Thermo King RD-II SR 30 User manual

RD-II SR
TK 41131-1-MM (Rev. 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:
RD-II SR 30 (088669) RD-II SR 50 230/3/60 EEC (088673)
RD-II SR 50 230/3/60 (088670) RD-II SR 50 220/3/50 EEC (088674)
RD-II SR 50 380-460/3/50-6 (088671) RD-II SR 50 380/3/50 EEC (088675)
RD-II SR 30 EEC (088672)
For further information, refer to…
Thermoguard µP-T Microprocessor Controller TK 41087
RD-II SR Parts Manual TK 41126
Operator’s Manual TK 41102
Diagnosing Thermo King Refrigeration Systems TK 5984
Refrigeration Systems TK 5715
Tool Catalog TK 5955
X426 and X430 Compressor Overhaul TK 6875
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. For detailed descriptions of Thermo King engines, compressors, or
refrigeration systems, see the appropriate Thermo King Overhaul Manual or Refrigeration Systems Maintenance
Manual.
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 the 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 environment and limit the potential harm to the
ozone layer that can result from allowing refrigerant
to escape into the atmosphere.
We strictly adhere to a policy that promotes the
recovery and limits the loss of refrigerant into the
atmosphere.
In addition, service personnel must be aware of
Federal regulations concerning the use of refriger-
ants and the certification of technicians. For addi-
tional information on regulations and technician
certification programs, contact your local THERMO
KING dealer.

Table of Contents
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
Maintenance Inspection Schedule. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Unit Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Unit Instruments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Unit Protection Devices. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Unit Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Pre-trip Inspection (Before Starting Unit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Selection of Operating Modes on CYCLE-SENTRY Equipped Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Restarting the Unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
After Start Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Loading Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Post Load Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Post Trip Checks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
µP-T System Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
General Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
µP-T Control System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
Microprocessor Power Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
Optional Electric Standby (Model 50 Units Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
Optional Model 50 Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
Standard Model 50 Features. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
Remote Control Panel Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
µp-T Alarms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
µP-T Unit Self Check Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
Electrical Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
Service Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
Alternator With Integral Regulator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
Charging System Diagnostic Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
Excessive Voltage Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
12V Alternators With Internal Regular Setting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
Battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
Unit Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
Electrical Contacts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
Charging System (12 Vdc) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
Preheat Buzzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
RPM Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
Glow Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
Condenser/Evaporator Fan Rotation (Electric Standby Operation) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
Defrost Air Switch Checkout and Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
High Capacity TherMax™ Heating System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38

Table of Contents (Continued)
Engine Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Engine Lubrication System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Crankcase Breather. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Engine Air Cleaner. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Engine Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Antifreeze Maintenance Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Engine Fuel System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Bleeding the Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Fuel Filter Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Electric Fuel Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Injection Pump Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Timing the Injection Pump to the Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Adjust Engine Valve Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Fuel Limit Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Engine Mounts for RD-II SR Unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
RD-II Idler Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Auto Start/Stop. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
TK 3.95 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Fuel Solenoid Diagnostic and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Engine Speed Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Integral Fuel Solenoid Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Refrigeration Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
System Evacuation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Evacuation is Important and is Critical to System Performance! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Set Up and Test of Evacuation Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Unit Evacuation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Unit Charging. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Refrigerant Leaks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Remove Evacuation Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Checking Compressor Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Compressor Pump Down and Checkout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
High Pressure Cutout. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Three-way Valve Condenser Pressure Bypass Check Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

Table of Contents (Continued)
Refrigeration Service Operations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .73
Accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .73
Compressor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .73
Condenser/Radiator Coil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74
Liquid Line Check Valve Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74
Dehydrator (Filter-Drier) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74
Evaporator Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75
Expansion Valve Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75
Heat Exchanger. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .76
High Pressure Cutout Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .77
High Pressure Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .77
Pilot Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .77
Pressure Regulator Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .78
Receiver Tank. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .78
Three-way Valve Condenser Pressure Bypass Check Valve Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .78
Three-way Valve Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .79
R-134a and R-404A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .81
Equipment Recommendations for use with R-134a and R-404A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .82
Refrigerant Recovery System—THE COLLECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85
Throttling Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .86
Hilliard Clutch Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .89
Structural Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93
Unit and Engine Mounting Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93
Unit Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93
Evaporator Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93
Condenser Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93
Fan Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93
Defrost Damper. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .94
Jackshaft Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .95
FanShaft Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .96
Fanshaft Assembly Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .96
RD-II SR Idler Pulley Seal Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .100
Mechanical Diagnosis. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .102
Electric Standby (Optional) Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .107
Refrigeration Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .109
Cool Cycle—RD-II SR with TherMax™ Heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .111
Condenser Cycle—RD-II SR with TherMax™ Heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .112
Heat and Defrost Cycle—RD-II SR with TherMax™ Heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .113
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .115

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.
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 automati-
cally in both CYCLE-SENTRY mode and Continuous
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
Avoid refrigeration oil contact with the eyes. Avoid pro-
longed or repeated contact of refrigeration oil with skin or
clothing. Wash thoroughly after handling refrigeration oil to
prevent irritation.
First Aid
In case of eye contact, immediately flush with plenty of
water for at least 15 minutes. Wash skin with soap and
water. CALL A PHYSICIAN.
ELECTRICAL HAZARDS
High Voltage
Units with optional Electric Standby utilize 460, 380 or 230
volt, 3 phase or 230 volt single phase AC power any time
the unit is operating in Electric mode. This voltage potential
is also present any time the unit is connected to standby
power. Extreme care must be used when working on the
unit, as these voltages are capable of causing serious injury
or death.
Precautions
1. When working on high voltage circuits on the refrigera-
tion 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 move-
ment.
2. Use tools with insulated handles that are in good condi-
tion. Never hold metal tools in your hand if exposed,
high voltage conductors are within reach.
3. Treat all wires and connections as high voltage until a
meter and wiring diagram show otherwise.
4. Never work alone on high voltage circuits on the refrig-
eration unit, another person should always be standing
by in the event of an accident to shut off the refrigera-
tion unit and to aid a victim.
First Aid
IMMEDIATE action must be initiated after a person has
received an electrical shock. Obtain immediate medical
assistance if available.
The source of electricity 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 (Cardio
Pulmonary Resuscitation) and call for emergency medical
assistance. If a pulse is present, respiration may be restored
by using mouth-to-mouth resuscitation, but call for emer-
gency medical assistance.

Safety Precautions (Rev. 04/03)
iii
Low Voltage
Control circuits used in the refrigeration unit are low volt-
age (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.
µP-T MICROPROCESSOR CAUTIONS
The following procedures may not be readily apparent, but
must be followed when working on units equipped with
µP-T microprocessors.
• Precautions must be taken to prevent electrostatic dis-
charge when servicing the microprocessor and related
components. A potential difference less than that
required to produce a small spark between a finger and
a doorknob can cause severe damage to solid state com-
ponents. Refer to the Thermoguard µP-IV Micropro-
cessor Controller Operations and Diagnosis Manual
(TK 41087) (T.I.P. Procedure #P41AA12B) and the
Electrostatic Discharge Training Guide (TK 40282) for
additional information.
• Never use testers consisting of a battery and a light bulb
to test circuits on any microprocessor based equipment.
• 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.

Safety Precautions (Rev. 04/03)
iv
PUB126

Safety Precautions (Rev. 04/03)
v
aea105

1
Specifications
ENGINE SPECIFICATIONS
Engine TK 3.95
Fuel Type No. 2 Diesel fuel under normal conditions
No. 1 Diesel fuel is acceptable cold weather fuel
Oil Capacity: Crankcase & Oil Filter
w/Bypass Oil Filter 12 quarts (11 liters) 13 quarts (12.3 liters)
Fill to full mark on dipstick
Oil Type API Type CD-SD
API Synthetic Type CD after first 500 hours
Oil Viscosity* Above 80 F (27 C): SAE 40
50 to 90 F (10 to 32 C): SAE 30
20 to 70 F (-7 to 21 C): SAE 20-20W
-15 to 40 F (-26 to 4 C): SAE 10W
Below 0 F (-18 C) continuously: SAE 5W
Engine rpm: Low Speed Operation
High Speed Operation 1600 rpm 2400 rpm
Engine Oil Pressure 35 to 60 psig (241 to 414 kPa)
Intake Valve Clearance .0079 in. (0.20 mm)
Exhaust Valve Clearance .0079 in. (0.20 mm)
Valve Setting Temperature Room temperature
Timing Injection Pump 14° BTDC
Injection Nozzle Pressure 1700 psig (11722 kPa)
Low Oil Pressure Sensor 10 ± 2 psig (69 ± 21 kPa)—shutdown
High Coolant Temperature Sensor 220 ± 5 F (100.4 ± 2.8 C)—shutdown
Engine Thermostat 180 F (82.2 C)
Coolant System Capacity 4.8 quarts (4.5 liters) with overflow tank
Radiator Cap Pressure 7 psig (48 kPa)
*Multi-viscosity weight oil with the recommended API classification may be used based on the ambient
temperature and straight weight viscosity recommendations above. The above recommendations are
written for mineral oil based lubricants.
BELT TENSION
Tension No. on TK Gauge 204-427
Engine/Compressor 70 to 80
Compressor/Jackshaft (Electric Motor) 64 to 70
Compressor/Evaporator Fan/Alternator 1/2 in. (13 mm) deflection
Alternator/Evaporator Fan 1/2 in. (13 mm) deflection
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)
2
R-134A REFRIGERATION SYSTEM
Compressor Model X426
Refrigerant Charge 9 lb. (4.1 kg) R-134a
Compressor Oil Charge 4 qt. 6 oz. (3.9 liters)*
Compressor Oil Type: R-134a (Solest 35) TK No. 203-413 (Ester base) required
Throttling Valve Setting 18 to 20 psig (124 to 138 kPa)
Heat/Defrost Method: Engine Operation
Electric Operation Hot gas Hot gas and optional electric heater strips (Model 50)
High Pressure Cutout 325 +25/-0 psig (2088 + 172/0 kPa)
Automatically reset @ 200 ± 20 psig
(1379 ± 138 kPa)
R-404A REFRIGERATION SYSTEM
Compressor Model X426
Refrigerant Charge 8 lb. (3.63 kg) R-404A
Compressor Oil Charge 4 qt 6 oz. (3.9 liters)*
Compressor Oil Type (Solest 35) TK 203-413 (Ester required)
Throttle Valve Setting 18 to 20 psig (124 to 138 kPa)
Heat/Defrost Method: Engine Operation
Electric Operation Hot gas Hot gas and optional electric heater strips (Model 50)
High Pressure Cutout 470 ± 7 psig (3241 ± 48 kPa)
Automatically reset @ 375 ± 38 psig
(2585 ± 262 kPa)
*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.
ENGINE CLUTCH—HILLIARD
Model TK No. 107-257 (Dwg. No. 5D44655G01)
Engagement 900 ± 100 rpm
Dynamic Torque 66 ft-lb (89.5 N•m) minimum @ 1600 rpm
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 .5 mfd 100 Vdc
NOTE: Disconnect components from unit circuit to check resistance.

Specifications (Rev. 04/03)
3
ELECTRICAL COMPONENTS
Current Draw (Amps) Resistance—
at 12.5 Vdc (Ohms)
Glow Plug 8.3 1.5 ± .15
Fuel Solenoid: Pull In
Hold In 30 to 40 .41 to.31 .97 12.8
Pilot Solenoid .657 19
Starter Motor 90 to 105 (cranking)
Damper Solenoid 5.7 2.2
DC Circuit Breakers 50 amp
20 amp
High Speed Solenoid 5 amp (approx) 2.5 (approx.)
Electrical Standby (Model 50 Unit Only)
Electric Motor:
Voltage/Phase/Frequency Horsepower Kilowatts rpm Full Load (amps)
Locked
Rotor
Amps
230/3/60 7.5 5.6 1765 21.2 70.1
460/3/60 7.5 5.6 1765 10.6 35.0
200/3/50 6.25 4.7 1465 21.4 65.5
380/3/50 6.25 4.7 1465 10.7 32.8
Electric Heater Strips (Optional): Number
Watts (each) 3 750
Resistance (each cold and disconnected) 67.5 ohms
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 .9 ±.05 in. (22.7 ± 1.27 mm) H2O

4
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)
5
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

6
Unit Description
The RD-II SR is a microprocessor based transport tempera-
ture control system, which utilizes the Thermoguard µP-T
microcontroller to manage most of the system’s functions.
The RD-II SR is a one-piece, front-mount, medium capacity
diesel powered cooling and heating system designed espe-
cially for straight trucks. The unit mounts on the front of a
truck with the evaporator portion protruding into the box.
Designed for use with totally chlorine free R-404A refriger-
ant. An optional R-134a unit is also available. There are two
basic models:
• RD-II SR 30: Cooling and heating on engine operation.
• RD-II SR 50: Cooling and hot gas heating on engine
operation and electric standby electric evaporator heat-
ers are optional.
Power is provided by the TK 3.95 three-cylinder, special
clean and silent diesel engine rated at 17.0 continuous
horsepower at 2400 rpm. A belt drive system transfers
energy to the compressor, unit fans and alternator.
Electric standby power (Model 50) is provided by a 5 horse-
power electric motor. A clutch on the diesel engine isolates
the engine during electric standby operation.
Belt driven, dual evaporator fans provide superior air throw.
Exclusive space condenser provides maximum cab clear-
ance and reduced truck body height on conventional chas-
sis. Cube saver evaporator optimizes space below the
evaporator for all types of cargo. Lightweight aluminum
frame allows increased payload.
The continuous monitoring function of the µP-T micropro-
cessor optimizes the Thermo King unit’s performance,
thereby reducing fuel consumption and unit down time. The
unit’s self check can be run before the daily distribution
route to identify any possible malfunctions. TherMax™
defrost/heating system increases unit heating capacity for
faster defrost.
The built-in CYCLE-SENTRY, an exclusive Thermo King
feature, automatically starts and stops the unit according to
temperature demands. In addition, a range of programmable
modes, like high speed pull-down, allow you to tailor your
unit’s performance to the load you are distributing.
The RD-II SR’s µP-T microprocessor continually monitors
unit performance and makes adjustments to pre-pro-
grammed parameters automatically. Troubleshooting is
simplified with 40 built-in alarm codes to alert the driver to
take corrective action before a problem develops. Diagnosis
is fast and complete.
The clutch engages fully at 900 ± 100 rpm on engine opera-
tion, constantly turning the compressor and fans at both
high and low speed.
Thermo King X426 Compressor
The RD-II SR unit features a Thermo King X426, four-
cylinder compressor with 25.9 in.3(424 cm3) displacement.
The features of the RD-II SR truck are as follows:
• µP-T Control System
• Choice of Installation for Control Box
• 5 Wire Remote Control (In-Cab or Truck Body Mount)
•AlertSystem
• Oil Level Detection
• CYCLE-SENTRY (Built-in as Standard)
• Return Temperature Sensor and Display
• Discharge Air Temperature Sensor and Display
• Coil Temperature Sensor
• Engine Coolant Temperature Sensor and Display
• Engine Tachometer Display
• Battery Voltage Display
• Phase Lockout (Model 50)
• Phase Correction (Optional, Model 50 Only)