Diagnosing

Thermo King
Bus
Air Conditioning
Systems
CONVERSIONS ENGLISH TO METRIC
1 Btu = 252 Gram-calories
1 Btu/Hr =.252 K cal/Hr
1 Btu/Hr-F =.453 K cal/Hr.C
1 Btu/Hr-Ft
2
-F = 4.88 K cal/Hr-M2-C
1 Cfm = 28.32 Liters/Minute
1 Cfm = 1.7 Cubic Meters/Hr
5/9 (F-32) = C
1 Foot =.3048 Meter
1 Square Foot =.0929 Square Meter
1 Cubic Foot =.0283 Cubic Meter
1 Gallon = 3.785 Liter
1 Inch = 2.54 Centimeters
1 Square Inch = 6.452 Square
Centimeters
1 Cubic Inch = 16.39 Cubic Centimeters
1 Inch H
2
0 = 2.54 Grams/CM
2
1 Pound = 453.6 Grams
1 PSI =.07031 Kg/CM
2
1 Watt = 3.413 Btu/Hr
Micron =.0000001 Meters
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.
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 a Thermo King product or its
mechanical failure.
Table of Contents
1
Safety Cautions 3
Responsible Refrigerant Handling 5
T-series Flow Diagram 6
R-series Flow Diagram 7
Diagnosing A System With an EPR Valve 8
Diagnosing A System Without an EPR Valve 9
EPR Non-Mechanical Cooling Problems 10
Conditions That Cause High Discharge Pressure 11
Conditions That Cause Low Discharge Pressure 11
Diagnosing Using The Liquid Line 11
Refrigeration System Access Tools 12-13
Compressor Service Valves 14
Gauge Manifold Installation (Standard Hose Fittings) 15-16
Gauge Manifold Installation (Low Loss Fittings) 17
Gauge Manifold Removal 18
Refrigerant Level Check 19-20
Adding Refrigerant 21
Charging An Evacuated Unit By Weight 22-23
EPR Valve Adjustment 24-27
Low Side Pump Down 28-29
Compressor Pump Down 30
Compressor Oil Pressure Check 31
Compressor Oil Level Check 32
Removing Compressor Oil 33
Adding Compressor Oil 34-35
Compressor Efficiency Test 36
Air Gap Adjustment 37
Testing For Air In System 38-39
Superheat 40-41
(Continued)
SAFETY
DIAGNOSTICS AND SERVICE TOOLS
SERVICE PROCEDURES
Table of Contents
2
Refrigerant Leak Check Tools 43
Leak Characteristics 44
Recommended Solders and Soldering Procedures 45-46
Refrigerant Recovery 47
Recovery From A Working Unit Without an Orit 10 Valve 48
Recovery From A Working Unit With an Orit 10 Valve 49
Recovery From Non-working Unit 50
System Evacuation and Clean Up 51-52
Multiple Evacuation 52
Compressor Oil Acid Test 53
Compressor Oil Filter Kit 54
Suction Line Filter 54
Refrigerant Types and Properties 55
Temperature Pressure Relationships Chart 56-57
Bus Refrigeration Terminology 59-72
LEAK TESTING / SOLDERING / CLEAN UP
REFRIGERANT TYPES AND PROPERTIES
TEMPERATURE CHARTS
GLOSSARY
3
Safety
DO NOT EXPOSE REFRIGERANT
TO OPEN FLAME AS TOXIC FUMES
MAY BE RELEASED
CAUTION: STAY CLEAR
OF FANS AND OTHER
MOVING PARTS
AJA785
CAUTION
ALL SERVICE VALVES MUST BE
BACK SEATED PRIOR TO
REMOVING SERVICE PORT CAPS.
NOTE: SOME VALVES MAY NOT
HAVE A BACK SEAT.
HAZARDOUS VOLTAGE
CAN CAUSE SEVERE
INJURY OR DEATH
AJA786
4
Safety
ALWAYS
Wear Eye Protection
and Protective Clothing
When Handling Refrigerant
ALWAYS
Wear Eye and Ear
Protection When Servicing
Refrigeration Units
CAUTION
Bus climate control systems are controlled by a
thermostat that may cycle the unit ON or OFF with
no prior warning. Condenser and evaporator fans
will start when the unit is cycled ON by the thermo-
stat. Do not wear loose fitting clothing or equip-
ment around operating climate control systems.
Always disconnect power to the unit before per-
forming any maintenance procedures.
AJA787
5
Safety
Responsible Refrigerant Handling
Knowledge and Skills
Vital to Human Health
Scientific Evidence indicates that CFC refrigerants con-
tribute to the depletion of the ozone layer and permits
an increase in the harmful ultraviolet rays that reach the
earth.
Protecting the ozone layer through responsible refrigerant
handling is the responsibility of all refrigeration and air con-
ditioning service technicians.
Service Tools -- Use the proper service tools. Gauge
manifold sets should include appropriate shutoff valves
or disconnects near the end of each service line.
Recovery Equipment -- Recovery equipment must be
used. Proper recovering, storing and recycling of refrig-
erants is an important part of all service work.
Service Procedures -- Recommended procedures
must be used to minimize refrigerant loss.
Components may be isolated by closing service valves
and performing system pump-downs.
Components unable to be isolated for service must be
repaired only after refrigerant is properly recovered.
ALWAYS
HANDLE REFRIGERANT RESPONSIBLY
AND PREVENT REFRIGERANT LOSS
TO THE ATMOSPHERE.
6
Diagnostics and Service Tools
T SERIES
BUS CLIMATE CONTROL SYSTEM
AJA789
AJA788
7
Diagnostics and Service Tools
R SERIES
BUS CLIMATE CONTROL SYSTEM
AJA791
8
Diagnostics and Service Tools
Diagnosing a System with a EPR Valve
SUCTION
LINE
A. COMPRESSOR SUCTION PRESSURE
Condition Low High
Frosty/Cold 1. Normal operation: Bus is
controlling thermostat with
light load and/or at higher
speeds.
2. EPR valve set too high.
3. Airflow through evap. is low.
Air filter dirty.
Evaporator coil dirty.
4. EPR valve set too low:
Coil frosted up.
5. Evaporator Blower Motor.
Low Voltage.
Electrical
Malfunction.
Fan Blades -
Damaged, Location,
Direction.
1. Normal operation:
Heavy load on the
evaporator
2. Expansion valve malfunction:
Feeler bulb making poor
contact with suction line
Needle erodedvalve
can not control properly
Adjustment has been
incorrectly set (low
superheat)
Dry/Warm 1. Low refrigerant charge.
2. Restriction in liquid line.
3. Expansion valve malfunction:
Inlet screen plugged.
Adjustment has been
incorrectly set (high
superheat).
Feeler bulb lost
charge.
4. Too much oil in system.
5. Restricted suction line.
6. Airflow through condenser
coil too cold.
1. Compressor malfunction:
Leaking discharge
valves.
Leaking piston reeds.
Worn piston/sleeve
assembly (blow-by).
2. Heavy load on evaporator:
Compressor turning too
slowly.
Belts slipping.
Clutch slipping.
B. COMPRESSOR DISCHARGE PRESSURE
Low High
Suction Line
Condition
Does Not
Apply
1. Low refrigerant charge.
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.
6. Restrictions to refrigerant
flow:
Liquid line restricted
Suction line blockage
1. Airflow into the 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 running
electrical malfunction.
Fan blade(s) broken or
incorrectly adjusted.
3. Restriction on high side of the
system:
In-line service valve
partially closed.
4. Non-condensables in system:
Air, nitrogen, and other
gases(?).
5. Hot air entering the condenser
coil.
9
Diagnostics and Service Tools
Diagnosing a System without a EPR Valve
SUCTION
LINE
A. SUCTION PRESSURE
Condition Low High
Frosty/Cold 1. Restricted airflow through
the evaporator coil
Iced up evaporator
coil
Dirty evaporator
coil
Plugged evaporator
filter
2. Evaporator blower motor
Low voltage
Electrical
malfunction
Fan blades
damage, location,
direction
1. Expansion valve malfunction:
Feeler bulb making poor
contact
Valve adjustmentopen
too much (low
superheat)
Valve needle eroded
2. Overcharge of refrigerant
Dry/Warm 1. Low refrigerant charge
2. Restricted drier
3. Expansion valve
malfunction:
Plugged screendirt, wax
Valve adjustmentclosed
too much (high superheat)
Internally frozen
expansion valveice from
moisture
Feeler bulb lost charge
4. Overfill of compressor oil
5. Restricted line in low side
6. Airflow through condenser
coil too cold
1. Leaking discharge valve plates
2. Leaking piston reed
3. Worn piston/sleeve assembly
blow-by
4. Heavy load on evaporator
5. Compressor turning slowly
6. Belt or clutch slipping
B. DISCHARGE PRESSURE
Low High
N/A 1. Low refrigerant charge
2. Cold air across condenser
coil
3. Discharge valve plates
leaking
4. Piston reed leaking
5. Inadequate compressor rpm
6. Low side restrictions
1. Overcharge of refrigerant
2. Air in the system
3. Airflow restricted across
condenser coil:
Dirty condenser coil
4. Condenser motor:
Low voltage
Electrical malfunction
Fan blade damage/
location
5. Restriction in discharge side
6. Nitrogen left in system
7. Hot air across condenser coil
N/A Does not apply.
10
Diagnostics and Service Tools
Non-Mechanical Cooling Problems
Check the suction line near the compressor. A cool, moist
line is normal. When line condition and refrigeration pres-
sures are near normal, look for problems outside of the
refrigeration system.
1. Excess Cooling Load.
a. Open doors.
b. Open windows.
c. Open escape hatch.
d. Large load of passengers.
e. Damaged, deteriorated insulation.
2. Dirty return air filter and/or evaporator coil.
The suction line
should feel cool or
cool and moist
AJA793
AJA794
11
Diagnostics and Service Tools
Conditions that can cause High Discharge Pressure
1. Air or non-condensables in system.
2. Restricted air flow across condenser, dirty condenser
fins, slow fan speed, fans running backwards, etc.
3. A restriction in the high pressure line between the com-
pressor and the receiver tank.
4. Overcharge of refrigerant during warm ambients.
5. Incorrect refrigerant.
6. High ambient temperature.
7. Heavy heat load in bus.
Conditions that can cause Low Discharge Pressure
1. Low refrigerant charge.
2. Lowside restriction.
3. Worn compressor.
4. Cold ambient temperature.
5. Incorrect refrigerant.
6. Light heat load in bus.
7. EPR valve closing too soon.
8. Restricted drier.
Diagnosing
Using the
Liquid Line
1. The liquid line
should be
slightly warmer
than the sur-
rounding air.
a. A low refriger-
ant charge may
cause the liquid
line
to be warmer
than normal.
b. A liquid line
restriction will
cause the line to
become cold
after the point of
restriction.
The Liquid line
should be warmer
than the surrounding air
AJA795
12
Diagnostics and Service Tools
Refrigeration System Access Tools
ACCESS VALVE ACTUATOR TK 204-625
Use the access valve
actuator to remove
refrigerant or oil from
1/4 in. male flare fittings.
Taking a compressor oil sample
QUICK DISCONNECT ACCESS VALVE-TK 204-679
Low loss fittings and quick disconnects keep pressure
in the gauge lines when the gauge manifold
is removed from the system.
13
Diagnostics and Service Tools
Use the gauge adapter fitting with pressure gauges to read
pressures with minimal refrigerant or oil loss.
GAUGE ADAPTER FITTING TK 204-626
AJA799
Compressor Oil Pressure Receiver Tank Pressure
AJA804
Service Procedures
14
COMPRESSOR SERVICE VALVES
The suction service valve (SSV) is generally larger than the
discharge service valve (DSV) but is built the same.
Full Out-Valve Back Seated
In 1/2 way-Valve Mid-seated
WARNING: Service valve stems and service ports
must be properly capped and torqued with seals or
O-rings installed. STEMS AND PORTS NOT PROP-
ERLY CAPPED WILL LEAK REFRIGERANT.
AJA803
Full Out,1/4 turn in-
Cracked Open to Service Port
Full In-Valve Front Seated
AJA800
AJA802
AJA801
Service Port
Cap
Service
Valve
Stem Cap
AJA805
Service Procedures
15
Gauge Manifold Installation
(Standard Hose Fittings)
1. Remove the large service valve stem caps from the
discharge and suction service valves. DO NOT remove
the small service port caps!
2. Turn both service valves fully counterclockwise to
back-seat the valves and close the service ports.
3. Remove the small service port caps from both service
valves.
4. Attach the low pressure gauge line to the suction ser-
vice port. Leave the fitting loose. (This loose connec-
tion will be used to purge air from the gauge manifold.)
5. Attach the high pressure line to the discharge service
port and secure the line finger tight.
(Continued)
Discharge
Service
Valve
Suction
Service
Valve
AJA806
Service Procedures
16
6. Turn the discharge service valve stem 1/4-turn clock-
wise to open the service port. (The high pressure
gauge should indicate pressure in the discharge side of
the system.)
7. Open the high side hand valve on the gauge manifo-
fold. Purge air from the gauge manifold service line
(yellow) and tighten the line fitting to the manifold hose
anchor.
8. Open the low side hand valve on the gauge manifold
and allow a small amount of refrigerant to escape from
the loose suction service port fitting and tighten hose
on SSV (This will purge air from the gauge manifold
and the red and blue gauge manifold lines).
9. Close both gauge manifold hand valves.
10. Turn the suction service valve stem 1/4-turn clockwise
to open the service port. (The low pressure gauge
should indicate pressure in the suction side of the sys-
tem.)
WARNING! NEVER operate the compressor with the
discharge service valve front seated. The valve is front
seated when the service valve stem is turned fully
clockwise.
connect to
manifold
DSV
valve
cracked
SSV
valve
back
seated
AJA807
Service Procedures
17
Gauge Manifold
Installation (Low
Loss Fittings)
1. Remove the large ser-
vice valve stem caps
from the discharge and
suction service valves.
DO NOT remove the
small service port
caps!
2. Turn both service
valves fully counter-
clockwise to back seat
the valves and close
the service ports.
3. Remove the small ser-
vice port caps from
both service valves.
4. Attach the high pres-
sure line (red) to the discharge service port and secure
the line finger tight.
5. Turn the discharge service valve stem 1/4-turn clock-
wise to open the service port. (The high pressure
gauge should indicate pressure in the discharge side of
the system.)
6. Open both hand valves on the gauge manifold.
7. Purge the gauge manifold yellow service line. This is
accomplished by slowly screwing a 1/4 inch flare fitting
into the low loss fitting on the gauge manifold yellow
service line. Allow a small amount of refrigerant to
escape from the service line and then remove 1/4 flare
fitting. Tighten the yellow service line fitting to the
gauge manifold hose anchor. (See illustration)
8. To purge the gauge manifold and low pressure line,
slowly screw a 1/4 inch flare fitting into the low loss fit-
ting on the low pressure (blue) line.
9. Close both gauge manifold hand valves.
10. Install the gauge manifold low pressure line (blue) on
the suction service port.
11. Turn the suction service valve stem 1/4-turn clockwise
to open the service port. (The low pressure gauge indi-
cates pressure in the suction side of the system.),
WARNING! NEVER operate the compressor with the
discharge service valve front seated. The valve is front
seated when the service valve stem is turned fully
clockwise.
AJA808
Service Procedures
18
Removing the Gauge Manifold
NOTE:Minimize oil and refrigerant transfer. Use the fol-
lowing 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.
8. Remove the gauge line from the discharge service
valve and cap the service port.
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.
12. Remove low pressure jumper and reconnect wiring.
Service Procedures
19
Check Refrigerant Charge Level
The charge level is very important to the efficient operation
of the unit, therefore, it must be checked as part of the
MONTHLY MAINTENANCE. This service procedure
addresses the method for checking and adding charge as
necessary.
Purpose: To have a charging procedure which will allow an
air conditioning technician to properly charge the system,
without over charging or under charging it, in all weather
conditions.
Scope: This bulletin supersedes all previous charging bul-
letins. This procedure only covers T-Series units with sight
glass indicators with a floating ball in the upper half of the
receiver tank.
Procedure:
During a visual check, when the receiver tank ball is not
floating in the upper sight glass, use the following "Top Off
Procedure" to check and replace the required reserve
charge (Locate and repair all leaks to stop further leakage).
1. Follow standard Thermo King procedures and connect
your service gauges to the compressor service valves
or standard access ports. Be sure to purge the air from
your lines.
2. Start the bus and run the engine in the FAST IDLE
MODE with the air conditioning turned on. This should
be between 1200 and 1600 compressor rpm. For
buses without the fast idle mode, elevate engine speed
until compressor speed is between 1200 and 1600
rpm.
NOTE: On some applications, a regular low idle engine
speed will not allow you to see the correct refrigerant
level and may result in an improperly charged system.
3. If the system has not been running you must run the
system long enough to separate the compressor oil
from the refrigerant AND pull the bus INTERIOR down
(or up) to WITHIN THE 65 TO 75 DEGREE RANGE.
This may take sometime if conditions are extreme, but
a minimum of 15 minutes should be allowed before
checking the charge level.
4. If the COMPRESSOR DISCHARGE PRESSURE is not
ABOVE 250 psig, use a piece of cardboard to partially
cover the condenser coil inlet grille.Do not shut off
condenser fans to raise pressure. This will drive the
pressure up into the range REQUIRED FOR CHECK-
ING AND CHARGING.
Service Procedures
20
5. Once the conditions of steps 2, 3 and 4 above have
been met, check the ball in the receiver tank upper
sight glass. The proper charge level for this "Top Off"
procedure will have the ball floating at the top of the
upper receiver tank sight glass.
6. If the ball is not at the top of the sight glass, follow stan-
dard Thermo King charging methods, add charge to
the system until the ball floats to the top of the sight
glass.
Note: If the system is low on charge, leak check and
repair accordingly.
Note: Add liquid refrigerant on the low side,
increasing the suction pressure no more than 25 psi.
When charging the system from a properly "Evacuated"
condition, (Refer to "Evacuating a System" procedure), we
strongly recommend that you weigh in the charge. This will
save you time and ensure the full reserve charge.
NOTE: Refer to unit maintenance manual specification
section for proper weight charge.
CAUTION: Air in the system will tend to collect in the
receiver tank forcing the refrigerant level down. If you
have air in your system, floating the ball may over-
charge the system. Check your system for air before
letting it go back into service.
CAUTION: AIR IN THE SYTEM WILL ELEVATE OPER-
ATING PRESSURES AND TEMPERATURES, which in
turn will begin a severe degradation process. AND,
which, if left unchanged, will result in system failure
which is NOT COVERED UNDER YOUR THERMO KING
WARRANTY.
Service Procedures
21
Adding Refrigerant
Todays refrigerants must be added as a liquid. Use this
procedure to add liquid refrigerant to the low side of an
operating unit. Bus should be at fast idle mode, 1200 to
1600 RPM in compressor.
1. Crack the discharge service valve (DSV) and open it to
the service port.
2. Mid-seat the suction service valve (SSV).
3. Set the refrigerant bottle to withdraw liquid refrigerant.
4. Operate the unit in cool and read the suction pressure.
5. Slowly open the gauge manifold low pressure hand
valve until suction pressure rises approximately 25 psig
above the normal operating pressure.
6. Gauge must show 250 lbs. discharge pressure with R-
22 and R-407C refrigerant.
Gauge must show 150 lbs discharge pressure with R-
12 and R-134A refrigerant.
7. Closely watch the receiver tank top sight glass. Imme-
diately stop adding refrigerant when refrigerant is seen
at the top of the sight glass.
8. Close the refrigerant bottle hand valve.
9. Remove the gauge manifold in the recommended man-
ner.
Adding Refrigerant
SSV
Mid
seated
DSV
Cracked
open
AJA809
Service Procedures
22
Charging an Evacuated Unit by Weight
1. Install a gauge manifold. Keep the unit off.
2. Recover the refrigerant and evacuate the system.
3. Place the refrigerant bottle on a scale and attach the
manifolds service line.
4. Open the bottle to withdraw liquid. Purge air from the
service line as required.
5. Record total refrigerant and container weight.
6. Check the unit data plate or unit Maintenance Manual
for refrigerant weight required.
7. Mid seat the compressor discharge service valve.
8. Open the discharge hand valve all the way on the
gauge manifold and begin charging the unit. Refriger-
ant flow can be felt as small pulsations on the manifold
service line.
9. Watch the scale and close the hand valve at the refrig-
erant bottle when the correct charge has been added.
10. If refrigerant flow stops before charging is complete,
close discharge manifold hand valve and return the
DSV to the cracked position. Add Liquid refrigerant into
the SSV with the unit running as described in the Add-
ing Refrigerant Procedure.
Service Procedures
23
UNIT
NOT
RUNING
Drawing shows liquid
refrigerant being added.
DSV
valve
mid-seated
SSV
valve
cracked
open
AJA810
To charge an evacuated unit, add liquid refrigerant to
the receiver tank or through the discharge service
valve. KEEP THE UNIT OFF.
To charge a running unit, add liquid through the
suction service valve. Control refrigerant flow to
increase suction pressure approximately 25 psi.
UNIT
RUNNING
IN COOL
Drawing shows liquid
refrigerant being added.
SSV
valve
mid-seated
DSV
valve
cracked open
AJA811
Service Procedures
24
Date: October 3, 1997
Service Bulletin
Subject: Evaporator Pressure
Regular (EPR) Adjustment
Application: ALL Thermo King Bus
units which are equipped with an
EPR valve.
(THIS PROCEDURE SUPERSEDES ALL PREVIOUS
EPR VALVE ADJUSTMENT PROCEDURES)
Read Me First:
The purpose of the EPR valve is to limit how low the pres-
sure inside of the units evaporator coil will go. Holding the
pressure at or above a set value also limits how low the coil
temperature can fall.The pressure and temperature, once
they have moved above the EPR valve setting, are depen-
dent on the heat load being accepted by the unit. The EPR
valve should not allow the pressure to fall below the point of
condensate freezing on the coil. To achieve that, the EPR
valve will stop or restrict the flow of refrigerant to hold the
pressure at or above the set point of the valve.
Once this valve is properly set it does not get out of
adjustment. The valve is factory set, but should be
checked as part of the delivery checkout procedure.
Adjustment if required, should be done by qualified
personnel only. NOTE: Improper adjustment of this
valve may cause damage to the system.
NOTE: The ambient temperature and the bus interior
must be above 80 F.
CAUTION: Do Not attempt to adjust this valve if the
ambient and bus interior temperatures are not above
80 F. Improper setting, and damage to the system may
result.
AJA8
Service Procedures
25
Procedure For Checking And Adjusting 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.
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 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 inte-
rior temperature above 80 F. Then return the unit to the
cool mode.
Note: you will need two people to finish the test.
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 cor-
rect and damage to the refrigeration system may
result.
(continued)
Service Procedures
26
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
valve. The pressure will drop and stabilize. This should
take one minute or less.
10. When the compound gauge stabilizes this is the set
point. The set point should be at the pressure stated on
the following table.
11. There should be a large difference between the com-
pound gauge [EPR valve] and the suction service valve
gauge readings (20-30 PSI or the compressor may
even go into a vacuum).
Note: You may need to jumper the low side pres-
sure cutout switch to be able to complete this set-
ting procedure.
Lower the engine/compressor speed to high idle and
switch the evaporator fan motor(s) back on.
12. Run the unit at high idle for more than 5 minutes to
clear the liquid refrigerant in the coil or compres-
sor damage may occur.
13. If the EPR valve requires adjustment, turn the adjusting
screw CW to increase the setting (raising coil tempera-
ture/pressure) and CCW to decrease the setting (low-
ering the coil temperature/pressure). Do not turn more
than 1/4 turn at a time.
Service Procedures
27
14. After every adjustment all covers must be reinstalled
and then run for at least 5 minutes before retesting.
15. If the setting is still incorrect, repeat steps 13 and 14.
16. When the setting is correct, recheck the setting twice
(steps #6 thru #13], you should get the same reading.
17. When the test is complete remove all gauges, jumper
wires and reinstall all covers back.
18. Check the refrigerant charge, oil level and return to ser-
vice.
Filed: F:\Bus\Usrefdat\procedur\eprset.doc
Type of EPR
valve:
ORIT-15 Large
type
ORIT-10 Small type
Refrigerant: Set pressures: Set pressures:
R-134a 24 +/-1 psig 24 +/-1 psig
R-22 50 +/-1 psig 50 +/-1 psig
R-407C 50+/-1 psig 50 +/-1 psig
R-12 27+/-1 psig 27 +/-1 psig
Service Procedures
28
Low Side Pump Down
Purpose: To test for internal (high side to low side) leaks
and to perform service on the low side without refrigerant
loss.
1. Check gauge manifold hose gaskets. They must not
leak during this test or the system may be contami-
nated with air!
2. Jumper out low pressure cut out (LPCO).
3. Install a calibrated gauge manifold on the SSV & DSV.
4. On units with Orit 10 EPR valve, mount the service
hose from the manifold gauge to the EPR service port.
Then open the low side hand valve.
On units with the Orit 15 EPR valve, shut the hand
valve on the pilot valve.
5. Run the unit in cool for ten minutes or longer.
6. Front-seat the receiver tank outlet valve (RTOV).
7. Pump down the lowside to a 25" vacuum.
8. Stop the unit.
9. Observe the low side gauge. Low side pressure should
remain below a 15" 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 -
Refrigerant boiling out of the compressor oil. (Restart
unit and pump down to 25" vacuum.)
High side to low side leaks at the compressor dis-
charge valve plates or hot gas bypass valve if
equipped.
The following services can be performed with the low side
pumped down and a slight positive pressure established on
the low side:
Add or remove refrigerant oil.
Clean the expansion valve screen.
Change the expansion valve.
Replace the liquid line drier.
Replace the compressor oil filter.
Replace lowside tubing.
Replace EPR valve.
Service Procedures
29
Shut The Hand
Valve on the
Pilot Valve
(Orit 15 only)
AJA813
Service Procedures
30
Compressor Pump Down
Purpose:
Service the compressor safely with a minimum loss of
refrigerant.
Check compressor for external leaks to the atmo-
sphere (if reading rises to zero and stays).
Check for internal leaks in the compressor (if reading
rises above zero).
1. Install gauge manifold set to monitor system pressures.
2. Bypass the Low Pressure Cutout (LPCO) to prevent
the clutch from disengaging.
3. Start and run the unit for 15 minutes to stabilize pres-
sures.
4. Front seat the suction service valve and pump down
the compressor to a 20 to 25 vacuum.
5. Stop the unit.
6. The crankcase pressure should remain below 0 PSI for
at least 15 seconds.
To Remove Compressor:
a. Pump down the compressor to a 15 inch vacuum.
b. Stop the unit.
c. Immediately front seat the discharge service valve.
d. Balance pressures through the gauge manifold to
1or 2 psig.
e. If 1 to 2 psig cannot be established, the refrigerant
must be recovered or a lowside pump down must be
performed.
NOTE: Pumping down the compressor causes refriger-
ant to boil off in the compressor. It may be necessary
to start and stop the unit several times before the com-
pressor will hold a vacuum.
NOTE: If you are going to service the compressor,
bleed some positive pressure, through the gauge man-
ifold, into the compressor. If you open the compressor
to the atmosphere while it is in a vacuum, you will draw
air into the compressor and contaminate the system.
Service Procedures
31
Compressor Oil Pressure Check
1. Install suction pressure gauge
2. Install gauge on compressor port A. It may be neces-
sary to pump down system and use a gauge line with a
schrader valve depresser.
3. With unit running observe gauge reading at compres-
sor oil pump, this is both suction pressure and com-
pressor oil pressure.
4. Read the suction pressure gauge.
5. Calculate oil pressure using the following sample as a
guide:
Pressure from port A 60 PSI
Suction pressure gauge reading - 25 PSI
Net oil pressure* = 35 PSI*
*Recommended net oil pressure should be
between 15&45 PSI.
Port
A
Schrader
Valve
in fitting
60 PSI
15-45
PSI
Suction pressure
Gauge
Service Procedures
32
Compressor Oil Level Check
The compressor oil level cannot be accurately checked
unless the unit has been operating for a period of not less
than 15 minutes and has air flow over the evaporator that
has attained a temperature of 70 to 80 F (21 to 27 C). This
will assure that the oil in the unit system has warmed suffi-
ciently to thin down and flow more readily through the sys-
tem, thus ensuring a more valid reading.
Check oil level and add oil if required when the following
operations have been performed
1. A major refrigeration component has been removed or
replace.
2. After recharging the unit.
3. After repair of a major refrigerant leak.
4. If a maintenance inspection procedure indicates the
system oil level is low.
NOTE: The unit does not consume oil. If the unit
requires additional oil, it is because there has been a
leak or a major repair to the system.
Check oil level by using the following procedure:
1. Start the unit.
2. If the bus temperature is above 70 F (21.1 C), put the
unit on COOL cycle and proceed to step 4.
3. If the bus temperature is below 70 F (21.1 C), put the
unit on HEAT cycle and operate until the bus tempera-
ture attains a minimum of 70 F (21.1 C). Proceed to
step 4.
4. Operate unit on COOL with 70 to 80 F (21 to 27 C) air
over the evaporator for a minimum of 15 minutes.
(continued)
Service Procedures
33
5. Ensure the unit is in COOL cycle. Check the oil level
with a flashlight while unit is operating. The compressor
oil level sight glass should indicate 1/4 to 1/2 full. If indi-
cator reading is low, oil must be added; proceed to
Adding Compressor Oil. If indicator reading exceeds
1/2 level, oil must be removed; proceed to Removing
Excess Oil.
NOTE: The compressor must be pumped down if oil is
added or removed. Pumping down the compressor
causes the oil to indicate lower than during normal
operation. Therefore, it is necessary to carefully note
the difference in oil level between normal operation
and when it is pumped down. Be sure to take this dif-
ference into account when adding or removing com-
pressor oil.
Removing Excess Oil
1. Pump the compressor down. Refer to Low Side Pump
Down Procedure or Compressor Pump Down Proce-
dure.
2. After stopping the compressor use the manifold gauge
set to adjust the compressor (low side) pressure to 1 to
3 psi. (Pressure measured at the compressor suction
service valve port).
3. Loosen the drain plug (DO NOT REMOVE) allowing
the oil to drain SLOWLY while watching the level in the
compressor sight glass.
NOTE: Heavy foaming of the oil as it leaves the com-
pressor may indicate an excess of refrigerant in the oil.
Run the system longer to insure a warm sump. Then
recheck level.
4. Tighten the drain plug and leak check.
5. Run the system again and confirm the refrigerant
charge level as well as recheck the oil level before
allowing the bus to return into service.
Service Procedures
34
Adding Compressor Oil
1. Estimate how much oil will be required to make the
level adjustment.
2. Perform a compressor pump down by following the
procedure indicated in this manual.
3. Stop the bus engine, turn off the bus power and operat-
ing safety switch to insure that no one can start the bus
while you are working on it.
4. Front seat the compressor discharge service valve in
addition to the suction service valve which was front
seated in step #2 above.
5. Balance pressures to
establish positive pressure
and recover excess refrig-
erant pressure.
6. Confirm which oil is to be
added to this system.
7. Hook up a vacuum pump
to your service gauges
which were connected in
step #2.
8. Hook up another service
hose to the oil pressure
port on top of the compres-
sor oil pump at the top rear
of the compressor.
9. Open the oil container.
Never leave oil contain-
ers open to the air for
long periods of time.
10. Put the hose from the oil pressure port into the con-
tainer of oil. Turn on the vacuum pump and lower the
pressure inside of the compressor to pull the oil into the
sump through the compressor oil pump until the oil
level is correct.
11. Secure the oil pump pressure port and replace the cap.
Continue evacuating the compressor sump area to
remove all air and noncondensable gasses which were
pulled in with the oil.
Balance System
both
valves
front-
seated
AJA815
Service Procedures
35
12. When evacuation is complete, back seat all system
valves, start the bus and A/C system and recheck the
compressor oil level.
13. Confirm the system refrigerant charge level, following
the correct procedures (noted in this manual) adjust
charge as required before allowing the bus to return to
service.
CAUTION: Always confirm which oil is in the system
you are servicing before you add oil. The wrong oil can
cause severe damage.
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. Measuring Container
Filled w/ Compressor
Oil
5. Discharge Service Port 11. Compressor Oil Sight
Glass
6. Suction Service Port
Service Procedures
36
Compressor Efficiency Test
Purpose:
Check the discharge valve plate reeds for leakage.
Check the piston reeds for leakage.
Check the piston to sleeve clearance.
1. Install gauge manifold set to monitor system pressures.
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 stabi-
lize system pressures.
EXAMPLE: On an 80 F day, your discharge pressure
will be approximately 240 psig.(With R-22 or
407-C refrigerant.)
4. Cover the inlet side of the condenser coil to increase
the discharge pressure 70-100 psig higher than nor-
mal.
EXAMPLE: If your discharge pressure is 240 psig after
15 minutes of operation, increase it 310-340 psig.
5. Front seat the suction service valve.
6. When the compressor reaches a 10 vacuum, observe
the discharge pressure. It should read as follows:
A. R-12 & R-134a 125 psig or higher
B. R-22 & R-407C 190 psig or higher
NOTE: If you cant increase the discharge pressure
higher than normal, 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 vac-
uum, 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 of vacuum for at least 15 seconds after unit
is turned off, the discharge valve reed(s) are defective.
Service Procedures
37
Air Gap Adjustment
1. Loosen the lock nuts on the three adjustment screws.
2. Using a 3/32 in. (2.4 mm) Allen wrench, turn each
adjustment screw in clockwise (CW) until the armature
bottoms out on the pulley.
3. Back each adjusting screw out counterclockwise
(CCW) 1-1/2 turns. This equals a .045 in. (1.143 mm)
air gap.
4. Double check air gap with feeler gauge per procedure
in step 3 of checking air gap (new clutch only).
5. Tighten the lock nuts. Make sure the adjusting screw
does not turn by holding it with an Allen
wrench.
6. Check the air gap in three different places 120 apart.
NOTE: The clutch should be checked monthly dur-
ing high usage periods
Allen Screw
Bottoms Out
Armature
AJA817
Wrench Tightening Locknut
3/32 in. (2.4 mm) Allen Wrench
Service Procedures
38
Testing For Air In The System
Ice Bath Sample Method Test
This inexpensive method requires that a small amount of
the systems refrigerant be placed in a sample bottle and
the bottle submerged in an ice bath.
Required Tools
Manifold Set, Sampling Bottle, Micron Gauge, Vacuum
Pump, Thermometer, Ice Water Bath Consisting of 75%
Ice,
Set of Refrigeration Wrenches to open and close valves.
Manifold Set Hookup Procedure
Attach manifold set as follows:
1. Connect low side hose to sample bottle.
2. Connect center hose to receiver tank service valve.
Valve remains closed.
3. Connect high side hose to evacuation pump.
CAUTION: If hoses are not connected properly, gauge
readings will be inaccurate.
Ice Bath Test Procedure
1. Open manifold gauges and evacuate all hoses, mani-
fold and sample bottle to 500 microns.
CAUTION: Check for leaks in the system.
(continued)
AJA819
AJA820
Service Procedures
39
2. Run the compressor to circulate any air that may be in
the system.
3. Close the high side gauge valve to isolate the micron
gauge and pump.
4. Open the receiver tank service valve to a count of four
(4). Then close the valve and count four (4) again.
5. Then close the low side gauge valve.
6. Place the sample bottle into the ice bath for 15 to 20
minutes. Stir the ice mixture occasionally.
NOTE: An ice water bath must be 75% ice in small
pieces and it should completely cover the sample. The
smaller the tank, the faster the temperature will equal
that of the ice water bath.
CAUTION: The procedure of taking the sample is
extremely important to avoid contaminating the
sample.
7. Compare low side gauge reading with your pressure/
temperature chart for 32F (0C).
R-12 = 30 psig (207.5 kPa)
R-22 = 57.5 psig (396.4 kPa)
R-134a = 27.3 psig (188.3 kPa)
R-407c = 50.9 psig (356.3 kPa)
READING MUST BE +/- ONE (1) psig (7 kPa).
If pressures exceed specifications, the refrigerant must be
reclaimed and the unit totally evacuated according to
proper evacuation procedures. After the system has been
evacuated, leak tested, and recharged with clean refriger-
ant, reconfirm the system operation. If system operation is
satisfactory, return the bus to service.
CAUTION: If the air and other non-condensables are
not removed, premature system failure will result.
AJA821
AJA822
Service Procedures
40
Superheat
Expansion Valve Measure (Superheat)
NOTE. Be sure the temperature reading instrument and
compound pressure gauge are accurately calibrated.
Procedure:
1. Pump down the low side into the receiver tank. Open
the receiver tank outlet valve to bleed the pressure
back to 1 to 3 psi in low side.
2. Install pressure gauge in the expansion valve external
equalizer line. This will indicate the pressure directly
and accurately. Use the Temperature Pressure Chart in
this manual to convert the pressure reading into tem-
perature.
Measure suction line temperature at point where feeler
bulb is attached.(See drawing)
3. Open the receiver tank outlet valve and operate the
unit for 15 minutes.
4. Subtract temperature reading obtained by Temperature
Pressure Chart conversion from the suction line tem-
perature to obtain the expansion valve setting (Super-
heat).
Thermo Bulb Suction Line Temperature (F)
-Suction Pressure Temperature Conversion (F)
Superheat (F)
NOTE: To establish stable condition, run the unit at
least 15 minutes at 1000 rpm engine speed so the
evaporator air inlet temperature reaches 70.0 to
80.0 (F) (21.0 to 27.0 C). Read pressure and tempera-
ture readings simultaneously. Temperature difference
should be 10.0 to 15.0 (F) (5.5 to 8.0 C).
CAUTION - Thermo King expansion valves are Factory
preset and do not require adjustment. It is very difficult
to establish controlled conditions in the field to accu-
rately adjust superheat. If it is verified that the super-
heat is out of range and before attempting to adjust the
expansion valve, the following three causes for an out
of range reading MUST be carefully checked.
Check the following:
1. Dirty air filters, or other cause of reduced air flow.
2. Sensing bulb leaking, bulb placed improperly (on refrig-
erant line, or bulb is not properly wrapped with insulat-
ing tape.
3. Kinked capillary tube.
Service Procedures
41
After these items have been checked and expansion valve
adjustment is unable to bring the superheat measurement
into range, then replace the expansion valve with factory
preset part.
Superheat Adjustment
1. Remove the cap over the adjusting stem.
2. To reduce superheat, turn the adjusting stem counter-
clockwise.
3. Make no more than one 1/4 turn of the stem at one
time, and observe the change in superheat closely to
prevent overshooting the desired setting. As much as
30 minutes may be required to obtain the new bal-
ance after the adjustment has been made.
4. When proper readings have been achieved, pump
down the low side into the receiver tank.
5. Remove the pressure gauge from the equalizer line
and thermometer.
6. Install the equalizer line, open the receiver tank and
check for leaks.
WHATS YOUR SUPERHEAT?
52
12
40
66#
52
Example: R-22 Refrigerant
To the suction pressure of 66PSIG
(at compressor)
Add estimated suction line loss 2 PSI
To obtain suction pressure....68 PSIG
(at Bulb)
converted to Temp
Your Superheat is
AJA823
Notes
42
Leak Testing/Soldering/Clean-Up
43
Refrigerant Leak Check Tools
and Recommended Testing Procedures
Units low on refrigerant must be tested for leaks and the
leaks must be repaired before adding refrigerant. Following
are recommended tools and testing procedures:
AC & DC Powered Electronic Detectors
DC detectors normally use a heated tip and convectional
currents to pull air samples across the sensor. Pumps used
are usually low capacity.
Travel Rate 1/2 inch per second.
Sensitivity As little as 1/2 oz. refrigerant loss per year.
AC powered electronic detectors normally react faster and
are the most reliable. A built-in pump pulls air across the
sensor.
Travel Rate 1/2 to 1 inch per second.
Sensitivity 1 /10 oz. refrigerant loss per year or less.
Liquid Leak Check Solutions
Leak check solutions are generally acceptable in areas that
are easily reached or where the air is saturated with refrig-
erant. However, several factors determine how well a solu-
tion will work. A good solution should:
Be bubble free
Have a high surface tension
Adhere to and not break away from the joint
Work for several minutes without evaporating
Be commercially made for leak detection
Leak Testing/Soldering/Clean-Up
44
Leak Characteristics
Multiple leaks may exist. Leak check beyond the first leak.
Component or line temperature may determine leak or
leak size. Leak test before and after running the unit.
Circulating refrigerant oil may temporarily plug leaks on
a unit that is operated. When possible, leak check before
running the unit.
Leak Testing Recommendations
Observe lines and components for an oil and dirt accu-
mulation indicating leak location.
Apply liquid bubble solution with soft brush to prevent
bubbles from forming. Allow several minutes to work,
Blow out confined areas with compressed air to remove
refrigerant accumulations.
In windy conditions, shield the leak area for leak testing.
Electronic Detectors
Calibrate frequently with a standard to be sure of reliabil-
ity.
Calibrate in fresh air to increase sensitivity.
Calibrate in slightly contaminated air to
reduce sensitivity.
Keep sensor free of dirt and refrigerant oil.
Move sensor slowly (1/2 inch per second).
Start leak testing at the top and work down.
Leak Testing/Soldering/Clean-Up
45
Recommended Solders and Soldering
Procedures
The following solders are recommended when servicing
Thermo King refrigeration systems:
Used With R-134a and R-12
Soft Solder (95/5, 95% tin, 5% antimony)
450 melting point.
TK 204-167
Flux Required Non-corrosive Paste TK 204-417
Identification Smooth, dull silver finish
Uses Low pressure, copper to copper
lines between the evaporator and
the compressor
Used With R-22 and R-407C
Silver Solder 15% (Phoson+) TK 204-634,
1250 melting point.
Flux Suggested None, may work better with white
flux, TK 203-365
Identification Dark, almost black appearance
Uses High pressure, copper to copper
connections. CANNOT be used
with steel
Silver Solder 35% TK 203-366
Flux Required TK 203-365, 1350 melting point.
Identification Bright, smooth, gold finish
Uses High strength, high pressure
connections made of dissimilar
metals (brass to copper,
copper to steel, etc.)
Leak Testing/Soldering/Clean-Up
46
Good soldering connections are frequently the result of
extensive practice. However, several factors and tech-
niques if properly observed will help ensure success for
even the inexperienced.
Tubing Fit
Too tight a fit between two pieces of swedged tubing may
not permit the solder to flow throughout the joint. Too loose
a fit will also weaken the connection.
A five thousandths of an inch space is recommended
between two pieces of a swedge joint. This is about equal
to two pieces of notebook or typing paper.
Cleanliness
Remove all grease or oil with solvent or clean rags.
Remove oxides from the tubing with scotch brite pads.
Sandpaper and steel wool are not recommended as they
may contaminate the connection or remove excess metal.
Wipe away loose oxide and abrasive particles to prevent
contamination.
Proper Flux
Use recommended fluxes to reduce oxide formation, to aid
in cleaning the connection and to help the solder flow.
AVOID getting flux inside the tubing.
Heat Control
Speed is important. Use a neutral flame large enough to
finish the job quickly and prevent oxide formation.
On swedge connections, heat the male tubing first, then
heat the entire connection evenly.
Cool slowly. Never cool with water or wet rags.
Leak Testing/Soldering/Clean-Up
47
Refrigerant Recovery
and Methods of Recovery
Whenever refrigerant is removed from a refrigeration unit
for service or after leak testing the unit, it must be recov-
ered to limit the potential harm it could cause to the envi-
ronment if it were allowed to escape to the atmosphere.
The following terms are used to refer to the process of
removing, storing and cleaning or purifying refrigerant:
Recovery . The process of removing refrigerant from a unit
and storing it in an external container for later processing.
Recycling . The process of removing moisture and/or oil
from refrigerant to prepare it for reuse.
Reclaiming . The process of cleaning refrigerant to meet
the standards of new refrigerant.
Leak Testing/Soldering/Clean-Up
48
Recovery from a Working Unit Without An
Orit 10 Valve
If a unit is operable and the compressor functions, the
refrigerant should be removed as a liquid. This is the fast-
est and most efficient method. Proceed as follows to
remove refrigerant as a liquid:
1. Install a gauge manifold on the SSV and the 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 unit's low side to force the refrigerant
into the condenser and receiver tank.
5. Set the recovery machine for liquid recovery and open
high pressure gauge hand valve. Remove the refriger-
ant through the receiver tank outlet service valve.
6. Recover refrigerant until proper recovery level is
achieved.
Recovery Unit
AJA824
Leak Testing/Soldering/Clean-Up
49
Recovery from a Working Unit
With An Orit 10 Valve
If a unit is operable and the compressor functions, the
refrigerant should be removed as a liquid. This is the fast-
est and most efficient method. Proceed as follows to
remove refrigerant as a liquid:
1. Install a gauge manifold on the SSV and the 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 vacuum, close the low
side hand valve on the gauge set.
5. Remove the service hose from the EPR valve and
attach to the recovery device. (Note: low loss fittings
must be used.)
6. Set the recovery machine for liquid recovery and open
high pressure gauge hand valve. Remove the refriger-
ant through the receiver tank outlet service valve.
7. Recover refrigerant until proper recovery level is
achieved.
Connect service
line to Orit valve
during low side
pump down
only
Recovery Unit
AJA825
Leak Testing/Soldering/Clean-Up
50
Recovery from a Non-functioning Unit
When a unit is inoperable or the compressor will not func-
tion, the refrigerant must be removed as a vapor. It can be
removed from almost 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.
1. On units equipped with an Orit 15 valve or no EPR
valve, attach gauge manifold hoses to the SSV and
DSV. If equipped with an Orit 10 valve, attach the man-
ifold hoses to the discharge valve and to the access
valve on the Orit 10 EPR valve.
2. Open both manifold hand valves.
3. Recover vapor refrigerant until proper EPA recovery
levels have been achieved.
Recovery Unit
AJA826
Leak Testing/Soldering/Clean-Up
51
System Evacuation and Clean-up
Refrigeration systems that have had service performed
with the system open to the atmosphere must be evacu-
ated to remove air and moisture that may have entered
during service.
In addition, systems that have been open to the atmo-
sphere for an extended period may require multiple evacu-
ations to be sure all air and moisture are removed.
Refrigeration systems that have had major service or
repairs, and systems suspected of having air, moisture, or
foreign particle contamination, must follow procedures out-
lined in TK 40229, "Clean-up of Refrigeration Systems with
Thermo King Compressors," and TK 40612, "Evacuation
Station Operation and Field Application
Normal Evacuation Procedure
1. Recover and totally recycle refrigerant making sure
contaminates are removed from the refrigerant using a
certified reclaiming / recycling machine.
2. Properly install evacuation pump and hoses. Attach
one evacuation hose to the receiver tank service valve
(high side) and the other hose to the suction side (low
side) Try to avoid evacuating from schrader valves.
Note: Units with EPR valves must be evacuated from
both sides of EPR valve. Refer to Service Bulletin No.
362 dated August, 1989.
3. Properly install micron gauge.
4. Install and tighten stem caps on service valves.
5. Evacuate to 500 microns. Once 500 microns are
reached, evacuate for 30 additional minutes.
(continued)
Leak Testing/Soldering/Clean-Up
52
6. Close off unit from pump, shut pump off.
7. Observe micron gauge. Micron level should not exceed
1500 microns within 5 minutes. Address problem if
gauge exceeds 1500 microns and re-evacuate. Use
nitrogen to purge system before re-evacuating.
Note: Leaks or high levels of moisture are common
reasons for a poor evacuation. Also, check evacuation
equipment and connections, and make sure schrader
valves and service valves are capped. Refer to Service
Bulletin No. 392, dated January, 1990.
8. Weigh in unit charge. (Check unit maintenance manual
for proper charge).
9. Check operating pressures. Ensure the temperature,
pressure relation vs. RPMs are within specifica-
tion.Your failure to perform the proper clean-up of the
system may effect unit warranty.
Multiple Evacuation
Perform a multiple evacuation if a system has been open to
the atmosphere for an extended period or as recom-
mended in TK 40229 "Clean-up of Refrigeration Systems
with Thermo King Compressors".
1. Check the evacuation equipment and repair as
required.
2. Open the shut-off valve and place the unit service
valves in the mid-seat position.
3. Evacuate the system to 2000 microns for 30 minutes.
4. Break the vacuum with nitrogen until a 2 to 5 lb. posi-
tive pressure is established.
5. Allow the nitrogen to remain in the system for 10 min-
utes or more.
6. Evacuate the refrigeration system to 1500 microns for
30 minutes.
7. Break the vacuum with nitrogen until a 2 to 5 lb. posi-
tive pressure is established
8. Change the liquid line drier.
9. Evacuate the system to 500 microns then continue to
evacuate for 30 minutes.
10. Close the hand valves on the gauge manifold.
11. Remove the vacuum pump and charge the unit with
refrigerant.
12. Prepare the unit for service.
Leak Testing/Soldering/Clean-Up
53
Compressor Oil Acid Test (Kit TK 203-346)
An acid test of the compressor oil must be done whenever
an acid condition is suspected. Perform an acid test when-
ever a unit has a substantial refrigerant loss, a noisy com-
pressor or dark/dirty oil as noted in TK 40229 "Clean-up of
Refrigeration Systems with Thermo King Compressors".
To complete an oil acid test:
1. Use an access valve (TK 204-625) on the compressor
oil pump service port and draw an oil sample.
Note: Two Thermo King acid test kits are available -
one for alkybenzene (synthetic) compressor oil and
one for polyolester compressor oil. Be sure to use the
correct test kit.
Clear Oil Appearance of good oil.
Black Oil Carbonization from operating a unit with
air and moisture in the system.
Brown Oil Results from moisture in the system
causing an acid condition and sub-
sequent copper plating.
Gray/Metallic Caused by wear metal from pistons
bearings, cylinders, etc.
2. Add oil to the test bottle up to the line on the neck.
3. Replace the cover and shake.
4. Compare the oil kit color with the color test strip.
Leak Testing/Soldering/Clean-Up
54
Compressor Oil Filter Kit (TK 20-123)
This oil filter is recommended for permanent installation on
units whenever a compressor has been replaced or the
system has had foreign particle contamination as defined in
TK 40229, "Clean-up of Refrigeration Systems with
Thermo King Compressors".
The filter cartridge is replaceable after performing a com-
pressor or low side pump down. The filter should be
changed annually.
Note: Can not be used on 4GB bus compressors.
Suction Line Filter
The suction line filter is designed for use when major sys-
tem contamination has occurred as defined in TK 40229,
"Clean-up of Refrigeration Systems with Thermo King
Compressors".
As indicated in the recommended clean-up procedure, the
compressor oil filter is also recommended for permanent
installation on systems requiring the use of a suction filter.
AJA827
Refrigerant Types and Pressures
55
Refrigerant Types/Properties
During unit cooling, refrigerant is the vehicle within the
refrigeration system that picks up the heat inside the bus. It
then carries the heat outside where it can be given up to
the outside air. Following are characteristics of refrigerants
and oils presently used in Thermo King units:
WARNING: Some autos, trucks and other air condition-
ing systems use PAG Polyalkylene Glycol compressor
lubricant. DO NOT mix with Thermo King Ester Base
Oils.
NOTE: Check unit maintenance manual for proper oil
to use on ShuttleAire.
Refrigerant Types/Properties
R-12 Container Color White
Oil Type Mineral Base TK 64-426, or Syn-
thetic TK 67-404
Leak Testing Liquid Bubble Solution or CFC
Electronic Detectors
R-22 Container Color Green
Oil Type Synthetic TK 67-404
Leak Testing Liquid Bubble Solution and CFC
Electronic Detectors
R-134a Container Color Light Blue or Brown
Oil Type Polyolester TK 203-413
Leak Testing Liquid Bubble Solution or Halogen
Electronic Detector
R-407C Container Color Medium Brown
Oil Type Polyolester TK 203-413
Leak Testing Liquid Bubble Solution or Halogen
Electronic Detector
Temperature Pressure Relationships
56
Temperature Pressure Relationships
57
Notes
58
Glossary
59
Bus Air Conditioning Terminology
Absolute Pressure
The pressure above a perfect vacuum, expressed in
pounds per square inch absolute (psia) or kilopascals
(kPa).
Ambient Air
The air surrounding an object.
Ambient Temperature Sensor
Measures outside air temperature and selects the tempera-
ture where the compressor is disabled.
Ambient Temperature
Temperature of the air surrounding an object.
Atmospheric Pressure
The atmosphere surrounding the earth extends many miles
above the surface of the earth. The weight of that atmo-
sphere pressing down on the earth is relatively constant
except for minor changes due to changing weather condi-
tions. As a basic reference for comparison, the atmo-
spheric pressure at sea level has been universally
established at 14.7 psi (100 kPa) and is equivalent to the
pressure exerted by a column of mercury 29.92 inches
high. At altitudes above sea level, the depth of the atmo-
spheric blanket surrounding the earth is less; therefore, the
atmospheric pressure is less.
Back Seated Service Valve
The valve stem is backed all the way out (counterclock-
wise). In this position, the valve outlet is open and the ser-
vice port is closed.
Boiling Point
The temperature at which a liquid vaporizes upon the addi-
tion of heat or by the reduction of pressure.
Boost Pump
Increases the flow of engine coolant to the heating coil.
Glossary
60
Box Temperature
A term use in transport refrigeration that refers to the tem-
perature within a bus body. Box temperature is the same as
return air temperature.
British Thermal Unit (BTU)
The amount of heat required to increase the temperature of
a pound of water one degree Fahrenheit.
Brushless Motor
An alternating current (AC) motor having no commutator or
brushes.
Calorie
The amount of heat required to raise temperature of one
gram of water one degree Celsius.
Capacity
Rate of heat transfer measured in tons, BTUs per hour, K
cal per hours, or Watts. Example: The refrigeration capacity
with R-22 is 125,000 BTU per hour at 2000 RPM and with
R-134a is 100,000 BTU per hour at 2000 RPM
Change of State
The process of changing from a liquid to a gas, gas to liq-
uid, solid to liquid, or liquid to solid.
Charge
1) The amount of refrigerant in a system.
2) The process of adding refrigerant to a system.
Check Valve
A valve that allows refrigerant to flow in only one direction.
Coil Drop
The term is often used in reference to the temperature dif-
ference of air entering the evaporator coil versus the tem-
perature out. Coil Drop can also be referred to as
Temperature Differential (TD).
Coil Temperature Sensor
Measures coil temperature, usually on the evaporator coil
to control freezing.
Glossary
61
Compound Gauge
A gauge that is calibrated in both pounds and inches to
measure pressure and vacuum. This gauge is normally
used to measure low side pressures.
Compressor
The refrigeration component that compresses refrigerant
vapor and creates refrigerant flow.
Compressor Capacity/Efficiency Test
A test used to check the condition of compressor piston
reeds, piston-to-cylinder wall clearance, piston and cylinder
condition, and compressor performance capability.
Compressor Pump Down
A service procedure used to check for internal leaks
through the discharge valve plates, and to perform service
work on the compressor.
Condenser
An arrangement of tubing in which the vaporized and com-
pressed refrigerant is liquefied as heat is removed.
Conduction
Heat transfer between two substances in physical contact.
Convection
Heat transfer between substances through the movement
of a fluid (gas or liquid).
Coolant Valve
Controls coolant flow to the heater coil.
Cool Mode (Reheat Position)
When the unit reaches set point, the clutch remains
engaged while the boost pump operates.
Cool Mode (Cycling Clutch)
When the unit reaches set point, the clutch cycles off. The
unit operates in vent.
Compressor Discharge Sensor
Active above 250F. Senses temperature of discharge gas
leaving the compressor.
Glossary
62
Dehydration
Process or removing moisture from a refrigeration system
or product. A refrigeration system is considered fully dehy-
drated when it can maintain a 2000 micron vacuum for five
minutes or longer.
Dehydrator
A device used to remove moisture from refrigerant. Drier.
Receiver drier.
Discharge Pressure
Operating pressure measured in the discharge line at the
compressor outlet.
Discharge Temperature
The temperature of refrigerant at the compressor outlet.
Distributor
A device located between the expansion valve and evapo-
rator coil designed to divide the flow of liquid refrigerant
among several parallel paths in the evaporator coil.
Drier
(See Dehydrator)
DSV
Discharge Service Valve
EPROM
Erasable Programmable Read-Only Memory. A program-
mable software chip that can be erased and repro-
grammed.
EPR Valve
Evaporator Pressure Regulator. Controls evaporator coil
temperature to prevent freezing.
Evacuation
The removal of non-condensable gases from the refrigera-
tion system.
Evaporation
A change of state from liquid to vapor.
Glossary
63
Evaporator
The part of the refrigeration system, located in the bus
interior, that absorbs heat during the cooling cycle.
Expansion Valve
A device that meters liquid refrigerant to the distributor and
evaporator coil in direct response to heat load on the evap-
orator.
Flash Gas
The instantaneous vaporization of refrigerant caused by
the reduction of pressure on liquid refrigerant when it
passes through a pressure reducing device.
Foaming
A condition caused by refrigerant boiling out of the com-
pressor oil. Foaming of the compressor oil is often seen
through the compressor oil sight glass for several minutes
after a unit is started.
Fractionation
When a refrigerant blend in the vapor form separates into
its individual refrigerant components.
Freeze Point
The temperature at which a liquid makes a physical change
to a solid. For water this change occurs at 32F (OC).
Freeze Thermostat
Senses and corrects coil freeze-up.
Freeze-Up
1. The formation of ice at the expansion valve.
2. The formation of a solid ice mass over the evaporator
coil reducing air flow.
Front Seated
When the stem of a service valve is turned in (fully clock-
wise) to stop refrigerant flow through the valve. The service
port is open when the valve is front seated.
Glossary
64
Frosting Back
1. The condition of frost formation on the suction line dur-
ing the cooling cycle. This happens when the suction
line temperature is below the dew point.
2. The formation of frost on the suction line, or any portion
of the compressor during the cooling or heating cycle
indicating liquid refrigerant is vaporizing at these loca-
tions.
Gas
Common terminology for refrigerant in the gaseous state.
See Vapor.
Gauge Pressure
The pressure reading measured on a gauge calibrated to
read zero psi (zero kPa) at atmospheric pressure.
Head Pressure
A term commonly used to mean discharge pressure.
Heat
Heat is a form of energy. Heat is often defined as energy in
transfer, for it is never content to stand still, but always
moving from a warm body to a colder body. The terms
warmer and colder are only comparative. Heat exists at any
temperature above absolute zero, even though it may be in
extremely small quantities.
Heat Exchanger
The component in which heat is transferred from one fluid
to the other. Normally, it transfers heat from the liquid line to
the suction line.
Heat Mode
The evaporator fan motor runs at selected speed, the boost
pump and coolant valve are activated, and the condenser
fan motor is stopped.
Heat of Compression
Heat added to refrigerant gas as a result of the work energy
used in compression.
Heat Radiation
Heat transfer through a substance without changing the
substance temperature.
Glossary
65
Heat Transfer
Heat always travels from a warm object to a colder object.
The rate of heat travel is in direct proportion to the temper-
ature difference between the two bodies. Heat can travel in
any of three ways: radiation, conduction, or convection.
Hertz
A unit of electrical frequency equal to one cycle per sec-
ond.
High Pressure Cut Out
A pressure-operated switch that opens to stop unit opera-
tion when discharge pressure reaches a predetermined
maximum.
High Pressure Relief Valve
A safety valve on the refrigeration system that allows refrig-
erant to escape from the system if pressures exceed a pre-
determined value.
High Side
The portion of the refrigeration system operating under
condensing pressure. That portion of a refrigeration system
between the compressor output and the expansion valve.
Hot Gas Bypass Valve
A solenoid valve controlled by a pressure switch used to
reduce condenser pressure. Excess condenser pressure is
piped to the evaporator inlet.
Inches of Vacuum
Pressure below atmospheric pressure.
Latent Heat
The heat added or removed from a substance that
accounts for a change in state without any measurable
change in temperature. For some substances there are two
conditions where latent heat is required to make the
change of state. They are - changing from a solid to a liquid
called fusion, and from liquid to vapor, or vapor to liquid
called vaporization or condensation.
Glossary
66
Latent Heat of Evaporation
A change of substance from a liquid to a vapor, or from a
vapor back to a liquid involves the latent heat of condensa-
tion. Since boiling is only a rapid evaporating process, it
might also be called the latent heat of boiling, the latent
heat of vaporization, or for the reverse process, the latent
heat of condensation. When one pound of water boils or
evaporates, it absorbs 970 BTU (1023 joules) and to con-
dense one pound of steam to water 970 BTU (1023 joules)
must be extracted from it.
Latent Heat of Fusion
A change of substance from a solid to a liquid, or from a liq-
uid to a solid involves the latent heat of fusion. When one
pound of ice melts, it absorbs 144 BTUs, and if one pound
of water is to be frozen into ice, 144 BTUs must be
removed from the water.
Latent Heat of Sublimation
A change in state directly from a solid to a vapor without
going through the liquid phase. The most common example
is the use of dry ice (solid carbon dioxide) for cooling. The
same process can occur with ice below the freezing point,
and is also utilized in some freeze-drying processes at
extremely low temperatures and high vacuums. The latent
heat of sublimation is equal to the sum of the latent heat of
fusion and the latent heat of evaporation.
LED
Light Emitting Diode. A small, neon bulb that operates at
low voltage (3 to 4 volts).
Liquid Line
The tube carrying liquid refrigerant from the receiver tank to
the expansion valve.
Load
1. The people being cooled and transported.
2. The amount of heat that is being removed by the refrig-
eration system.
3. The power output of a generator.
4. The resistance of a device to which power is delivered.
Glossary
67
Low Pressure Cut Out
A pressure-operated switch that opens to stop unit opera-
tion when suction pressure reaches a predetermined mini-
mum.
Low Side
The part of a refrigeration system normally under low pres-
sure during the cool mode. (This includes the liquid line
during a low side pump down.)
Motor Driver
DC to AC inverter used to supply voltage to the brushless
AC motor.
Perfect Vacuum
29.92 Hg (29.92 inches of mercury)
Piston Reeds
Ring-shaped reeds (one way valves) located on top of each
piston in a reciprocating compressor. As the piston moves
down in the cylinder, the reed opens to allow refrigerant
gas to move from the crankcase area to the area above the
piston. As the piston moves up in the cylinder, the reed
closes to trap refrigerant gas above the piston. The com-
pressor capacity test is used to check the condition of pis-
ton reeds.
Pressure
The push exerted against container walls by a liquid or gas,
usually measured in pounds per square inch or kilopascals
(kPa).
Pressure Drop
1. Loss in line pressure from one point to another due to
restriction.
2. Loss of pressure due to condensing vapor.
3. Loss of pressure due to a leak in the system.
Product
The cargo being temperature-controlled.
PSIA
Pound per square inch - Absolute. See Absolute Pressure.
Glossary
68
PSIG
Pounds per Square Inch Gauge. Pressure in pounds per
square inch as displayed by a gauge calibrated to zero
when open to the atmosphere.
Pump Down
A procedure used to service a refrigeration system. Refrig-
erant in a charged unit is pumped and stored in one part of
the system while servicing another part of the system.
Purging
Releasing a vapor through a refrigeration system to atmo-
sphere to remove contaminants from the system. The rec-
ommended vapor used for purging dry nitrogen.
Radiation
Radiation is the transfer of heat by waves similar to light
waves or radio waves. For example, the suns energy is
transferred to the earth by radiation.
Receiver Tank
A refrigerant storage tank.
Reclaim
The process of cleaning refrigerant to like-new condition. A
process normally done by a licensed reclaiming service not
an infield practice.
Reclaimer
A machine used for removing refrigerant from a unit,
removing contaminants from the refrigerant, and placing
the refrigerant into a storage container.
Recover
To remove refrigerant from a system and store it in an
external container without testing or processing it.
Recycle
A procedure that removes refrigerant from a unit, cleans
the refrigerant through a series of filters, and returns the
refrigerant to the unit or a bottle.
To clean refrigerant for reuse by removing oil and contami-
nants through single or multiple passes through moisture
absorption devices such as replaceable core filter driers.
Considered an infield practice.
Glossary
69
Refrigerant
The fluid or vehicle used to carry heat from one point to
another in the refrigeration system. It picks up heat as it
vaporizes and gives up heat as it condenses.
Return Air Sensor
Measures coach interior air temperature, usually mounted
in the return air flow of the evaporator.
Return Air Temperature
See Box Temperature.
RTOV
An abbreviation for Receiver Tank Outlet Valve, which is
the service valve on the recovery tank.
Saturated Vapor
The condition when a refrigerant has liquid form present
with the vapor. This occurs in the evaporator when refriger-
ant is making the change from liquid to vapor or in the con-
denser when the refrigerant is condensing.
Saturation Temperature
The condition where temperature and pressure allow both
liquid and vapor to exist simultaneously. A saturated liquid
or vapor is one at its boiling point, and for water at sea
level, the saturation temperature is 212 F (I00 C). At higher
pressure, the saturation temperature increases, and with a
decrease in pressure, the saturation temperature
decreases.
Sensible Heat
The heat required to change temperature of a substance.
When the temperature of water is raised from 32 F to 212
F, an increase in sensible heat content is taking place.
Set Point
The temperature selected on a thermostat or micro control-
ler. This is normally the desired temperature.
Short Cycling
The circulation of air from the evaporator outlet and back to
the evaporator inlet without properly circulating through the
load. Short cycling is normally caused by improper ducting
practices. This may also refer to improper clutch operation.
Glossary
70
Sight Glass
A system component that permits visual inspection of oil
and/or refrigerant level and condition.
Slugging
The return of either refrigerant or oil to the compressor in a
liquid condition. Slugging can cause knocking and com-
pressor damage. Sometimes called liquid slugging.
Solenoid Valve
An electromagnet valve that can be opened or closed elec-
trically.
Specific Gravity
Specific gravity (sp.gr.) is a ratio comparing the weight of a
substance to the weight of an equal volume of water. Water
is considered to have a specific gravity of one. Objects
which float on water have a specific gravity of less than
one. Objects which sink in water have a specific gravity
greater than one.
Specific Heat
Heat required to change the temperature of a given unit of
a substance compared to the amount of heat required to
change the temperature of an identical amount of water. It
is expressed in BTUs per pound per degree Fahrenheit or
joules per kilogram kelvin.
SSV
Suction Service Valve.
Suction Line
A flexible line, to absorb vibration, that carries refrigerant
from the evaporator back to the compressor.
Suction Reeds
See Piston Reeds
Superheated Vapor
Vapor that has heat added to it after it has changed from a
liquid to a vapor without any additional change in pressure.
Glossary
71
TD
The abbreviation for Temperature Differential or Tempera-
ture Difference. The term is often used in reference to the
temperature difference of air entering the evaporator coil
versus the temperature out. TD can also be referred to as
Coil Drop.
Temperature
Temperature is the word used to describe the intensity of
heat. In the United States, temperature is normally mea-
sured in degrees Fahrenheit, but the Celsius scale is widely
used in other parts of the world.
Thermodynamics
Thermodynamics is the branch of science that explains the
mechanical action of heat. There are several fundamental
laws of thermodynamics. The first and most important of
these laws is that energy can neither be created nor
destroyed, but can be converted from one type to another.
Thermostat
Controls electrical devices in bus based on temperature.
Ton
The common unit used to measure refrigeration effect. The
amount of heat absorbed by one ton (2000 lb.) of ice as it
changes to liquid over a 24-hour period. It is the refrigerat-
ing equivalent of 12,000 BTUs per hour. (One pound of ice
absorbs 144 B.t.u. As it melts. One ton of ice absorbs
288,000 B.t.u. When one ton of ice melts in 24 hours, the
rate is 288,000 (24 or 12,000 B.t.u. per hour.)
Unloader Valve
Used on some compressors to limit capacity by either shut-
ting off suction gas or bypassing gas back to the suction
side of the compressor.
Valve Plate (Discharge Valve Plate)
An internal part of the compressor located above each pis-
ton. It operates as a check valve, allowing refrigerant gas to
leave the area above the piston while preventing its return
when the piston is on the down-stroke. The compressor
pump down procedure is used to check valve plate condi-
tion.
Glossary
72
Vapor
Common terminology for refrigerant in a gaseous state.
See Gas.
Vent Mode
Coach interior air is recirculated.
Volumetric Efficiency
The ratio of actual volume of refrigerant gas pumped by the
compressor to the volume displaced by the compressor
pistons.
Watt
A term defining the cooling ability of a unit.
One Watt = 3.42 BTU
TK 51066-3-MS (10-00) Printed in U.S.A.