clockwise.
6. The ohmmeter should read greater than
3 K ohms.
1.
Motor Mounting Bolts (3)
2.
Mounting Plate
3.
Fresh Air Linkage Arm
4.
Connector plug
5.
Actuator Motor
Figure 16: Actuator Motor/Mounting Plate
Assembly
4. Loosen the shaft linkage mounting screw.

5. Remove three (3) actuator mounting screws
and nuts from motor mounting plate. (See
Figure 16, item 1)
NOTE: The linkage remains intact and normally
does not need to be removed.
6. Remove and discard the old actuator motor, if
required.
63
Actuator Motor Installation
5. Secure the connector harness with tie band.
1. Install the new actuator motor and secure it to

the motor mounting plate with mounting
screws and nuts. (See Figure 16, item 1)
6. Restore power to unit.
2. Before installing the plate assembly, apply

Locktite to threads of the shaft linkage
mounting screw.
7. Calibrate the damper using a PC with

SMART-PAC software.
8. Test the fresh air damper to ensure proper
operation. See Fresh Air Damper Operation
Test on page 62.
d. Run the damper to the fully closed
position. Inspect it to ensure the damper
seals tightly and the linkage does not bind.
1
2
e. Run the damper to the fully open position

to ensure the linkage does not bind.
9. Install fresh air cowl. Tighten all mounting
screws securely. See AI2 Fresh Air Cowl
Removal and Installation earlier in this
chapter.
10. Return the bus to service.
1.
Shaft Linkage Mounting Screw; HH 8-32 SS
2.
Screw Goes to Shaft Flat on Actuator Motor

Shaft
Figure 17: Plate Assembly on Actuator Shaft
3. Install the plate assembly connecting arm.

(See Figure 18, item 2) It should be flush with
the end of the actuator shaft.
4. Install the power connector
NOTE: If necessary, apply voltage to rotate
actuator shaft so shaft linkage mounting
screw can be installed in the flat on the
actuator shaft.
64
3
6
2
1
1.
Damper Door Linkage Arm
5.
Damper Bracket
2.
Actuator Arm
6.
Damper Gasket
3.
Acutator Mounting Plate
7.
Damper Door
4.
Actuator Motor
Figure 18: Fresh Air Actuator Motor Assembly
65
66
Refrigeration Maintenance
Monthly
6,000 Miles
(10000 km)
Quarterly
18,000 Miles
(30000 km)
Annually
Visually check refrigerant hoses and tubing for signs of deterioration

or chafing.
Hoses and tubing OK _______
Hose and/or tubing needs replacement.
Specify which ones _______
Visually inspect for leaks of refrigerant and oil

No leaks _______, Leaks detected _______
Check dry eye in the liquid line sight glass for moisture content.
OK _______, Perform system cleanup _______
Check compressor oil level and color (1/4 to 1/2 sight glass after
30 minutes of operation).
Procedures
Check refrigerant charge.
Make sure discharge pressure is 250 psig (1724 kPa) on R-22
systems.
The ball in the top receiver tank sight glass should be floating and
the liquid line sight glass (if equipped) should be full and clearno
bubbles.
Charge: OK _______, Needs charging _______
NOTE: Check this twice monthly during air conditioning
season.
Install service gauge manifold set. Record operating pressures,

temperatures, and suction line condition.
Suction: Fast Idle _______ psig, Full Throttle_______ psig
Discharge: Fast Idle _______ psig, Full Throttle_______ psig
Ambient _______ F, Return Air _______ F, Suction Line _______
Check compressor oil for acidity.

Safe _______, Marginal _______, Acidic _______
Check compressor efficiency.

OK _______, Replace or rebuild compressor _______
Check evaporator pressure regulator (EPR) valve operation. See

Specifications chapter for normal readings. _______ psig
Replace filter-drier (liquid line dehydrator) a minimum of once a year

or any time the system is opened.
Check hot water control (coolant) valve operation.

OK _______, Repair or Replace _______
67
Safety
WARNING: Make sure the unit and bus
cannot start while servicing the system.
Many service procedures are regulated by federal,
state, and local laws. EPA certified technicians
must perform regulated refrigeration service
procedures using approved equipment and
complying with all federal, state, and local laws.
Avoid skin contact with refrigerants.

Refrigerant contact on skin causes frostbite.
Do not vent refrigerants to the atmosphere.

Recovery of refrigerant is required by most
government regulations. Refer to local laws
for the proper handling of refrigerants and
refrigerant oils.
Wear the proper clothing when handling

refrigerants. Wear goggles to prevent exposure
from liquid refrigerant to face and eyes. Use
butyl-lined gloves when handling refrigerants.
Refrigerant Service Safety

Procedures
Observe these precautions while performing
refrigerant procedures:
General Refrigerant Handling

Procedures
Use the recommended procedures found in

this manual when servicing equipment.
Do not apply open flame or heat the tank

above 125 F (52 C). To charge the A/C
system, immerse the tank in 70 F to 80 F (21
to 27 C) water.
Use clean tools to prevent contamination

when opening a refrigeration system or oil
containers.
Do not expose refrigerant oil to air longer than

necessary. Refrigerant oil absorbs moisture
when exposed to air. Use sealed containers
when storing refrigerant.
Do not pour oil into another container unless

absolutely necessary. If you must use another
container, make sure it is clean and dry.
Do not mix different refrigerants. Different

refrigerants and oils are incompatible.
Do not fill refrigerant tanks completely. Allow

space for liquid expansion. To monitor the
amount of liquid in a tank, weigh the tank
before and during the filling operation.
Do not weld or steam clean near A/C lines and

components. Excessive heat builds up
dangerous system pressures.
Reinstall refrigerant tank cap after each use.

This provides protection to the valve and
safety plug.
DANGER: Breathing refrigerant reduces
the oxygen level in the blood. Inhaling
high concentrations of refrigerant vapor is
harmful and can cause heart
irregularities, unconsciousness, or death.
Intentional misuse or deliberate
inhalation may cause death.
WARNING: Do not use a Halide torch to
test for leaks. When refrigerants come in
contact with a flame, a highly toxic gas is
produced. This toxic gas is extremely
dangerous and may cause death!
68
Do not breathe refrigerant fumes or vapor.

Conduct test procedures in areas with good
ventilation.
Polyolester Oil Handling

Procedures
Do not mix Polyolester oil with other

compressor oils.
Do not use equipment contaminated with

automotive type polyalkylene glycol (PAG)
oils.
Accessing Components
Access Area:
Equipment
Use
Oil test kit
Detects acid, water, and other

contaminants.
Reads system pressures and
allows for correct system
servicing.
Component:
Condenser Grille (top Condenser Coils

of unit)
Refrigerant Lines
Refrigerant gauge
manifold set
Condenser Fan
Motor Orifice Panel
Quick disconnect
access valves
Evaporator Roadside
and Curbside Access
Panels
Blower Motor Assemblies
Keep pressure in gauge lines

when gauge manifold is
removed from compressor.
2-Stage vacuum
pump (greatly
reduces evacuation
time)
Must have a minimum rate of

5 cfm (0.14 m3/minute), and
efficiency rating of 20
microns, and correct vacuum
lines and valves.
Electronic micron
gauge
Must have vacuum level

readings from 25,00050
microns.
Ambient Sensor
EPR Valve (curbside)

Coolant Valve (roadside
Return Air Filter Grille Control Panel

(bus interior)
Expansion Valve
Liquid Line Sight Glass
Return Air Filters
Filter Drier
Receiver Tank
HVAC Service Equipment

Correct HVAC servicing requires the following
equipment. This service equipment is available
through the Thermo King tool catalog (TK 5955)
and your local TK dealer.
NOTE: For some procedures, you may need
additional equipment: long hoses, jumper wires,
and a second evacuation pump.
\
Equipment
Thermometer with
remote reading dial
Use
Do not use an infrared
touchless thermometer for air
temperature readings. It will
give inaccurate readings.
Oxygen acetylene
Flux must not contain
torch, solder, and flux ammonia or muriatic acid.
Suction line service
filter with replaceable
activated core.
Removes contaminants and

moisture. Leave in system up
to 48 hours, install as
indicated for flow, service
when pressure exceeds
35 psig (2135 kPa).
Leak detector
Use an electronic halogen

leak detector or soap
solution.
DANGER: Do not use a Halide torch to

detect leaks. When a flame comes in
contact with refrigerant, toxic gases are
produced that might cause suffocation.
CAUTION: Do not use a mechanically

actuated gauge. Excessive vacuum will
destroy the gauge.
TK Evacuation
Station
(TK no. 204-725)
Recommended; other
stations may work.
Charging/evacuation
hose
1/4 ID x 48 in. long, rated at

900 psig (6200 kPa) working
pressure.
1/2 ID x 48 in. long, rated at
500 psig (3400 kPa) working
pressure.
Charging/evacuation
hose
Refrigeration ratchet
wrenches (square
box type).
Sizes 3/16 in., 1/4 in.,

5/16 in., and 3/8 in.
Service Valve Positions

The suction and discharge service valves provide
connections for the gauge manifold to the
compressor for system diagnosis, service, and
repair. Familiarize yourself with these valve
positions:
Back-seated: Normal operating
position. The
service valve is fully closed:
Figure 19: Valve Fully Counterclockwise

(Back-seated)
69
Front-seated: Checking and removing
the
compressor. The service valve is open, and access
to the system is closed:
Gauge Manifold Positions

The gauges indicate low and high side pressures.
Operate one or both hand valves to perform the
different service operations:
Figure 20: Valve Fully Clockwise (Front-seated)
DANGER: Do not start the unit with the

discharge valve front-seated. Pressure
buildup could cause an explosion.
Open to Service Port: Servicing
position. Access
to the system and the service ports:
Figure 23: Hand Valves Open to Center Port
Figure 21: Valve Turned Half Way In (Open to

Service Port
Gauge Manifold Connections

Before You Proceed
Note the following before you proceed with a
gauge manifold connection:
If a procedure requires the compressor to

operate at a suction pressure below 5 in.
vacuum (-17 kPa), place a jumper across the
low pressure cutout switch to prevent
compressor shutdown.
Use of the quick disconnect access valve

during evacuation increases the time required
to reach the correct micron level.
Figure 24: Hand Valves Closed to Center Port
Gauge Connections: Balancing

Pressure, Removing Refrigerant,
and Charging System
Figure 25: Balancing Pressure
Figure 22: Quick Disconnect Access Valve
70
4. Make sure both service valves are fully

back-seated.
5. Remove the small service port caps from the
suction and discharge service valves.
6. Attach the high side hose (high pressure
gauge) to the discharge service valve port.
Tighten the fitting finger tight.
7. Attach the low side hose (compound gauge) to
the suction service valve port. Tighten the
fitting finger tight.
8. Open the service manifold hand valves fully.
9. Attach the center manifold hose to the hose
anchor. Tighten the fitting finger tight.
10. Open the discharge service valve.
Figure 26: Removing Refrigerant
11. Loosen the low side hose (compound gauge)

at the compressor. Purge the discharge hose,
manifold, and suction hose of air from the
compressor end of the suction hose. Tighten
the fitting.
12. Loosen the center hose at the hose anchor and
purge the hose. Tighten the fitting.
13. Close the gauge manifold hand valves to the
center port.
14. Open the suction service valve 1/2 turn. You
can now use the gauge manifold to check
system pressures and perform most service
procedures.
Figure 27: Charging the System
Attachment and Purging

Use this procedure for attaching a gauge manifold
to a compressor before performing service
procedures.
NOTE: If you leave the manifold in place for

more than a few minutes, tighten the suction and
discharge valve packing or replace stem caps to
stop refrigerant leaks.
NOTE: Use of access valves or quick disconnect

fittings is recommended to minimize refrigerant
loss.
1. Inspect the gauge manifold for correct hose
and fitting connections.
2. Clean dirt and moisture from the service ports.
3. Remove large valve stem caps from the
compressor suction and discharge service
valves.
71
8. Remove the gauge line from the discharge

service valve and cap the service port.
2
9. Back seat the suction service valve and cap the

valve stem.
10. Cap the discharge service valve stem.
11. Secure all manifold lines to manifold hose
anchors when the manifold is not in use.
3
12. Remove low pressure jumper and reconnect

wiring.
Compressor Pumpdown
Use this procedure to:
1.
Compound Gauge
2.
High Pressure Gauge
3.
Discharge Service Valve (DSV)
4.
Suction Service Valve (SSV)

Figure 28: Connecting Gauge Manifold
Removing the Gauge Manifold

NOTE: Minimize oil and refrigerant transfer.
Use the following gauge manifold removal
procedure to maintain system integrity without
the need to use a different gauge manifold for
each type of refrigerant.
1. Jumper the low pressure cut out.
2. Operate the unit in the cool mode.
3. Back seat the discharge service valve.
4. Open both manifold hand valves.
5. Front seat the suction service valve and pump
down the compressor to a 20 vacuum. Turn
the unit off.
6. Establish compressor crankcase pressure
between 1 and 3 psig.
7. Remove the gauge line from the suction
service valve and cap the service port.
72
Test compressor for leaks to the atmosphere (a

leak is indicated by a reading that goes to zero
and stays there)
Test compressor discharge valve plates for

leakage (indicated by a reading that goes to
zero, then rises above zero)
Service or remove the compressor.
NOTE: When servicing or removing the

compressor, open the suction service valve to
equalize pressure to 2 to 3 psig (14 to 21 kPa) on
the compound gauge before disconnecting
service valves from the compressor.
1. Attach a gauge manifold to the compressor
(see Gauge Manifold Attachment, Purging,
and Removal).
2. Bypass the low pressure cutout switch
(LPCO) to prevent the clutch from
disengaging.
3. Start and run the unit for 15 minutes to
stabilize pressures. Run the bus engine at a
fast idle (900 to 1200 RPM).
NOTE: When the crankcase pressure is
greater than the suction pressure, the
crankcase is isolated from the system.
Closing the suction service valve and starting
the unit for pumpdown causes the check
valve to close and the compressor to go into a
vacuum. If necessary, start and stop the unit
several times until all the refrigerant has
boiled off the oil. Allowing the compressor to
warm up for 15 minutes results in a much
smoother pumpdown.
4. Before starting the pumpdown, make sure oil

has returned to the compressor. Make sure the
sump body is lukewarm.
3. To prevent the compressor from stopping,

install a jumper wire across the low pressure
cutout (LPCO) switch.
5. Front seat the suction service valve. Pump

down the compressor to a 20 to 25 in. vacuum.
4. Start the unit. Change the setpoint to the

lowest possible setting to keep unit running in
cool mode.
6. Stop the unit.

7. If the compound gauge rises out of 20 to 25 in.
vacuum, run the unit again. Repeat this
procedure until the reading remains below
0 psig for at least 15 seconds.
5. Run the bus engine at fast idle (900 to 1200

RPM) for 15 minutes or more to stablize the
system.
6. Front seat the receiver tank outlet valve or the
liquid line shutoff valve.
7. Observe the compound gauge reading. Pump
down the low side to a 2025 in. vacuum. Stop
the unit.
Figure 29: Compound Gauge
Low Side Pumpdown
8. Observe the compound gauge reading. Low

side pressure should remain below a 15 in.
vacuum for two minutes or longer. If pressure
rises to zero and stops, there is a low side leak
to the atmosphere. If pressure continues to rise
above zero, the following may be responsible:
Purpose: To test for internal (high side to low

side) leaks and to perform service on low side
without refrigerant loss.
Refrigerant boiling out of the compressor

oil. (Restart unit and pump down to 25 in.
vacuum.)
1. Attach the gauge manifold to the compressor

(see Gauge Manifold Attachment, Purging,
and Removal in this chapter).
High side to low side leaks at the

compressor discharge valve plates or hot
gas bypass valve if equipped.
2. Units Equipped with EPR Valve Only. See

the Specifications chapter to see which EPR
valve the unit has, then do one of the
following:
a. Internal Spring Type EPR. After
attaching the gauge manifold set to the
compressor, attach the center gauge
manifold hose to the Schrader valve on the
inlet to the EPR valve. Open the low side
hand valve on the gauge manifold to allow
refrigerant to bypass the EPR valve during
the pumpdown.
b. Pilot Type EPR. Close the EPR pilot line
shutoff valve (if equipped). This valve is
located near the EPR valve.
NOTE: Remember to open the pilot line
shutoff valve when finished.
9. To perform service on the low side, establish a

slight positive pressure by opening the high
side hand valve on the gauge manifold to
bleed 2 to 3 psig (14 to 21 kPa) into the low
side.
CAUTION: To prevent air and moisture
contamination, do not open the low side of
system while in vacuum.
Refrigerant Recovery
When refrigerant is removed from a unit for
service, after leak testing, or to remove air, you
must recover it with a recovery machine to limit
the potential harm it could cause to the
atmosphere.
CAUTION: Venting refrigerant is illegal.
Check with your local government
agencies for definitions of venting and
your legal responsibilities.
73
Recovery from a Working Unit

This procedure is for units with an Orit 15 EPR
valve or no EPR valve. For units with an Orit 10
EPR valve, see "Recovery from a Working Unit
with an Orit 10 EPR Valve" below.
If the unit and compressor are operable, remove
the refrigerant as a liquid. To remove refrigerant
as a liquid:
1. Install a gauge manifold on the suction service
valve (SSV) and the receiver tank outlet valve
(RTOV).
2. If you have an Orit 15 EPR valve, close the
pilot valve hand valve.
3. Attach the service line to the recovery
machine inlet.
4. Pump down the units low side to force the
refrigerant into the condenser and receiver
tank.
5. Set the recovery machine for liquid recovery.
Open the high pressure gauge hand valve.
Remove the refrigerant through the receiver
tank outlet service valve.
6. Recover refrigerant until proper recovery level
is achieved.
Recovery from a Working Unit with

an Orit 10 EPR Valve
This procedure is for units with an Orit 10 EPR
valve only. Use of a low-loss fitting on the service
line is required for this procedure.
If the unit and compressor are operable, remove
the refrigerant as a liquid. To remove refrigerant
as a liquid:
1. Install a gauge manifold on the suction service
valve (SSV) and the receiver tank outlet valve
(RTOV). Install the service line onto the
access port on the Orit 10 EPR valve.
2. Open the manifold low side hand valve.
3. Complete a low side pump down.
4. When you have achieved a 20 in. vacuum,
close the low side hand valve on the gauge set.
74
5. Remove the service hose from the EPR valve

and attach it to the recovery machine. You
must use low loss fittings for this connection.
6. Set the recovery machine for liquid recovery
and open the high pressure gauge hand valve.
Remove the refrigerant through the receiver
tank outlet service valve.
7. Recover refrigerant until proper recovery level
is achieved.
Recovery from a Non-functioning

Unit
When a unit or compressor is inoperable, you
must remove refrigerant as a vapor. Remove it
from any convenient service port on the
compressor or receiver tank. Because refrigerant
must evaporate in the unit before removal, it is
less efficient and more time consuming than the
liquid removal process.
To remove refrigerant as a vapor:
1. On units equipped with an Orit 15 valve or no
EPR valve, attach gauge manifold hoses to the
suction service valve (SSV) and discharge
service valve (DSV).
2. On units equipped with an Orit 10 valve,
attach the manifold hoses to the discharge
valve and the access valve on the EPR valve.
3. Open both manifold hand valves.
4. Recover vapor refrigerant until you achieve
correct EPA recovery levels.
Removing Air from Recovered

Refrigerant
Not all recovery machines remove air from
refrigerant. If you are unsure which type of
machine you have, read the manual. Thermo King
recommends that you follow manufacturers
instructions exactly.
If the machine only removes the refrigerant to a
drum, you can remove air by allowing the drum to
stabilize for several hours, then venting the air
from the top of the drum. Measure the drum
temperature and pressure, then refer to the
Temperature-Pressure chart to verify that only
refrigerant in the drum. If air is in the drum, draw
only liquid from that drum.
Refrigerant Evacuation
CAUTION: You must use an electronic

micron gauge with vacuum level readings
from 25,000 to 50 microns for acceptably
accurate readings. Do not use a
mechanically actuated micron gauge.
Read the instruction manual before
operating the micron gauge.
When Evacuation Is Required

Evacuation is required:
When a new system is installed
When the refrigerant has been removed from

the system
When the system is opened for service or

maintenance repairs (example: compressor
replacement, hose replacement, coil or tubing
repairs, etc.)
Whenever an extremely wet condition has

developed inside a system.
NOTE: A system contaminated with moisture

must also have a more frequent filter-drier
change schedule.
Problems Caused by Poor

Evacuation
Noncondensables such as air and dry nitrogen in a

system will cause:
Elevated operating temperatures and pressures
Breakdown of compressor oils
Incorrect refrigerant charge.
1
8587a
1.
Two Stage Vacuum Pump
Moisture and other contaminants (like cleaning

solvents) in a system will cause:
2.
Calibration Standard
3.
Micron Gauge
4.
Evacuation Quality Hoses
5.
Thermistor Sensor
Acid buildup in the oil, which corrodes

components, scratches sight glasses, and
causes copper plating
Chemical reactions with refrigerants that

degrade their properties
Breakdown of the filter-drier core elements,

which causes plugged filters and valves.
Evacuation Stations
An evacuation station consists of a vacuum pump,
micron gauge, valve manifolds, and the special
hoses required for deep vacuum operation.
Portable gauges with separate hoses are also
usable.
Thermo King Dealers have this equipment
available. Contact your local Thermo King Dealer
for more information.
Figure 30: Thermo King Evacuation Station

TK No. 204-725
Evacuation Time Considerations

Evacuation time depends on system construction
and the amount of contaminants. Factors that
increase evacuation time are:
Long hoses
Hoses with small diameters
Hoses constructed of materials other than

heavy wall rubber or plastic polymer (TK No.
204-537 or 204-536)
75
Expansion valves and other control valves that

cause restrictions, requiring three-point
evacuations. (Evacuation from both high and
low side should be standard operating
practice.)
Schrader valves. Do not use Schrader valves
unless absolutely necessary. They slow down
the evacuation process dramatically.
Excessive moisture. A large vacuum pump

can cause moisture to freeze, slowing down
the evacuation process.
Amount of contamination. Excessive

contamination can cause slow evacuation.
Leaks. A constant pressure rise indicates a

leak. Find and repair leaks before evacuation.
Evacuation pump oil condition. Contaminated

evacuation pump oil prevents the pump from
operating at maximum efficiency.
Evacuation Procedure
CAUTION: You must use an electronic
micron gauge with vacuum level readings
from 25,000 to 50 microns for acceptably
accurate readings. Do not use a
mechanically actuated micron gauge.
Read the instruction manual before
operating the micron gauge.
CAUTION: Venting refrigerant is illegal.
Check with your local government
agencies for definitions of venting and
your legal responsibilities.
1. Before evacuating, recover refrigerant to
0 psig (0 kPa) or EPA requirement and leak
test the system.
2. Make connections to the refrigerant supply
bottle prior to evacuation. Leave the valve on
the refrigerant supply bottle closed during
evacuation process. This prevents air and
moisture contamination when charging.
3. Connect evacuation hoses to the following
access ports:
a. The high side port at the compressor
discharge service valve port.
76
b. The low side port at the compressor

suction service valve port.
c. If possible, connect a third evacuation
hose to the service port on the receiver
tank outlet valve or the liquid line service
valve.
NOTE: Systems equipped with EPR valves or
other regulating devices may require the
third connection to ensure full evacuation.
Some systems have a built-in bypass that
makes the third port connection unnecessary.
4. Connect the micron gauge:
a. If you are using the Thermo King
Evacuation Station, the micron gauge is
part of the equipment. Follow operating
instructions for the station.
b. If you are using a manifold gauge set,
connect the micron gauge at the vacuum
pump hand valve. You must be able to
isolate the micron gauge without breaking
a line open before charging the unit.
NOTE: Valves on the manifold gauge set
should be the packless type with O-ring seals
on valve stems.
5. Check evacuation equipment for leaks:
a. With the unit access valves back seated
securely, run the vacuum pump to
evacuate only the hoses and manifold
gauge set. The pump should pull the
pressure down to 500 microns (or less) in
a few minutes. If it does, go to step 5b. If
the pressure does not reach 500 microns,
proceed as follows:
Connect the micron gauge directly to

the vacuum pump and run it again. If
the pressure reaches 500 microns,
check and repair the hoses, manifold
gauge set, and connections. Repeat
step 5a.
If the pump will not lower the pressure

to 500 microns, change the vacuum
pump oil, then repeat step 5a. If the
vacuum pump is very contaminated, a
second oil change may be necessary.
R
is
ur
e
ss
Pr
e
If the pump still cannot lower the

pressure to 500 microns, replace the
pump and repeat step 5a.
ta
nt
C
on
s
If the pump still does not lower the

pressure to 500 microns, use a
different micron gauge to confirm the
reading. If the 500 micron pressure
level is reached, replace the micron
gauge and repeat step 5a.
Pressure Rise
Leak
b. Once the evacuation equipment proves to

be leak free, go to step 6.
6. Evacuate the system by opening the unit
access valves to port and starting the vacuum
pump.
Figure 31: Leak
If the pressure rises and levels off,

evacuate for a longer period. The rise is
due to moisture that must be removed.
Start the vacuum pump, open the valve at
the outlet of the vacuum pump, and repeat
step 7 through step 9 until the micron level
remains below 1500.
8. When the micron gauge indicates a pressure

reading of 500 microns, continue the
evacuation for another 30 minutes.
If the pressure continues to increase at a

steady rate, there is a leak. Follow
standard procedures to locate and repair
the leak, then repeat the evacuation
process.
is
e
Levels Off
If the pressure reading stays below 1500

microns for 5 minutes, you can charge the
system. Backseat the open service valves.
Moisture
ss
Pr
e
10. Watch the micron gauge for 5 minutes. The

reading will rise as system pressure equalizes.
Pressure Rise
9. After 30 minutes, close the valve at the outlet

of the vacuum pump to isolate the vacuum
pump from the system. Leave the micron
gauge connected to the system only. Stop the
vacuum pump.
ur
e
7. Replace the service valve stem caps tightly.

The packings will leak during evacuation.
Time
Time
Figure 32: Moisture
NOTE: Large amounts of moisture in the

system can, over a longer period of time,
raise the system pressure back to near zero.
77
Refrigerant Charging
Charging an Evacuated Unit by

Weight
Checking the Refrigerant Charge
IMPORTANT: Handle blended refrigerants only

in liquid form to ensure that the mixture remains
balanced.
Make sure these criteria are met before checking

the refrigerant charge:
The ambient temperature must be above 80 F

(27 C).
1. Evacuate the system. See Evacuation

Procedure in this chapter.
The interior temperature must be between 70

and 80 F (21 and 27 C).
The discharge pressure must be above 250

psig for R-22 and R-407C and above 150 psig
for R-134a.
2. Connect a gauge manifold to the system.

Connect the high side gauge line to the
compressor discharge service valve port or to
one of the service ports on the liquid line of
the unit. (Ports can vary due to application
differences.)
All fans must be running at high speed.
If alarm codes are indicated or there are

bubbles in the liquid line sight glass, do not
charge the unit and flag the bus for service.
To check the refrigerant charge:

1. Start the system and set the bus engine to run
at high idle (1200 to 1500 RPM compressor
speed).
2. Verify that the compressor is operating and the
compressor clutch is pulled in.
3. Run the system for a minimum of 15 minutes.
The compressor sump should be warm to
touch.
4. After 15 minutes, observe the sight glass as
follows:
T Series: Receiver tank sight glass should

be at least 1/2 full with ball floating.
Roofmount: Liquid line sight glass should

be clean and free of bubbles for 2 to 5
minutes.
5. If the receiver tank indicator ball is not

floating or there are bubbles in the liquid line
sight glass, the unit is low on charge. Leak
check and repair the system, then add
refrigerant per the Charging from a Partially
Charged State procedure.
3. Connect a refrigerant supply bottle to the

center hose of the gauge manifold. Purge all
non-condensable gases from the hoses and
gauge manifold before opening the unit
service valves.
4. If you know the amount of refrigerant charge
the unit holds, weigh the charge as follows:
a. Weigh the full refrigerant bottle.
b. Subtract the amount of charge required.
c. The resulting number is the final bottle
weight after a full system charge.
Bottle weight (Total)
Unit charge
=Final bottle weight
5. Make sure the suction service valve is closed.

Open the discharge service valve or open the
service valve to which the high side gauge line
is connected.
6. With the unit off, open the high side gauge
valve to allow liquid refrigerant to flow into
the discharge or liquid line of the unit (see
step 2).
7. Observe the scale. When the required amount
of refrigerant has flowed into the unit, close
the high side gauge valve and the discharge
service valve (or the service valve to which
the high side gauge line is connected).
8. If the refrigerant stopped flowing into the unit
before the full refrigerant charge was reached:
78
a. Close the high side gauge valve and close

the discharge service valve (or the service
valve to which the high side gauge line is
connected).
13. Replace all service caps. Leak check the unit

and repair any leaks found.
b. Start the system and run the bus engine at

high idle (1200 to 1500 RPM compressor
speed) for 2 to 3 minutes.
Charging from a Partially Charged

State
c. Open the suction service valve. Crack

open the low side gauge valve to allow
liquid refrigerant to slowly flow into the
compressor suction service valve port.
NOTE: If the suction hose does not have a
restrictive orifice, restrict the refrigerant flow
with the low side gauge valve. Watch the
suction gauge as you open the valve. Do not
allow the suction pressure to rise more than
25 psig (172 kPa). Periodically close the low
side gauge valve to verify the true suction
pressure, then readjust the flow back to no
more than 25 psig (172 kPa) above that
value.
9. Watch the scale until the required amount of
refrigerant is added. Close the low side gauge
valve. Run the system 5 to 10 minutes.
10. Check the discharge pressure. If the discharge
pressure is not above 250 psig (1724 kPa) for
R-22 and R407C systems, or 150 psig
(1034 kPa) for R-134a systems, partially
block the condenser air flow to raise the
pressure to that level. Maintain the interior bus
temperature between 70 and 75 F (17 and
24 C).
11. Check the liquid line sight glass or the
receiver tank sight glass (whichever is used).
The liquid line sight glass should be full and
clear with no bubbles. The indicator ball
should be floating in the top of the receiver
tank sight glass. If there are bubbles in the
liquid line sight glass or if the receiver tank
indicator ball is not floating, add liquid
refrigerant through the suction service valve
(see step b) until the liquid line sight glass is
clear or the indicator ball floats.
12. After confirming the charge, close the
refrigerant supply bottle valve, close all
service valves, remove the manifold gauge set,
and turn off the bus engine.
14. Release the bus back into service.
IMPORTANT: Handle blended refrigerants only

in liquid form to ensure that the mixture remains
balanced.
1. Connect a gauge manifold to the system (see
Gauge Manifold Attachment, Purging, and
Removal).
2. Connect a refrigerant supply bottle to the
center hose of the gauge manifold. Purge all
non-condensable gases from the hoses and
gauge manifold before opening the unit
service valves.
3. Start the unit. Run the bus engine at high idle
(1200 to 1500 RPM compressor speed) for 2
to 3 minutes.
4. Check the discharge pressure. The discharge
pressure must be above 250 psig (1724 kPa)
for R-22 and R407C systems, or 150 psig
(1034 kPa) for R-134a systems. If not,
partially block the condenser air flow to raise
the pressure. Maintain the interior temperature
between 70 and 75 F (17 and 24 C).
5. Open the suction service valve. Crack open
the low side gauge valve to allow liquid
refrigerant to slowly flow into the compressor
suction service valve port.
NOTE: If the suction hose does not have a
restrictive orifice, restrict the refrigerant flow
with the low side gauge valve. Watch the
suction gauge as you open the valve. Do not
allow the suction pressure to rise more than
25 psig (172 kPa). Periodically close the low
side gauge valve to verify the true suction
pressure, then readjust the flow back to no
more than 25 psig (172 kPa) above that
value.
6. Watch the liquid line sight glass or the
receiver tank sight glass (whichever is used).
Add liquid refrigerant until the liquid line
79
sight glass is clear or the indicator ball is

floating in the top of the receiver tank sight
glass. Close the low side gauge valve.
7. After confirming the charge, close the
refrigerant supply bottle valve, close all
service valves, remove the manifold gauge set,
and turn off the bus engine.
8. Replace all service caps. Leak check the unit
and repair any leaks found.
2. Attach a gauge manifold (see Gauge

Manifold Attachment, Purging, and
Removal).
3. Attach the center hose of the gauge manifold
to a refrigerant bottle. Purge the center hose of
air.
4. Pressurize the system with 2 to 3 psig (14 to
21 kPa) of refrigerant.
5. Close (front seat) both hand valves on the

gauge manifold.
Leak Testing
6. Disconnect the center hose from the

refrigerant bottle.
Testing a Pressurized System for

Leaks
Inspect the system for refrigerant oil and dirt

accumulation (which indicate refrigerant
leaks), component damage, and the audible
release of refrigerant.
Blow out confined areas with compressed air
to remove refrigerant accumulations. In windy
conditions, shield the leak area.
Use a regularly calibrated electronic leak
detector capable of detecting fluorine-based
refrigerants, or use a leak check solution to
leak test the refrigeration system. Leak check
solutions work best in areas easily reached or
where air is saturated with refrigerant. Apply
liquid solution with a soft brush to prevent
bubbles from forming and allow several
minutes to work.
Multiple leaks may exist. Always leak check

beyond the first leak.
Leak check before and after running the unit.

Components and line temperature can affect
leak size, and circulating refrigerant can
temporarily plug leaks.
7. Connect the center hose from the gauge

manifold to a source of nitrogen. Adjust the
pressure regulator to 200 psig (1379 kPa). See
Using Pressurized Nitrogen for more
information.
CAUTION: Nitrogen (N) is under
2200 psig (15169 kPa) pressure in a full
cylinder at 70 F (21 C). Handle with care.
8. Pressurize the system with nitrogen gas to
200 psig (1379 kPa).
9. Close the supply valve on the nitrogen bottle.
10. Use an electronic leak tester or soap solution
to inspect all joints and connections. If you
detect leaks, loosen the supply line hose
fittings to release the pressure.
CAUTION: Do not use a Halide torch.

Figure 33: Testing for Refrigerant Leaks
Testing an Empty System for Leaks

Use this procedure for systems that have lost most
or all of their refrigerant.
1. Check the entire system for refrigerant oil
leaks and component damage.
80
11. Repair leaks as necessary. Recheck the system

when repairs are complete.
12. When testing is complete, remove the
remaining trace amount of refrigerant and
nitrogen.
13. Evacuate the system and charge per

Refrigerant Charging procedures in this
chapter.
Using Pressurized Nitrogen

Use dry nitrogen (N) for dehydration, pressure
testing, purging, and soldering. Observe the
correct handling of high-pressure nitrogen
cylinders:
Keep the protective cap on the cylinder when

not in use.
Secure the cylinder in a proper storage area or

fasten the cylinder to a cart.
Do not expose to excessive heat or direct

sunlight.
Do not drop, dent, or damage the cylinder.
Use a pressure regulator and a safety pressure

relief valve as part of the pressure testing
equipment. The safety pressure relief valve
should be the non-adjustable, non-tampering
type. The valve should bypass if the pressure
exceeds its setting.
Open the supply valve slowly. Use regulators

and safety valves in good condition.
The regulator should have two gauges, one for

tank pressure and one for line pressure. The
equipment allows you to leak test, purge, or
dehydrate a system safely.
The following pressures apply:

Maximum Pressure
Procedure
psig
kPa
Leak Testing Low Side
150-175
1034-1206
Leak Testing High Side
100-250
689-1724
Purging Dehydration
10-20
69-138
Soldering
34
CAUTION: Nitrogen (N) is under

pressure (2200 psig [15170 kPa]), or
greater (full cylinder at 70 F [21 C]).
To use pressurized nitrogen to dehydrate,
pressure-test, purge, or solder a system:
1. Attach a gauge manifold set to the system.
2. Close (front seat) both hand valves on the
gauge manifold.
3. Connect the center hose from the gauge
manifold to the pressure regulator outlet on
the nitrogen supply bottle. Adjust the pressure
regulator to the correct pressure for the
required procedure.
4. Purge the system from high side to low side.
1.
Pressure Regulator Outlet (Pressure Test

Line to System)
2.
Safety Valve
3.
Pressure Regulator
4.
Line Pressure
5.
Tank Pressure
6.
Tank
Figure 34: Typical Pressurized Gas Bottle with

Pressure Regulator and Gauges
81
Contaminants
Types of Contaminants
An HVAC system is contaminated when it has
anything other than the correct refrigerant and
clean compressor oil. The following are the main
contaminants, in order of importance:
Contaminant
Results of Contaminant
Air
Oil breakdown
Refrigerant breakdown
Acid buildup
Valve leaks
System failure
Moisture
Metal corrosion and plating

Freezing in expansion valve
Acid buildup
Filter-drier saturation and
corrosion1
2. Attach a recovery machine and recover the

refrigerant (and air) from the system to 0 psig
(0 kPa) or EPA requirements.
3. Install a new filter-drier. See Filter-Drier
Removal and Installation in this chapter.
5. Charge the system. See Charging
Procedures in this chapter.
6. Run the system. Monitor system pressures to
confirm that the system is working properly.
Observe the sight glasses to confirm that the
charge level is good.
7. Remove the gauge manifold and other service
equipment.
8. Perform a final leak test of fittings and caps to
ensure that no leaks remain.
9. Place the system back in operation.
System failure
Dirt, Dust,
Metal
Particles
Severe damage to close

tolerance items (pistons,
bearings, valve plates, expansion
valve, etc.)
Acid
Deterioration of soft metals and

metal plating
Corrosion of compressor bearings
Holes in tubing
Figure 35: Contaminants in a System
A corroded filter drier can be a source of particles in the

system.
The following procedures describe how to clean a

contaminated system: removing air, removing
moisture, and replacing a compressor due to
long-term contamination.
Removing Air: Unit Contaminated

for a Short Period
Purpose: To remove air from a system in which
the air was detected early and the damage to the
system is minimal.
1. Attach a gauge manifold. See Gauge
Removal.
82
Removing Air: Unit Contaminated

for a Long Period
Purpose: To remove air from a system in which
the air was not detected early and damage to the
system is extensive.
NOTE: To change the filters, perform a low side
pump down.
Removal.
2. Attach a recovery machine and recover the
(0 kPa).
3. Test the compressor oil for acid. If the
compressor oil is acidic, change it.
4. Remove the compressor heads and discharge
manifold. Inspect the upper end of the
compressor:
a. If the discharge valve plates have bluish
streaks, replace the valve plates.
b. If the discharge valve plates have a
brownish red coating, clean the assemblies
with solvent. Flush, blow dry, oil, and
reuse the plates.
c. If you see damage inside the cylinders,

such as scored cylinder walls or damage
from particles or pieces of metal, replace
the compressor.

10. Run the system for 24 hours with all filters in
place, then re-test the compressor oil for acid.
d. If the valve plates have been moving

inside the head area and no damage to the
block has occurred, inspect and replace
parts as needed.
a. If the oil is not acidic, perform a low side

pumpdown, remove the suction line filter
from the system, replace the filter-drier,
and evacuate the low side.
e. Inspect the gaskets and cylinder O-rings to

see if they are hard, brittle, or warped.
Replace all gaskets and O-rings. Do not
reuse the old ones.
NOTE: For torque sequences, see TK 6075,
X426 and X430 Compressor Overhaul for
Bus Air Conditioning, or TK 40079 for
X640 compressor.
5. Replace O-rings in the discharge line from the
compressor to the condenser.
6. Install a suction line filter for system cleanup.
b. If the oil is still acidic, perform a low side

pumpdown, change the compressor oil,
replace the suction filter cartridge, and
replace the filter-drier. Run the system for
24 hours, then retest the compressor oil for
acid. Repeat this step until the compressor
oil tests negative for acid.
Observe the sight glasses and confirm that the
equipment following proper procedures. See
Removal.
Removing Moisture
Purpose: To remove moisture from a system.
The following indicate moisture contamination:
Moisture indicator has changed color
Acid test shows compressor oil is acidic.
Use the following procedure to remove moisture:

Manifold Attachment, Purging, and Removal
1.
Suction Line Filter
Figure 36: Suction Filter Kit
2. Perform a low side pump down.

3. Change the compressor oil.



5. Evacuate the low side.

6. Run the system for 24 hours, then retest the
compressor oil for acid.
83
a. If the oil is not acidic, replace the

filter-drier.


and replace the filter-drier. Run the system
for 24 hours, then retest the compressor oil
for acid. Repeat this step until the
compressor oil tests negative for acid, or
until three new filter-driers have been
used. If the oil is still acidic after three
new filter-driers, replace the refrigerant
charge. See Removing Air: Unit
Contaminated for Short Period above.

9. Run the system for 24 hours with all filters in
place, then test the compressor oil for acid.
a. If the oil is not acidic, perform a low side
pumpdown, remove the suction line filter
from the system, replace the filter-drier,
and evacuate the low side.

Observe the sight glasses and confirm that the

replace the suction filter cartridge, and
replace the filter-drier. Run the system for
24 hours, then re-test the compressor oil
for acid. Repeat this step until the
compressor oil tests negative for acid. In
extreme cases, add a compressor oil filter
to aid clean up. Leave it in place until the
next service interval.

Removal in this chapter.
Replacing a Compressor
Purpose: To replace a compressor that has failed
due to long-term system contamination.
The following indicate major compressor failure:
The compressor will not turn; it is locked
The compressor oil is black or gray.

Manifold Attachment, Purging, and Removal
in this chapter.
2. Attach a recovery machine. Recover the
(0 kPa) or EPA requirements.
3. Replace the damaged compressor with a new
or rebuilt one. Use new oil.
4. Replace all O-rings in the discharge line from
the compressor to the condenser. This
prevents leaks from developing.
5. Install a suction line filter for system cleanup.
84
10. Run the system. Monitor the system pressures

to confirm that the system is working
properly. Observe the sight glasses and
confirm that the charge level is good.
Removal in this chapter.
Ice Bath Test for Air and Other

Non-Condensables
Purpose: To test refrigerant for contaminants.
Required Tools
Gauge manifold set
Sampling bottle
Micron gauge
Vacuum pump
Thermometer
Ice water bath (75 percent ice in small pieces,

25 percent water)
Set of refrigeration wrenches.
Refrigerant
Pressure1
R-22
57.5 psig (396.4 kPa)
R-407C
50.9 psig (351 kPa)
R-134a
27.3 psig (188.3 kPa)
Gauge Manifold Attachment Procedure

Attach the gauge manifold set as follows:
1. Connect the low side hose to the sample
bottle.
2. Connect the center hose to the receiver tank
service valve (or liquid line service valve).
Leave the valve closed.
3. Connect a line to suction service valve on
compressor. Leave valve closed. See Figure
37 on page 86.
4. Connect the high side hose to the evacuation
pump.
Ice Bath Test Procedure
CAUTION: Use extreme care in taking
the sample. It is critical that the sample
not be contaminated.
1. Open the manifold gauges. Evacuate hoses,
manifold, and sample bottle to 500 microns.
CAUTION: Ensure that there are no leaks
in the system.
Reading must be 1 psig [7 kPa].
8. There are two outcomes of this test:

a. Non-condensables detected: If pressures
exceed specifications, evacuate the unit
according to evacuation procedures. After
the system is evacuated, leak tested, and
recharged with clean refrigerant, test
system operation. If the system operation
is satisfactory, return the bus to service.
b. Non-condensables not detected: If ice
bath testing proves negative (no
non-condensible), make sure receiver tank
or liquid line service valve is closed. Start
the bus and run the compressor at fast idle.
Open both gauge manifold valves, then
slowly open suction service valve to line
and bleed the refrigerant back into system.
Leave compressor valve open until the
pressure stabilizes. Back seat the suction
service valve. Purge all lines.
c. Remove gauges, lines, etc. Replace all
service caps, and covers. Return bus to
service.
2. Run the compressor to circulate air, if any, in

the system.
3. Close the high side gauge valve to isolate the
micron gauge and pump.
4. Open the receiver tank service valve for a
count of four. Close the valve for another
count of four.
5. Close the low side gauge valve.
6. Submerge the sample bottle in the ice bath for
15 to 20 minutes. Make sure the sample is
completely covered. Stir the ice bath
occasionally.
7. Compare the low side gauge reading with your
pressure/temperature chart for 32 F (0 C):
85
3
4
6
5
8
9
1
10
13
11
12
Refrigerant Pressures at 32 F (0 C):
R-22 = 57.5 psig (396.4 kPa)
R-134a = 27.3 psig (188.3 kPa)
R-407C = 50.9 psig (351 kPa)
(Reading must be 1 psig [7 kPa])
1.
Temperature 32 F (0 C)
8.
Suction Line
2.
Gauge Manifold Set
9.
Hose Manifold Assembly
3.
Suction Gauge
10.
Micron Gauge
4.
Discharge Gauge
11.
Vacuum Pump
5.
Receiver Tank
12.
Ice Bath 75%, 25% Ice Water
6.
Suction Service Valve
13.
Sample Bottle of Refrigerant
7.
Compressor
Figure 37: Ice Bath Sample Method
Compressor Oil Procedures

The quantity of oil will not change unless there is
a leak or someone has added or removed oil from
86
the system. However, the level in the compressor

sight glass will change depending on factors such
as ambient temperature and system operating
characteristics. To get an accurate reading, check

the oil level when the system has run for at least
30 minutes. The correct level should be between
1/4 and 1/2 of the compressor oil sight glass.
should be between 1/4 and 1/2 of the sight

glass. (General rule: If the oil level can be
seen in the sight glass, the oil level is good.)
Adding Compressor Oil

CAUTION: Stop the bus engine and A/C
system before adding oil. Ensure the unit
and bus cannot be run during servicing.
CAUTION: Before adding oil, confirm
which oil is in the system. The wrong oil
can cause severe damage to your system.
CAUTION: The vacuum pump method is
the only to add oil to a charged system. Do
not use hand pump.
1. Estimate how much oil is needed. Verify the
correct oil for the system.
2. Pump down the compressor. See Compressor
Pumpdown.
1.
Oil Drain Plug
2.
Oil Fill Plug
3.
Oil Sump Pump
4.
Suction Service Valve Fitting
5.
Figure 38: Compressor Components
3. Turn off the bus power and operating safety

switch to ensure that the bus cannot run.
4. Front seat the compressor discharge service
valve.
5. Balance pressures to establish positive
pressure and to recover excess refrigerant
pressure.
Checking the Oil Level

CAUTION: The unit must be running
when you check the oil, but do not work
on operating equipment when the unit is
running. Serious injury or death could
result.
1. Run the air conditioning system at a high idle
engine speed (1200 to 1500 RPM) for at least
30 minutes. Operate it in reheat mode, or jump
the unit heating to keep the A/C on.
2. Confirm by touch that the compressor sump
area is warm. If it is cool, it may have liquid
refrigerant mixed in the oil.
3. Be sure the compressor is sitting in a level
position (i.e., not tilted). Check the
compressor sight glass. The correct oil level
6. Connect a vacuum pump to the service
gauges. (Service gauges should still be
Figure 39: Balance SystemBoth Valves

Front Seated
connected from the compressor pumpdown).
87
7. Connect a clean service hose to the oil

pressure port. This is located on top of the
compressor oil pump at the top rear of the
compressor (see Figure 40 on page 89).
8. Open the oil container. Insert the clean service
hose from the oil pressure port into the can to
below the oil level.
CAUTION: If the oil level drops below the
hose opening, air will be sucked into the
compressor during this procedure. Ensure
the hose is below the oil level at all times.
CAUTION: Refrigerant oil attracts
moisture from the air. Do not leave oil
containers open to the air for long periods
of time.
88
1.
Oil Drain Plug
7.
Service Manifold Gauge
2.
Oil Fill Plug
8.
Micron Gauge
3.
Oil Pump Port
9.
Vacuum Pump
4.
Shut-off Valve
10.
Oil Container Filled with Compressor Oil
5.
Discharge Service Port
11.
6.
Suction Service Port

Figure 40: Adding Compressor Oil
89
9. Turn on the vacuum pump. Lower the pressure

inside the compressor to pull the oil into the
sump through the compressor oil pump.
10. Observe the compressor oil sight glass. When
the oil level is 1/4 to 1/2 in. (6 to 12 mm) from
the bottom of the sight glass, secure the oil
pump pressure port and replace the cap.
Continue evacuating the compressor sump
area to remove air and non-condensable gases
that were pulled in with the oil.
2. With the unit running, observe the gauge

reading at compressor oil pump. This reading
is both suction pressure and compressor oil
pressure. Install a compound gauge on the
suction service valve fitting. Run until the
suction pressure stabilizes.
11. When evacuation is complete, open all system

valves, start the bus and A/C system, and
recheck the compressor oil level.
12. Confirm the system refrigerant charge level.
See Charging Systems. Adjust the charge as
required before returning the bus to service.
Removing Excess Oil

1. Pump down the compressor. See Compressor
Pumpdown.
2. Stop the compressor. Use the gauge manifold
to adjust the compressor (low side) pressure to
2 to 3 psig (14 to 21 kPa). Measure the
pressure at the compressor suction service
valve port.
3. Loosen the drain plug but do not remove it.
Allow the oil to drain slowly while watching
the level in the compressor sight glass.
NOTE: Heavy foaming of the oil as it leaves
the compressor indicates refrigerant in the
oil. If you observe foaming, run the system
longer before performing this procedure.
4. Tighten the drain plug. Leak test the system.
See Testing System for Leaks.
5. Run the system. Confirm the refrigerant
charge level. Check the oil level before
returning the bus to service.
1.
Oil Pump Port A
2.
Schrader Valve in Hose
3.
Compound or Suction Pressure Gauge

Figure 41: Checking Oil Pump Pressure
3. Calculate the oil pressure by subtracting the

suction pressure reading from the oil pump
port gauge reading:
Checking Compressor Oil Pressure
Example:
1. Install a gauge on the compressor oil pump

port (A) located at the top of the oil pump
cover (see Figure 41 below). If necessary,
pump down the system and use a gauge line
with a Schrader valve.
Pressure from oil pump port (A)
Compound gauge (suction

pressure) reading
Net compressor oil pressure
90
65 psig
(448kPa)
35 psig
(241 kPa)
30 psig
(207 kPa)
Compressor Efficiency Check

Perform a compressor efficiency check if the
system is not cooling correctly and you have
verified that all other system components are
operating properly.
NOTE: This procedure applies to Thermo King
X426, X430, and X640 compressors.
1. Install a gauge manifold set. See Gauge
Removal.
2. Bypass the Low Pressure Cutout (LPCO) to
prevent the clutch from disengaging.
3. Start and run the unit at fast idle for 15
minutes to stabilize system pressures.
Example: On an 80 F (27 C) day, your
discharge pressure will be approximately 240
psig (1655 kPa) (with R-22 or 407C
refrigerant).
4. Cover the inlet side of the condenser coil to
increase the discharge pressure 70 to 100 psig
(483 to 689 kPa) higher than normal.
Example: If your discharge pressure is 240
psig (1655 kPa) after 15 minutes of operation,
increae it 310 to 340 psig (2137 to 2344 kPa).
5. Front seat the suction service valve.
6. When the compressor reaches a 10 in. vacuum
(-34 kPa), observe the discharge pressure. It
should read as follows:
a. R-134a
125 psig or higher

(862 kPa)
b. R-22 & R-407C 190 psig or higher
(1310 kPa)
NOTE: Foam or bubbles are indications of
refrigerant in the oil. If this occurs, start the
compressor a few times to complete the
pumpdown. Starting the pumpdown from a
warm compressor minimizes this condition.
IMPORTANT: If the head pressure cannot be
raised by 100 psig (689 kPa) prior to the
pumpdown or the vacuum will not stay below
15 in. (-51 kPa), the compressor may require
repair or replacement. Check the following:
Piston reed(s) or discharge valve plate reed(s)

may be defective.
Compressor may have excessive piston to

sleeve clearance.
Unit may be low on refrigerant.
NOTE: If the compressor will not pull at least a

15 inch (-51 kPa) vacuum, the piston reed may
be defective or the piston to sleeve clearance may
be excessive.
If the compressor will pull a deep vacuum, but
not stay below 15 inches (-51 kPa) of vacuum for
at least 15 seconds after unit is turned off, the
discharge valve reed(s) are defective.
CAUTION: Eliminate all other
possibilities before repairing the unit. Be
sure you have allowed enough time for the
refrigerant to leave the oil during the
pumpdown. Repeat the test if necessary.
Compressor Removal and

Installation
Operating Compressor Removal
NOTE: See TK Service Bulletin No. 390 for
service valve torque values on the compressor for
your unit.
and Removal.
2. Place a jumper wire across the LPCO to allow
the compressor to pull a slight vacuum.
3. Pump down the compressor to a vacuum of
approximately 10 in. Hg (-34 kPa). Stop the
unit.
4. Stop the bus and switch off the bus battery. If
there is a safety off switch in the engine
compartment, turn it off.
5. Front-seat the compressor discharge service
valve.
6. Use the gauge manifold hand valves to raise
the pressure in the compressor to 0 psig
(0 kPa) before removal from bus.
7. Recover the refrigerant remaining in the
compressor with a recovery or recycling
machine.
91
CAUTION: Do not vent refrigerant to the

atmosphere.
8. Unbolt the discharge and suction service
valves from the compressor. Cap the ports on
the compressor body to prevent
contamination.
9. Move the valve and hose assemblies out of the
way. Secure them in place to prevent
interference with the following operations.
10. Loosen and remove the drive belts from the
compressor.
11. Unbolt the compressor from its mounting
cradle.
12. Disconnect the remaining wires and pressure
lines from the compressor.
13. Remove the compressor from the bus.
6. Move the valve and hose assemblies out of the

way. Secure them in place to prevent
interference with the following operations.
7. Loosen and remove the drive belts from the
compressor.
8. Unbolt the compressor from its mounting
cradle.
9. Disconnect the remaining wires and pressure
lines from the compressor.
10. Remove the compressor from the bus.
NOTE: Check and note the oil level of the
removed compressor. If the level is correct, the
new compressor must have the same amount of
oil.
Compressor Installation
1. Check and adjust (if necessary) the oil level of
the new compressor.
NOTE: Check and note the oil level of the

removed compressor. If the level is correct, the
new compressor must have the same amount of
oil.
Non-Operating Compressor
Removal
and Removal.
2. Turn off the bus battery. If there is a safety off
switch in the engine compartment, turn it off.
3. Front-seat the compressor suction and
discharge service valves.
4. Recover the refrigerant remaining in the
compressor with a recovery or recycling
machine.
CAUTION: Do not vent refrigerant to the
atmosphere.
5. Unbolt the discharge and suction service
valves from the compressor. Cap the ports on
the compressor body to prevent
contamination.
CAUTION: Do not mix oils and

refrigerants that are not compatible.
Serious damage to your system will result.
2. Mount the compressor.
If mounting bolts are used in the belt

alignment process, do not tighten them
now. Assemble all hardware loosely.
If mounting bolts are not used for belt

alignment, then secure them.
3. Remove the protective caps from the service

valve ports on the compressor body. Inspect
the ports to ensure that nothing has been left
inside the compressor. Clean the gasket
surfaces for the service valves. Check the
compressor body to ensure it is clean. Oil the
gaskets with the system refrigerant oil.
4. Mount the service valves on the compressor
body. Torque the mounting bolts to the
specified torque value. Connect any other
refrigerant or oil lines required by your
system.
6. Pressurize the compressor with nitrogen to
100 psig (689 kPa) and test for leaks.
92
7. Evacuate the compressor to a stabilized

pressure below 1500 microns.
8. While the compressor is being evacuated,
connect control wires, install and align the
drive belts, and check the tightness of all bolts
and connections.
NOTE: See the bus manufacturer manual
for alignment and belt tension tools and
procedures.
9. When evacuation is complete, close the gauge
manifold valves and remove the evacuation
equipment. Leave the gauge manifold
attached to the compressor to monitor system
operation.
10. Back-seat the compressor suction and
discharge service valves.
11. Run the bus A/C in high idle (12001500 rpm
compressor speed).
12. Check that all fans are working and that the
system is cooling.
13. Operate the system for at least 30 minutes,
then check the compressor oil level. The oil
level should be 1/4 to 1/2 from the bottom of
the sight glass. Add or remove oil if necessary.
NOTE: The compressor body must be warm
to the touch before checking oil.
14. Check refrigerant charge and add refrigerant if
needed.
15. Stop the bus. Recheck the tightness of all
bolts. Recheck the drive belts for correct
tension.
93
Compressor Crankshaft Seal

Set Screw Type Metal Bellows
Crankshaft Seals
Thermo King has designed two stainless steel
bellows crankshaft seal assemblies for the X426,
X430 and X640 compressors used in bus air
conditioning applications. These new stainless
steel bellows seals provide higher tolerance to
heat experienced in bus engine compartments, and
reduce leak potentials by eliminating the carbon
seal face.
The early model stainless steel bellows assembly

was manufactured between May 1992 and
November 1996.
This early model style drive plate can be
identified by a groove around the outer rim
surface.
Early Model SS Bellows Shaft Seal

Shaft Seal
Used with Drive Plate
TK No. 22-751
TK No. 22-790
1.
Hard Ring
2.
Rotating Bellows
3.
Install Beveled Surface Against

Crankshaft Shoulder
4.
Compressor Side
5.
Assembled Together in the Parts Box
6.
Carbon Sealing Face (1992 to1996)
Figure 43: Stainless Steel Bellows Crankshaft Seal

TK No. 22-751
1.
NOTE: Groove signifies for use with only

stainless steel bellows seal, TK No. 22-751.
Figure 42: Compressor Front Drive Plate
TK No. 22-790
94
Starting November 1996 to date, Thermo King

introduced a new improved stainless steel bellows
crankshaft seal (TK No. 22-1100). This seal
utilizes a bronze sealing face and is compatible
only with the compressor front drive plate
TK No. 22-754. This drive plate does not have a
groove on the outer rim.
Later Model SS Bellows Shaft Seal
Shaft Seal
Used with Drive Plate
TK No. 22-1100 TK No. 22-754
1.
Hard Ring
2.
Rotating Bellows
3.
Install Beveled Surface Against

Crankshaft Shoulder
4.
Compressor Side
5.
Assembled Together in the Parts Box
6.
Bronze Sealing Face (1996 to date)

Figure 45: Stainless Steel Bellows
Crankshaft Seal TK No. 22-1100
Installation of Set Screw Type Metal

Bellows Seal
1.
NOTE: No groove for use with Neoprene

Bellows Seal or Stainless Steel Bellows
Seal TK No. 22-1100.
Figure 44: Compressor Front Drive Plate
TK No. 22-754
Drive plate TK No. 22-754 is compatible with

older compressors that use the Neoprene Bellows
crankshaft seal (units manufactured prior May
1992). Older model compressors which use this
front drive plate can be upgraded to use the new
stainless steel bellows crankshaft seal
(TK No. 22-1100).
New stainless steel shaft seal and new style seal
plate, when used together, are compatible with
older model X426, X430, and X640 compressors.
1. Remove the compressor from the unit and

remove the clutch or drive coupling to access
the seal plate.
2. Clean the outside of the seal plate.
3. Remove the seal plate from the compressor.
4. Remove the old hard ring (mating ring), lip
seal, and o-rings from the seal plate.
5. Loosen the set screws that secure the bellows
to the crankshaft. These set screws typically
use an 1/8 inch Allen wrench, which is
provided with the new seal kit.
NOTE: A modified 1/8 in. (3.2 mm) Allen
wrench with a 1/2 in. (12.7 mm) shank is
included with the Stainless Steel Bellows
Crankshaft Seal Kit. If you lose this wrench,
you can modify a standard 1/8 in. (3.2 mm)
Allen wrench. The shortened shank should
be no longer than 1/2 in. (12.7 mm). See the
figure below.
95
1
2
1.
Shorten Wrench
Figure 46: Special Allen Wrench
AGA577
5
3
6. Remove the old bellows from the crankshaft.

Use a small pry bar or screwdriver on each
side of the bellows, but do not scratch the
crankshaft when removing the bellows.
7. Back out the set screws from the new bellows

and apply a small amount of removable thread
locking compound (Loctite 242-31-blue
TK No. 203-400) to the set screw threads.
CAUTION: Keep the orange protective
cap in position until final assembly.
1.
Set Screw
2.
Seal Faces
3.
Hard Ring
4.
O-ring
5.
Bellows
Figure 48: Set Screw Type Bellows Seal
8. Apply clean compressor oil (same type used in

compressor) to the o-ring inside the bellows.
9. Slide the bellows onto the crankshaft with the
chamfer inside the clamp ring facing the
crankshaft shoulder (see Figure 49 on page
96). Leave the orange protective cap on the
bellows.
AGA576
2
1.
Clamp Ring Installed with Chamfer

Facing Crankshaft Shoulder
2.
Orange Protective Cap
10. Use seal installation tool TK No. 204-995 to

install the bellows squarely on the crankshaft.
Clean the seal installation tool and place it on
the crankshaft.
1
2
3
Figure 47: Cross Section of

Set Screw Type Bellows Seal
AGA1256
1.
Crankshaft
2.
Bellows
3.
Seal Installation Tool TK No. 204-995

Figure 49: Bellows Installation with
Tool TK No. 204-995
96
12. Tighten the set screws to approximately 45

in.-lb (5.0 Nm) with the Allen wrench
provided.
13. Remove the seal installation tool.

2
14. Install the new lip seal in the seal plate with
the lip side facing out and the flat side facing
toward the compressor.
15. Apply clean compressor oil to the new o-ring

and install it in the seal plate. Apply clean
compressor oil to the new hard ring. Ensure
that the hard ring installation tool
(TK No. 204-953) is clean. Use the hard ring
installation tool to push the hard ring (with the
polished surface toward the installation tool)
fully into the seal plate. Do not pinch the
o-ring.
1.
2.
Seal Installation Tool TK No. 204-995
3.
Tighten Knob On Seal Installation Tool
Figure 50: Seal Installation Tool Placed on

Compressor Crankshaft
11. Turn the knob on the seal installation tool until

the tool bottoms out.
4
If the installation tool is not available, use the

pad in the new seal packaging to protect the
polished surface of the hard ring during
assembly. A substitute installation tool should
have a diameter approximately the same size as
the O.D. of the polished surface.
CAUTION: After dipping seal parts in
compressor oil, assemble immediately. The
rubber parts/o-rings will swell slightly,
and be impossible to install after several
minutes exposed to air.
CAUTION: DO NOT pinch O-ring.
1
2
3
1.
2.
Seal Installer Tool TK No. 204-995
3.
Knob Completely Tightened to Crankshaft
4.
Special Allen Wrench (Kit Supplied)

Figure 51: Seal Installation Tool Secured To
Crankshaft and Tightening Set Screws
97
oil to the polished surfaces of the seal and to

the lip seal from package number 3 before
assembling.
CAUTION: Oil applied to the seal faces
must be absolutely clean.
17. Install the seal plate on the compressor body.
1.
Install Seal with Lip Facing Outward
2.
O-ring Facing Seal Plate
3.
Polished Face Surface
4.
Mating Ring Installation Tool (TK No. 204-953)
5.
Mating Ring
6.
Seal Plate
7.
Seal
Figure 52: Seal Installation
CAUTION: Do not bump the hard ring

into the end of the crankshaft during
assembly.
18. Hold the seal plate against the spring tension
of the bellows until three opposing seal plate
mounting screws are started. Then turn each
of these screws one turn at a time to evenly
pull the seal plate to the compressor body.
snug. Install the remaining mounting screws.
Torque the mounting screws to 28 ft-lb
(38 Nm) in a criss-cross pattern.
CAUTION: Do not touch or damage the

polished seal face surfaces.
1.
Do Not Touch Surface.

Hold Only By The Side Edge.
Figure 53: Installation of Mating Ring (Hard Ring)
1.
Inside Diameter Chamfer Seats

Against Crankshaft Shoulder
2.
Mating Ring (Hard Ring)
3.
Rotating Bellows
4.
Locking Collar
Figure 54: Installation of Seal Assembly
16. Remove the orange protective cap from the

bellows. Clean the hard ring and the primary
ring (bronze ring on the bellows) with the
alcohol wipes found in package labeled 1.
Then clean the polished mating surfaces of
both rings with the lint free dry wipes from
package number 2. Apply clean compressor
98
Brass Sealing Washers Used In

Discharge Line Connections
A brass sealing washer is used on the discharge
line. It replaces the neoprene O-ring previously
used in the discharge line. Neoprene O-rings are
still used on some suction fittings.
CAUTION: When tightening the

connections, be sure to use three (3)
wrenches. One wrench is used to hold the
fitting and associated tubing from
twisting. The second wrench is used to
turn the vibrasorber/hose fitting. The third
wrench is used to prevent the
vibrasorber/hose from twisting. Failure to
use three wrenches during the installation
can cause twisted vibrasorbers/hoses and
the potential for the connections to come
loose during operation, which can result
in system leaks.
Leak Check: After installation, leak check with an
Figure 55: Fitting and Brass Sealing Washer
You must use the following procedures when

using the metal washer:
Handling: Handle the washer with care so as not to
damage the sealing ridges.
electronic leak detector before releasing the full

charge. Charge and top off if necessary.
Tightness Check: Check fittings for tightness and
leaks in 3 months, then at 6 month intervals.
NOTE: All O-ring seals used on JIC fittings and

all O-ring face seals used on suction fittings are
made of neoprene.
Fitting Cleanliness: Wipe
clean of contamination
(i.e., oil grease, O-ring particles, etc.) Do not use
abrasive cleaners.
Sealing Surfaces: Do not use
washers with
damaged sealing surfaces. The sealing surfaces in
the fitting must be free of visible defects such as
scratches and pitting.
Mounting: When positioning the
washer in a
fitting that points downward, apply a small
amount of petroleum jelly to the outer edge of the
fitting groove. This will retain the washer when
attaching the tube or hose.
Tightening Torque: Tighten fittings
of both sizes
(No. 16 and No. 20) to 180 ft-lb (244 Nm).
99
SAE J639 Service Fittings

Some units with R-134a and R-407C are equipped
with SAE J639 service fittings which require
special gauge manifold sets to fit the SAE J639
fittings.
The gauge manifold set number is TK No.
204-747. The service fittings for this unit are
shown below.
1.
2.
3.
Flexible Line Connector

O-ring Seal Positioned in Groove
Compressor Line
Figure 58: JIC Fitting
Figure 56: Suction Adapter

with or without Depressor
1.
2.
3.
Adapter
O-ring
Connector Nut
Figure 59: O-ring Face Seal

Figure 57: Discharge Adapter
with or without Depressor
O-Ring Seal Fitting

Replacement
1. Pump down the low side or recover the
refrigerant charge as necessary. See Low
Side Pump Down and Refrigerant
Recovery.
2. To break threaded line connections, use two
wrenches. A neoprene O-ring is used at
flexible line connections and at condenser line
connections to ensure a positive seal. Install a
new O-ring seal whenever a line connection is
broken. O-rings should never be reused.
100
3. Before the line is connected, apply clean

compressor oil of the same type used in the
system to O-ring and flares to facilitate
connection. Use two wrenches to tighten the
flexible connections. To connect a flexible
line to a metal line, hand tighten connector nut
on flexible line against the adapter fitting.
Support the adapter fitting with a wrench, and
tighten the connector nut with another wrench
until the fitting bottoms out. The connection
bottoms out when tight, reducing the chance
of over or under torque.
Refrigeration Hose Inspection

Inspect hose assemblies in operation frequently
for leakage, kinking, abrasion, corrosion, and
other signs of wear or damage. Replace worn or
damaged hoses immediately. Check the lay line of
the hose to be sure that the hose is not twisted.
If the hose is installed with a twist in it, high

operating pressure tends to force it straight. This
can loosen the fitting nut. Twisting can cause
reinforcement separation, and the hose could burst
at the point of strain.
Dents
Cover damage
Crushed hoses
Twists or bends in hoses.
3. Incorrect installation can cause:
1.
Incorrect bend radius
Incorrect hose routing
Incorrect clamping
Excessive compression
Excessive tension
Excessive hose torsion.
Lay Line
Figure 60: Hose Alignment
Suction and Discharge Hose

Installation
Use three (3) wrenches for hose installation.
Failure to use three wrenches during the
installation can cause twisted vibrasorbers and the
potential for the connections to come loose during
operation, which can result in system leaks:
1. Use one wrench to hold to hold the fitting and
associated tubing from twisting.
2. Use the second wrench to turn the
vibrasorber/hose fitting.
3. Use the third wrench to prevent the
vibrasorber/hose from twisting.
Tightening Torque
Tighten steel and brass fittings of all sizes
(No. 16, No. 20, and No. 24) that use either
neoprene or brass O-rings to 180 ft-lb (244 Nm).
Figure 61: Typical Suction and

Discharge Hose Installation
Causes of Failure
1. Improper storage can cause:
Permanent deformities
Crushed hoses
Corroded hoses.
2. Incorrect handling can cause:
101
All flexible lines should be kept as short as the

specific application allows. Observe the handling,
design, and installation instructions in this
chapter.
1.
Yes Good Bend Radius
2.
NO Kinks; Observe Proper Bend Radius
3.
Motion
4.
Motion Side to Side
5.
Yes Hose Will Absorb Motion
6.
NO Side to Side Motion will Loosen or Crack Hoses by Causing a Twisting Action in the Hoses
7.
This Movement OK
8.
This is not OK
Figure 62: Hose Routing
102
Design
These guidelines illustrate ideal situations. They
should be followed as closely as possible.
1.
Correct Use of Curved Fitting; Smooth Bend
2.
IncorrectSharp Bend; Possible Compression
3.
Correct
4.
Incorrect
Figure 63: Ideal Hose Routing
1.
Correct
2.
Incorrect Motion Subjects Hose to Torsional Stresses
3.
Incorrect Motion Carries Hose Out of Plane of Original Hose Axis

Figure 64: Correct and Incorrect Hose Alignment
103
1.
Correct
2.
Correct Neutral Hose Ends Maintained
3.
Incorrect
4.
Incorrect Stress Reversal Bending Next to Fittings

1.
Correct
2.
Incorrect Twisted on Installation

Service Valves
Maintenance on the discharge service valves and
suction service valves involves periodically
tightening the packing nut. The valves are a
permanently assembled unit and must be replaced
in total if defective.
104
CAUTION: Do not overtighten packing

nut.
1.
Inlet or Outlet Depending on Application
5.
Packing Gland Nut
2.
Front Seat
6.
Protective Cap
3.
Back Seat
7.
Stem
4.
Service Port
8.
Packing Material
Figure 67: Service Valve
Suction Service Valve Removal

Use this procedure when the discharge service
valve does not require service.
2. Remove the suction hose from the suction
service valve before loosening the service
valve mounting bolts.
3. Remove service valve mounting bolts and
remove the service valve from the compressor
body.
4. Clean all surfaces, being careful not to allow
dirt, etc. into the compressor port.
Discharge Service Valve Removal

Use this procedure when servicing the discharge
service valve, or both service valves.
1. Recover the refrigerant charge (see
Refrigerant Recovery).
NOTE: If the suction service valve is to be
removed, refer to steps 2 through 4 of
Suction Service Valve Removal.
2. Loosen the discharge hose to service valve

connection before loosening the service valve
mounting bolts.
3. Remove service valve mounting bolts and
remove the service valve from the compressor
body.
4. Clean all surfaces, being careful not to allow
dirt, etc. into the compressor port.
Service Valve Installation

1. Confirm that surfaces are clean and free from
scratches.
2. Coat the gaskets or o-ring with refrigerant oil
(same oil used in this system).
3. Mount the gasket or o-ring and valve on the
compressor body using the mounting
hardware that you removed. Tighten bolts
finger tight, then tighten to a torque value of
22 ft-lb (30 Nm).
4. Attach the hoses to the service valves and
torque per specifications.
5. Leak test the system following standard
procedures.
105
6. If all refrigerant was removed from the

system, evacuate the complete system. If only
the low side was opened, evacuate the low
side only. Follow procedures in this manual to
complete the evacuation down to an equalized
pressure below 1500 microns.
7. If the system is empty, charge the system. If
the low side was pumped down, open the
receiver tank outlet valve or the liquid line
shutoff valve.
Condenser Coil Removal and

Installation
CAUTION: Use extreme care when
working with the exposed coil fins. Coil
fins are very sharp and can cause painful
lacerations.
Removal
8. Start the unit and check the refrigerant charge

and compressor oil level.
2. Remove the screws securing the orifice panel

to the frame. Remove the orifice panel
assembly.

Removal and Installation
3. Unsolder the condenser inlet and outlet tubes.
The valve contains a spring loaded piston that lifts

when the refrigerant pressure exceeds the spring
force. When pressure drops below setpoint, the
valve will reset. The valve might leak refrigerant
after it has relieved excess pressure. Tapping the
valve lightly may help the valve reseat and seal
properly. The valve is non-repairable and requires
no adjustment. If the valve fails to reseat properly,
the valve must be replaced.
NOTE: Before starting replacement procedure,
use your parts manual to identify the correct
valve for your unit.
Removal
4. Seal the inlet tube to prevent contamination.

5. Remove the screws securing the condenser to
the frame.
6. Lift the condenser coil directly outward from
the unit.
CAUTION: Remove the condenser coil
carefully to prevent fin damage.
DANGER: Do not solder on a closed
system. Pressure can build up and may
cause an explosion. Use Nitrogen purge or
open a service during soldering
procedures to prevent pressure buildup.
NOTE: Purge the residual pressure before

unsoldering tubes.
2. Unscrew and remove the high pressure relief

valve. Discard the old valve.
7. Repair the condenser coil as necessary.
Installation
1. Apply a refrigerant oil (same type as used in
the system) to the o-ring and threads of the
high pressure relief valve.
2. Install and tighten the high pressure relief
valve.
3. Pressurize the refrigeration system and test for
leaks. If no leaks are found, evacuate the
system.
106
Installation
1. Place the condenser coil in the frame.
2. Secure the condenser coil to the frame and
tighten the screws.
3. Solder the inlet and outlet tubes to the
condenser coil.
4. Pressurize the system and leak test the solder
joints and the rest of the system.
5. If no leaks are found, evacuate the system.
6. While evacuating the system, finish
assembling the unit. Recheck hardware to
ensure tightness.
Receiver Tank Removal and

Installation
CAUTION: Inspect receiver tank for
corrosion. Clean any areas of existing
corrosion and paint with rust preventive
paint to prevent further corrosion. Replace
any receiver tank that shows excess
corrosion that could cause refrigeration
leakage.
Removal
NOTE: On rooftop units the receiver tank is
typically located in the center of the evaporator
near the condenser. The receiver tank may be
protected by sheet metal plates. The plates must
be removed to remove the receiver tank.
NOTE: On T Series units the receiver tank is
typically located on the curbside of the unit next
to the frame.
NOTE: If soldering is required, it is strongly
recommended that dry nitrogen be used to purge
the system during any solder operations (see
Using Pressurized Nitrogen).
2. Remove the evaporator covers, if required.
4. Remove the upper plate holding the receiver

tank in position, if required.
5. Hook up your refrigerant recovery or
reclaiming machine to the system.
CAUTION: Some recovery machines will
not recover refrigerant in a liquid form.
Follow procedures for your machine.
CAUTION: Purge the system with dry
nitrogen during any solder operations (see
Using Pressurized Nitrogen). Failure to
use nitrogen during soldering procedures
will cause scale build-up inside the system
and cause system malfunction.
6. If unsoldering, hook up and turn on the dry
nitrogen purge.
unsoldering tubes.
7. Disconnect or unsolder the liquid line fittings
between the condenser and tank.
8. Remove the hardware holding # 12 fitting
(liquid line) to the bulkhead, if required.
9. Disconnect the fitting from the filter-drier
inlet, if required.
10. Remove the receiver tank outlet valve
mounting bolt if equipped and unsolder lines
from tank, if required.
11. Disconnect the condenser pressure switch
wires from the wire harness and remove the
condenser pressure switch from the receiver
inlet line, if needed.
12. Remove the receiver tank mounting bolts and
remove the receiver tank.
13. Secure nitrogen purge, and cover open tubes
until ready to install new tank. This will keep
dirt, etc. out of the system.
CAUTION: Discard the receiver tankit
is not repairable and must not be reused
for any other purposes. Only the sight
glass is repairable.
3. Remove the center mounting channel, if

required.
107
Installation
1. If soldering, clean all fittings in preparation
for soldering. A hard silver bearing solder
(such as TK No. 203-364) is required for this
operation. A soft solder must not be used.
Follow all standard shop procedures for the
soldering process. Refer to Silver Brazing
and Soft Soldering TK publication no. 7949
for additional information.
CAUTION: Do not put soldering flux
inside the refrigerant system.
2. Mount the new receiver tank using the
mounting hardware from the old tank, or
replace with new parts.
3. Install the receiver tank outlet valve mounting
bolt, if so equipped.
4. Apply refrigerant oil (same type as used in the
system) to condenser pressure switch threads
(tee assembly), if so equipped.
5. Install the condenser pressure switch securely
and connect the switch wires to the wire
harness, if removed.
6. Connect the fitting to the filter-drier inlet, if
required. Use a backing wrench to prevent
tubing from twisting.
7. If soldering, turn on the dry nitrogen purging
gas. This will prevent oxygen in the air from
causing scale buildup inside the new tank or
tubing.
NOTE: Scale of this type left in the system
will contaminate the compressor oil, plug
filters or expansion valves and support
chemical break down and reaction between
other components of the system.
8. Connect or resolder hardware holding #12
(liquid line) fitting to the bulkhead, if
required. Use a backing wrench to prevent
tubing from twisting.
9. Connect or resolder the liquid line fittings
between the condenser and the tank.
10. Secure nitrogen purge. Clean flux and other
external scaling from the tank and tubing.
108
11. Replace the upper plate that holds the receiver

tank in position, if required.
12. Replace the center mounting channel, if
removed.
13. Replace evaporator covers, if removed.
system.
Filter-Drier Removal and

Installation
NOTE: Some systems may be equipped with a
Pilot operated EPR Valve. If the unit is equipped
with a pilot line shutoff valve, this valve MUST
be closed during a low side pump down.
Removal
1. Determine if the unit has one or two hand
valves and proceed as follows:
a. If the unit has one hand valve, pump down
the low side and equalize the pressure in
the low side to slightly positive (see Low
Side Pumpdown).
b. If the unit has two hand valves, shut the
valves off, then proceed to step 2 (no low
side pumpdown necessary).
2. If the unit has a filter-drier outlet valve, close
it to minimize moisture infiltration into the
system.
3. Disconnect the filter-drier fittings and remove
the filter-drier from the system. Hold the
filter-drier with a backup wrench to keep
from twisting the tubes.
Installation
1. Clean all fittings.
2. Remove the protective caps from the new
filter-drier, install new o-rings (supplied with
new filter drier), and apply oil of the same
type used in the compressor to the o-rings and
threads.
NOTE: Some filter-drier connections do not

use o-rings.
3. Install the new filter-drier as quickly as
possible and observe the following
considerations:
Observe the IN designation printed on

the inlet side of the filter-drier. To prevent
improper installation of the filter-drier,
ensure the arrow on the filter-drier points
in the direction of refrigerant flow.
Hold the filter-drier with a backup wrench
to keep from twisting the tubes when
tightening or removing the nuts.
The longer the filter-drier remains open to
air, the more moisture it will absorb.
4. Evacuate the low side or the filter-drier as

follows:
2. Unlatch and carefully lift the evaporator

access panel.
3. Remove the cover supports.
4. Remove the hardware holding the cover
hinges and covers in position.
5. Remove the covers and set aside.
6. Unbolt the unit control panel, harnesses, and
tubing from center support channel.
7. Remove the center support channel and set
aside.
8. Unsolder the suction line.
DANGER: Do not solder on a closed system.
Pressure can build up and may cause an
explosion. Use Nitrogen purge or open a service
valve during soldering procedures to prevent
pressure build up.
If the unit does not have a filter-drier

outlet valve, evacuate the low side.

unsoldering suction tubes.
If the unit has a filter-drier outlet valve,

hook the evacuation equipment to the
service port on the filter-drier outlet valve
and evacuate the filter-drier and tubing
between the between the two service
valves.
9. Remove hardware and support plates holding

coil assemblies in position.
5. Once the evacuation has been completed, back

seat the service valves, remove the evacuation
equipment, replace caps and open the service
valves and pilot line shutoff valve (if
equipped).
10. Use a hoist to lift the curbside and roadside

evaporator/heater coil assemblies. Remove
them from the unit frame.
11. Unbolt the coil header plate from the coil
supports (both ends).
6. Leak test all fittings, secure the valve packing,

to prevent leakage of refrigerant.
DANGER: Do not solder on a closed system.

Pressure can build up and may cause an
explosion. Use Nitrogen purge or open a service
valve during soldering procedures to prevent
pressure build up.
7. Run the system and check the refrigerant

charge level and compressor oil level.

Evaporator/Heater Coil
Removal and Installation
CAUTION: Use extreme care when
working with the exposed coil fins. Coil
fins are very sharp and can cause painful
lacerations.
Removal
12. Unsolder the joints holding evaporator/heater

coils in position.
13. Remove leaking evaporator/heater coil
assembly.
Installation
CAUTION: Handle the coil carefully to
prevent fin damage.
109
1. Position the new evaporator/heater coil to

match bolt pattern on interconnecting plates
and mating tubes.
2. Solder refrigerant and coolant lines to the
header plates (while purging with nitrogen).
3. Replace the evaporator/heater coil assemblies
into the unit frame. Use a hoist to lift the
curbside and roadside evaporator/heater coil
assemblies. Carefully lower the unit to bus
roof.
4. Install hardware and support plates that hold
coil assemblies in position.
Usually three types of service are performed on

the expansion valve.
1. Replace the expansion valve because the
power element is damaged. A broken power
element causes the valve to close and the unit
to operate in a vacuum.
2. Clean and secure the power element sensor
bulb to the suction line. Poor contact of the
sensor bulb causes the valve to operate by air
temperature. This will be indicated by frosting
of the suction line, and a slight rise in suction
pressure will be noted due to flooding of the
coil. Be sure to wrap the bulb and suction line
with insulating tape.
3. Remove and clean the inlet screen.
5. Resolder the suction line.

system.
7. Locate and install the center support channel.

8. Bolt unit control panel. Install harnesses and
tubing into center support channel.
9. Replace covers.
10. Install hardware that holds cover hinges and
covers in position. Secure as required.
11. Replace cover supports. Secure as required.

12. Close evaporator covers and secure latches.
Expansion Valve
The thermostatic expansion valve meters liquid
refrigerant into the evaporator coil at a
pre-determined rate to keep the coil fully
refrigerated and to ensure complete vaporization
of the refrigerant before it leaves the coil. The
expansion valve is controlled by the temperature
and the pressure in the suction line.
Thermo King expansion valves are factory preset
and do not require adjustment. When diagnosing
refrigeration problems, eliminate all other
possible causes before servicing the valve.
The expansion valve must be serviced by an
experienced refrigeration mechanic.
110
1.
Removable Liquid
Line Fitting
6.
Needle and Seat
2.
Power Head
7.
Adjusting Stem
3.
External Equalizer
8.
Inlet Screen
4.
Outlet
9.
Inlet
5.
Sensor Bulb
Figure 68: Expansion Valve
Removal
2. Be sure the unit and the bus cannot be run
while the system is being serviced.
3. Remove the sensor bulb from the clamps.
Take care not to kink the capillary tube.
4. Unsolder and disconnect the equalizer, inlet

and outlet line connections. Remove the
expansion valve.
5. Clean the screen and replace in the expansion

valve.
Installation
7. Evacuate the low side (refer to the procedure

in this chapter).
1. Clean the tubing connections before installing

the valve.
2. Compare the new valve to the one just
removed. Adjust the length of the sensor bulb
capillary tube. Secure it to valve body in the
same manner as the original valve. This
prevents damage to the tube by vibration
induced chaffing. Once the length is adjusted,
feed the bulb through the required routing.
6. Reinstall the removable liquid line fitting.
8. Open all valves.

9. Run the system and check the refrigerant
charge and oil level.
10. Release the bus to service.
Sensor Bulb Contact
3. Position the valve in the unit and solder the

equalizer, inlet, and outlet lines. Use a heat
sink to prevent damage to the valve.
4. Position the remote sensor bulb in the clamp
on the side of the suction line in exactly the
same spot from which it was removed. Take
care not to kink the capillary tube.
6. If no leaks are evident:
a. Evacuate the low side (refer to the
procedure in this chapter).
b. Open all valves.
c. Run the system and check the refrigerant
charge and oil level.
d. Release the bus to service.
Cleaning In-line Screen

pressure in the low side to slightly positive of
the refrigeration system (see Low Side Pump
Down).
2. Be sure the unit and the bus cannot be run
while the system is being serviced.
3. Remove the removable liquid line fitting.
4. Remove the screen from the expansion valve.
NOTE: A small tool with slight hook may be
needed to pull the screen from the expansion
valve.
1.
Side View - Bulb installed on side of

suction line
2.
End View - Bulb on side of suction line 4

or 8 oclock position
Figure 69: Sensor Bulb Location
1. Remove the insulating tape from the sensor

bulb.
2. Loosen two copper bands.
3. Remove the sensor bulb from the suction line.
4. Clean the suction line and the sensor bulb with
fine abrasive paper or cloth. Do not use acids
or polishes to clean copper.
5. Coat the sensor bulb and suction line with a
light film of oil to prevent oxidation.
6. Install the sensor bulb in clamps on the side of
the line in the original position. Tighten the
clamps and replace the insulation on the bulb.
111
Superheat: Measurement and

Adjustment
NOTE: Be sure the temperature reading
instrument and compound pressure gauge are
accurately calibrated.
Measurement
NOTE: To properly check the superheat, you

must have stable operating conditions. To
establish stable operating conditions, run the
unit at least 15 minutes at 1000 rpm engine
speed so the evaporator air inlet temperature
reaches 70 to 80 F (21 to 27 C). Read the
pressure and temperature simultaneously when
calculating the superheat. The superheat should
be 10 to 15 F (5.5 to 8 C).
CAUTION: Thermo King expansion
valves are factory preset and do not
require adjustment. Establishing
controlled conditions in the field is
difficult. Before adjusting the expansion
valve, check the following causes for an
out-of-range reading.
2. Install a pressure gauge in the in the external

equalizer line to expansion valve. This will
give you an accurate suction pressure reading.
3. Open the receiver tank outlet valve (or liquid
line shutoff valve) and run the unit. Allow the
system to run until oil has returned to the
compressor and the interior of the bus has
cooled to within 5 F (2.8 C) of the thermostat
setpoint.
4. To obtain the expansion valve superheat
setting:
Measure suction line temperature near the

expansion valve sensor bulb (located on
the suction line).
Using the Pressure-Temperature Chart,
convert the pressure measured at the
equalizer line to the equivalent
temperature.
Subtract the suction pressure to
temperature conversion (obtained from
Pressure-Temperature Chart) from the
suction line temperature.
Example:
Suction Line Temperature (F) Near Sensor Bulb
-Suction Pressure to Temperature Conversion (F)
=Superheat (F)
5. Check the following:
Dirty air filters or other cause of reduced

airflow.
Sensor bulb leaking, bulb placed

improperly on refrigerant line, or bulb not
properly wrapped with insulating tape.
Kinked capillary tube.
6. After the above items have been checked,

replace the expansion valve with a factory
preset part if necessary.
Adjustment
1. Remove the cap over the adjusting stem.
2. To reduce superheat, turn the adjusting stem
counterclockwise.
3. Make no more than one turn of the stem at one
time. Observe the change in superheat closely
to prevent overshooting the desired setting. As
much as 30 minutes may be required to obtain
the new balance after the adjustment has been
made.
4. When the proper readings have been achieved,
pump down the low side and equalize the
pressure in the low side to slightly positive.
5. Remove the pressure gauge and thermometer
from the equalizer line.
6. Install the equalizer line, open the receiver
tank outlet valve (or liquid line shutoff valve),
and check for leaks.
112
7. Replace the cap for the adjustment stem.

Torque it to 12.5 to 15 ft-lb (17 to 20.3 Nm).
8. Return bus to service.
EPR Valve Considerations

Some systems have an evaporator pressure
regulator (EPR) valve. For R-22 and R-407C
systems, the EPR valve is set to 50 psig
(345 kPa). For R-134a systems, the EPR valve is
set to 24 psig (165 kPa). This valve functions
during low load conditions to limit the evaporator
coil temperature. Under these conditions with the
valve operating, pressure readings taken with a
compound gauge may be misleading, and service
operations such as low side pumpdowns are not
effective when the EPR valve is functioning.
WARNING: Make absolutely sure that

you remove this jumper wire when you
have completed checking and repairs to
the EPR valve.
Evaporator Pressure Regulator

(EPR) Valve (Pilot Type)
NOTE: Eliminate all other possible causes
before servicing the EPR valve. The EPR valve
must be serviced by an experienced air
conditioning mechanic.
CAUTION: Improper adjustment of this
valve may cause damage to the system.
For service purposes, the EPR valve is provided

with a pilot line shutoff valve. To correctly
perform service procedures, close this shutoff
valve.
CAUTION: When operating normally, the
EPR valve closes when pressure in the
evaporator coil reaches 50 psig (345 kPa)
for R-22 and R-407C systems. For R-134a
systems, the EPR valve is set to 24 psig
(165 kPa). For this reason, a low side
pumpdown performed in the usual
manner will not evacuate the system as
expected. To prevent releasing refrigerant
unexpectedly, follow the instructions in
this manual regarding the EPR for service
operations.
CAUTION: If the EPR pilot line shutoff
valve is closed for service operations, it
must be opened before placing the unit
back in service.
NOTE: The following information pertains to
units with Reliance motors and IntelligAIRE I or
IntelligAIRE II.
In order to prevent setting a Code 14 alarm
(Evaporator/Drive Fault shutdown), you must add
a jumper wire from the fault wire on the
evaporator drive to a good chassis ground. This
will temporarily fool the ECM into believing that
the drive is still running.
1.
Test Fitting (Schrader Valve Port)
2.
Adjustment Screw
3.
Pilot Line Shutoff Valve
Figure 70: Pilot Type EPR Valve with

NOTE: The EPR valve DOES NOT get out of

adjustment. The valve is factory set, but should
be checked as part of the delivery checkout
procedure.
NOTE: Adjustment if required, should be done
by qualified personnel only.
If it appears that adjustment is necessary, there are
two possibilities:
113
1. The valve has been set incorrectly at some

previous time;
1
2. The valve has mechanically malfunctioned

(i.e., dirt in seat, warped valve) or something
else in the unit is wrongidentify and correct
the problem.
CAUTION: The ambient temperature and
the bus interior must be above 80 F (28 C).
This should be maintained for proper
setting of the valve. Improper adjustment
of this valve may cause damage to the
system.
3
2
CAUTION: Do not attempt to adjust this

valve if the ambient and bus interior
temperature are not above 80 F (28 C).
Improper setting, and damage to the
system may result.
NOTE: A compressor discharge pressure of

250 psig (1,724 kPa) for R-22/R-407C systems or
150 psig (1034 kPa) for R-134a systems should
be maintained while adjusting the valve.
Procedure for Checking and

Adjusting the EPR Valve
NOTE: The following information pertains to
units with Reliance motors and IntelligAIRE I or
IntelligAIRE II.
In order to prevent setting a Code 14 alarm
(Evaporator/Drive Fault shutdown), you must add
a jumper wire from the fault wire on the
evaporator drive to a good chassis ground. This
will bypass the ECM drive fault.
the EPR valve.
1. Install service gauges on the compressor and
jumper the low pressure cutout.
2. Install a compound gauge on the pressure tap
on the evaporator side of the EPR valve.
1.
Suction Gauge
4.
Pressure Tap
2.
Suction Line
5.
Pilot Type EPR Valve
Pilot Line
Shutoff Valve
Figure 71: Pilot Type EPR Valve
3. Replace all covers removed to install the

compound gauge on the EPR valve.
4. Be careful not to pinch the hose on the
compound gauge, seal all areas that will leak
air when the unit is running.
5. Start the bus, run at either fast idle or slow idle
for at least ten minutes. This will return the oil
to the compressor.
6. If necessary, turn the heat mode on and raise
the interior temperature above 80 F (28 C).
Then return the unit to the cool mode.
NOTE: You will need two people to finish the
test.
114
7. One person raises the engine/compressor

speed to maximum governed speed. (if not
governed 2/3-throttle point.)
CAUTION: You must increase the
compressor speed (step# 7). If you dont,
the set point WILL NOT BE CORRECT
and damage to the air conditioning
system, may result.
8. When the bus engine is maintained at high
speed, shut off the evaporator fan motor(s).
9. Watch the compound gauge installed on the
EPR. The pressure will drop and stabilize.
This should take one minute or less.
14. After every adjustment, all covers must be

reinstalled and then run for at least 5 minutes
before rechecking the EPR setting.
15. Recheck the EPR setting (steps 6 through 10).
16. If the setting is still incorrect, repeat steps 13
and 14.
17. When the setting is correct, recheck the setting
twice (steps #6 through #10), you should get
the same reading.
18. When test is complete, remove all gauges,
jumper wires and reinstall all covers back to
their proper position.
the EPR valve.
10. When the compound gauge stabilizes this is

the setpoint. The setpoint should be at the
pressure stated on the following table.
Refrigerant
Pressure Setting
R-134a
24 1 psig
(166 7 kPa, 1.6 0.07 bar)
R-22
50 1 psig
(345 7 kPa, 3.4 0.07 bar)
R-407C
50 1 psig
(345 7 kPa, 3.4 0.07 bar)
R-12
27 1 psig
(186 7 kPa, 1.9 0.07 bar)
19. Check the refrigerant charge, oil level and

return to service.
Repair
Service of the EPR valve includes replacement of
the pilot assembly, internal parts, or the entire
valve. There are only two possible valve
malfunctions: failure to open and failure to
regulate.
EPR Pressure Setting Table

Failure to Open
NOTE: There should be a large difference
between the compound gauge (EPR valve) and
the suction service valve gauge readings (20-30
psig of the compressor may even go into a
vacuum).
11. Lower the engine/compressor speed to high
idle and switch to the evaporator fan motor(s)
back on.
Failure to Regulate
Pilot line (high pressure supply line) pinched,

shut, or plugged replace or clean pilot line.
T-seal (Tetraseal) between adaptor and valve

body does not seal. If this should occur,
pressure can bleed out of the chamber faster
than can be supplied by the pilot valve;
replace Tetraseal.
12. Run the unit at high idle for more than 5

minutes to clear the liquid refrigerant in the
coil or compressor damage may occur.
13. If the EPR valve requires adjustment, turn the
adjusting screw CW (clockwise) to increase
the setting (raise the coil
Pressure/temperature) and CCW
(counterclockwise) to decrease the setting
(lower the coil temperature/pressure). Do not
turn more than 1/4 turn at a time.
Dirt or foreign material holding pilot port

open. Disassemble and clean pilot port.
NOTE: The T-seal should be replaced any

time the pilot assembly is removed from the
valve body.
Dirt or foreign material lodged between piston

and sleeve, causing hang-up or excessive
scoring in the sleeve or the piston. This allows
115
the high pressure to bleed out of the chamber

above the piston. Clean or, if necessary,
replace the piston and the sleeve.
Inlet strainer to pilot line plugged with foreign

material. Clean or replace strainer.
Refrigerant flow through pilot line restricted

by oil in the pilot line either due to a trapped
pilot line or too much oil in the system. Check
the pilot line to be sure that it is open and that
it does not serve as an oil trap.
Figure 72: Tetraseal Size for ORIT-15
Pilot Assembly Replacement (ORIT-15)

Refer to Figure 73 Pilot Type EPR Valve
Components on page 117 and Figure 74
Cutaway View of ORIT 15 Pilot Type EPR
Valve on page 118 to help identify components.
CAUTION: The pilot line shutoff valve
must be closed to properly pump down the
low side.
5. Remove the cap screws and remove the

adaptor from the main valve body.
6. Replace the gasket under the adapter.
NOTE: Two gaskets are supplied with each
pilot assembly kit. The correct gasket for the
ORIT-15 is the Tetraseal (not composition)
gasket.
Pilot line (high pressure supply line)
Evaporator pressure sensing line
7. Reassemble the valve. Replace the cap screws

with the cap screws included with the pilot
assembly kit. Before completely tightening
the cap screws, rotate the pilot valve to
properly align the three lines that connect to
pilot assembly. Attach and tighten these
connections. Then tighten the cap screws to a
torque of 15 ft-lb (20.3 Nm). The pilot
assembly replacement is now complete.
Compressor suction pressure sensing line.
3. Place a wrench on the bottom connection of

the pilot assembly. Turn counterclockwise and
remove the pilot assembly from the adapter.

2. Disconnect the three lines connected to the
pilot assembly. They are:
4. Replace the copper flare gasket and install the

new pilot assembly. Place a wrench on the
bottom connection of the pilot assembly. Turn
clockwise until the pilot assembly is firmly in
place. Do not align the three lines that connect
to pilot assembly at this time.
10. Open all valves and start the unit.

11. Check the unit operation, the refrigerant
charge level, and compressor oil level.
Piston (Internal Parts) Replacement
(ORIT 15)
2. Disconnect the three lines connected to the
pilot assembly. They are:
116
Pilot line (high pressure supply line)
Evaporator pressure sensing line
Compressor suction pressure sensing line.
3. Remove the cap screws and remove lift the

complete pilot assembly, adaptor, and body
flange off the main valve body.
4. Remove the piston assembly by screwing one
of the cap screws into the threaded hole in the
center of the piston and using the cap screw as
a handle. Inspect all other internal parts for
wear or dirt.
5. Replace the piston assembly, body sleeve, and
kick off spring.
6. Install a new gasket and reassemble the valve.
Before completely tightening the cap screws,
rotate the pilot valve to properly align the
three lines that connect to pilot assembly.

Attach and tighten these connections. Then
tighten the cap screws to a torque of 15 ft-lb
(20.3 Nm). The pilot assembly replacement is
now complete.
9. Open all valves and start the unit.
1.
Tetraseal
7.
Screwcap
2.
Adaptor
8.
Pistonassembly
3.
Flangebody
9.
O-ring groove
4.
Screeninlet strainer
10.
Sleevebody
5.
Kitpilot assembly
11.
O-ring
6.
Adaptoroutlet
12.
Springbottom
Figure 73: Pilot Type EPR Valve Components
117
13
14
1.
Test Fitting
8.
Pilot Assembly
2.
Adjustment Spring
9.
Pin Guide
3.
Adjustment Screw
10.
Bottom Spring
4.
Pilot Diaphragm
11.
Main Valve Piston
5.
12.
Kick Off Spring
6.
Pilot Line (High Pressure)
13.
Evaporator Pressure Sensing Line
7.
Push Rods
14.
Compressor Suction Pressure Sensing Line
Figure 74: Cutaway View of ORIT 15 Pilot Type EPR Valve
118
EPR Valve Removal

CAUTION: Systems equipped with EPR
valves require a pump down procedure,
which is different from other systems.
Follow this procedure closely or pressure
will be left inside the low side of your
system. Failure to do so may result in
personal injury. Refer to Low Side Pump
Down procedure found in the
Refrigeration Maintenance chapter of this
manual.
1. Follow procedures to pump down the low side
of the system or remove all the refrigerant
from the system. Complete removal of
refrigerant is the preferred method.
2. Remove the Schrader valve from the test
fitting on the EPR valve to vent excessive heat
from the system.
3. Disconnect the pilot line from the pilot
assembly.
4. Use heat shields to protect the unit insulation
during soldering.
4. Disconnect the pilot line to the pilot assembly.

5. Replace the heat shields to protect the
insulation.
CAUTION: Use a nitrogen purge during
soldering to prevent internal scaling.
CAUTION: Use care to prevent excess
solder from flowing into the valve during
soldering.
CAUTION: To avoid heat damage when
soldering the valve, direct the flame away
from the valve body and avoid excessive
heat on the diaphragm of the pilot valve.
6. Solder the valve into place using Thermo
Kings recommended solder, flux and
procedures.
NOTE: To reduce the chance of overheating
the EPR valve, use 95-5 solder (TK No.
204-167) or equivalent may be used. Use
Flux TK No. 204-417.
7. Replace the Schrader valve core.
8. Connect the pilot line to the pilot assembly.
CAUTION: Use a nitrogen purge during

soldering to prevent internal scaling.
5. Heat the joints and remove the failed valve,
being careful not to damage the connecting
tubing.
EPR Valve Installation
9. Then proceed with evacuation, leak testing,

and charging procedures to prepare the system
for operation. Open all valves and start the
unit.
NOTE: New EPR valves are factory set. After

installation, verify the setting and adjust only if
necessary.
1. Clean the tubes for soldering and apply a
minimum amount of flux to the tubes. Follow
standard Thermo King soldering procedures
for this operation (Reference Silver
Brazing & Soft Soldering TK 7949.)
2. Place the new valve in position and wrap
damp rags around the valve as a heat sink.
3. To protect the core from heat damage, remove
the Schrader valve core from the new EPR
valve which allows the system to vent during
soldering.
119
120
Structural Maintenance
Procedures
Monthly
6,000 Miles
(10000 km)
Quarterly
18,000 Miles
(30000 km)
Annually
Inspect condenser coil for cleanliness.
Inspect evaporator/heater coil for cleanliness.
Inspect outer areas of the unit for loose, damaged, or broken parts.
OK _______, Make repairs _______
Specify defect______________________________
Clean or replace return air filter (more frequently if necessary).
Clean condenser and evaporator drains. Make sure that the

evaporator drain hose check valves (kazoos) are in place and in
good condition.
Check the engine coolant hoses and hose clamp condition on heater
coil system.
Clean condenser and evaporator coils.
Check engine coolant for antifreeze protection down to -30 F (-34 C)

to prevent heater coil freeze up.
Antifreeze protection _______ F, (_______ C).
Tighten compressor, unit, and fan motor mounting bolts and brackets
(more frequently if necessary).
Check condenser air seals.
WARNING: Ensure the unit and the bus

will not start while you are servicing the
system.
Unit Compressor and Electric

Motor Mounting Bolts
Check and tighten all unit compressor and electric
motor mounting bolts yearly.
Unit Inspection
Inspect the unit monthly for loose or broken wires
or hardware, compressor oil leaks, or other
physical damage which might affect unit
performance and require repair or replacement of
parts.
Evaporator, Heater and

Condenser Coil Inspection and
Cleaning
shop light, placed on the opposite side of the coil,

provides a means of determining if a dirt buildup
is present within the fins of the coil. Light should
be visible directly through the coil fins across the
entire face area of the coil.
When the coil is found to be dirty, the following
cleaning procedure should be used:
1. Remove surface lint, dirt, and debris from the
air inlet side of the coil using a soft bristle
brush or shop vacuum. Brush or vacuum in the
direction of the fins to prevent fin damage.
2. Spray the fins of the coil with low or medium
pressure, warm soapy water (dish soap works
well) using a garden-type, pressurized sprayer.
This breaks down dirt and oil film.
NOTE: Do not use high-pressure washers,
which may damage fins. Do not use caustic
cleaning solutions, which may result in
corrosion.
The evaporator, heater, and condenser coils

should be inspected to be free of dirt, lint, and
debris during regularly scheduled A, B, and C
maintenance intervals. Viewing the coil with a
121
3. Flush the coil clean with clear, low or medium

pressure water, first in the opposite direction
of the airflow through the coil using a garden
hose with a spray nozzle. This removes the
major amounts of dirt buildup.
4. Flush in the other direction to remove dirt. Be
careful not to spray through the evaporator
and heater coils into the inside of the bus. If
necessary, place cardboard or a suitable plate
across the inlet face of the evaporator/heater
coils to prevent spraying into the bus.
5. Inspect drain pans and drain hoses. They
should be clean, open (not kinked), and
draining freely.
6. Continue to flush the entire face area of the
coils and drain pans until clear water comes
out of all of the drain hoses at the ground
level.
7. Inspect each evaporator/heater coil drain lines
at ground level to ensure that they each have a
rubber check valve (kazoo) in place.
Missing or damaged evaporator/heater drain
line check valves allow air to be drawn up the
drain lines, thus preventing evaporator
condensate water from draining. Also, dirt and
engine fumes are drawn up the drain lines.
Install new check valves if missing, or replace
them if they are damaged or hardened.
8. Inspect each of the condenser coil drain lines
at ground level to be open and unobstructed.
There should not be a check valve on the
condenser coil drain lines as they will plug
due the high volume of rainwater, bus wash
water, and dirt present in the condenser coil
area.
9. Inspect and straighten coil fins using an
appropriate coil fin comb.
Drain Lines
Clean the evaporator and condenser drains
monthly to be sure the lines remain open. Make
sure kazoos (end valves) are in place on the
evaporator drain.
Coolant Antifreeze in Heating

Units
Thermo King specification requires that all bus air
conditioning units equipped with heater coils must
be operated with a mixture of 50 percent ethylene
glycol and 50 percent water in the bus coolant
system.
When heating is required, the coolant valve and
the boost pump are energized. This permits
coolant to flow through the heating coil.
If cooling only is required, there is no coolant
circulation through the heater coil. In some
conditions, the evaporator can run below freezing
point and if there is no antifreeze in the coolant,
the heater coil can freeze and will be damaged.
Also be aware that the system could possibly have
been installed on the bus and tested with pure
water. If the coolant in the engine was replaced by
antifreeze and the heating system in the AC unit
was not operated, there will still be only pure
water in the heater coil. This can freeze at low
ambient or when the unit is operating in cooling
mode.
Evaporator Coil Return Air

Filter
The location and accessibility of the evaporator
coil return air filter can vary depending on unit
application. On some rooftop units it can be
accessed by opening the evaporator cover or the
filter can be installed on the backside of the return
air grille. This also applies to T Series rear mount
units.
1. Unscrew evaporator covers and remove the
filters.
2. Using compressed air, blow in direction
opposite normal air flow to remove
accumulated dust.
3. Wash filter material in warm soapy water.
Flush water in direction opposite to normal air
flow.
4. Remove excess water and install filter.
Replace filter if necessary.
5. Close and secure evaporator access covers.
122
Internal Return Air Filter
2. Using compressed air, blow in direction

opposite normal air flow to remove
accumulated dust. Wash filter material in
warm soapy water. Flush water in direction
opposite to normal air flow.
The internal return air filter covers the control

panel and is accessed from inside the bus.
1. Unscrew the three screws and swing down the
return air grille and remove the return air
filter.
3. Remove excess water and install filter.

Replace filter if necessary.
4. Close return air filter grille. Tighten all screws
securely.
AEA1940
1
1.
Screws
2.
Hinges
Figure 75: Return Air Filter (Internal)
123
124
Air Conditioning Diagnosis and Analysis

Analysis Overview
Diagnosis Procedure
Servicing a system consists of checking system

pressures and temperatures while the bus engine is
running at high idle, typically about 1000 engine
rpm. When servicing a system, you should be
aware of two main factors in operation:
1. Identify components in the system. To identify

components, see the above list, your unit
service manual, and the unit itself.
Running at high idle operates the system in

the lower half of its normal operating range.
Therefore, when testing a system, be mindful
about conditions that could occur at operating
extremes. Otherwise, you may not find the
problem.
Systems vary greatly. You should be familiar
with the system you are working with and be
aware of differences among systems.
Examples of possible differences are:
2. Verify that the bus has the proper air flow

throughout the system. The air conditioning
ducts must be free from obstructions.
3. Determine that each component is working
correctly.
Are the evaporator fans running and in the

proper range of speed?
Do the inlet air filters require cleaning?
Is the condenser coil clean? Coils with top

air inlets in particular can fill with leaves
and other debris.
Are the condenser fans running and at

proper speed?
Two speed condenser fans
Two and three speed evaporator fans
Reheat or cycling clutch modes
Thermostats adjustable from 62 F to 82 F

(17 C to 28 C).
What is the unit thermostat setpoint and

what is the interior temperature of the bus?
Is there refrigerant in the system?
If the system is running, what is the

refrigerant charge level? (Check the sight
glasses closelyuse a flashlight.)
If the system does not function, is power

present at the main power studs on the
unit? Is there power to the unit controls?
What are the compressor discharge and

suction pressures while the unit is
operating? (See the table on the page 126.)
Electronic thermostats with limited or no

adjustment possible
Systems with or without EPR valves
Compressors configured in any of the

following ways:
No unloaders
With unloaders
Different displacements and sizes
Smaller systems (such as the ShuttleAIRETM)

for small buses) have different characteristics
and can be more sensitive or less sensitive to
conditions such as charge level than other
units.
125
Typical Operating Pressures
System Analysis
The following table shows typical operating

pressures when the system is operating at normal
ambient temperatures in the High Idle mode
(engine speed 800 to 1000 rpm and X426, X430,
or X640 compressor speed 900 to 1500 rpm).
Failure of the system to stay within normal ranges

can have several causes. Causes and solutions of
these problems are described in the System
Analysis Table on the following pages.
EPR
With
EPR
Refr.
Discharge
Pressure1
Suction
Pressure2
190-270 psig
20-75 psig
R-22/ (1310-1862 kPa) (138-517 kPa)
R-407C (13.4-19.0 kg/cm2) (1.4-5.3 kg/cm2)
(13.1-18.7 bar)
(1.4-5.2 bar)
190-270 psig
50-80 psig
Without R-22/ (1310-1862 kPa) (345-552 kPa)
EPR R-407C (13.4-19.0 kg/cm2) (3.5-5.6 kg/cm2)
(13.1-18.7 bar)
(3.4-5.5 bar)
With
EPR
10-45 psig
100-175 psig
(69-310 kPa)
(689-1207 kPa)
R-134a
(7.0-12.3 kg/cm2) (0.7-3.2 kg/cm2)
(6.9-12.1 bar)
(0.7-3.1 bar)
30-50 psig
120-175 psig
Without
(207-345 kPa)
(827-1207 kPa)
R-134a
(8.4-12.3 kg/cm2) (2.1-3.5 kg/cm2)
EPR
(8.3-12.1 bar)
(2.1-3.4 bar)
When checking the refrigerant charge, the discharge
pressure must be above 250 psig (1724 kPa) for R-22 and
R-407C systems, or above 150 psig (1034 kPa) for R-134a
systems. Block the airflow to the condenser coil if needed, to
raise pressure.
WARNING! Do NOT turn off the condenser fans to
raise head pressure.
2 Suction pressure will vary greatly depending on unit
evaporator coil load (bus interior temperature). For best
results, allow the unit to reach the thermostat setpoint
(normally set at 70 3 F [17 2 C]).
1
126
System Analysis: Causes for Failure to Stay Within Temperature Range

Cause
Solution(s)
Excessive load
Frequent stops
Long loading stops
Open or loose windows and doors
Loose body panels
Poor insulation
Too many passengers
1. Perform structural maintenance inspections regularly.

2. Repair leaks.
See the Structural Maintenance chapter in this manual.
Blocked filter or dirt on coils

Dust and lint buildup on evaporator return air
filter
Dirt buildup on condenser or evaporator coils
1. Clean the evaporator air filter by reverse flushing with

warm, soapy water. Recoat the filter with RP Filter Coat,
TK# 203-334 or equivalent.
2. Flush the coils with warm soapy water at medium
pressure.
See the Structural Maintenance chapter in this manual.
Incorrect belt tension

Loose: compressor will not operate at the
correct speed and the belts can slip, damaging
the clutch and pulley.
Tight: Create a load on the bearings and clutch,
causing premature wear and possible pulley
breakage.
Adjust per the belt specification. For belt specification, see

the Specifications chapter in this manual or bus or belt
manufacturer information.
Excessive oil in circulation

Restriction in filter-drier causing low suction
pressure
Restriction in expansion valve causing low
suction pressure
Remove excess oil. See the Removing Excess Oil

procedure in this manual.
NOTE: For accurate results, check the oil when the
compressor is warm and the system is operating in
normal range.
Restriction of liquid line

Low suction pressure at high speeds
Temperature change at point of restriction
Flashing of refrigerant is occurring
1. Check the filter-drier.

2. Check the in-line service valves.
3. Check the expansion valve inlet screen.
4. Check for yellow sight glass, indicating a wet system.
5. See the procedures in this manual for replacing the
filter-drier, in-line service valves, and expansion valve,
and for checking for moisture content.
Low refrigerant charge

Low suction pressure
Hot liquid line
Warm suction line
Hotter than normal compressor discharge
temperatures
Decreased cooling capacity
NOTE: An EPR valve will amplify these
conditions.
Charge the system. See the Charging procedures in the

Refrigeration Maintenance chapter in this manual.
High refrigerant charge

High compressor discharge pressure
Malfunction of unloaders
Evacuate and recharge the system. See the Evacuation and

Charging procedures in this manual.
Air in refrigeration system

Dark oil
High compressor discharge temperatures
High compressor discharge pressure
False refrigerant level indication (air trapped in
receiver tank)
Erratic action of expansion valve (possibly
hissing noises at expansion valve)
1. Test for air in the system. See Removing Contaminants

in this manual.
2. Evacuate and recharge the system See the Evacuation
and Charging procedures in this manual.
127
System Analysis: Causes for Failure to Stay Within Temperature Range

Cause
Solution(s)
Expansion valve set incorrectly

1. Low superheat:
Flooding at the compressor
High suction pressures
2. High superheat:
Warm suction line temperature
Low suction pressures
Adjust the expansion valve. See the Expansion Valve

Adjustment (Superheat) section in this manual.
NOTE: The expansion valve is preset and should not
require adjustment. Verify that the expansion valve is
the problem by rechecking all other components before
adjusting.
Expansion valve malfunctioning

1. Valve sticks open due to dirt or ice in the valve:
Excessive sweat on suction line
High compressor oil level, indicated by sump
being cool to the touch
Refrigerant charge level appears low
2. Valve sticks closed due to loss of charge in
sensor bulb:
High discharge pressure
Low suction pressure
No cooling
Warm suction line and coil
Low oil level in compressor
3. Valve operation is erratic:
Low system charge level
Air in the system
Moisture frozen in valve
Dirt in valve inlet screen
Block in liquid line before expansion valve
Sensing bulb not in good contact with suction
line
1. Verify that the expansion valve is the cause by rechecking

all other possible causes. (The expansion valve rarely
fails.)
2. If the expansion valve is bad, replace it. See the
Expansion Valve Removal and Installation section in this
manual.
Plugged filter-drier
Restriction of refrigerant at filter-drier
Outlet line cooler than inlet line
Frost or sweating on outlet line
Particles in the system caused by breakdown of
filter-drier (extreme cases only)
1. To prevent plugging, perform routine maintenance

inspection of the filter-drier.
2. To replace, see the Filter-Drier Removal and Installation
section in this manual.
128
Troubleshooting Compressor Suction and Discharge Pressures

The following tables describe high and low
suction and discharge pressure symptoms for
systems with and without EPR valves.
Troubleshooting Systems With EPR Valves

A. Compressor Suction Pressure
Suction Line
Condition
Low
High
Frosty/Cold
1. Normal operation: Bus is controlling on

thermostat with light load and at higher
speeds
2. EPR valve set too high
3. Airflow through evaporator is restricted:
Air filter dirty
Evaporator coil dirty
Plugged evaporator filter
4. Evaporator blower motor problem
Electrical malfunction
Fan blades broken or incorrectly
adjusted
5. EPR valve set too low: Coil frosted up
1. Normal operation: Heavy load on the

evaporator
2. Expansion valve malfunction:
Sensor bulb making poor contact with
suction line
Needle erodedvalve can not control
properly
Adjustment has been incorrectly set (low
superheat)
3. Overcharge of refrigerant
Dry/Warm
1. Low refrigerant charge

2. Restriction in liquid line
Inlet screen plugged
Sensor bulb lost charge
Adjustment has been incorrectly set
(high superheat)
4. Too much oil in system
5. Restricted suction line
6. Airflow through condenser coil too cold
1. Compressor malfunction:
Leaking discharge valves
Leaking/Broken piston reeds
Worn piston/sleeve assembly
(blow-by)
2. Heavy load on evaporator:
3. Compressor turning too slowly
4. Belt or clutch slipping
B. Compressor Discharge Pressure

Low
Suction Line
Condition Does
Not Apply

2. Light load on evaporator:
Bus interior temperature cool
Dirty air filters
EPR set too lowcoil frosted up
Airflow through evaporator is low for
some reason
3. EPR valve incorrectly adjustedtoo high
causing low refrigerant flow
4. Compressor speed low
5. Airflow through condenser is cold
(blow-by)
High
1. Airflow into condenser is low or restricted
Dirty coil
Debris in the coil inlet
2. Condenser fan or motor problem:
Motor running on low speed
Motor not runningelectrical
malfunction
adjusted
3. Restriction on high side of the system:
In-line service valve partially closed
4. Non-condensables in the system: Air,
nitrogen, and other gases (?)
5. Hot air entering the condenser coil
129
Troubleshooting Systems Without EPR Valves

A. Compressor Suction Pressure
Suction Line
Condition
Low
High
Frosty/Cold
1. Normal operation: Bus is controlling on

thermostat with light load and/or at higher
speeds
2. Airflow through evaporator is restricted:
Air filter dirty
Evaporator coil dirty
Plugged evaporator filter
3. Evaporator blower motor problem
Electrical malfunction
adjusted
1. Normal operation: Heavy load on the

evaporator
Feeler bulb making poor contact with
suction line
Needle erodedvalve can not control
properly
Adjustment has been incorrectly set (low
superheat)

2. Restriction in liquid liner
Inlet screen plugged
Sensor bulb lost charge
Adjustment has been incorrectly set
(high superheat)
4. Too much oil in system
5. Restricted suction line
6. Airflow through condenser coil too cold
(blow-by)
2. Heavy load on evaporator:
3. Compressor turning too slowly
Dry/Warm
B. Compressor Discharge Pressure

Low
Suction Line
Condition Does
Not Apply
130

2. Compressor speed low
3. Airflow through condenser is cold
4. Restrictions to refrigerant flow:
Liquid line restricted
Suction line blockage
(blow-by)
High
1. Airflow into condenser is low or restricted
Dirty coil
Debris in the coil inlet
2. Condenser fan or motor problem:
Motor running on low speed
Motor not runningelectrical
malfunction
adjusted
3. Restriction on high side of the system:
In-line service valve partially closed
4. Non-condensables in the system: Air,
nitrogen, and other gases (?)
5. Hot air entering the condenser coil
Temperature Pressure Relationship
Vapor Pressure, psig
F
-50
-48
-46
-44
-42
-40
-38
-36
-34
-32
-30
-28
-26
-24
-22
-20
-18
-16
-14
-12
-10
-8
-6
-4
-2
0
2
4
6
8
10
12
14
16
18
20
22
24
26
28
30
32
34
36
38
40
42
44
46
C
-45.6
-44.4
-43.3
-42.2
-41.1
-40.0
-38.9
-37.8
-36.7
-35.6
-34.4
-33.3
-32.2
-31.1
-30.0
-28.9
-27.8
-26.7
-25.6
-24.4
-23.3
-22.2
-21.1
-20.0
-18.9
-17.8
-16.7
-15.6
-14.4
-13.3
-12.2
-11.1
-10.0
-8.9
-7.8
-6.7
-5.6
-4.4
-3.3
-2.2
-1.1
0.0
1.1
2.2
3.3
4.4
5.6
6.7
7.8
R-22
6.1
4.8
3.4
2.7
2.0
0.5
1.3
2.2
3.0
3.9
4.8
5.8
6.9
7.9
9.0
10.1
11.3
12.6
13.8
15.1
16.4
17.9
19.4
20.9
22.4
23.9
25.6
27.4
29.1
30.9
32.7
34.7
36.8
38.8
40.9
43.0
45.3
47.7
50.0
52.4
54.8
57.5
60.2
63.0
65.7
68.5
71.6
74.7
77.8
R-134a
18.5
17.4
16.9
16.2
15.4
14.7
13.7
12.7
11.7
10.7
9.8
8.6
7.4
6.2
5.0
3.8
2.2
0.7
0.3
1.0
1.8
2.7
3.6
4.5
5.4
6.3
7.3
8.4
9.4
10.5
11.6
12.8
14.1
15.4
16.7
18.0
19.5
21.0
22.5
24.0
25.6
27.3
29.1
30.9
32.7
34.5
36.5
38.6
40.7
R-407C
11.0
9.9
8.7
7.5
6.2
4.8
3.4
1.9
0.3
0.6
1.5
2.3
3.2
4.2
5.2
6.2
7.2
8.3
9.5
10.7
11.9
13.2
14.5
15.9
17.4
18.9
20.4
22.0
23.7
25.4
27.1
29.0
30.8
32.8
34.8
36.9
39.1
41.3
43.6
45.9
48.4
50.9
53.5
56.1
58.9
61.7
64.6
67.6
70.7

F
48
50
C
8.9
10.0
R-22
80.9
84.0
R-134a
42.8
44.9
R-407C
73.8
77.1
131

F
52
54
56
58
60
62
64
66
68
70
72
74
76
78
80
82
84
86
88
90
92
94
96
98
100
102
104
106
108
110
112
114
116
118
120
122
124
126
128
130
132
134
136
138
140
142
144
146
148
150
C
11.1
12.2
13.3
14.4
15.6
16.7
17.8
18.9
20.0
21.1
22.2
23.3
24.4
25.6
26.7
27.8
28.9
30.0
31.1
32.2
33.3
34.4
35.6
36.7
37.8
38.9
40.0
41.1
42.2
43.3
44.4
45.6
46.7
47.8
48.9
50.0
51.1
52.2
53.3
54.4
55.6
56.7
57.8
58.9
60.0
61.1
62.2
63.3
64.4
65.6
R-22
87.5
91.0
94.5
98.0
101.6
105.5
109.5
113.4
117.4
121.4
125.8
130.2
134.7
139.1
143.6
148.5
153.5
158.4
163.4
168.4
173.9
179.4
184.9
190.4
195.9
201.9
208.0
214.1
220.2
226.3
233.0
239.7
246.4
253.1
259.9
267.2
274.6
282.0
289.4
296.8
304.8
312.9
321.0
329.1
337.2
346.0
354.9
363.7
372.6
381.5
R-134a
47.3
49.7
52.1
54.5
56.9
59.6
62.4
65.1
67.9
70.7
73.8
76.9
80.1
83.2
86.4
89.9
93.5
97.0
100.6
104.2
108.2
112.2
116.2
120.2
124.3
128.9
133.3
137.8
142.3
146.8
151.8
156.8
161.8
166.8
171.9
177.4
183.0
188.6
194.2
199.8
205.9
212.0
218.2
224.3
230.5
237.2
244.0
250.8
257.6
264.4
Shaded Numerals Inches HG Below 1 ATM
132
R-407C
80.4
83.9
87.4
91.0
94.8
98.6
102.5
106.5
110.7
114.9
119.3
123.7
128.3
133.0
137.8
142.7
147.8
153.0
158.3
163.7
169.2
174.9
180.7
186.7
192.8
199.0
205.3
211.9
218.5
225.3
232.3
239.4
246.7
254.1
261.7
269.4
277.4
285.5
293.7
302.2
310.8
319.6
328.6
337.7
347.1
356.7
366.4
376.4
386.5
396.9
133
Refrigeration Diagram
Figure 76: Typical Refrigeration Diagram with Description of Operation
134
Index
A
about this manual 5
actuator
fresh air damper 62
motor installation 64
motor removal 63
actuator motor
tests 63
air conditioning
diagnosis and analysis 125
diagnosis procedure 125
air in refrigeration system, symptoms 127
alarms
code number 10 46
ambient temperature sensor 33
auto mode 40
B
battery removal hazards 18
belt tension 127
blocked filter, symptoms 127
boost pump 34, 57
brass sealing washers used in discharge line
connections 99
C
charging
from a partially charged state 79
from an evacuated state 78
coil temperature sensor 33
compressor
clutch 34
discharge sensor 35
efficiency check 91
failure 84
oil 86
adding 87
checking pressure 90
checking the level 87
removing excess 90
oil sight glass 34
pumpdown 72
service valve positions 69
shutdown, jumpering to prevent during servicing 70
X430 description 27
compressor and electric motor mounting bolts 121
compressor crankshaft seal 94
installation of set screw type metal bellows seal 95
set screw type metal bellows 94
compressor specifications 25
condenser
coil
inspection and cleaning 121
removal and installation 106
fan motors 34
pressure switch 33
testing
removal, and installation 56
condenser axial fan motors 58

motor removal and installation 59
motor testing 58
contents, manual, description of 5
cool mode
(cycling clutch) 41
coolant
antifreeze in heating units 122
temperature switch 33
valve 34
burnout and repair 57
curbside, definition 7
curbside/roadside terminology, explained 7
D
dirt on coils, symptoms 127
discharge line connections, brass sealing washers
used in 99
discharge service valve removal 105
displays, selecting 41
drain lines 122
E
electric motor mounting bolts 121
electrical
hazards 18
engine coolant hazards 18
EPR 113
installation 119
removal 119
repair 115
EPR valve
considerations 113
removal 115
evacuation 75
evacuation station 75
evaporator
blower motor 34
coil temperature sensor 33
pressure regulator (EPR) 33
evaporator blower motor
test procedure 59
evaporator coil
evaporator coil return air filter 122
evaporator pressure regulator (EPR) valve (pilot type)
113
evaporator/heater blower motor 34
evaporator/heater coil
excessive load, symptoms 127
excessive oil in circulation, symptoms 127
expansion valve 110
cleaning in-line screen 111
installation 111
malfunctioning, symptoms 128
removal 110
sensor bulb contact 111
135
Index
set incorrectly, symptoms 128
superheat measurement and adjustment 112
setup mode 42
internal return air filter 123
fan motors, condenser axial 58

fan speed, selecting 41
fan switch 33
filter-drier
plugged 128
first aid 19
battery acid 20
engine coolant 19
refrigerant 20
refrigerant oil 19
fresh air damper actuator 62
fresh air damper operation test 62
fresh air damper setting, selecting 41
leak testing 80
liquid line
restriction 127
sight glass 34
solenoid valve 33
low pressure cutout switch 34
testing, removal, and installation 55
low refrigerant charge, symptoms 127
low side pumpdown 73
G
gauge manifold
attachment and purging 72
connections 70
removing 72
general practices
safety 17
H
heat mode 41
heater coil
high pressure cutout switch 34
testing, removal, and installation 54
high pressure relief valve 34
high refrigerant charge, symptoms 127
hose installation, suction and discharge 101
HVAC service tools 69
I
ice bath test 84
in-line screen, cleaning 111
IntelligAIRE 41
IntelligAIRE II 27
alarm code display mode 45
calibrate mode 42
components 37
control system
description 37
description 33
diagnostics 42
display module
deluxe 39
description 38
standard 38
features 37
hourmeter and real time clock display mode 44
PC interface 37
service test mode 42
136
M
major compressor failure 84
manual, how to use 5
matrix, how to use 5
micron gauges 75
mode switch (MSW) 33
model systems, how to use list 5
O
operating mode 40
selecting 41
operating pressures, typical 126
operating procedures 41
O-ring seal fitting replacement 100
P
polyolester oil handling procedures 68
pressure, balancing with gauge manifold 70
pressurized nitrogen 81
R
receiver tank removal and installation 107
refrigerant
charging, gauge manifold connection 71
evacuation 75
handling procedures 68
hazards 18
oil hazards 19
recovery 73
removal, gauge manifold connection 71
refrigeration hose inspection 100
removing air
unit has run for a long period 82
unit has run for a short period 82
removing contaminants 82
removing moisture 83
restriction in liquid line 127
return air temperature sensor 33
roadside, definition 7
roadside/curbside terminology, explained 7
Index
SAE J639 service fittings 100

safety precautions
refrigerant service 68
sensor bulb contact 111
service valve positions 69
service valves 104
discharge service valve removal 105
installation 105
suction service valve removal 105
set screw type metal bellows crankshaft seals 94
setpoint, changing 41
specifications
electrical controls 23
motors 23
refrigerant 24
refrigerant controls 24
standard display 41
suction service valve removal 105
superheat measurement and adjustment 112
switch
water coolant temperature 33
system analysis 127
Temperature Pressure Relationships 131

testing system for leaks 80
tools for servicing 69
U
unit
compressor and electric motor mounting bolts 121
inspection 121
unit controls
compressor clutch 34
compressor discharge sensor 35
return air temperature sensor 33
V
vent mode 41
W
water (coolant) temperature switch 33
wiring and harness inspection 54
137
Index
138
Wiring and Schematic Diagrams Index
Dwg No.
Drawing Title
1E11954
LRTHP-M6 1000 Schematic Diagram
1E11955
LRTHP-M6 1000 Wiring Diagram
Page
141
142 143
139
Wiring and Schematic Diagrams Index
140
LRTHP-M6 1000 Schematic DiagramPage 1 of 1
141
LRTHP-M6 1000 Wiring DiagramPage 1 of 2
142
LRTHP-M6 1000 Wiring DiagramPage 2 of 2
143

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LRT-HP (900273)

TK 54264-3-MM (Rev. 0, 01/09)

Copyright 2009 Thermo King Corp., Minneapolis, MN, USA.

The maintenance information in this manual covers unit models:

X426, X430 Compressor Overhaul for Bus Air Conditioning

Silver Brazing & Soft Soldering

IntelligAIRE II Diagnostic Manual

IntelligAIRE II Operator Manual

IntelligAIRE II Pocket Guide

Electrostatic Discharge Training Guide

Thermo King Bus A/C Preventive Maintenance Forms

Diagnosing Thermo King Bus Air Conditioning Systems

About This Manual

About This Manual

Provides detailed safety information. You should be familiar with the

Model Systems and Update

Lists unit specifications.

Gives an overview description of your unit including standard and

Unit Controls and Operation

Gives more detailed descriptions of the features specific to your unit.

Provides description of controller, operating procedures, and circuit board

Maintenance Inspection Schedule

Table of routine maintenance procedures.

Provides detailed maintenance procedures required for your unit.

Air Conditioning Diagnosis and

Provides troubleshooting information for diagnosing problems.

About This Manual

Provides general Temperature-Pressure information for refrigerants.

Wiring and Schematic Diagrams

Wiring and Schematic diagrams applicable to the unit.

About This Manual

Contacting Thermo King Service

Bill of Material (usually located on the condenser/evaporator serial plates)

Who to call: Your Thermo King Service Representative.

Using the Model Tables in Model Systems and Update Matrices

About This Manual

symbol appears next to a point that is

DANGER: Do not inhale refrigerant. Use

CAUTION: If soldering is required, use

Battery Removal Hazards

Engine Coolant Hazards

DANGER: Store refrigerant in proper

Refrigerant Oil Hazards

CAUTION: Do not mix refrigerant oils

not induce vomiting. Immediately

not induce vomiting. Immediately

flush eyes with large amounts

victim to fresh air and use CPR

LRT-HP (900273) System Kits

Driver Display Kit

Software Application File

Software Configuration Fil

Starter Solenoids (2 Used)

Solenoid Actuated Contactor (SPNO)Ground on

51.054.0 10% ohms @ 77 F (25 C)

Control Panel Relays (9 used)

Double Pole Single Throw (DPST)

Voltage: Maximum Vdc @ 85 C