Thermo King KD-II SR User manual

KD-II SR
TK 41079-1-MM (Rev. 3, 04/03)
Copyright©1996 Thermo King Corp., Minneapolis, MN, U.S.A.
Printed in U.S.A.

The maintenance information in this manual covers unit models:
KD-II SR 30 (097195) KD-II SR 50 230/3/60 EEC (097199)
KD-II SR 50 230/3/60 (097196) KD-II SR 50 220/3/50 EEC (097200)
KD-II SR 50 380-460/3/50-6 (097197) KD-II SR 50 380/3/50 EEC (097201)
KD-II SR 30 EEC (097198)
For further information, refer to…
KD-II SR µP-T Parts Manual TK 41109
KD-II SR µP-T Operator’s Manual TK 41083
Thermoguard µP-T Microprocessor Controller TK 41087
Diagnosing Thermo King Refrigeration Systems TK 5984
Tool Catalog TK 5955
The Collector Refrigerant Recovery Unit TK 40956
The information in this manual is provided to assist owners, operators and service people in the proper upkeep
and maintenance of Thermo King units.
This manual is published for informational purposes only and the information so provided should not be considered
as all-inclusive or covering all contingencies. If further information is required, Thermo King Corporation should be
consulted.
Sale of product shown in this manual is subject to Thermo King’s terms and conditions including, but not limited to,
the Thermo King Limited Express Warranty. Such terms and conditions are available upon request.
Thermo King’s warranty will not apply to any equipment which has been “so repaired or altered outside the manu-
facturer’s plants as, in the manufacturer’s judgment, to effect its stability.”
No warranties, express or implied, including warranties of fitness for a particular purpose or merchantabil-
ity, or warranties arising from course of dealing or usage of trade, are made regarding the information, rec-
ommendations, 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 environ-
ment 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 regula-
tions concerning the use of refrigerants and the certification of
technicians. For additional information on regulations and tech-
nician certification programs, contact your local THERMO KING
dealer.

Table of Contents
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
Maintenance Inspection Schedule. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Unit Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Unit Instruments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Unit Protection Devices. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Unit Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Pre-trip Inspection (Before Starting Unit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Starting Unit (Full Unit Self Check) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Selection of Operating Modes on CYCLE-SENTRY Equipped Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Products Requiring Continuous Run Operation for Air Flow. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Products Acceptable for CYCLE-SENTRY Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Restarting the Unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
After Start Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Loading Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Post Load Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Post Trip Checks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Unit Photographs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
µP-T System Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
General Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
µP-T Control System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
Microprocessor Power Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
Optional Electric Standby (Model 50 Units Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
Standard Model 50 Features. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
Optional Model 50 Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
Serial Number Locations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
Remote Control Panel Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
µp-T Alarms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
Alarm Code Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
µP-T Unit Self Check Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
Electrical Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
Service Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
Alternator with Integral Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
Charging System Diagnostic Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
Excessive Voltage Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
12V Alternators with Internal Regular Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
Battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
Unit Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
Electrical Contacts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
Charging System (12 Vdc) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
Preheat Buzzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
Rpm Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
Glow Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48
Condenser/Evaporator Fan Rotation (Electric Standby Operation) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49
Defrost Air Switch Checkout and Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49
KD-II SR Units Equipped with a Three-Phase Electric Motor and
a Phase Converter That Operates on Single-Phase Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51

Table of Contents (Continued)
Electrical Maintenance (continued)
Conversion System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Start System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Run System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Troubleshooting the Phase Conversion System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Electric Motor Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
High Capacity TherMax™ Heating System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Engine Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Engine Lubrication System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Crankcase Breather. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Engine Air Cleaner. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Engine Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Antifreeze Maintenance Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Engine Fuel System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Bleeding the Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Fuel Filter Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Electric Fuel Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Injection Pump Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Timing the Injection Pump to the Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Adjust Engine Valve Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Fuel Limit Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Engine Mounts for KD-II SR Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Belt Tensions (Units Manufactured Prior to 1-97) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Auto Start/Stop. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Idler Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
KD-II SR Idler Pulley Seal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
KD-II SR Idler Pulley Seal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Integral Fuel Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
TK 3.74 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Fuel Solenoid Diagnostic and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Engine Speed Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Refrigeration Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
System Evacuation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Evacuation is Important and is Critical to System Performance! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Set Up and Test of Evacuation Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Unit Evacuation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Unit Charging. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Remove Evacuation Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Refrigerant Leaks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Refrigerant Charge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Checking Compressor Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Compound Pressure Gauge (Optional Equipment) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
High Pressure Cutout. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Compressor Pump Down and Checkout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Low Side Pump Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Three-way Valve Condenser Pressure Bypass Check Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104

Table of Contents (Continued)
Refrigeration Service Operations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .107
Accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .107
Compressor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .108
Condenser/Radiator Coil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .108
Liquid Line Check Valve Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .108
Dehydrator (Filter-Drier) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .108
Evaporator Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .109
Expansion Valve Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .109
Heat Exchanger. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .110
High Pressure Cutout Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .111
High Pressure Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .112
Pilot Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .112
Pressure Regulator Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .112
Receiver Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .113
Three-way Valve Condenser Pressure Bypass Check Valve Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .113
Three-way Valve Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .114
KD-II SR Compressor Pulley Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .116
R-134a and R-404A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .117
Equipment Recommendations for use with R-134a and R-404A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .120
Refrigerant Recovery System—THE COLLECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .121
Hilliard Clutch Maintenance (Prior 4-97) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .123
Hilliard Clutch Maintenance (Starting 4-97) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .127
Structural Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .133
Unit and Engine Mounting Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .133
KD-II SR Lift Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .133
Unit Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .133
Evaporator Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .133
Condenser Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .133
Defrost Damper. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .134
Jackshaft Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .135
Fan Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .137
Fan Shaft Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .137
Fan Shaft Assembly Overhaul. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .138
Mechanical Diagnosis. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .143
Electric Standby (Optional) Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .149
Refrigeration Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .151
Cool Cycle—KD-II with TherMax™ Heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .153
Condenser Evacuation Cycle—KD-II with TherMax™ Heating. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .154
Heat and Defrost Cycle—KD-II with TherMax™ Heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .155
Wiring Diagrams and Schematics Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .157

i
Safety Precautions
GENERAL PRACTICES
1. ALWAYS WEAR GOGGLES OR SAFETY
GLASSES. Refrigerant liquid, refrigeration oil, and
battery acid can permanently damage the eyes (see First
Aid under Refrigeration Oil).
2. Never operate the unit with the compressor discharge
valve closed.
3. Keep your hands, clothing and tools clear of the fans
and belts when the unit is running. This should also be
considered when opening and closing the compressor
service valves.
4. Make sure gauge manifold hoses are in good condition.
Never let them come in contact with a belt, fan motor
pulley, or any hot surface.
5. Never apply heat to a sealed refrigeration system or
container.
6. Refrigerants in the presence of an open flame produce
toxic gases. These gases are severe respiratory irritants
capable of causing death.
7. Make sure all mounting bolts are tight and are of cor-
rect length for their particular application.
8. Use extreme caution when drilling holes in the unit.
The holes may weaken structural components, and
holes drilled into electrical wiring can cause fire or
explosion. Holes drilled into the refrigeration system
will release refrigerant.
9. Use caution when working around exposed coil fins.
The fins can cause painful lacerations.
10. Use caution when working with a refrigerant or refrig-
eration system in any closed or confined area with a
limited air supply (for example, a truck box or garage).
Refrigerant tends to displace air and can cause oxygen
depletion resulting in suffocation and possible death.
11. Use caution when using ladders or work platforms.
Follow manufacturer’s instructions.
AUTO START/STOP
CAUTION: The unit may start automatically and at
any time when the unit On-Off switch is in the ON
position. Units with the CYCLE-SENTRY option start
automatically in both CYCLE-SENTRY mode and Contin-
uous mode. Be sure to turn the On-Off switch OFF before
opening doors or inspecting or working on any part of the
unit.
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.
When working on transport refrigeration systems, a recov-
ery process that prevents or minimizes refrigerant loss to the
atmosphere is required by law. In addition, service person-
nel must be aware of Federal, State and local regulations
governing the use of refrigerants and certification of techni-
cians.
When refrigerants are exposed to the atmosphere in liquid
form, they evaporator rapidly, freezing anything they con-
tact. If they contact the skin, severe frostbite can result.
First Aid
In the event of frost bite, the objectives of First Aid are to
protect the frozen area from further injury, to warm the
affected area rapidly and to maintain respiration.
• EYES: For contact with liquid, immediately flush eyes
with large amounts of water and get prompt medical
attention.

Safety Precautions (Rev 04/03)
ii
• SKIN: Flush area with large amounts of lukewarm
water. Do not apply heat. Remove contaminated cloth-
ing and shoes. Wrap burns with dry, sterile, bulky
dressing to protect from infection/injury. Get medical
attention. Wash contaminated clothing before reuse.
• INHALATION: Move victim to fresh air and use CPR
if necessary. Stay with victim until arrival of emer-
gency medical personnel.
REFRIGERATION OIL
Observe the following precautions when working with or
around synthetic or polyol ester refrigerant oil:
• Do not allow refrigerant oil to contact your eyes.
• Do not allow prolonged or repeated contact with skin or
clothing.
• To prevent irritation, you should wash thoroughly
immediately after handling refrigerant oil. Rubber
gloves are recommended when handling polyol ester
oil.
First Aid
• EYES: Immediately flush eyes with large amounts of
water for at least 15 minutes while holding the eyelids
open. Get prompt medical attention.
• SKIN: Remove contaminated clothing. Wash
thoroughly with soap and water. Get medical attention
if irritation persists.
• INHALATION: Move victim to fresh air and restore
breathing necessary. Stay with victim until arrival of
emergency personnel.
• INGESTION: do not induce vomiting. Contact a local
poison control center or physician immediately.
ELECTRICAL HAZARDS
Microprocessor Service
Precautions must be taken to prevent electrostatic discharge
when servicing the microprocessor controller and related
components. Potential differences considerably lower than
those which produce a small spark from a finger to a door
knob can severely damage or destroy solid-state integrated
circuit components.
The following procedures must be rigidly adhered to when
servicing units to avoid microprocessor damage or
destruction.
1. Disconnect all power to the unit.
2. Avoid wearing clothing that generates static electricity
(wool, nylon, polyester, etc.).
3. Do wear a static discharge wrist strap (TK P/N
204-622) with the lead end connected to the micropro-
cessor’s ground terminal. These straps are available at
most electronic equipment distributors. DO NOT wear
these straps with power applied to the unit.
Refer to the THERMOGUARD µP-IV Microprocessor
Controller Operations and Diagnosis Manual (TK
41087) (T.I.P. Procedure #P41AA12B) and the Electro-
static Discharge Training Guide (TK 40282) for addi-
tional information.
4. Avoid contacting the electronic components on the cir-
cuit boards of the unit being serviced.
5. Leave the circuit boards in their static proof packing
materials until ready for installation.
6. If a defective controller is to be returned for repair, it
should be returned in the same static protective packing
materials from which the replacement component was
removed.
7. After servicing the controller or any other circuits, the
wiring should be checked for possible errors before
restoring power.

Safety Precautions (Rev 04/03)
iii
8. Never use testers consisting of a battery and a light bulb
to test circuits on any microprocessor based equipment.
9. Before connecting or disconnecting the battery, the
microprocessor switch must be turned OFF.
NOTE: The following T.I.P. Procedures may be found in
Operation and Diagnosis Manual TK 41087.
• Replacing and calibrating the return air and discharge
sensor.
• Replacing the µP-T microprocessor.
• Welding on the unit or truck.
Welding of Units or Truck Bodies
When electric welding is to be performed on any portion of
the temperature control unit, truck or truck chassis when the
temperature control unit is attached, it is necessary to ensure
that welding currents are NOT allowed to flow through the
electronic circuits of the unit.
These procedures must be rigidly adhered to when servicing
units to avoid damage or destruction of the controller.
1. Disconnect all power to the unit.
2. Disconnect all wire harnesses from the controller.
3. Switch all of the electrical circuit breakers in the con-
trol box to the OFF position.
4. Weld unit and/or container per normal welding proce-
dures. Keep ground return electrode as close to the area
to be welded as practical. This will reduce the likeli-
hood of stray welding currents passing through any
electrical or electronic circuits.
5. When the welding operation is completed, the unit
power cables, wiring and circuit breakers must be
restored to their normal condition.
High Voltage
When servicing or repairing a temperature control unit, the
possibility of serious or even fatal injury from electrical
shock exists. Extreme care must be used when working with
a refrigeration unit that is connected to a source of operating
power, even if the unit is not operating. Lethal voltage
potentials can exist at the unit power cord, inside the control
box, at the motors and within the wiring harnesses.
Precautions
1. Be certain the unit On/Off switch is turned OFF before
connecting or disconnecting the standby power plug.
Never attempt to stop the unit by disconnecting the
power plug.
2. Be certain the unit power plug is clean and dry before
connecting it to a power source.
3. When working on high voltage circuits on the tempera-
ture control unit, do not make any rapid moves. If a tool
drops, do not grab for it. People do not contact high
voltage wires on purpose. It occurs from an unplanned
movement.
4. Use tools with insulated handles that are in good condi-
tion. Never hold metal tools in your hand if exposed,
energized conductors are within reach.
5. Treat all wires and connections as high voltage until a
meter and wiring diagram show otherwise.
6. Never work alone on high voltage circuits on the tem-
perature control unit. Another person should always be
present to shut off the temperature control unit and to
provide aid in the event of an accident.
7. Have electrically insulated gloves, cable cutters and
safety glasses available in the immediate vicinity in the
event of an accident.

Safety Precautions (Rev 04/03)
iv
First Aid
IMMEDIATE action must be initiated after a person has
received an electrical shock. Obtain immediate medical
assistance if available.
The source of shock must be immediately removed by
either shutting down the power or removing the victim from
the source. If it is not possible to shut off the power, the
wire should be cut with either an insulated instrument (e.g.,
a wooden handled axe or cable cutters with heavy insulated
handles) or by a rescuer wearing electrically insulated
gloves and safety glasses. Whichever method is used do not
look at the wire while it is being cut. The ensuing flash can
cause burns and blindness.
If the victim must be removed from a live circuit, pull the
victim off with a non-conductive material. Use the victim’s
coat, a rope, wood, or loop your belt around the victim’s leg
or arm and pull the victim off. DO NOT TOUCH the vic-
tim. You can receive a shock from current flowing through
the victim’s body. After separating the victim from the
power source, check immediately for the presence of a pulse
and respiration. If a pulse is not present, start CPR (Car-
diopulmonary Resuscitation) and call for emergency medi-
cal assistance. If a pulse is present, respiration may be
restored by using mouth-to-mouth resuscitation, but call for
emergency medical assistance.
Low Voltage
Control circuits used in the temperature control unit are low
voltage (24 volts ac and 12 volts dc). This voltage potential
is not considered dangerous, but the large amount of current
available (over 30 amperes) can cause severe burns if
shorted or ground.
Do not wear jewelry, watch or rings when working on the
unit. If these items contact an electrical circuit, severe burns
may result.
UNIT DECALS
Serial number decals, refrigerant type decals and warning
decals appear on all Thermo King equipment. These decals
provide information that may be needed to service or repair
the unit. Service technicians should especially read and fol-
low the instructions on all warning decals.
Refrigerant Decal
1. Below the fuel filters, inside the engine
access door.
2. On the evaporator beside the expansion valve.
3. Beside the serial number plate on top of the
unit frame above the switch panel.
4. On the top of the condenser coil.
Refrigerant Decal Locations
AEA1635

Safety Precautions (Rev 04/03)
v
AEA40

Safety Precautions (Rev 04/03)
vi
AEA38

1
Specifications
ENGINE SPECIFICATIONS
Engine TK 3.74
Fuel Type No. 2 Diesel fuel under normal conditions
Oil Capacity: Crankcase & Oil Filter
w/Bypass Oil Filter 9 qt (8.6 liters) 10 qt (9.6 liters)
Fill to full mark on dipstick
Oil Type API Type CF-4, CG-4 or better
API Synthetic Type CF-4, CG-4 or better after first
500 hours
Oil Viscosity* Multi-grade Oil Ambient Temperature F (C)
SAE 5W-30 -22 to +86 F (-30 to +30 C)
SAE 10W-30 -4 to +86 F (-20 to +30 C)
SAE 10W-40 -4 to +104 F (-20 to +40 C)
SAE 15W + 5 F to +140 F (-15 to +40 C)
Engine rpm: Low Speed Operation
High Speed Operation 1625 ± 25 rpm 2425 ± 25 rpm
Engine Oil Pressure 35 to 60 psig (241 to 414 kPa)
Intake Valve Clearance 0.0079 in. (0.20 mm)
Exhaust Valve Clearance 0.0079 in. (0.20 mm)
Valve Setting Temperature Room temperature
Timing Injection Pump 14° BTDC
Injection Nozzle Pressure 1706 psig (11720 kPa)
Low Oil Pressure Sensor 10 ± 3 psig (69 ± 21 kPa)—shutdown
High Coolant Temperature Sensor 220 ± 5.0 F (104.4 ± 2.8 C)—shutdown
Engine Thermostat 180 to 190 F (82.2 to 87.8 C)
Coolant System Capacity 4 quarts (3.81 liters) with overflow tank
Radiator Cap Pressure 10 psig (69 kPa)
Drive Belts to compressor, fans, 12 V alternator, water
pump and electric motor (jackshaft)
*Multi-viscosity weight oil with the recommended API classification may be used based on the ambient
temperature. The above recommendations are written for mineral oil based lubricants.
R-134a REFRIGERATION SYSTEM
Compressor Model X214
Refrigerant Charge 8 lb. 5 oz. (3.77 kg) R-134a
Compressor Oil Charge 66 oz. (1.95 liters)*
Compressor Oil Type: R-134a (Solest 35) TK No. 203-413 (Ester base) required
Suction Pressure Regulator Setting
Special Setting KD-II Single Phase 18 psig (124 kPa) 18 psig (124 kPa)
Heat/Defrost Method:Engine Operation
Electric Operation Hot gas Hot gas and electric heater strips (Model 50)
High Pressure Cutout 325 +25/-0 psig (2088 + 172/0 kPa)
Automatically reset @ 200 ± 20 psig
(1379 ± 138 kPa)

Specifications (Rev. 04/03)
2
R-404A REFRIGERATION SYSTEM
Compressor Model X214
Refrigerant Charge 7.5 lb. (3.4 kg) R-404A
Compressor Oil Charge 66 oz. (1.95 liters)*
Compressor Oil Type: R-404A (Solest 35) TK No. 203-413 (Ester base) required
Suction Pressure Regulator Setting
Special Setting KD-II Single Phase 18 psig (124 kPa) 18 psig (124 kPa)
Heat/Defrost Method:Engine Operation
Electric Operation Hot gas Hot gas and electric heater strips (Model 50)
High Pressure Cutout 470 ± 7 psig (3241 ± 48 kPa)
Automatically reset @ 375 ± 38 psig
(2585 ± 262 kPa)
NOTE: Compressors are equipped with an oil filter. Every 2 years of operation or whenever there is a
major service procedure performed, both the compressor oil filter and filter-drier must be changed.
*When the compressor is removed from the unit, oil level should be noted or the oil removed from the
compressor should be measured so that the same amount of oil can be added before placing the
replacement compressor in the unit.
HIGH PRESSURE RELIEF VALVE
Opens 500 ± 50 psig (3448 ± 345 kPa)
Closes 400 psig (2758 kPa)
ENGINE CLUTCH—HILLIARD (Prior April 1997)
Model TK No. 107-257 (Dwg. No. 5D44655G01)
Engagement 900 ± 100 rpm
Dynamic Torque 66 ft-lb (89.5 N•m) minimum @ 1600 rpm
ENGINE CLUTCH—HILLIARD (Starting April 1997)
Model TK No. 107-272 (Dwg. No. 2C21375G01)
Engagement 600 ± 100 rpm
Dynamic Torque 66 ft-lb (89.5 N•m) minimum @ 1600 rpm
BELT TENSION
Tension No. on TK Gauge 204-427
New Belt Field Reset
Engine/Compressor 75 ± 3 70 ± 3
Compressor/Motor Drive (Jackshaft) 72 ± 3 67 ± 3
Compressor/Evaporator Fan/Alternator 55 ± 3 50 ± 3
Alternator/Evaporator Fan 55 ± 3 50 ± 3
Water Pump 1/2 in. (13 mm) deflection
NOTE: These are the original factory settings. Because it is difficult to use the TK gauge 204-427 in the
field, adjust each belt to allow 1/2 inch (13 mm) deflection at the center of the longest span.
NOTE: Belts should be tensioned cold and again tensioned cold after 10 hours of unit running.

Specifications (Rev. 04/03)
3
ELECTRICAL CONTROL SYSTEM
Control System Voltage 12.5 Vdc
Battery Charging System 12 V 23 amp brush type integral alternator
Voltage Regulator Setting 14 V @ 70 F (21.1 C)
Alternator/Regulator Capacitor 4.7 mfd 50 Vdc
Alternator/Output Capacitor 0.5 mfd 100 Vdc
NOTE: Disconnect components from unit circuit to check resistance.
ELECTRICAL COMPONENTS
Current Draw (Amps) Resistance—
at 12.5 Vdc (Ohms)
Glow Plug 8.3 1.5 ± .15
Fuel Solenoid: Pull In
Hold In 18 to 25 0.5 to 0.7 0.9 to 1.1 11 to 13
Pilot Solenoid 0.657 19
Starter Motor 90 to 105 (cranking)
Damper Solenoid 5.7 2.2
DC Circuit Breakers 50 amp
High Speed Solenoid 5 amp (approx.) 2.5 (approx.)
Electrical Standby Compressor Motors (Model 50 Unit Only)
Voltage/Phase/Frequency Horse- power Kilowatts rpm Full Load (amps)
Locked
Rotor
Amps
Unit Full
Load*
Amps
220/3/50 4.2 3.1 1450 12.7 55 12.7
230/1/60 5 3.7 1750 18 80 25
230/3/60 5 3.7 1750 14.4 58 21
460/3/60 5 3.7 1750 7.2 58 12
380/3/50 4.2 3.1 1450 7.3 55 12
*w/Heater Strips
Electric Heater Strips (Optional): Number
Watts (each) 3 750

Specifications (Rev. 04/03)
4
STANDBY POWER REQUIREMENTS
Supply Circuit Breaker 30 amp/230 V
20 amp/460 V
Extension Cord Size Up to 50 ft—12 gauge
75 ft—10 gauge
AIR SWITCH
Air Switch Setting 0.7 ±.05 in. (17.78 ± 1.3 mm) H2O

5
Maintenance Inspection Schedule
Fuel
Island
Pre-trip
Every
750
Hours
Annual/
3,000
Hours
Maintenance interval may be extended to 1000 hours when
equipped with bypass oil filter.
Inspect/Service These Items
ENGINE
•Check engine oil level.
•Check radiator coolant. (CAUTION: DO NOT remove radiator cap
while coolant is hot.)
•Inspect belts for condition and proper tension (belt tension tool No.
204-427).
•Check engine oil pressure hot, on high speed. Record psig.
•••
Listen for unusual noises, vibrations, etc.
•Change engine oil and filters (hot).
•Change oil bath air cleaner element, replace dry type element, clean
and service crankcase breather, and check air cleaner hose for
damage.
•Change fuel filter.
•Drain water from fuel tank and check vent.
•Inspect/clean electric fuel pump filter.
•Change engine coolant every two years. Maintain year around anti-
freeze protection at -30 F (-34 C).
•Check and adjust engine speeds (high and low speed).
•Check condition of engine mounts.
ELECTRICAL
•Check unit charging voltage (14 volts nominal)
•Check defrost initiation and termination.
•Inspect battery terminals and electrolyte level.
•Check operation of protection shutdown circuits.
•Check µP-T sensor calibration in 32 F (0 C) ice water bath.
•Inspect wire harness for damaged wires or connections.
•Check air switch setting.
•Inspect electric motor bearings.*
•Inspect electrical contacts for pitting or corrosion.
•Inspect DC (battery charging) alternator bearings and brushes.*
*With belt removed, spin bearings by hand. Listen for noise (bearings roll freely).

Maintenance Inspection Schedule (Rev. 04/03)
6
REFRIGERATION
•Check refrigerant level and compressor oil condition.
•Check suction pressure regulator regulating pressure on defrost or
heating cycle.
•Replace dehydrator (every two years) and check discharge and
suction pressures.
STRUCTURAL
•Visually inspect unit for fluid leaks (coolant, oil, freon).
•Visually inspect unit for damaged, loose or broken parts (includes air
ducts and bulkheads, if so equipped).
•Inspect tapered roller bearing fanshaft and idler for leakage and
bearing wear (noisy).*
•Clean entire unit including condenser and evaporator coils and
defrost drains.
•Check all unit, fuel tank and electric motor mounting bolts, brackets,
lines, hoses, etc.
•Check damper door adjustment and operation.
•Inspect clutch.*
*With belt removed, spin bearings by hand. Listen for noise (bearings roll freely).
NOTE: Compressors are equipped with an oil filter. Every 2 years of operation or whenever there is a
major service procedure performed, both the compressor oil filter and filter-drier must be changed.
Fuel
Island
Pre-trip
Every
750
Hours
Annual/
3,000
Hours
Maintenance interval may be extended to 1000 hours when
equipped with bypass oil filter.
Inspect/Service These Items