TK 60690-3-MM X500 Rev.0.1 Print Date 2011-02-28

X-series HVAC System
X500 Cooling
X500 Heating & Cooling
Maintenance Manual
TK 60690-3-MM Revision 0.1 (Print Date: February 28, 2011)
Copyright © 2011 Ingersoll Rand Corporation, Thermo King

Electronically Printed in Czech Republic
1
The maintenance information in this manual covers unit model:
X500 N - 1000, 24V 901717
X500 W - 1000, 24V 901719
X500 N - 1004, 24V 901718
X500 W - 1004, 24V 901721
For further information, refer to:

X500 Parts Manual TK 60680
Stocking Guide X500 N - 1000, 24V, 901717 TK 60673
Stocking Guide X500 W - 1000, 24V, 901719 TK 60675
Stocking Guide X500 N - 1004, 24V, 901718 TK 60674
Stocking Guide X500 W - 1004, 24V, 901721 TK 60676
ClimaAIRE ID Service Manual TK 60020
Evacuation Station Operation and Field Application TK 40612
Silver Brazing and Soft Soldering TK 7949
Tool Catalog TK 5955
Transport Temperature Control Systems TK 50951
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, Ingersoll Rand / Thermo King Corporation should be consulted. The above manuals
may be purchased from your local Thermo King dealer.
Sale of product shown in this manual is subject to Thermo King’s terms and conditions
including, but not limited to, the Thermo King Limited Express Warranty. Such terms and
conditions are available upon request. Thermo King’s warranty will not apply to any equipment
which has been “so repaired or altered outside the manufacturer’s plants as, in the
manufacturer’s judgment, to effect its stability.”
No warranties, express or implied, including warranties of fitness for a particular purpose or

merchantability, or warranties arising from course of dealing or usage of trade, are made
regarding the information, recommendations, and descriptions contained herein. Manufacturer
is not responsible and will not be held liable in contract or in tort (including negligence) for any
special, indirect or consequential damages, including injury or damage caused to vehicles,
contents or persons, by reason of the installation of any Thermo King product or its
mechanical failure.
2
Recover Refrigerant
At Thermo King, we recognize the need to preserve the environment and limit
the potential harm to the ozone layer that can result from allowing refrigerant to
escape into the atmosphere.
We strictly adhere to a policy that promotes the recovery and limits the loss of
refrigerant into the atmosphere.
In addition, service personnel must be aware of Federal regulations concerning
the use of refrigerants and the certification of technicians. For additional
information on regulations and technician certification programs, contact your
local THERMO KING dealer.
R-134a
WARNING: Use only Polyol Ester-based refrigeration compressor oil in R-134a.
See Thermo King Parts Manual for part number.
Do not mix Polyol Ester and standard synthetic compressor oils. Keep
Polyol Ester compressor oil in tightly sealed containers. If Polyol Ester
oil becomes contaminated with moisture or standard oils, dispose of
properly – DO NOT USE.
When servicing Thermo King R-134a unit, use only those service tools
certified for and dedicated to R-134a refrigerant and Polyol Ester
compressor oils. Residual non-HFC refrigerants or oils will
contaminate R-134a systems.
3
1. About This Manual
Purpose
The purpose of this manual is to provide general maintenance information necessary to operate and
maintain the climate control unit (HVAC unit, A/C unit) at peak operating standards and best lifetime.
This includes safety information, unit information such as technical specification, general unit
description, maintenance procedures and some diagnostic and troubleshooting information.
Before you call Thermo King Service

Before you call Thermo King Service, have the following information on hand (for exact data see serial
plate on your unit):
 Unit type (commonly typed on serial plate after code DESC)
 System or Model number (commonly coded on serial plate after code ITEM)
System number has usually six digits format (example 901902)
Model number is the same as System number but with M letter at the end (example 901902M)
 Serial number
Who to call: your Thermo King Dealer Representative or Thermo King Service Center.
Blank Pages
This manual may contain blank pages at the end of chapters. This is normal. There is no information
missing from the manual.
Roadside/Curbside Terminology
Roadside/Curbside terminology: These terms can be confusing because of differences between North
America and Europe. Please note:
 Curbside: The side of the bus to the driver right when the driver is in his seat and facing
forward.
 Roadside: The side of the bus to the driver left when the driver is in his seat and facing forward.
4
2. Table of Contents
1. About This Manual ...................................................................................................................................4
2. Table of Contents.....................................................................................................................................5
3. List of Figures ..........................................................................................................................................7
4. List of Abbreviations................................................................................................................................8
5. Safety Precautions...................................................................................................................................9
5.1. General Practices ...........................................................................................................................9
5.2. Electrical Hazards.........................................................................................................................10
5.3. Refrigerant Hazards......................................................................................................................11
5.4. Compressor Oil Hazards...............................................................................................................12
5.5. First Aid ........................................................................................................................................13
6. System Description................................................................................................................................14
7. Specifications.........................................................................................................................................15
7.1. HVAC System...............................................................................................................................15
7.2. Electrical System ..........................................................................................................................16
7.3. Compressor (Optional)..................................................................................................................17
7.4. Weight and dimensions.................................................................................................................18
8. Rooftop Unit Description .......................................................................................................................19

8.1. General description.......................................................................................................................19
8.2. Main parts of rooftop units.............................................................................................................20
8.3. Photos and Illustrations.................................................................................................................23
9. Compressor Description........................................................................................................................25
9.1. General description.......................................................................................................................25
9.2. TM compressors ...........................................................................................................................25
9.3. Small Compressor Oil Charge Specifications - R134a ...................................................................26
10. Operating Instructions ........................................................................................................................27

10.1. Basic A/C System - Theory of Operation .......................................................................................27
10.2. Control System .............................................................................................................................29
10.3. ClimaAIRE ID and ClimaAIRE II....................................................................................................30
10.4. ClimaAIRE ID controller ................................................................................................................30
10.5. Inspection Recommendations .......................................................................................................46
10.6. Maintenance Inspection Schedule.................................................................................................47
10.7. Special Tools, Equipments and Supplies.......................................................................................49
10.8. Tightening Torque Requirements ..................................................................................................50
11. Refrigeration System Maintenance.....................................................................................................52

11.1. Service Tools................................................................................................................................53
11.2. Contamination ..............................................................................................................................54
11.3. Compressor Oil Color Code ..........................................................................................................55
11.4. Refrigerant Recovery....................................................................................................................55
11.5. Refrigerant Leak Test Procedure ..................................................................................................56
11.6. Evacuation....................................................................................................................................57
11.7. System Charging from an Evacuated Condition ............................................................................61
11.8. Using Pressurized Nitrogen...........................................................................................................61
12. Refrigeration/Heating Repairs ............................................................................................................63
5
12.1. Filter-Drier Replacement...............................................................................................................63
12.2. Thermostatic Expansion Valve Replacement ................................................................................64
12.3. Pressure Switches Replacement ..................................................................................................68
12.4. Relief Valve Replacement.............................................................................................................69
13. Electrical Maintenance & Repairs.......................................................................................................70

13.1. Relays and fuses replacement ......................................................................................................70
13.2. Evaporator Blower Replacement...................................................................................................72
13.3. Condenser Fan Replacement .......................................................................................................73
13.4. Fresh Air Damper Motor Replacement ..........................................................................................75
13.5. Ambient Temperature Sensor Replacement..................................................................................76
14. Mechanical Maintenance & Repairs ...................................................................................................78

14.1. Unit Maintenance..........................................................................................................................78
14.2. Cleaning.......................................................................................................................................78
14.3. Fresh Air Filter Replacement ........................................................................................................79
14.4. Return Air Filter Replacement.......................................................................................................80
14.5. Coil Air Filter Replacement ........................................................................................................81
15. Troubleshooting..................................................................................................................................82
15.1. Air Conditioning Diagnosis and Analysis .......................................................................................82
15.2. Causes for Failure to Stay Within Temperature Range..................................................................83
15.3. Compressor suction pressure conditions.......................................................................................85
15.4. Compressor discharge pressure conditions...................................................................................86
16. Temperature-Pressure Chart ..............................................................................................................87
17. Index ....................................................................................................................................................89
18. Schemes, Diagrams and Drawings Index...........................................................................................91
19. Appendix .............................................................................................................................................92
6
3. List of Figures
Figure 1: X500 Unit dimensions .................................................................................................................... 18
Figure 2: X500 Rooftop unit .......................................................................................................................... 19
Figure 3: X500 Outside view......................................................................................................................... 23
Figure 4: X500 Inside view............................................................................................................................ 24
Figure 5: TM compressors (Illustration photo) ............................................................................................... 25
Figure 6: A/C refrigeration system (example) ................................................................................................ 27
Figure 7: Application diagram ....................................................................................................................... 29
Figure 8: CAID Driver panel.......................................................................................................................... 30
Figure 9: CAID Keys in Setup/Calibration/Test mode .................................................................................... 34
Figure 10: CAID Function menu structure ................................................................................................... 34
Figure 11: CAID List of functions................................................................................................................. 35
Figure 12: CAID Test mode 1 - Cooling/Heating control .............................................................................. 35
Figure 13: CAID Test mode 1- Blower control ............................................................................................. 35
Figure 14: CAID Test mode 1- Fresh air control .......................................................................................... 36
Figure 15: CAID Scheme of relay test procedure ........................................................................................ 36
Figure 16: CAID List of calibrations............................................................................................................. 37
Figure 17: CAID Calibration function structure............................................................................................. 38
Figure 18: CAID Setup function structure .................................................................................................... 39
Figure 19: CAID Controller parameters ....................................................................................................... 40
Figure 20: CAID Scheme of hourmeter ....................................................................................................... 42
Figure 21: CAID List of alarm codes............................................................................................................ 44
Figure 22: CAID Driver panel connectors .................................................................................................... 44
Figure 23: CAID List of inputs ..................................................................................................................... 45
Figure 24: CAID List of outputs ................................................................................................................... 45
Figure 25: Special Tools ............................................................................................................................. 49
Figure 26: Testing for Refrigeration Leaks .................................................................................................. 56
Figure 27: Evacuation Station and Unit Hookup (example).......................................................................... 58
Figure 28: Constant Pressure Rise After Evacuation Indicates System Leak............................................... 59
Figure 29: Pressure Rise that Levels Off After Evacuation Indicates Moisture in System ............................. 60
Figure 30: Typical pressurized gas bottle with pressure regulator and gauges............................................. 62
Figure 31: Filter-Drier Installation (example)................................................................................................ 63
Figure 32: Thermostatic expansion valve installation (example) .................................................................. 64
Figure 33: Example of solder type valve and sensor bulb position ............................................................... 65
Figure 34: Pressure switches installation (example) .................................................................................... 68
Figure 35: Electrical switchboard (example)................................................................................................ 70
Figure 36: Fuse extractor............................................................................................................................ 71
Figure 37: Evaporator blower installation (example) .................................................................................... 72
Figure 38: Condenser fan assembly (example) ........................................................................................... 73
Figure 39: Condenser fan (example)........................................................................................................... 74
Figure 40: Damper Connector Plug Wiring Diagram.................................................................................... 75
Figure 41: Fresh Air Damper Motor............................................................................................................. 76
Figure 42: Ambient temperature sensor (example)...................................................................................... 77
Figure 43: Fresh air filter (example) ............................................................................................................ 79
Figure 44: Return air filter (example)........................................................................................................... 80
Figure 45: Coil Air filter installation (illustrative picture)................................................................................ 81
Figure 46: Typical Operating Pressures ...................................................................................................... 82
7
4. List of Abbreviations
The following abbreviations are used in the text and in the drawings in appendix too.
A/C Air Conditioning HTS HTS: Heating water temperature

ALT Alternator HVAC Heating, Ventilation and Air
Conditioning
ATS Ambient Temperature (Sensor) HV Hand (shut-off) valve
BP Boost Pump IND Indicator, Liquid
BPR Boost Pump Relay LPCO Low Pressure Cutout Switch
CAID ClimaAIRE ID driver panel LV Low Voltage (see “Specifications”)
CAII ClimaAIRE II driver panel PWR Power Supply
CFM Condenser Fan Motor PWM Pulse Width Modulation
CFR Condenser Fan Relay RPM Routines per minute
CL Clutch RT Receiver tank
CPS Condenser Pressure Switch RTS Return Air Temperature Sensor
CR Compressor RV Relief valve (safety relief valve)
CTS Evaporator Coil Temperature (Sensor) SG Sight glass
DM Damper Motor (Fresh air damper
SM Servo motor
servomotor
DTS Duct (Damper) Air Temperature SP, SPc Set point
DVE Discharge Vibration Eliminator SRV SafetyRelief Valve
ECM Electronic Control Module SV Solenoid Valve, Liquid Line
EFM Evaporator Fan Motor TXV Thermostatic Expansion Valve
EFR Evaporator Fan Relay
EFRL Evap. Fan Relay - Low speed
EFRH Evap. Fan Relay - High speed
EFRM Evap. Fan Relay - Mid speed
F1 Fuse, Low Voltage
FADM Fresh Air Damper (Motor)
FD Filter-drier
FTS Fresh Air Temperature
HPCO High Pressure Cutout Switch
8
5. Safety Precautions
Thermo King recommends that all services be performed by a Thermo King dealer. However, you
should be aware of several general safety practices:
The exclamation symbol appears next to a point that is particularly important.
DANGER: Denotes the possibility of serious injury or death.
WARNING: Denotes the possibility of serious equipment damage or serious personal

injury.
CAUTION: Denotes the possibility of minor to severe equipment damage or personal

injury.
5.1. General Practices
WARNING: Before any repair or similar action the side covers must be completely
removed from the unit to access interior of unit. Insure you are using best practice for
working at height paying special attention during removal of cover as it could move
due to the influence of the wind.
DANGER: Do not operate the compressor with the discharge valve closed. This
condition increases internal pressure, which can cause an explosion
DANGER: Never apply heat to a sealed refrigeration system or container. Heat

increases internal pressure, which will cause an explosion.
DANGER: Refrigerant in the presence of an open flame, spark or electrical short

produces toxic gases that are severe respiratory irritants.
DANGER: Keep your hands, clothing and tools clear of fans, pulleys, or belts when
working on a unit that is running. Loose clothing might entangle moving fans, pulleys,
or belts, causing serious injury or possible death.
DANGER: Do not inhale refrigerant. Use caution when working with refrigerant or
a refrigeration system in any confined area with a limited air supply, such as a bus or
garage. Refrigerant displaces air and can cause oxygen depletion, resulting in
suffocation and possible death
WARNING: Make sure your gauge manifold hoses are in good condition before
using them. Never let them come in contact with moving belts, motors, pulleys or hot
surfaces. Defective gauge equipment can damage components or cause serious injury.
WARNING: Wear goggles or safety glasses when working around air conditioning
systems or batteries. Refrigerant liquid, oil and battery acid can permanently damage
your eyes.
9
WARNING: Use extreme caution when drilling. Holes might weaken structural
components. Holes drilled into electrical wiring can cause a fire or explosion.
WARNING: Exposed coil fins can cause lacerations. Service work on the evaporator
or condenser coils is best left to a certified Thermo King technician.
WARNING: Be careful when using ladders or scaffolding to install or service air

conditioning systems. A work platform is recommended for servicing rooftop units.
Follow the manufacturer's instructions, safety labels and warnings.
CAUTION: Make sure all mounting bolts are tight and are the correct length for
their applications. Improper torque and incorrect bolt lengths can damage equipment.
CAUTION: If soldering is required, use dry nitrogen to purge the system during any
solder operations. Refer to “Using Pressurized Nitrogen” at the end of the
Refrigeration Maintenance chapter
5.2. Electrical Hazards
DANGER: Any time anybody entering the roof must be sure, that the main power
lines are OFF and nobody can switch it on if somebody is on the roof.
When servicing or repairing an air conditioning unit, the possibility of serious or even fatal injury from
electrical shock exists. Extreme care must be used when working with a air conditioning unit that is
connected to a source of operating power, even if the unit is not running. Lethal voltage potentials can
exist at the unit power cord, inside the electric switchboard box, at the motors, at any junction box and
within the wiring harnesses.
Precautions
 Always turn the A/C Unit OFF. Then disconnect the unit from the primary power source (power
supply) before attempting repair or replacement of major components.
 Use tools with insulated handles. Use tools that are in good condition. Never hold metal tools in
your hand if exposed, energized conductors are within reach.
 Do not make any rapid moves when working with high voltage circuits. Do not grab a falling
tool or other object. People do not contact high voltage wires on purpose. It occurs from an
unplanned movement.
 Treat all wires and connections as high voltage until ammeter and wiring diagram show
otherwise.
 Never work alone on high voltage circuits on the refrigeration unit. Another person should
always be standing by in the event of an accident to shut OFF the refrigeration unit and to aid a
victim.
 Have electrically insulated gloves, cable cutters and safety glasses available in the immediate
vicinity in the event of an accident.
10
WARNING: Control circuits used by air conditioners are low voltage (24 VDC for
example). This voltage is not dangerous, but the large amount of amperage available
from the alternator will cause severe burns if accidentally shorted to ground with metal
objects, such as tools.
WARNING: Do not wear jewelry, watches or rings because they increase the risk of
shorting out electrical circuits and damaging equipment or causing severe burns
WARNING: Use caution when working with electrical circuits that have capacitors.
Some capacitors hold a significant charge that will cause burns or shocks if
accidentally discharged. Make sure capacitors are discharged before working on
electrical circuits.
CAUTION: When working with electrical circuits that contain microprocessors,

always wear an ESD wrist strap (TK No. 204-622) and connect the opposite end to the
chassis ground or CH terminal. This precaution will prevent electrostatic discharge
from damaging circuits.
CAUTION: Certain service procedures on air conditioning equipment require that

the system be de-energized. When this precaution is necessary, ensure the battery’s
master switch or service switch is turned OFF. Confirm that power has been removed
before servicing. Equipment that is connected to power is dangerous to service.
5.3. Refrigerant Hazards
DANGER: Do not use a Halide torch. When a flame comes in contact with
refrigerant, toxic gases are produced that will cause suffocation, even death
DANGER: Store refrigerant in proper containers, out of direct sunlight and away
from intense heat. Heat increases pressure inside storage containers, which will cause
them to burst.
DANGER: Do not use oxygen (O2) or compressed air for leak testing systems.
Oxygen mixed with refrigerant is combustible.
WARNING: Wear protective garments and goggles or safety glasses when working
with refrigerant to prevent frostbite and eye injuries.
WARNING: Wear butyl lined gloves when handling refrigerant to help prevent
frostbite.
CAUTION: All charging using the newer refrigerants (Azeotropic blends) must be
done in liquid state. Failure to do this will decrease system operating efficiency. Refer
to the charging procedures found in this manual for your unit
CAUTION: When recovering or transferring refrigerant, use a process that prevents
11
refrigerant from escaping into the atmosphere. Refrigerant damages the earth’s upper
ozone layer.
CAUTION: Refrigerant in a liquid state evaporates rapidly when exposed to the

atmosphere, freezing anything it contacts. Be careful when handling refrigerant to
protect your skin from frostbite.
5.4. Compressor Oil Hazards
WARNING: Protect your eyes from contact with compressor oil. The oil will cause
serious eye injuries. Avoid prolonged or repeated contact with compressor oil. To
prevent irritation, wash your hands and clothing thoroughly after handling the oil.
CAUTION: Do not mix compressor oils because that will cause system damage.
CAUTION: Use dedicated equipment to prevent contaminating the system with the
wrong type of oil or refrigerant.
CAUTION: Thermo King uses a variety of compressor oils. Oil used in the system
must be verified. Check “Specification” chapter in this manual for correct oil. Using
incorrect oil will invalidate the warranty.
CAUTION: When servicing TK units, do not use equipment that might be

contaminated with PAG oils.
CAUTION: Store compressor oil in an approved sealed container to avoid moisture

contamination.
CAUTION: Do not expose compressor oil to the air any longer than necessary. The
oil will absorb moisture, which results in much longer evacuation times and possible
system contamination.
CAUTION: Wipe up spills immediately. Compressor oil can damage paints and
rubber materials.
12
5.5. First Aid
Compressor Oil
Eyes
Immediately flush with water for at least 15 minutes. CALL A PHYSICIAN. Wash skin with soap and
water.
Ingestion
Do not induce vomiting. Immediately contact local poison control center or physician.
Refrigerant
In the event of frostbite, protect the frozen area from further injury, warm the area rapidly and maintain
respiration.
Eyes
Immediately flush eyes with large amounts of water. CALL A PHYSICIAN.
Skin
Flush area with large amounts of warm water. Do not apply heat. Remove contaminated clothing and
shoes. Wrap burns with dry, sterile, bulky dressing to protect from infection. CALL A PHYSICIAN.
Wash contaminated clothing before reuse.
Inhalation
Move victim to fresh air and use CPR (cardio pulmonary resuscitation) or mouth-to-mouth resuscitation
to restore breathing, if necessary. Stay with victim until emergency personnel arrives.
13
6. System Description
General features
Thermo King’s SR rooftop air conditioning units delivers superior comfort to passenger's area. The
X500 system is one-piece rooftop HVAC unit uniquely designed to meet various customer requests and
expectations. From these reasons is X500 system available in two versions: 1000 and 1004.
The differences are:
 1000 - version with cooling feature - the evaporator coil is simple
 1004 - version with cooling and heating feature - the evaporator coil consists of two sections -
one for cooling, one for heating.
The X500 system is generally intended for small city. The X500 unit is always located on the bus roof
(in the text called rooftop unit). This location gives easy access from the top of the vehicle which
facilitates service and maintenance.
The rooftop unit contains one refrigeration circuit. The refrigeration medium is charged/transported by
compressor via installation pipes & hoses. Compressor is an optional part, different types can be select
by car builder, Thermo King recommends TM compressors. The compressor is usually located in bus
engine area, can be also mounted on specially designed drive kit.
The X500 unit, compressor and other accessories is controlled by common ClimaAIRE control system
and individual switchboard installed inside of rooftop unit. This control system allows driver to control
the operating conditions via ClimaAIRE ID driver panel located on bus dashboard.
Parts of system SR 380

1. Rooftop units
 X500 N - 1000, 24V, (system number 901717)
 X500 W - 1000, 24V, (system number 901719)
 X500 N - 1004, 24V, (system number 901718)
 X500 W - 1004, 24V, (system number 901721)
2. Compressor
 TM-16 compressor - optional
3. Control system
 ClimaAIRE ID
4. Fresh air option
 Fresh air damper (electric, flap)
 No fresh air
5. Covers
6. Accessories (optional)
 Harnesses, hoses, fittings, heating parts etc.
14
7. Specifications
7.1. HVAC System
System X500 - 1000 X500 - 1004
System nr. 901717 901719 901718 901721
Version narrow wide narrow wide
Cooling Capacity Rated 14.5 kW 14.5 kW
Test conditions Ambient temperature 35 °C 35 °C
Interior dry temperature 27 °C 27 °C
Interior wet temperature 19 °C 19 °C
-1 -1
Compressor RPM 4 000 min 4 000 min
Heating Capacity Total --- 34 kW
Test conditions Medium temp. inlet --- 80 °C
Return air temperature --- -20 °C
Medium flow --- 16.7 l/min
Air Flow at 0 mm water external pressure Return Air Return Air
3 3
High Speed 2 900 m /h 2 900 m /h
3 3
Middle Speed 2 130 m /h 2 130 m /h
3 3
Low Speed 1 527 m /h 1 527 m /h
Fresh Air (optional) Fresh Air (optional)
30 % 30 %
Refrigerant Type HFC R-134a
Charge 2.2 kg
Maximum ambient operating temperature 50 °C
Low Pressure Cutout Switch (LPCO) Open 69 ± 21 kPa (10 ± 3 psig)
Close 275 ± 34 kPa (40 ± 5 psig)
High Pressure Cutout Switch (HPCO) Open 2482 ± 69 kPa (360 ± 10 psig)
Close 1654 ± 69 kPa (240 ± 10 psig)
Condenser Pressure Switch (CPS) Open 1200 ± 69 kPa (174 ± 10 psig)
Close 1703 ± 69 kPa (247 ± 10 psig)
High Pressure Relief Valve (RV) Open 3447 +517/-103 kPa (500 +75/-15 psig)
15
7.2. Electrical System
X500 - 1000 X500 - 1004
Power Supply Voltage
Nominal 12 VDC 24 VDC
Maximal 13,5 VDC 27 VDC
Fuses
Controller power supply (PWR) 1x 5 A (32 VDC) 1x 5 A (32 VDC)
Evaporator blower motors (EFM1 - 4) 4x 10 A (32 VDC) 4x 10 A (32 VDC)
Condenser fan motors (CFM1 - 2) 2x 20 A (32 VDC) 2x 20 A (32 VDC)
Compressor clutch (CR) 1x 5 A (32 VDC) 1x 5 A (32 VDC)
Boost pump (optional) --- 1x 15 A (32 VDC)
Alternator (optional) 1x 80 A (32 VDC) 1x 50 A (32 VDC)
16
7.3. Compressor (Optional)
Compressor Model TM-16
Type Svash-plate type
Number of cylinders 6
Maximum speed 6 000 RPM
Refrigerant R-134a
1
Compressor oil type Polyol Ester Based Type (required) TK No. 203-515 *
2
Compressor oil charge 0.15 litre *
Temperature operating range -20 °C to +65 °C
Weight (approx., incl. oil and clutch) 7 - 10 kg (depends on clutch type and accessories)
Maximum speed 6 000 RPM
Refrigerant R-134a
1
Compressor oil type Polyol Ester Based Type (required) TK No. 203-515 *
2
Compressor oil charge 0.18 litre *
Temperature operating range -20 °C to +65 °C
Maximum speed 6000 RPM
Refrigerant R-134a
1
Compressor Oil Type Polyol Ester Based Type (required) TK No. 203-515 *
2
Compressor Oil charge 0.5 litre *
Temperature Operating Range -20 °C to +65 °C
*1
Do not use or add standard synthetic or mineral oils to the refrigeration system. If ester based oil becomes
contaminated with moisture or with standard oils, dispose of properly - DO NOT USE!
*2
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 maintained in the replacement
compressor.
17
7.4. Weight and dimensions
X500 - 1000 X500 - 1004
Weight (net, without compressor)
NARROW 86 kg NARROW 94 kg
WIDE 93 kg WIDE 101 kg
Dimensions (max.)
Length 2200 mm
Width NARROW 1520 mm
WIDE 1800 mm
Height 184 mm
BEA730
Figure 1: X500 Unit dimensions
18
8. Rooftop Unit Description
8.1. General description
The X500 air conditioning cooling or cooling & heating system provides the cooling, dehumidifying
and heating of the air for passenger area to keep the conditions comfortable.
The X500 unit can be easily accessed from the top of the vehicle which facilitates service and
maintenance. Important components (e.g. filter-drier) are arranged for easy access and service through
side covers.
The X500 system is equipped with refrigeration circuits with one compressor. Can be used several
different models of compressor. For details see Section 9.
Control system consists of ClimaAIRE driver panel in versions ClimaAIRE ID, located on driver's
dashboard, and electrical switchboard installed in the rooftop unit.
BEA718
Figure 2: X500 Rooftop unit
The X500 rooftop units in all versions consist of closed sealed refrigerant circuit with evaporator and
condenser coils, electrical circuit with evaporator blowers and condenser fans, control system, unit
frame and covers and auxiliary elements.
Cooling/heating is accomplished by drawing air (return air) from the cab interior to the entrance
chamber where is mixed with fresh air (in case of system with fresh air dumper otherwise is used return
air only). This mixed air (return air) passes through the evaporator coil, heater (optional) and then enters
the blower. The evaporator blowers pressurize the conditioned air and this pressure move the air from
HVAC unit into the vehicle air distribution system.
19
8.2. Main parts of rooftop units
The primary assemblies are:
 Condenser coil with integrated liquid receiver tank
 Condenser fans
 Refrigeration circuit components
o Filter-drier
o Sight glass
o Liquid solenoid valve
o Evaporator coil assemblies incl. thermostatic expansion valve
o Heating coils - incorporated to evaporator coil (version 1004 only)
 Evaporator blowers
 Fresh air damper (optional)
 Air filters (optional)
 Control system - see Section 10.2, page 29.
 Unit protections devices
 Structural frame and covers
The complete HVAC system consists of rooftop unit and compressor. For compressor see Section 9,
page 25. For more information see also refrigerant circuit diagrams on page 27.
8.2.1. Condenser Coil

The rooftop unit contains two aluminum micro-channel wavy fin condenser coil assembliesthat mounts
in front part of rooftop unit.
Pressurized refrigerant gas is discharged by the compressors into the condenser coil for the condensing
phase of the refrigeration cycle. Air is drawn through the coils by one propeller type fan. Refrigerant
gas condenses in the condenser coil, returning the refrigerant to the liquid state.
The condenser coil has liquid receiver tank holds reserve liquid refrigerant that is needed to support
variable system demands.
8.2.2. Condenser Fan

The rooftop unit contains two condenser fan assemblies. The fans are designed for pulling of fresh air
from internal area of HVAC unit and this function effect the air flow through the condenser coils.
The condenser fan assembly is one-piece equipment consists of electrical motor, rotor with blades,
permanently sealed ball bearings and plastic protective grille.
The fans are located in the top cover above condenser coil and are mounted via grille and bolts to the
condenser cover.
8.2.3. Filter-Drier
The filter-drier (dehydrator) is a cartridge soldered type unit intended for protection the refrigerant
against:
 moisture - by absorbing and retaining it deep within the desiccant
 foreign matter - the filter-drier will filter out scale, solder particles, carbon, sludge, dirt or any
other foreign matter with negligible pressure drop. Fine particles that would go through an
ordinary strainer are removed down to a minimum size in one pass filtration.
 acid - the hydrochloric, hydrofluoric, and various organic acids are adsorbed and held by the
desiccant in a manner similar to the adsorption of moisture
20
 oil sludge and varnish - all refrigeration oils break down to produce varnish, sludge and organic
acids and here are removed
For location of the filter-drier see "Figure 4: X500 Inside view" in following section, page 24.
8.2.4. Evaporator/Heating Coil Assemblies

The evaporator coil is an aluminum, wavy fin, copper tube type. Liquid refrigerant flows from the
receiver tank to the evaporator coil through the expansion valve. The expansion valve restricts and
controls the flow of liquid refrigerant to the evaporator. The pressure and temperature condition inside
of the evaporator (refrigerant side) and outside of evaporator (air side) results in heat transfer from the
refrigerated air to the evaporator. X500 units contain two evaporator coils located on left and right side
of unit.
In the versions 1004 (cooling and heating) the evaporator/heating coils are divided into cooling section
and separate heating section both connected to refrigeration and heating system too. To assist in
preventing corrosion buildup and freezing the heating coil(s) should be operated with a particular
coolant mixture. For coolant specification follow the instruction of the bus engine manufacturer.
The X500 system contains two evaporator or evaporator/heating coils. The drain pan underneath the
evaporator coil is intended to capture any water condensation from the coil surface. Drain lines allow
the water to flow away from the unit.
8.2.5. Evaporator Blowers

The blowers draw the air from vehicle area and/or fresh air from outside and discharge the conditioned
air back into the vehicle air distribution system.
The blowers are located on sides of unit and are accessible under side covers.
8.2.6. Fresh Air Damper (optional)

The fresh air damper controls an amount of fresh air from outside. Air damper consists of damper motor
and air flap. This flap can regulate ratio between return air (entering from bottom, from passengers area)
and fresh air (entering from upside through air intake, from outside). This air mixture runs to the air coil
filters, evaporator/ heating coil and by blowers is discharged back to the vehicle air distribution system.
The X500 system can contains one fresh air damper located in rear section.
8.2.7. Air Filters (optional)

Inside the rooftop unit are located coil filters (in front of evaporator filters) intended to filter return or
mixed air to prevent impurities accumulation on coils.
Rooftop unit in version with fresh air damper is equipped with fresh air filters to remove impurities
from the ambient air running through evaporator coils. This filter is located on behind the fresh air
damper.
On the bus ceiling can be mounted (as recommended) return air grilles contains return air filter. See bus
manufacturer documentation for more information.
The filters are disposable only, for changing frequency refer to maintenance chapter in this manual.
8.2.8. Unit Protection Devices
High Pressure Switch (HPCO)

The high pressure switch is located on the high pressure line in refrigeration circuit. The relay-type
contact of this switch is a part of low voltage (control) circuit, under normal operation is the contact
closed.
21
If the discharge pressure rises above limit value (see “Specifications”), the switch/contact will open and
the compressor will stop immediately. At the same time the control system will receive the information
about this situation.
Low Pressure (LPCO) Switch

The low high pressure switch is located on the low pressure line in refrigeration circuit. The relay-type
contact of this switch is a part of low voltage (control) circuit, under normal operation is the contact
closed.
If the suction pressure drops below limit value (see “Specifications”), the switch/contact will open and
the compressor will stop immediately. At the same time the control system will receive the information
about this situation.
Safety Relief Valve (SRV)

A safety (high pressure) relief valve is installed in the refrigeration circuit on the high pressure
(compressor output) line to avoid excessive pressure build-up within the refrigeration system from
extraordinary and unforeseen circumstances.
The valve is a spring-loaded piston type that opens when refrigerant pressure exceeds limit value.
8.2.9. Structural Frame and Cover

The rooftop unit structural frame is manufactured partly from ABS and partly from aluminum. The
evaporator section frame is made from ABS.
Front top cover with condenser fans located above condenser coil is made from aluminum, the rear top
cover provided access to electrical switchboard and fresh air damper is made from aluminum too. Side
covers are manufactured from ABS plastic and fixed with bolts.
Unit Decals
Serial number, refrigerant type and warning decals/nameplates are situated on different places on the
unit. These decals provide information that may be necessary for service or repair of the unit. Service
technicians should especially read and follow the instructions on all warning decals.
Serial Number Locations
 Electric motors: nameplate attached to the motor housing.
 Compressor: nameplate attached to the compressor housing.
 Unit: nameplate typically in the corner of the unit - under side cover.
22
8.3. Photos and Illustrations
5
4
1
3
BEA719
1 Unit front - condenser section 5 ABS right side cover

2 ABS left side cover 6 Top rear cover
3 Fixing bolts 7 Condenser fan assembly
4 Back side - Fresh air intake (not visible)
Note: Right side = curbside, left side = roadside (see page 4)
Figure 3: X500 Outside view
23
13
14
12
11
15 10
1
2 8
7
1
2 6
5
4 BEA720
3
1 Unit frame 9 Electrical circuit connection

2 Condenser coil 10 Evaporator coil - left side
3 Filter-drier 11 Fresh air damper
4 Sight glass 12 Electrical switchboard
Refrigeration circuit connection (in/out)
5 13 Coil filter - right side
and pressure switches
6 Coil temperature sensor (CTS) 14 Evaporator blower assembly - right side
7 Evaporator blower assembly - left side 15 Tank receiver
8 ABS plastic base
Note: Shown unit is in version 1004 (heating/cooling) and equipped with fresh air option.
Note: Right side = curbside, left side = roadside (see page 4)
Figure 4: X500 Inside view
24
9. Compressor Description
9.1. General description
For X500 systems can be used different models of compressor (see "Specification"). Model/type of
compressor depends on your HVAC system configuration and bus manufacturer. For exact
determination of used type and model see the nameplate on body of compressor.
9.2. TM compressors
The TM compressors are vehicle type small compressors designed for HVAC applications. The purpose
of this equipment is to deliver and energize the refrigerant to the rooftop air conditioning unit.
Main features of TM compressors:
 Compact design
 Balanced Swash Plate design offers low pulsation noise, quiet and smooth operation, less
vibration, and lower horsepower requirements.
 High Efficiency
o Cooling capacity is stable throughout the entire RPM operating range.
 High Durability
o MoS2 coated steel swash plate provides additional protection during liquid slugging and
high load conditions.
o Ball and shoe design promotes lubrication for better compressor durability.
o Needle bearings insure high durability for long life and high speed operation.
o Lip Shaft Seal insures excellent sealing integrity and extends compressor life.
 Optimized lubrication system with oil pump and sight glass.
BEA646
Figure 5: TM compressors (Illustration photo)
25
9.3. Small Compressor Oil Charge Specifications - R134a
Refrigerant Charge
kg 0,5 0,9 1,4 1,8 2,3 2,7 3,2 3,6 4,1 4,5 5 5,4 5,9 6,4
pounds 1 2 3 4 5 6 7 8 9 10 11 12 13 14
TM-16
Initial oil charge Oil to add
150 ml (5 oz) (add 24 ml per 0.9 kg of refrigerant - 0.8 oz oil per 2 lb of refrigerant)
ml 22 44 68 88 112 133 157 177 201 222 245 266 290 325
oz 0,75 1,5 2,3 3 3,8 4,5 5,3 6 6,8 7,5 8,3 9 9,8 11
TM-21
180 ml (6 oz) (add 24 ml per 0.9 kg of refrigerant - 0.8 oz oil per 2 lb of refrigerant)
ml 22 44 68 88 112 133 157 177 201 222 245 266 290 325
oz 0,75 1,5 2,3 3 3,8 4,5 5,3 6 6,8 7,5 8,3 9 9,8 11
TM-31
500 ml (16,9 oz) (add 24 ml per 0.9 kg of refrigerant - 0.8 oz oil per 2 lb of refrigerant)
ml 12 23 35 47 59 71 83 95 106 118 130 142 154 177
oz 0,4 0,8 1,2 1,6 2,0 2,4 2,8 3,2 3,6 4,0 4,4 4,8 5,2 6
This table gives amounts of compressor oil to add to refrigerant circuit above the initial charge (given
on the left), per the amount of refrigerant in a HVAC system (for amount of refrigerant in HVAC refrig.
circuit see "Specifications" on page 15).
NOTE: Recommended values are intended as a guideline only. Amounts vary depending on amount
of oil in the compressor during operation. Compressors with larger oil sumps require less additional
oil. See the compressor maintenance chapter in next manual for all procedures.
NOTE: After oil replacement always check the oil level in compressor, use a flashlight to observe the
compressor oil sight glass located on compressor body. Oil level should be approximately in the
middle of the sight glass.
CAUTION: Do not overcharge the system with oil. Doing so will damage the compressor.
CAUTION: Do not mix PAG and POE oils. Verify that the oil type in the compressor and the
system match. Drain compressor oil and replace with system oil if necessary.
CAUTION: Type of oil R-134a is TK No. 203-515.
26
10.Operating Instructions
10.1. Basic A/C System - Theory of Operation
The major components of the A/C unit are all connected in a closed common system to form
a refrigerant circuit, other components are designed for heating feature and for control system.
BEA721
ATS Ambient temperature sensor FD Filter-drier

CTS Coil temperature sensor SG Sight glass
RTS Return air temperature sensor RT Receiver tank
CPS Condenser pressure switch RV Relief valve (safety relief valve)
HPCO High pressure cutout switch TXV Thermostatic expansion valve
LPCO Low pressure cutout switch
Figure 6: A/C refrigeration system (example)
27
The refrigerant system circulates refrigerant (energized by compressor) between the evaporator coils
and the condenser coils to provide the requested exchange of heat energy.
The evaporator blowers drives the air with higher temperature (return air or mixed air) across the
evaporator coils. The heat energy is absorbed by the refrigerant (a low pressure, low temperature liquid)
that inside of the coils evaporates. The cooled air is discharged into vehicle air distribution system.
As the refrigerant evaporates, a low pressure, low temperature, heat-laden vapour is formed. The
refrigerant needs to release the heat energy. Compressor's suction continuously draws the heat-laden
vapours from the evaporator coils. As the vapours are compressed, it increases its pressure, changing it
to high pressure, high temperatured vapour. This increases the vapour temperature and pressure to
facilitate heat transfer to the ambient air and establish a condensing temperature.
As the high-temperature vapours travels through the condenser coils, the heat is dispersed into the
cooling fins, and ambient air is circulated by the condenser fans. As the heat is removed, the vapours
condenses back into a liquid. Thus, the heat absorbed by the refrigerant from the evaporator, is
transferred to the condenser and given off to ambient air.
The high temperature liquid is maintained under high pressure in the small receiver installed after the
condensers, where it is stored until needed. The receiver serves as a reservoir for the variable demands
of liquid refrigerant from the system.
From the receiver tank liquid refrigerant flows through the filter-drier (dehydrator), where impurities,
solids, and moisture are removed. From the filter-drier, the high temperature, high pressured liquid
flows through to the expansion valves. The expansion valves restrict and control the flow of liquid
refrigerant to the evaporator coils where it again absorbs heat from bus interior air (return air).
Before expansion valves can be added feeder branch designed for FrontBox (optional equipment)
connection.
Beside evaporator coils can be added heating coils (for cooling/heating 1004 systems only) intended for
heating feature, connected to bus heating system.
28
10.2. Control System
The control system handles all system functions to maintain the passenger's area at the proper
temperature. The control system consists of controller (driver panel) and control panel (electrical
switchboard) located inside of the rooftop unit.
For X500 system is intended ClimaAIRE ID control system.
The controller communicates with control panel (switchboard) and compressor or other optional
equipment via Thermo King uniquely designed harnesses.
BEA722
Figure 7: Application diagram
The control system is monitoring all important values through low voltage signal inputs and operates
the rooftop unit and compressor within normal conditions through low voltage signal outputs.
29
10.3. ClimaAIRE ID and ClimaAIRE II
The driver panel in X500 system usually works like a terminal (bus driver panel, HMI - Human
Machine Interface) and controller too. Collects and sends bus driver commands to the rooftop unit
switchboard (and compressor and other optional auxiliary equipment), and it conversely receives and
displays HVAC system status to her/him.
10.4. ClimaAIRE ID controller
7 8 9 10 11 12
13 14 BEA133
1 2 3 4 5 6
1 ON/OFF key 8 Temperature icons

2 Mode select key (ESCAPE) 9 Display
3 Temperature key (blue) (DOWN key) 10 Clutch & Boost pump icons
4 Temperature key (red) (UP key) 11 Blower mode icons
5 Blower speed key (ENTER) 12 Fresh air mode icons
6 Fresh air select key 13 Red alarm
7 A/C mode icons 14 Yellow alarm
Figure 8: CAID Driver panel
10.4.1. Operating elements
ON/OFF key Press the key to turn the unit ON

When the unit is in operation this Press the key again to turn the unit OFF
key can be used for restart of
controller Red alarm indicator
Yellow alarm indicator
Mode select key Reheat/Auto mode
A/C mode
Heat mode
Ventilation mode
30
Display Return air temperature icon
Setpoint icon
Red - Boost pump icon
Blue - Compressor clutch icon
Temperature key DOWN (blue)

Use UP or DOWN key to increase/decrease
temperature setpoint
Temperature key UP (red)
Blower speed key Automatic blower speed

High blower speed
Medium blower speed
Low blower speed
Fresh Air select key Auto mode
Open (100% fresh air)
Half open (50% fresh air)
Closed (Recirculated air only)
10.4.2. Operating concept of ClimaAIRE ID system

The controller (driver panel) ClimaAIRE ID (CAID) uses two possible operating modes:
 Normal operating mode
 Setup/Calibration/Test mode
10.4.3. Normal operating mode

After start (the power supply is activated) the driver panel is set to normal operating mode. In the
normal operating mode the system is running built-in control and diagnostic system.
Functionality of driver panel can be significantly determined by parameters in set-up menu (see chapter
"Function 5: Set Up of controller (SE)" below).
On display can be shown:
 setpoint value - requested temperature (default setting, labeled with setpoint icon)
 Hi or Lo text - in case of Manual mode - see description in Manual mode chapter below
 temperature of return air - when this feature is set by parameter rt (see "Figure 19: CAID
Controller parameters") - rt = 01
If the return air temperature is shown on display (labeled with return air temperature icon) then
in case of setpoint change by pressing of UP or DOWN key the new setpoint will be shown for
3 seconds.
 no information (dark, blind display) - when this feature is set by parameter rt (see "Figure 19:
CAID Controller parameters") - rt = 02
If the driver panel is set to dark mode with parameter rt = 02 then no information is shown on
display. Only in case of setpoint change by pressing of UP or DOWN key the new setpoint will
be shown for 3 seconds. All other icons on driver panel are visible.
Temperature on the display is shown in °C (default setting) or in °F.
31
Mode select
In normal operating mode - Auto mode - the controller selects the right mode (cool or heat or
ventilation) automatically.
 Reheat/Auto mode - unit will operate in cool or heat mode based on operating conditions to
ensure proper air temperature and humidity. The cooling and heating function can be used
simultaneously (this is "Reheat mode")
 A/C mode - unit will operate in cool mode (based on operating conditions) or ventilation
 Heat mode - unit will operate in heat mode (based on operating conditions) or ventilation
 Ventilation mode - unit will be in ventilation only, cooling or heating will be disabled
NOTE: The Heat mode can be applicable only for HVAC units in 1004 version (cooling/heating).
Blower speed select

The evaporator blowers move the conditioned air from HVAC unit into bus interior. Selection of blower
speed determines air flow (amount of air) from HVAC unit into vehicle. In AUTO position the blower
speeds are controlled automatically.
NOTE: When CA ID controller is used in HVAC system equipped with two speeds blowers the LOW
and HIGH blower speeds are applicable - the MEDIUM speed position is not used and if selected
than blowers run in low speed only.
Fresh air / Smog

Using fresh air key driver can control amount of fresh air flows through HVAC unit or can close air
damper in case of smog. This "smog mode" can be easily set by pressing fresh air button.
Automatic mode - the fresh air damper is controlled automatically

Fresh air damper open (100 % FA)
Half open - fresh air damper at 50% position (50 % FA)
Recirculated air - fresh air damper closed (0 % FA)
If no key was pressed in last 2 seconds and fresh air button is pressed once, the FA symbol and
recirculated air symbol lights up together and the fresh air damper is closed for next 10 minutes. After
this period the controller returns to previous FA state (indicated by FA symbol).
If FA key is pressed once more than the "smog mode" is canceled and FA damper position can be
selected.
Automatic ON feature
Depending on Ao parameter (see "Figure 19: CAID Controller ") the controller (driver panel) will be
switched ON or stays OFF depending on state when power supply was switched OFF:
 If the driver panel was ON when power supply was switched OFF; on next system start -
power supply ON - the driver panel will also start (internal memory keeps the last operating
status; parameter Ao is set to 00)
 If the driver panel was OFF when power supply was switched OFF; on next system start -
power supply ON - the driver panel will stay OFF (internal memory keeps the last operating
status; parameter Ao is set to 00)
OR the driver panel always will be switched ON when the power supply is switched ON
(parameter Ao is set to 01)
32
Lock function
Depending on Lc parameter (see "Figure 19: CAID Controller ") the driver panel buttons functions are
obvious or described further (factory settings) or:
 blower speed key and fresh air select key are locked, have no response on pressing (Lc =01)
 mode select key, blower speed key and fresh air select key are locked (Lc=02)
 all buttons except ON/OFF key are locked (Lc=03)
Manual mode
ClimaAIRE ID can control HVAC unit in manual mode to operate system directly in heating or cooling.
Manual mode has to be enabled by parameter Lt in driver panel setup.
In automatic mode operator can change the setpoint in range from LS (minimal value of setpoint) to HS
(maximal value of setpoint), default range is from 17 °C to 27 °C. When the control mode is changed to
Manual mode then setpoint value can be set to Lo command instead of LS or to Hi command instead of
HS value:
 Lo command switches ON continual signal for compressor/clutch (relay output CR = 1)
 Hi command switches ON continual signal for boost pump (relay output BPR = 1)
With both commands red or blue icons on the right side of display are switched ON. These icons
indicate heating system (boost pump) or cooling (compressor) operation.
By Lt parameter (Lt=02) Manual mode can be enabled with limited duration for 5 minutes. The function
is the same as in above described Manual mode but after 5 minutes:
o Hi command switches back to HS value and thereafter driver panel operates HVAC system
automatically
o Lo command switches back to LS value and thereafter driver panel operates HVAC system
automatically
Here the described Manual mode is conditioned with a normal operation - Auto mode. By pressing of
Mode select key and selection of Ventilation or Heat or A/C mode the Manual mode is non-functional
(the Lo/Hi command can stay on display but blue/red icon will switch down).
NOTE: Direct heating command in manual mode is applicable only for HVAC units in 1004 version
(cooling/heating), in version 1000 (cooling) is used ventilation function only.
Economic cool mode

Depending on EC parameter (see "Figure 19: CAID Controller ") the driver panel in STANDARD
COOL mode can operate blower(s) in three speeds (low, medium, high) or in ECONOMY COOL mode
can operate blower(s) in medium or high speed only. This feature affect only COOL mode when
compressor is in operation.
33
10.4.4. Setup/Calibration/Test mode
For access to Setup/Calibration/Test mode the driver panel needs to be in normal operation. Press
and hold the Temperature DOWN key and the Temperature UP key simultaneously for 3 seconds till
text (Function 1) "t-1" will be displayed.
In Setup/Calibration/Test mode the buttons on the panel uses different function - see following table.
ON/OFF key ARROW - DOWN key (blue)
ENTER key ARROW - UP key (red)
ESCAPE key
Figure 9: CAID Keys in Setup/Calibration/Test mode
ClimaAIRE ID functions
Press the UP or DOWN key repeatedly to scroll
through the function menu. In the
Test/Setup/Calibration mode the operator can
use functions listed in following table.
In main menu of Setup/Calibration/Test mode
the operator can switch the control system OFF
on every time by pressing of the ON/OFF key.
No changes will be applied.
When any function is selected and any value is
changed by DOWN key or UP key, in the same
moment is the change saved to memory.
The driver panel Setup/Calibration/Test mode
always waits for switching OFF (soft restart) -
the Setup/Calibration/Test mode must be
finished by pressing ON/OFF key. Next start
(soft restart) returns the system to the normal
operating mode immediately.
NOTE: In Setup/Calibration/Test mode the
HVAC unit is out of operation.
BEA688
Figure 10: CAID Function menu structure
34
Nr. Symbol Function
1 t1 Test mode 1 - basic test of HVAC unit
2 rt Relay test
3 Pr Set up of program number and reading of firmware version
4 CA Calibration of temperature sensors
5 SE Set Up of controller
6 AL Reading and clearing of alarms
7 Hr Reading of hourmeter
Figure 11: CAID List of functions
CAID - Function 1: Test mode 1 (t1)

The TEST MODE 1 can used for testing of basic operations. TEST MODE 1 allows to operate the unit
manually independently of control system/control diagrams - for example for charging of refrigeration
system or testing of HVAC unit.
In Setup/Calibration/Test mode with DOWN or UP key select "t1" and press ENTER key. In "Test
mode 1" are available following tests:
1. Cooling/Heating control
Press "Mode key" to change heating and cooling outputs. The following table is
used to verify of all relay outputs and function of heating and cooling
Function Relay / output ON Relay / output OFF LED
Ventilation
Heating BP, MCV CR Red - ON
Cooling CR BP, MCV Blue - ON
Auto / Reheat CR, BP, MCV pulsing Red & Blue - ON
Figure 12: CAID Test mode 1 - Cooling/Heating control
2. Blower speed control
Press "Blower speed key" to change evaporator blower speed. The following table
is used to verify of all relay outputs and functions of evaporator blowers.
Symbol Relay / output ON Relay / output OFF
LOW speed EFL EFH, EFM
MEDIUM speed EFL, EFM EFH
HIGH speed EFL, EFM, EFH -
Auto - EFL, EFM, EFH
Figure 13: CAID Test mode 1- Blower control
35
3. Fresh Air control
Press "Fresh Air key" to change position of fresh air dampers and the following
table is used to verify of all relay outputs and functions of fresh air dampers.
Symbol Relay / output ON Relay / output OFF
Re-circulation - DM
Fresh air damper 50% open DM pulsing -
Fresh air damper 100% open DM -
Figure 14: CAID Test mode 1- Fresh air control
CAID - Function 2: Relay test (rt)

In Setup/Calibration/Test mode select "rt" function and press ENTER key.
On the display will show the relay or output symbol and each press of the UP or DOWN key will scroll
to the next item (see following figure). Press ENTER key and corresponding relay/output is energized.
Display Description Signal Note

EL Evaporator low speed relay EFRL
En Evaporator medium speed relay EFRM
EH Evaporator high speed relay EFRH
CL Compressor clutch relay CR Blue icon is ON
bP Boost pump relay BPR Red icon is ON
low side output - for compatibility with old
C0 Modulating coolant valve MCV
ClimaAIRE I
C1 Modulating coolant valve MCV high side output
low side output – Fresh air damper open (100%),
d0 Damper output DM
for compatibility with old ClimaAIRE I
d1 Damper output DM high side output – Fresh air damper open (100%)
Figure 15: CAID Scheme of relay test procedure
After test press ESCAPE key to continue with another function or press ON/OFF key.
CAID - Function 3: Set up of program number (Pr)

In Setup/Calibration/Test mode with DOWN or UP key select "Pr" function and press ENTER.
First the firmware version in two steps will be displayed for and then the program number stays
displayed. To change of this program number press the DOWN key or UP key as required.
NOTE: If you want to select a program number which is not available in current firmware version,
you have to upload a new firmware. For more information refer to ClimaAIRE ID Service Manual
(TK 60020-3-MM).
When the desired program number is shown press ENTER key to save a new program number to
memory. To leave of program setup without any changes press ESCAPE key. Press UP or DOWN key
to continue with another function or press ON/OFF key to save all changes and switch OFF (soft restart)
the system.
36
CAID - Function 4: Calibration (CA)
The controller is checked at factory but after HVAC unit installation the calibration mode should be
used to verify and adjust temperature sensors functionality in the field.
NOTE: Calibration is not a repair for defect sensors or bad connections.
In Setup/Calibration/Test mode select "CA" function with UP or DOWN key and press ENTER key. On
the display is shown name of parameter to calibration.
 Press ENTER again to see its current value.
 To leave the parameter unchanged press ESCAPE key.
 To change the value press DOWN key or UP key as required.
Each press of UP or DOWN key is representing value change about 0.2 degree (0.2 °C). Example:
for increasing of current value for one degree up (+1 °C) press UP key five times.
Because the two digit display don't allow to shows decimal numbers every press of UP or DOWN
key isn't noticeable. However on the right side of display is small orange dot, if this dot is visible
the current value is higher about half degree or more than displayed value (e.g. if the value was 11
degree and the UP key was pressed three times the dot will appears, the value is now between
11.5 and 12 degree).
If the UP or DOWN key is pressed and hold than the value is changing quickly (repeatedly) until
the key is released.
The calibration range/correction for temperature sensors is from -1 °C to +26 °C.
 Press ESCAPE to save new value and continue to next parameter.
If ON/OFF key is pressed now a new value is also saved and the system will restart (soft restart).
 With UP or DOWN key select next parameter to continue in calibration.
After calibration press ESCAPE key to return to Function menu or press ON/OFF key to switch OFF
(soft restart) the system.
Nr. Display Description / Note
1 rA Return air temperature sensor
2 Ct Evaporator coil air temperature sensor
3 At Ambient temperature sensor
4 CF Clutch feedback - no calibration
5 Ub Battery voltage on PWR - no calibration
Figure 16: CAID List of calibrations
37
BEA689
Figure 17: CAID Calibration function structure
Function 5: Set Up of controller (SE)

This setup mode can be used to configure the controller for a specific application or conditions.
In Setup/Calibration/Test mode with UP or DOWN key select "SE" function and press ENTER key.
The system to check/change of the parameters is similar as for calibration. On the display will show
parameter symbols and each press of the UP key will scroll to the next parameter (see following figure).
If required parameter (symbol) is displayed press ENTER key to see its current value.
 To leave the parameter unchanged press ESCAPE key.
 To change the value press DOWN key or UP key to set new parameter as required.
38
Press MODE key to save and continue with another parameter or press ON/OFF key to switch OFF the
system. At the end always press ON/OFF key to save all changes and switch OFF (soft restart) the
system.
BEA690
Figure 18: CAID Setup function structure
39
Par. Preset Unit Min. value Name Description
value Max. value
Ab 07 °C 0 °C For compressor protection only. If ambient temp.
Ambient switch
is below this parameter the compressor (clutch)
15 °C point
will not start
Fr -3 °C -5 °C Evaporator Freeze protection of evaporator. If temperature
+5 °C antifreeze switch on evaporator coil (CTS) is lower than this
point parameter the compressor will be switched OFF.
NOTE: It is not recommended to change this
parameter.
rh 01 - - Reheat mode 00 - reheat mode disabled – economy auto mode
01 - reheat mode enabled
02 - DELTA T is enabled, reheat is disabled
03 - DELTA T is enabled, reheat is ensabled
dt 07 °C 1 °C Delta T Offset for control of return air temperature.
15 °C Set point SPc = Ambient temperature ATS minus
Delta T value.
If the result is less then 22, then SPc = 22 °C
The lowest possible SPc is the setpoint selected
Ao 00 - - Automatic On 00 = controller will operate the unit in the same
mode as when power was switched OFF
01 = controller will start the unit every time power
is switched on
LS 17 °C 15 °C Low set point Minimum value of set point.
30 °C
HS 27 °C 15 °C High set point Maximum value of set point.
30 °C
00 = Setpoint shown on display
Default value on the 01 = Return air temperature shown on display
rt 00 - -
display 02 = Blind display - setpoint value shown for
3 seconds after any change
Old ClimaAIRE I 00 = CAID as original
0C 00 - -
replacement 01 = CAID as replacement of ClimaAIRE I
°C = Temperature on the display in °C
un °C - - Celsius/Fahrenheit
°F = Temperature on the display in °F
EL 45 % 0% Low speed of Low value/frequency for PWM output *
100 % blower
En 66 % 0% Medium speed of Medium value/frequency for PWM output *
100 % blower
Eh 100 % 0% High speed of High value/frequency for PWM output *
100 % blower
00 - Automatic mode - no possibility to set Lo
Lt 00 - -
Limited temperature and Hi setpoint on display
setpoint 01 - Manual mode, Lo/Hi setpoint available
02 - Manual mode limited for 5 minutes only
EC 00 - - Economic cool 00 = Standard cool mode - default value
mode 01 = Economic cool mode
HO 0 °C 0 °C Setpoint for HEAT mode will be increased by
Heat offset
5 °C offset compare to COOL and REHEAT mode
Lc 00 - - Lock function 00 - no lock (default value)
01 - blower speed key and fresh air select key are
locked (have no function in operation)
02 - mode select key, blower speed key and fresh
air select key are locked
03 - all buttons except ON/OFF key are locked
* PWM output is used on the systems with blower speed controllers or brushless motors
Figure 19: CAID Controller parameters
40
CAID - Function 6: Reading and clearing of Alarms (AL)
In Setup/Calibration/Test mode select "AL" function with UP or DOWN key and press ENTER key. All
alarm codes will be displayed for 2 seconds and at the end will be displayed "dE".
 For list of alarm codes see "Figure 21: CAID List of alarm codes"
 If no alarm is stored (e.g. previously alarms were cleared) the "no" label will be displayed for 1
second and no more action will be executed.
NOTE: If necessary to keep the alarm codes in memory readable by this way, press ON/OFF key, the
driver panel will be switched OFF and the alarms remains recorded.
 Press the ENTER key to clear all alarms. On the display appears "00" for a short time and then
the system returns to Function menu, on the display will show "AL".
NOTE: Alarms cleared through driver panel remain in internal memory - in history - and can be
read through connected PC with Service software.
At the end always press ON/OFF key to switch OFF (soft restart) the system.
41
CAID - Function 7: Reading of hourmeter (Hr)
In Setup/Calibration/Test mode with UP or DOWN key select "Hr" function and press ENTER key.
The symbols and each value will be automatically displayed in following scheme and at the end will be
again displayed "Hr".
NOTE: Detailed hourmeter (with minute resolution) is available via PC connection and Service
software.
The whole procedure can be repeated by pressing ENTER key again. With UP or DOWN key select
next function or press ON/OFF key to switch OFF the system.
Display Description Example

Un UNIT
Hr hours
XX 01
YY number of hours in operation 10
ZZ 23 = total running time 11 023 hours
CL COMPRESSOR (Clutch)
Hr hours
XX 00
number of hours when the
YY compressor (clutch) request 05
signal was set ON
ZZ 22 = total "compressor" time 522 hours
CL COMPRESSOR (Clutch)
CY cycles
NN 00
number of ON/OFF cycles
PP 44
during unit operation
RR 11 = total 4 411 ON/OFF clutch cycles
Fr FREEZE
CY cycles
NN number of evaporator coil 00
freeze protection
PP occurrences 00
(see parameter "Fr" in
RR 15 = total 15 freeze conditions occurrences
Figure 19: CAID Controller )
Figure 20: CAID Scheme of hourmeter
42
10.4.5. ClimaAIRE ID Diagnostic System
After start the driver panel is in normal operating mode. In the normal operating mode is running the
built-in diagnostic system.
The ClimaAIRE I D driver panel uses dual alarm system with two levels of signals:
 WARNING (yellow alarm symbol)
 ALARM (red alarm symbol)
When any red alarm (ALARM) appears the alarm code will be blinking on the display until some button
is pushed. If any yellow alarm (WARNING) appears the alarm code will be blinking on the display
for 5 sec.
The alarm codes are stored in the memory to identify possible fault conditions. Up to 40 alarms codes
can be stored. The records can be displayed on the driver panel with the procedure described above. The
complete history can be read by the PC only.
Alarms description
The WARNING (yellow alarm) symbol will be ON in the case of:
 Low value of any temperature sensor:
o temperature sensor defect
o short circuit of the harness to sensors
o temperature is lower than -35 °C (-31 °F) – resistance of the sensor or of the total circuit
is lower than 1,25 kOhm
 High value of any temperature sensor:
o temperature sensor defect
o open circuit of the harness to sensors
o temperature is higher than 75 °C (167 °F) – resistance of the sensor or of the total circuit
is higher than 2,9 kOhm
With yellow alarm conditions the unit will continue in operation with the wrong data from the sensor.
The ALARM (red alarm) symbol will be ON or blinking in the case of:
 HPCO or LPCO switch is open longer than 10 minutes (alarm code 6)
 HPCO or LPCO switch is cycling - switched OFF 5 times per 10 minutes (alarm code 5)
 Inverter alarm (alarm code 31 - 37, special program for electric bus units only)
Any red alarm will switch the unit to the VENTILATION mode with automatic blower speed. The
driver can change the blower speed manually. The compressor and condenser fans are stopped.
The alarm symbols can be removed by restart of control system (use the ON/OFF key to switch OFF,
wait for 2 seconds, switch ON). After restart - if the reason for alarm is still in existence - the alarm
symbol can appears again. If the alarm comes up again, don't restart the unit more times. In that case
immediately contact the service department or Thermo King representative.
For detail list and description of alarms refer to ClimaAIRE ID Service Manual (TK 60020-3-MM).
43
Alarm Code Name Symbol Description
01-04 not used -
HPCO or LPCO switch is switched off
05 Clutch cycling RED
5 times per 10 minutes
HPCO or LPCO switch is switched off
06 Long delay of HPCO or LPCO RED
longer than 10 minutes
07 RTS Low YELLOW RTS: Return Air Temperature
CTS: Evaporator Coil Temperature
08 RTS High YELLOW ATS: Ambient (Fresh) Air Temperature
09 CTS Low YELLOW
Low = short circuit or temperature is
10 CTS High YELLOW lower than -35 °C
(the limit value is -35 °C)
11 ATS Low YELLOW
12 ATS High YELLOW High = open circuit (disconnected
sensor) or temperature is higher than
13 - 30 not used - 75 °C (the limit value is 75 °C)
31 - 37 Inverter Alarms RED for SR10E only
Figure 21: CAID List of alarm codes
Freeze Protection
Temperature of evaporator coil is measured by sensor (CTS). If this temperature is lower than value in
parameter Fr for more than 30 seconds - that can be dangerous for freezing - the compressor output
signal (CR) is switched OFF (see also "Figure 19: CAID Controller " on page 40). Compressor (and
condenser fan also) can return to operation if temperature of evaporator coil rises approx. 5 °C above
Fr parameter for more than 1 minute.
Compressor Protection
Compressor output (CR) can be switch ON (compressor can start) only if ambient temperature (ATS) is
higher than value of parameter Ab (see "Figure 19: CAID Controller " on page 40).
10.4.6. ClimaAIRE ID Inputs and Outputs

Control system inputs are used to monitor system performance and determine operating conditions.
System outputs are used to control of all system component operations.
BEA691
Figure 22: CAID Driver panel connectors
For detail specification of CAID inputs/outputs refer to ClimaAIRE ID Service Manual (TK 60020-3-MM).
44
Operating range
Input Pin Description Note
(min - max)
Ambient temperature -35 °C +75 °C
ATS P1-09
sensor -31 °F 167 °F
Return air temperature -35 °C +75 °C
RTS P1-10
sensor -31 °F 167 °F
-35 °C +75 °C
CTS P1-11 Coil temperature sensor
-31 °F 167 °F
Pressure sensor/switch
31B P1-12 digital, high side input
(LPCO, HPCO)
Supply
P1-13 Supply ground 0 VDC 5 VDC
ground
Power
P1-14 Power supply 10 VDC 35 VDC max. 100 mA
supply
Figure 23: CAID List of inputs
NOTE: For temperature inputs must be used sensors TK 41-4157, TK 41-4335 or TK 41-8780 only.
Output PIN Description Standard type
EFRH P1-01 Blower speed (high) control 0/1 relay, low side output
EFRM P1-02 Blower speed (medium) control 0/1 relay, low side output
0/1 relay, low side output

DM (DR) P1-03 Fresh air damper 0/50%/100%
or PWM 20 kHz, high side output
CR P1-04 Compressor clutch 0/1 relay, low side output
BPR P1-05 Boost pump 0/1 relay, low side output
EFRL P1-06 Blower speed (low) control 0/1 relay, low side output
P1-07 Sensor ground ---
MCV P1-08 PWM 20 kHz, high side output
NOTE: Each output can be set as low side or high side output by the firmware. Outputs MCV and
DM - in configuration of replacement of ClimaAIRE I – low side outputs
Figure 24: CAID List of outputs
The driver panel (controller) is equipped with communication connector and can be connected to
portable PC for testing and monitoring (use ClimaAIRE Computer Adapter Kit TK 204-1063).
For more information see ClimaAIRE ID Service Manual (TK 60020-3-MM).
45
10.5. Inspection Recommendations
To keep the correct functions of the A/C unit you must periodically execute the following maintenance
procedures. The schedules should be used during the initial service periods (at least during warranty
period).
WARNING: When inspecting or servicing the A/C system, follow all safety rules and
operating procedures, otherwise physical harm could result.
Thermo King reserves the right to deny warranty coverage on claims due to lack of maintenance or
neglect. Claims in question must be supported by maintenance records.
If you are not really experienced in following actions please call for help Thermo King Service Center
otherwise is here risk of damage or complications. In case of any question or unclear situation please
contact your supplier or directly Thermo King manufacturer.
All maintenance intervals are based on normal operating conditions. Unusual or extraordinary
conditions require more frequent service intervals. For example, high air pollution could require more
frequent replacement of air filters. Coordinate the maintenance inspection schedule with the Bus
Preventive Maintenance Schedule.
Off Season Operation Of Bus Air Conditioning System

In order for the A/C system to be ready for operation, normal preventive maintenance is
necessary operate all systems periodically, especially during the off season. By operating the
system weekly for short intervals (5 to 10 minutes) year round, the internal parts of the
compressor will remain lubricated. Offseason operation also helps to reduce compressor shaft
seal leakage and allows early detection of refrigerant loss.
Wintertime Operation
The A/C system is operating in wintertime with heating and fresh air functions, periodical
maintenance also in off season is necessary to maintain the functions of the A/C system. Prior
to operating the compressor during winter months, you must warm up the coach interior to
normal operating temperature (15 to 21°C [60 to 76°F]). Unless this precaution is taken, liquid
refrigerant might be forced into the compressor, causing severe damage.
WARNING: Covers must be completely removed from the unit to access interior of
unit. Insure you are using best practice for working at height paying special attention
during removal of cover as it could move due to the influence of the wind.
46
10.6. Maintenance Inspection Schedule
10.6.1. Intervals
The following intervals are just a recommendation. The periods may vary - this depends on ambient
conditions, pollution or local transportation laws. Please use common sense then judging replacement of
filters and cleanliness based on first four months of service.
If you need any help please contact Thermo King Representative or Service.
10.6.2. Refrigeration/Heating System
Monthly Quarterly Annually
10.000 km 30.000 km Procedure - Required Activity - Corrective Action

6,000 Miles 18,000 Miles
Check refrigerant charge. Make sure discharge pressure is
   150 psig (1034 kPa) on R-134a systems.
NOTE: This should be done twice monthly during air
conditioning season.
   Visually inspect condition of refrigerant hoses and tubing.
   Visually inspect for leaks of refrigerant and oil.

Check dry eye in the liquid line sight glass for moisture
   content.
Install service gauge manifold set and check system
  operating pressures, temperatures and suction line
conditions.
 Replace filter-drier (liquid line dehydrator).

NOTE: The filter-drier should be changed anytime the
system is opened.
 Check heating water valves operation.
10.6.3. Compressor

   Check compressor oil level and color.

Visually inspect compressor drive belts for excessive wear,
   tension and alignment (refer to bus manufacturer and/or belt
supplier for proper tension).
Compressor function checks - see maintenance requirement
 in corresponding Appendix.
 Check compressor oil for acidity.
 Visually inspect coolant hoses and tube installation.
47
10.6.4. Electrical and Control System

Semi-annually Check evaporator blower motors speed, voltage and

amperes (all motors).
Semi-annually Check condenser fan motor speed, voltage and amperes (all
motors).
 Inspect all wires and terminals for damage or corrosion. If

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

low speed operation.
 Check HPCO and LPCO pressure switches.
10.6.5. Structural - Mechanical Parts

   Inspect condenser coils for cleanliness.
   Inspect all evaporator coils for cleanliness.

Visually inspect unit for loose, damaged or broken part, bolts
   and rivets.
   Clean or replace air filters (more frequently if necessary).

Clean condenser and evaporator drains. Make sure the
 evaporator drain hose check valves (kazoos) are in place
and in good condition.
 Clean condenser and evaporator coils.

Check coolant for antifreeze protection down to -30 °F (-
 34°C) to prevent evaporator/heater coils freeze up.
 Tighten all compressor, blowers, fans motor, covers and unit

mounting bolts and brackets (more frequently if necessary).
48
10.7. Special Tools, Equipments and Supplies
For maintenance and repairs use basic hand tools in size and type corresponding to intended task.
For replacement parts (air filters, filter-drier etc.) please refer to Parts Manual (see the Thermo King
publication number on page 3).
On some tasks can be necessary to use a special tools or equipments listed in following figure or in a
chapter 11.1 on page 53.
NOTE: Types and suppliers of suitable tools can vary from country to country, usually more products
are available in open market. In any doubt about suitable tool please contact your local Thermo King
dealer or directly Thermo King Representative.
Refrigerant gauge manifold set Reads system pressures and allows for correct
1.
system servicing.
Quick disconnect access valves Keep pressure in gauge lines when gauge
2.
manifold is removed from compressor.
2-Stage vacuum pump (greatly See chapter 11.1 on page 53.
3.
reduces evacuation time)
4. Portable Reclaim Unit See chapter 11.1 on page 53.
Electronic micron gauge Must have vacuum level readings from 25,000 to
5.
50 microns.
6. Electronic Leak Detector Use an electronic halogen leak detector or soap
solution.
WARNING: Do not use a Halide torch to
detect leaks. When a flame comes in contact
with refrigerant, toxic gases are produced that
might cause suffocation.
7. Expander Tool Set example: REFCO 14297

8. Fin Comb 14142 example: REFCO 14142
9. Digital Temperature Tester example: REFCO WM-150
10. Digital Multimeter
11. Clamp Tester
12. Pin Extractor Tool
13. PC with diagnostic software
Do not use an infrared touchless thermometer for
15. Thermometer with remote reading dial air temperature readings. It will give inaccurate
readings.
Oxygen acetylene torch, solder, and
16.
flux.
17. Oil Test Kit Thermo King P/N 203-457
(TM)
18. Loctite Threadlocker Type 277, Part no. 27731
(TM)
19. Loctite Anti-seize thread lubricant Type 8150, Part no. 15376
Figure 25: Special Tools
49
10.8. Tightening Torque Requirements
Step 1: Locate both groups for bolt and nut in following table:
Strength
Group Fastener Material Finish Marking
Class
A Head bolt, machinery type Steel Zn Pl 5.8 5.8
B Head bolt, machinery type Steel Zn Pl 5.8 8.8
C Head bolt, machinery type Steel Zn Pl 10.9 10.9
D Head bolt, machinery type Steel Blk Ox Wx 12.9 12.9
E Head bolt, machinery type St. Steel Passiv
B Nut, Regular Steel Zn Pl 8
C Nut, Regular Steel Zn Pl 10
GRA2-
- Nut, Regular St. Steel Passiv None
CL70
- Nut, Prev Torq Lock Steel Zn Pl ISO-2320 None
A Head bolt, machinery type Steel Zn Pl 5.8 5.8
Step 2: Select bolt/nut torque by size & group:
Group A Group B Group C Group D Group E
Size Nominal Torque in [kg.m] or *[kg.cm]

M2 1.6* 2.5* 3.2* 3.8* 2.2*
M2.5 3.5* 5.6* 7* 8* 4.5*
M3 6* 10* 13* 17* 10*
M3.5 10* 16* 21* 25* 14*
M4 15* 24* 31* 39* 23*
M2 1.6* 2.5* 3.2* 3.8* 2.2*
M5 33* 52* 65* 75* 43*
M6 58* 89* 115* 135* 77*
M7 99* 157* 197* 232* 132*
M8 140* 215* 279* 328* 188*
M10 277* 426* 5.5 6.5 373*
M12 483* 7.5 10 11 6.5
M14 7.7 12 15t 18 10
M16 12 19 24 28 16
M18 16.5 26 33 39 22
M20 23 37 47 55 31.5
M22 32 51 64 75 -
M24 40.5 64.5 81 95 -
50
Step 3: Adjust both numbers for special conditions:
Condition Adjustment
Fine Threads +10%
-50%
Thin or Jam Nut
(do not add to Schedule E - see Note 3)
Anti-Seize Lubricant -20%
Unplated Carbon Steel +10%
Step 4: Choose the lower value of the nut and bolt values.
Minimum Torque = 0.9 x nominal torque
Maximum Torque = 1.2 x nominal torque

Step 5: Set fastener to required torque.
Notes
1. Torque values are “First-On” and are not applicable to re-used fasteners.
2. Torque values listed are seating torques (not break-away values which may be substantially
different).
3. Group E torque values are based on stainless steel screws used with anti-seize lubricant.
To convert units Kg.m to Ft.lb multiply values by 7.233

To convert units Kg.cm to Kg.m multiply values by 0.01
IMPORTANT:
Every time when you will tighten stainless steel screws or nuts use anti-seize thread lubricant.
51
11.Refrigeration System Maintenance
Some these service procedures on the refrigeration system can be regulated by Federal, State or Local
laws. Please check the situation and coordinate all the actions with this regulations and Health&Safety
rules.
All regulated refrigeration service procedures must be performed by an EPA certified technician, using
approved equipment and complying with all Federal, State and Local laws.
WARNING: Make sure the unit and bus cannot start while servicing the system.
WARNING: Covers must be completely removed from the unit to access interior of
unit. Insure you are using best practice for working at height paying special attention
during removal of cover as it could move due to the influence of the wind.
IMPORTANT:
When charging the refrigeration system, always charge from liquid side and use the refrigerant in a
liquid state. Don't charge vapor in the system!
Thermo King recommend always to replace the whole (remaining) refrigerant and recycle the
retrieved portion properly per governing laws. Then use new refrigeration charge by correct
recommended weight in liquid state. In case of leak do not “top off” the refrigeration system.
Basic steps in case of troubles with refrigeration system:

4. Recovery (disposal) of remaining refrigerant
 Vapor recovery
 Liquid recovery
5. Leak Test - identification, location of point of trouble
6. Repair & Check
7. Evacuation
 System preparation and hookup
 Evacuation
 Pressure rise test
8. Charging
9. Functional test of system
General information
If refrigerant has leaked or been removed from the system, check entire system for possible component
damage and compressor oil loss.
If any system leak or damage was found, repair the system, recheck the system after repair and conduct
system evacuation.
If the system has some remaining pressure (some refrigerant is present in the system), and the leak is
NOT found, using a leak detector is recommended. Soap and bubbles is the best tool to check minute
leaks that the electronic leak detectors cannot find.
52
If the leak is already found and the system is almost flat (empty), we recommend evacuating the system
AFTER the repair is done (for example after tightening a fitting).
After any repair we recommend to execute the Leak Test to be sure that system is tight.
As the oil used in scroll compressor is very viscous, rarely an oil charge would be lost. If this happens,
the compressor would have failed already and it that case we recommend replacing the compressor (or
two compressors in sets of 2, depending on unit design), charging the proper oil charge for new
compressor(s) and do the evacuation and charging procedures described further. After compressor
replacement recheck the system again.
It is generally good practice to replace the filter-drier whenever the system is opened and exposed to
ambient for an extended period of time. Refer to the Refrigeration Manual (Thermo King Manual TK
50951) for system cleanup after a compressor failure or repair or replacement of basic components.
IF THERE IS A SUSPICION OF BIG LEAK, IT IS RECOMMENDED THE WHOLE CHARGE IS
RETRIEVED (REMOVED) AND A NEW CHARGE IS PLACED INTO THE SYSTEM AFTER
PERFORMING THE EVACUATION AND CLEANUP STEPS - SEE IMPORTANT NOTE ABOVE.
In the following text are procedures usually described by using of Thermo King evacuation station.
Always follow the safety instructions, procedures and working instructions in specific equipment
manufacturer’s documentation.
11.1. Service Tools
CAUTION: When servicing Thermo King R-134a refrigeration systems, use only
service tools (i.e., vacuum pump, refrigerant recovery equipment, gauge hoses, and
gauge manifold set) certified for and dedicated to R-134a refrigerant and Polyol Ester
based compressor oils. Residual non-HFC refrigerants or non-Ester based oils will
contaminate HFC systems.
Unit Service Fittings

The unit uses a hermetically sealed refrigeration system. If you need to recover the refrigerant charge,
you must use the appropriate fittings to connection on service (access) ports (if no service (access) ports
are present then fittings under low (LPCO) or high (HPCO) pressure switches can be used). Install the
service fittings on the suction line and discharge line process tubes located in the compressor
compartment.
Leak Detectors
Detect leaks with soap bubbles and with Halogen leak detector such us model H10G (TK 204-712) or
portable model H10N (TK 204-756) Or certified 407C leak detector from respectable suppliers.
Manifold Gauge Set and Hoses

Use a manifold gauge set and hoses dedicated for use with R-134a only.
Evacuation Station
A key element in maintaining high efficiency and low maintenance cost in a transport refrigeration
system is the ability to keep the system free of moisture a non condensable materials. Contaminants and
moisture are best removed by a vacuum system. The Thermo King Evacuation Station TK 204-725 has
been designed to efficiently evacuate the refrigeration system for all Thermo King products.
53
Vacuum Pump
Use a two-stage (for example TK 204-713 or TK 204-699), three-stage, or five-stage pump for
evacuation. Because residual refrigerant may be present in used vacuum pumps, a new pump should be
used and dedicated strictly as an R-134a refrigerant pump. Use only recommended vacuum pump oils
and change oil after every major evacuation. Because vacuum pump oils are highly refined to obtain
low vacuums, failure to follow these recommendations may result in acidic conditions that will destroy
the pump.
System Cleanup Devices

Use cleanup devices such as suction line filters if they are properly cleaned with new filters and
cartridges. Remove all standard petroleum and synthetic compressor oils to prevent contamination of R-
134a systems.
Refrigerant Recovery
Use only refrigerant recovery equipment approved for and dedicated to R-134a recovery.
Compressor Oil Acid Test

Perform an oil acid test (oil test kit TK203-457) whenever a system has a substantial refrigerant loss, a
noisy compressor, or dark/dirty oil - see chapter „Compressor Oil Color Code“.
11.2. Contamination
When contaminants have entered the system, a thorough cleanup is required to prevent damage or loss
of compressor. The purpose of evacuation is to remove moisture and air from the refrigeration system.
Even small quantities of air or moisture in a system can cause severe problems.
The presence of moisture, oxygen, and heat under certain conditions can result in many forms of
drainage. Corrosion, sludge, copper plating, oil breakdown, carbon formation, and eventual compressor
failure can be caused by these contaminants. Things that will contaminate a system are (in order of
importance):
 Air (oxygen as a contaminant). Oxygen in the air reacts with the oil. The oil begins to break
down and can eventually lead to carbonization in the compressor and acid buildup. The longer
this breakdown process goes on, the darker the compressor oil becomes until finally the color is
black, indicating major system contamination.
 Moisture in a system will cause metal corrosion and plating. It can freeze in the expansion valve
and cause intermittent operational problems. It reacts in the oil to begin acid buildup.
 Dirt, dust, metal particles, other foreign materials. Particles in the system will cause severe
damage to all close tolerance items. Don't leave a system open to the infiltration of dirt. If you
must open a system for any reason, seal off the open areas as soon as possible. Don't work in a
dirty environment.
 Acid. Air and moisture cause a chemical breakdown of the oil and the refrigerant. The acid will
accelerate the deterioration of the softer metals (i.e., copper) and cause metal plating as the
softer material begins to cover the inside of the system. This condition can result in the total
destruction of your equipment.
IF ANY OF THE ABOVE CONDITIONS ARE PRESENT PLEASE RECYCLE THE REFRIGERANT,
PERFORM A REFRIGERATION SYSTEM CLEANUP - USE A NEW REFRIGERANT THAT HAS NOT
BEEN CONTAMINATED.
54
11.3. Compressor Oil Color Code
When unusual color of oil is detected or presence of moisture is signalized by moisture indicator then
perform a compressor oil acid test.
 Black oil indicates carbonization caused by air in the system.
 Brown oil indicates copper plating caused by moisture in the system.
 Gray or metallic oil indicates bearing wear or piston scoring.
IF THE COMPRESSOR OIL SHOWS AN ACID CONDITION, CHANGE THE OIL, THE IN-LINE
OIL FILTER, THE FILTER-DRIER AND PERFORM A REFRIGERATION SYSTEM CLEANUP.
11.4. Refrigerant Recovery
CAUTION: Use only refrigerant recovery equipment approved for and dedicated to
R-134a recovery.
It is recommended the whole charge is retrieved and a new charge is placed into the system after
performing the leak and evacuation steps.
When removing refrigerant from a Thermo King refrigeration system, use a recovery process that
prevents or absolutely minimizes the refrigerant that can escape to the atmosphere. Typical service
procedures that require removal of refrigerant from the system include:
 Reducing the refrigerant pressure to a safe working level when maintenance must be performed
on high-pressure side components.
 Emptying the system of refrigerant when an unknown amount of charge is in the system and a
proper charge is required.
 Emptying the system of contaminated refrigerant when the system has become contaminated.
Procedure
1. Locate the service (access) ports on high pressure side (compressor output pipe) and low pressure
side (compressor input line). Carefully remove the caps from ports. If no service (access) ports are
present then fittings under low (LPCO) or high (HPCO) pressure switches can be used.
2. Install a gauge manifold low pressure line to the service (access) ports on low pressure side
(compressor input pipe). Attach the gauge manifold high pressure line to the service (access) ports
on high pressure side (discharge line - compressor output pipe). Attach the service line to the
recovery station. Purge the lines.
Vapor Recovery
1. Install a gauge manifold on the system. Attach the service line to the recovery machine and purge
the lines. Set the recovery machine for vapor recovery.
2. Keep the system OFF and partially open (mid-seat) the discharge line service valve.
3. Turn on the recovery machine and open (back seat) both gauge manifold and hand valves.
4. Continue to operate the recovery machine until system pressures drop to 0 kPa (0 bar, 0 psig)
pressure. Follow the liquid recovery instruction in next section.
55
Liquid Recovery
1. Switch ON and operate the system to build discharge pressures to approximately 1380 kPa (13.80
bar, 200 psig).
2. Stop the refrigeration system. Set the recovery station for liquid recovery and turn the station on.
3. Open (back seat) the manifold gauge high pressure hand valve.
4. Operate the recovery machine until the system pressures reach approx. 0 kPa (0 bar, 0 psig).
5. Close the manifold gauge valves, stop the recovery station and disconnect the lines.
11.5. Refrigerant Leak Test Procedure

Use a reliable Halogen leak detector such as model H10G (TK No. 204-712) or model H10N (TK No.
204-756) - portable, to leak test the refrigeration system. Inspect carefully for signs of compressor oil
leakage, which is the first sign of a leak in the refrigeration system.
NOTE: Due to environmental concerns and personal safety, the use of a Halide torch is no longer
recommended.
Procedure
1. Locate the service (access) ports on high pressure side (compressor output pipe) and low pressure
side (compressor input line). Carefully remove the caps from ports. If no service (access) ports are
present then fittings under low (LPCO) or high (HPCO) pressure switches can be used.
2. Attach gauge manifold compound gauge line to the port on low pressure side (near low pressure
cutout switch, LPCO). Attach high pressure gauge line to the port on high pressure side (near high
pressure cutout switch, HPCO).
3. Attach a refrigerant bottle charging hose to center of manifold gauge set. Purge charging hose of
air.
4. Connect the charging hose to a source of nitrogen - see chapter „Using Pressurized Nitrogen“
below, carefully follow the safety precautions!
CAUTION: Nitrogen (N2) is under 15,170 kPa (151.70 bar) pressure in a full
cylinder at 21°C. Do not use oxygen, acetylene, or any other type of pressurized gas in
the system.
Figure 26: Testing for Refrigeration Leaks
56
5. Pressurize the system with neutral Nitrogen (gas) until 345 kPa (3.45 bar) vapor pressure is
achieved.
6. Close both hand valves on manifold gauge (front seated).
7. Close the supply valve on the nitrogen bottle.
8. Disconnect the refrigerant charging hose.
9. Check the system with an electronic leak detector to inspect all joints and connections. (Use soap
solution as an alternative test component.)
10. Release pressure and reclaim nitrogen back from system.
11.6. Evacuation
Before performing an evacuation be sure you have conducted the leak check and the system is repaired
and no leaks are found.
System Preparation and Connecting to Evacuation Station
CAUTION: Do not evacuate a system until you are certain that the system is leak
free. A system with less than a full charge of refrigerant should be thoroughly leak
tested. Leaks found must be repaired.
1. Recover refrigerant from the system - see Chapter „Refrigerant Recovery“ and reduce the system
pressure to the proper level (US Federal Law requires a -17 to -34 kPa [-0.17 to -0.34 bar, 5 to 10
in. Hg] vacuum that is dependent upon the recovery equipment used).
2. Break vacuum with refrigerant and equalize system pressure to 0 kPa (0 bar, 0 psig). Replace the
liquid line filter-drier (dehydrator) in refrigeration system.
3. Confirm that the evacuation station functions properly and determine “Blank Off” Pressure. The
Blank Off Pressure of the Vacuum Pump is the deepest vacuum that the vacuum pump an attain
when isolated from the rest of the system. If a vacuum pump (isolated from a system) is started and
the micron meter responds quickly by going to a deep vacuum, the operator can be confident that
the pump and oil are in good condition. If the vacuum pump fails to reach a deep vacuum within 5
minutes, the operator should suspect the condition of the oil or the pump. It is recommended that
the pump oil be changed first to see if the rate of reaching a deep vacuum is improved.
4. Connect the evacuation station and refrigerant tank with manifold gauge set (optional) to the
system as indicated in example on the diagram on Figure 29 on page 58. Connect evacuation hoses
to the fittings (service access ports) installed on the suction line and liquid line - see high pressure
side (compressor output pipe) and low pressure side (discharge line - compressor output pipe). If
no service (access) ports are present then fittings under low (LPCO) or high (HPCO) pressure
switches can be used.
5. Open evacuation station valves (V1, V3 and V4). It is only necessary to open valve V2 when a
reading on the Micron Meter is desired. This is especially true when starting to evacuate a system
and large amounts of moisture and oil will be passing by the sensor.
6. Open the vacuum pump „Iso Valve“ built into the pump housing below the handle. It is
recommended that the valve be kept open at all times.
7. If connecting a refrigerant tank and gauge manifold to the evacuation station, close the manifold
gauge and refrigerant tank valves to prevent refrigerant from being drawn from the tank.
57
1
V4
V3
V2
2
V1
3
4
6
5 7
8 BEA700
1 Service connection ports (example) 6 Gas ballast valve

2 Sensor 7 ISO valve
3 Micron Meter 8 Two stage vacuum pump
4 Calibration Standard V1, V2, V3, V4 - valves
5 To AC Power
Figure 27: Evacuation Station and Unit Hookup (example)
System Evacuation
1. Turn on the vacuum pump. Open the gas ballast valve located on top of the pump housing behind
the handle (the valve is fully open at two turns counterclockwise). Evacuate the system to 500
microns to achieve a final equilibrium pressure of 2000 microns or less. The final equilibrium
pressure is determined with the Thermo King Evacuation Station using the following procedure
(called a pressure-rise test):
a. Evacuate the system using the evacuation station until the vacuum level reaches 1000 microns.
Then close the gas ballast valve.
b. Continue evacuation to 500 microns or until vacuum stabilizes at its lowest level. Contamination
may delay reaching the lowest level for a period of several or more hours.
c. Close valve to isolate the vacuum pump from the system.
d. Observe the vacuum level on the micron meter. When the meter has stabilized, the value indica-
ted on the micron meter is the equilibrium pressure. This reading must be 2000 microns or less.
NOTE: The presence of refrigerant in the compressor oil may prevent a low vacuum reading from
being achieved. Compressor oil can continue to outages for long periods of time.
58
2. If the vacuum level appears to stall above 500 microns, back seat the discharge service valve and
observe the micron meter.
3. Close valve V1 when the desired vacuum level has been reached.
4. Wait five minutes then read the micron meter.
5. If the vacuum level remained below 2000 microns for five minutes, the system is ready to charge.
a. A system that is leak free and dry will remain below 2000 microns for five minutes.
b. A system that rises above 2000 microns but stabilizes below atmospheric pressure is probably
contaminated with moisture or has refrigerant outgassing from the compressor oil. Additional
evacuation is required.
c. A drop in pressure indicates that the compressor oil is out-gassing and further evacuation is
necessary.
d. An increase in pressure indicates that a leak exists or there is moisture in the system. Perform a
“Pressure Rise Test” and evaluate.
e. A system that continues to rise without stabilizing has a leak and must be repaired.
Pressure Rise Test

Evacuate the system and close valve V1. With valves V3 and V4 open, the pump is isolated and the
system is held under a vacuum. If the micron meter rises, one of the following conditions exist.
 Leak
Watch the movement of the micron meter needle indicating pressure level. If the needle
continues to rise (the pressure in system increase) until it reaches atmospheric pressure, it is an
indication that a leak exists somewhere in the system. When a leak is in a system, the vacuum
will eventually stabilize at atmospheric pressure.
4
1 Constant Pressure Rise Indicates Leak

2 Time Axis
1
3 Pressure (Vacuum)
4 Atmospheric Pressure
Figure 28: Constant Pressure Rise After Evacuation Indicates System Leak
59
 Moisture
When the pressure rise and then stabilizes at a level below atmospheric pressure, this indicates
that the system is vacuum tight, but is still wet and requires additional dehydration and
evacuation time.
4
1 Pressure Rise that Levels Off

Indicates Leak
2 Time Axis
1
3 Pressure (Vacuum)
4 Atmospheric Pressure
2
Figure 29: Pressure Rise that Levels Off After Evacuation Indicates Moisture in System
Factors Affecting the Speed of System Evacuation

The time required to evacuate a system varies. Factors that influence evacuation time are:
 System size
 Amount of moisture contained in the system
 Ambient temperature
 Internal restrictions within the system
 External restrictions between the system and the vacuum pump
 Hose diameter and length. Laboratory tests show that the evacuation time can be significantly
reduced by larger diameter hoses and shorter hoses. To obtain optimum pumping speed, keep
hoses as short as possible and as large in diameter as possible.
Heat Saves Time

Applying heat to a system decreases evacuation time. Increasing the temperature of the compressor oil
and refrigerant speeds up the vaporization of any water present in the system. Heat lamps, electric
heaters, and fans can be applied to the compressor crankcase and other parts of the system to increase
the temperature of the refrigerant and compressor oil.
WARNING: Do not use a torch or other concentrated heat source to heat the
compressor or other refrigeration system component.
End of Evacuation Process

1. Close valve V4.
2. Open the gas ballast valve (located on top of the pump housing behind the handle).
3. Stop the vacuum pump.
60
11.7. System Charging from an Evacuated Condition
IMPORTANT:
When charging the system, always charge from liquid side and use the refrigerant in a liquid
state. Do not charge vapor in the system!
In case of leak do not “top off” the refrigeration system. Always reclaim all remaining charge
(and send it to special recycling stores) and use new refrigeration charge by correct
recommended weight in liquid state.
1. Connect the charging hose to the port on high pressure side (on liquid line, near high pressure
cutout switch, HPCO). if no service (access) port is present then fitting under high (HPCO)
pressure switch can be used.
2. Charge the proper amount of liquid refrigerant into system, for example by using a „push/pull“
reclaim unit. For amount of the R-134a refrigerant see “Specifications”.
3. Close the refrigerant tank valve when the correct amount (by weight) of refrigerant has been added.
4. Remove charging hose and reinstall caps on service (access) ports (or high pressure cutout HPCO
valve if necessary). Check this connecting points with an electronic leak detector.
5. Perform a system functional check out.
11.8. Using Pressurized Nitrogen
WARNING: Nitrogen (N2) is under 15,170 kPa (151.70 bar, 2200 psig) or greater
pressure. Pressure is for full cylinder at 21 C (70 F). Do not use Oxygen (02),
acetylene, or any other pressurized gas on refrigeration systems or any component of a
system.
Safety Precautions
Observe the proper handling of cylinders:
 Keep protective cap on cylinder when not in use.
 Secure cylinder in proper storage area or fastened to cart.
 Do not expose to excessive heat or direct sun light.
 Do not drop, dent, or damage cylinder.
 Use a pressure regulator and a safety pressure relief valve as part of the pressure testing
equipment. The safety pressure relief valve should be the non- adjustable, non-tempering type.
The valve should bypass any time the pressure exceeds its setting.
 Open valve slowly. Use regulators and safety valves that are in good working order.
 The regulator should have two gauges: one to read tank pressure, the other to read line pressure.
Properly maintained equipment will allow leak testing, purging, and dehydration to be done
safely.
61
1 Line Pressure
2 Tank Pressure
3 Tank
4 Pressure Test Line to System
5 Safety Valve
6 Pressure Regulator
Figure 30: Typical pressurized gas bottle with pressure regulator and gauges
With dry nitrogen (N2), you can dehydrate, pressure test, purge, and solder refrigeration systems.
Always use the correct equipment in the correct way to ensure safety.
WARNING: Improper use of high pressure cylinders can cause physical damage to
components, personal injury, and cause stress that leads to failure of components.
Procedure
1. Attach a gauge manifold. Close both hand valves on the gauge manifold (front seated).
2. Connect charging hose to nitrogen source. Adjust pressure regulator to the proper pressure for the
required procedure.
3. Purge system high side to low side. The following procedures should use the following maximum
gas pressures:
 Leak Testing: 1034 to 1200 kPa
 Purging/Dehydration: 69 to 138 kPa
 Soldering: 35 kPa
62
12.Refrigeration/Heating Repairs
WARNING: Before any repair the side covers must be completely removed from the
unit to access interior of unit. Insure you are using best practice for working at height
paying special attention during removal of cover as it could move due to the influence
of the wind.
12.1. Filter-Drier Replacement

Removal
1. Switch OFF the unit/control system. Turn OFF all power supply.
2. Locate the filter-drier, release and remove the side cover.
3. Release and remove the fixing holder.
4. Carefully release and disconnect the filter-drier fittings and remove the filter-drier from the system.
NOTE: Hold the filter-drier with a backup wrench to keep from twisting the tubes.
8
2
BEA723
4 5 6
1 Condenser coil 5 Filter-drier

2 Unit frame 6 Fixing holder
3 Pipe from tank receiver / condensers 7 Sight glass (liquid indicator)
4 Connection fittings (inlet) 8 Pipe to evaporators
Figure 31: Filter-Drier Installation (example)
Installation
1. Clean connection fittings.
2. Remove the protective plugs from the new filter-drier, install new O-rings (supplied with new
filter-drier), and apply to the threads appropriate amount of oil of the same type used in the
63
compressor to the O-rings and threads.
3. Install the new filter-drier as quickly as possible and observe the following considerations:
 Observe the “IN” designation printed on the inlet side of the filter-drier. To prevent improper
installation of the filter-drier, ensure the arrow on the filter-drier points in the direction of
refrigerant flow.
 Hold the filter-drier with a backup wrench to keep from twisting the tubes when tightening or
removing the nuts.
 The longer the filter-drier remains open to air, the more moisture it will absorb.
4. Fix the filter drier with clamp.
5. Evacuate the filter-drier section - filter-drier and tubing between the two service valves:
 Hook the evacuation equipment hoses to the service ports on the filter-drier inlet valve and
outlet valve.
 Evacuate the filter-drier section (for more information refer to chapter 11).
6. Leak test all fittings, secure the valve packing, to prevent leakage of refrigerant.
7. Switch ON A/C system and test the functionality.
8. Close covers and fix cover with fixing bolts.
12.2. Thermostatic Expansion Valve Replacement

The thermostatic expansion valve meters liquid refrigerant into the evaporator coil at a predetermined
rate to keep the coil fully refrigerated and ensure complete vaporization of the refrigerant before it
leaves the coil. The expansion valve is controlled by the temperature and the pressure in the suction
line.
Thermo King expansion valves are factory preset and do not require adjustment. When diagnosing
refrigeration problems, eliminate other possible causes before servicing the valve.
The expansion valve must be serviced by an experienced refrigeration mechanic.
BEA724
Figure 32: Thermostatic expansion valve installation (example)
64
Usually two services are performed on the expansion valve:
1. Replacing a damaged power element. A broken power element causes the valve to close and the
unit to operate in a vacuum.
2. Cleaning and securing the power element sensor bulb to the suction line. Poor contact of the sensor
bulb causes the valve to operate by air temperature, indicated by frosting of the suction line and a
slight rise in suction pressure to flooding of the coil. Wrap the bulb and suction line with insulating
tape, TK Part No. 203-428.
C
4
5
B
1
6 BEA427
1 Sensor bulb 5 Fixed orifice A Side view

2 Outlet pipe 6 Filter B End view
3 Power head 7 Inlet pipe C Location of bulb on side of suction
4 line 4 or 8 o’clock position
Adjustment
Figure 33: Example of solder type valve and sensor bulb position
Sensor Bulb Contact

1. Remove the insulating tape from the sensor bulb, mark the original bulb position.
2. Loosen two copper bands, remove the sensor bulb from the suction line.
3. Clean the suction line and the sensor bulb with fine abrasive paper or cloth. Do not use acids or
polishes to clean copper.
4. Coat the sensor bulb and suction line with a light film of oil to prevent oxidation.
5. Install the sensor bulb in clamps on the side of the line in the original position. Tighten the clamps
and replace the insulation on the bulb.
65
Superheat: Measurement and Adjustment
NOTE: Be sure the temperature reading instrument and compound pressure gauge are calibrated.
Measurement
1. Install a pressure gauge in the expansion valve external equalizer line. This will indicate the
pressure.
2. Run the unit. Allow the system to run until the interior of the bus has cooled to within 5 degrees of
thermostat set point.
3. Subtract the temperature reading obtained from the suction line near the expansion valve sensor
bulb on the unit suction line to obtain the expansion valve superheat setting. Using the Pressure-
Temperature Chart in this manual, convert the pressure measured at the equalizer line to the
equivalent temperature.
Example:
Sensor Bulb Suction Line Temperature (°C/F)
-Suction Pressure Temperature Conversion (°C/F)
=Superheat (K)
NOTE: To properly check the superheat, you must have a stable condition. To establish a stable
operating condition, run the unit at least 15 minutes so the evaporator air inlet temperature reaches
21 °C to 27 °C (70 °F to 80 °F). Read the pressure and temperature difference simultaneously.
Temperature difference should be 5.5 to 8 K.
CAUTION: Thermo King expansion valves are factory preset and do not require
adjustment. Establishing controlled conditions in the field is difficult. Before adjusting
the expansion valve, check the following causes for an out-of-range reading.
4. Check the following:

 Dirty air filters or other cause of reduced air flow.
 Sensor bulb leaking, bulb placed improperly on refrigerant line, or bulb not properly wrapped
with insulating tape.
 Kinked capillary tube.
5. After the above items have been checked, replace the expansion valve with a factory preset part if
necessary.
Adjustment
1. Remove the cap over the adjusting stem.
2. To reduce superheat, turn the adjusting stem counterclockwise.
3. Make no more than one turn of the stem at one time. Observe the change in superheat closely to
prevent overshooting the desired setting. As much as 30 minutes may be required to obtain the new
balance after the adjustment has been made.
4. Remove the pressure gauge and thermometer from the equalizer line.
5. Return bus to service.
66
Thermostatic Expansion Valve Removal
DANGER: Do not solder on a closed system. Pressure can build up and may cause
an explosion. If soldering is required, use dry nitrogen to purge the system during any
solder operations. Refer to “Using Pressurized Nitrogen”.
Removal
2. Locate the expansion valve, release and remove the cover from top or side cover (always remove
the cover to avoid any damage).
3. Recover the refrigerant from the system. See chapter 11 and refer to “Evacuation procedure”.
4. Remove the insulation.
5. Remove the sensor bulb from the clamps, taking care not to kink the capillary tube.
6. Unsolder the equalizer and the inlet and outlet line connections. Remove the expansion valve.
Installation
1. Clean tubing connections before installing the valve.
2. Compare the new valve to the one removed. Adjust the length of the sensor bulb capillary tube.
Secure it to the valve body in the same manner as the original valve. This prevents damage to the
tube by vibration-induced chafing. Once the length is adjusted, feed the bulb through the required
routing.
3. Position the valve in the unit, insert the grommet if necessary and solder the equalizer and the inlet
and outlet lines. Use a heat sink to prevent damage to the valve.
4. Taking care not to kink the capillary tube, position the remote sensor bulb in the clamp on the side
of the suction line in exactly the same spot from which it was removed.
5. Charge the system, once the charging has been completed pressurize the unit and check for leaks.
6. Add insulation where necessary.
7. Switch ON A/C system, start the unit and test the functionality.
67
12.3. Pressure Switches Replacement
The rooftop unit contains three pressure switches - HPCO, CPS, LPCO. These switches are basically
the same design, located in one place, the replacement procedure is very similar.
NOTE: Before starting replacement procedure, use your parts manual to identify the correct spare
pressure switch for your unit.
1 2 3 4
BEA725
5 6 7
1 CPS pressure switch 5 Fixing binder

2 HPCO pressure switch 6 Connection flange (output pipe)
3 Service port 7 LPCO pressure switch
4 FrontBox connection pipe (optional)
Figure 34: Pressure switches installation (example)
Removal
2. Release fixing bolts, carefully open and remove side cover.
3. Fix the cover in open position by cover support.
4. Locate the non-functional pressure switch.
5. Check and ensure there is no voltage present, disconnect pressure switch connector, release the
wires, remove fixing binders.
6. Remove the pressure switch.
NOTE: Install the new switch immediately to minimize the amount of air entering the system.
68
Installation
1. Clean connection thread from rests of sealing.
2. Apply threadlocker Loctite(TM) to the threads of the new switch.
3. Install new switch, connect the wires, fix the wires with binders.
4. Pressurize the unit and check for leaks.
6. Insert and close side cover, fix the cover with fixing bolts.
12.4. Relief Valve Replacement

The relief valve contains a spring loaded piston that lifts when the refrigerant pressure exceeds the
spring force. When pressure drops below set point, the valve will reset. The valve might leak refrigerant
after it has relieved excess pressure. Tapping the valve lightly may help the valve reseat and seal
properly.
The valve is non-repairable and requires no adjustment. If the valve fails to reseat properly, the valve
must be replaced.
NOTE: Before starting replacement procedure, use your parts manual to identify the correct valve
for your unit.
Removal
2. Carefully open and remove both side covers.
3. Release, disconnect and remove both condenser fans, unrivet the condenser cover (remove all
rivets on perimeter and 6 rivets from central part of cover), remove the condenser cover.
4. Recover the refrigerant from the system. See chapter 11 and refer to “Evacuation procedure”.
5. Remove the valve.
NOTE: Install the new switch immediately to minimize the amount of air entering the system
Installation
1. Apply threadlocker Loctite(TM) to the threads of the new sensor.
2. Install and tighten new valve.
3. Evacuate the system (for more information refer to chapter 11 Refrigeration System Maintenance).
4. Charge the system - see chapter 12 on page 61.
5. Once the charging has been completed pressurize the unit and check for leaks.
6. Return the condenser cover in original position, use appropriate rivets to fix the cover, insert and
connect the condenser fans, fix the fans with bolts.
7. Close and fix both side cover with fixing bolts.
69
13.Electrical Maintenance & Repairs
IMPORTANT: SAFETY FIRST! When servicing or repairing an air conditioning unit, the
possibility of serious or even fatal injury from electrical shock exists. Extreme care must be
used when working with a air conditioning unit. Always respect safety rules, follow “Safety
Precautions”, respect valid local laws and general Health&Safety prescripts.
of the wind.
Inspect and maintain electrical parts under “Maintenance Inspection Schedule”.
Preventively spray contacts and terminals with an electrical cleaner. A good grade of cleaner will also
provide waterproofing that can help prevent voltage leaks.
13.1. Relays and fuses replacement

Relays and fuses are located on both sides of control panel (electrical switchboard). The relays on top of
panel are accessible via top cover, the fuses are accessible from bottom (through bus ceiling). For
access to fuses is necessary open return air grille.
1 2 3 4 5
BEA726
6 7 8
1 Unit frame 5 RTS sensor

2 Harnesses 6 Fixing binders
3 RTS connector 7 Fuses (not visible, on back side of board)
4 Relays 8 Board
Figure 35: Electrical switchboard (example)
70
Procedure - Relays
2. Release all fixing bolts on top rear cover, carefully remove the top rear cover.
3. Check and ensure there is no voltage present.
4. Locate the reason of dysfunction, check why the relay was broken. Eliminate the problem first.
5. For more details refer to schematic and wiring diagrams. In case of any question or unclear
situation please contact your supplier or directly Thermo King manufacturer.
6. Pull out damaged relay, install new relay (parameters of new part must correspond to the old one).
7. Return the top rear cover in original position, use appropriate bolts to fix the cover.
Procedure - Fuses
2. Release and open return air grille: use cross-head screwdriver, unscrew all bolts and slowly swing
down the return air grille.
4. Locate the reason of dysfunction, check why the fuse was broken. Eliminate the problem first.
5. For more details refer to schematic and wiring diagrams. In case of any question or unclear
situation please contact your supplier or directly Thermo King manufacturer.
6. Pull out damaged part, to remove damaged fuse always use the fuse extractor tool.
BEA435
Figure 36: Fuse extractor
7. Install new fuse, parameters of new part must correspond to the old one.
8. Install the return air grille with filter, close the grille, carefully fix the grille with fixing bolts.
Overvoltage Suppressor
To the power supply terminals is connected overvoltage suppressor. If replacement is necessary just
release and remove the bolts from terminal, unscrew the fixing bolts. Take a care of connection of new
suppressor, assure the correct polarity, red wire connects to (+) terminal, blue wire to (-) terminal.
71
13.2. Evaporator Blower Replacement
Removal
2. Release all 3 fixing bolts, carefully open and remove side cover.
4. Disconnect the connectors of blower wiring from resistor block, tag the connector's position.
5. Remove fixing binder where necessary.
6. Unscrew fixing bolts and release blower holders on both sides of blower.
7. Lift the entire blower assembly from unit. 10 9
1
8
2
5
7
6
BEA727
1 Coil filter 6 ABS base plate

2 Evaporator coil 7 Unit frame
3 Drain pad 8 Insulation
4 Evaporator blower 9 Resistor block
5 Harness with fixing binders 10 Coil filter holder
Figure 37: Evaporator blower installation (example)
Installation
1. Insert a new blower into unit, insert blower holders and tighten the fixing bolts.
2. Connect the connector of blower wiring to resistor block (check the tags for the same position), fix
the wires with fixing binder where necessary.
72
4. Return the side cover into original position, fix cover with fixing bolts.
13.3. Condenser Fan Replacement
BEA030
Figure 38: Condenser fan assembly (example)
The condenser axial fan is a non-repairable assembly with non-detachable motor. When this motor
malfunctions, the complete fan assembly must be replaced.
Fan Removal
1. Switch OFF the unit/control system.Turn OFF all power supply.
2. Check and ensure there is no voltage present and the fan cannot start.
3. Release 4 fixing bolts on the perimeter of fan, remove the fan from his position and move the fan
on the top of cover.
4. Locate and disconnect fan cable.
Motor Test Procedure

Refer to the “Specifications” chapter for correct voltage.
To test the motor:
1. Disconnect the motor power plug from the unit wire harness.
2. Apply 12 / 24 VDC to the red wire and ground to the black wire. The motor should run at full
speed. If it does not, then the motor is not operable and must be replaced.
73
3. Disconnect the black wire from ground and the motor should stop. If the motor fails this test, it
must be replaced.
BEA677
3
4
1 Condenser compartment cover 3 Fixing bolts

2 Condenser fan in operating position 4 Unit frame with insulation
Figure 39: Condenser fan (example)
Installation
1. Check the electrical parameters on new fan.
2. Set new fan on the top of cover, connect the fan connector, fix the cable with fixing binders. Use
the grommet to safe the fan cable on the cover edge.
3. Insert the fan into operating position, insert the fixing bolts with washers, tighten the bolts.
74
13.4. Fresh Air Damper Motor Replacement
NOTE: Fresh air damper is optional accessories, not all units are equipped with fresh air
damper motor.
The damper motor (TK 41-2755) is a non-repairable DC motor used for fresh air damper applications in
bus A/C units.
Before damper motor replacement use following tests to determine if the motor is functioning correctly.
AFR73
Figure 40: Damper Connector Plug Wiring Diagram
Rotation Test
1. Apply + 24 Vdc on Pin 6 and ground Pin 4. The actuator shaft should turn counter clockwise.
2. Apply + 24 Vdc on Pin 4 and ground Pin 6. The actuator shaft should turn clockwise.
Ohmmeter Test
1. Place an ohmmeter between pins 1 and 3.
2. The ohmmeter should read 4.7 KOhm ± 20 percent.
3. Place the ohmmeter test leads between pins 1and 2. Apply + 24 Vdc on Pin 6 and ground Pin 4.
The actuator shaft should turn counter clockwise.
4. The ohmmeter should read less than 1 KOhm.
5. Apply + 24 Vdc on Pin 4 and ground Pin 6. The actuator shaft should turn clockwise.
6. The ohmmeter should read greater than 3 KOhm.
NOTE: If actuator fails these tests, it must be replaced.
Damper Motor Removal

NOTE: The damper motor can be removed without disassembling of the fresh air system.
1. Switch OFF the unit/control system. Turn OFF all power supply. Ensure the unit and bus can't run
while you are servicing the system.
2. Release all fixing bolts on top rear cover, carefully remove the top rear cover.
3. Locate the non-functional air damper motor.
4. Unplug the cable from damper motor connector, release the fixing binder where necessary.
5. Release the fixing bolts, remove (pull out) the damper motor from unit.
75
2
AFR74
1. Connector plug 3. Actuator shaft

2. Mounting screw holes for fixing bolts
Figure 41: Fresh Air Damper Motor
Installation
1. Insert new or repaired damper motor into original position, insert the fixing bolts with washers,
tight the bolts.
2. Connect the damper motor connector, fix the cable with fixing binders where necessary.
3. Return the top rear cover in original position, use appropriate bolts to fix the cover.
13.5. Ambient Temperature Sensor Replacement

Removal
2. Carefully open and remove both side covers.
3. Release, disconnect and remove both condenser fans, unrivet the condenser cover (remove all
rivets on perimeter and 6 rivets from central part of cover), remove the condenser cover.
4. Disconnect temperature sensor connector, release and remove fixing binders, release grommet from
unit frame.
5. Remove the temperature sensor.
76
1
3 7
BEA728
4 2 5 6
1 Top cover 5 Temperature sensor

2 Unit frame 6 Grommet
3 Condenser coil (right side) 7 Condenser coil (left side)
4 Fixing binders
Figure 42: Ambient temperature sensor (example)
Installation
1. Pull up the grommet on new sensor wires, the sensor pull through the hole in unit frame.
2. Fix the sensor with binders to the frame, set the grommet to correct position, connect the
connectors.
3. Return the condenser cover in original position, use appropriate rivets to fix the cover, insert and
connect the condenser fans, fix the fans with bolts.
4. Close and fix both side cover with fixing bolts.
6. Insert and close both side covers, fix the covers with fixing bolts.
77
14.Mechanical Maintenance & Repairs
of the wind.
14.1. Unit Maintenance

Inspect the unit under schedule in chapter “Service Guide”.
If you have any queries, please contact your local dealer or Thermo King Service.
14.2. Cleaning
HVAC Unit Box and Covers
Use a mild alkaline cleaner or common cleaning agent to clean the cover.
Frequently open both side covers and fresh air damper cover and use vacuum cleaner to dirt, debris,
impurities from coils, grilles and complete unit inside area.
CAUTION: Before cleaning (opening the rooftop unit) always switch OFF the
unit/control system.
Unit Evaporator Coils

Clean the evaporator coils by blowing low pressure compressed air both sides of the coil. The vacuum
cleaner can be also carefully used. At the end inspect coil and fins for damage, and repair if necessary.
Check the drain pan area for cleanliness, remove all solid impurities and dust.
CAUTION: Don’t use water or water spray to clean evaporator coil!
Unit Condenser Coils

Before cleaning:
1. Switch OFF the unit/control system. Turn OFF all power supply
2. Open and remove both side covers
3. Release, disconnect and remove both condenser fans.
4. Unrivet the condenser cover (remove all rivets on perimeter and 6 rivets from central part of
cover), remove the condenser cover.
Clean the condenser coils by blowing low pressure compressed air or a medium pressure warm water
spray from the inside of the coil outward (opposite direction of normal airflow). Inspect coil and fins for
damage, and repair if necessary.
If a buildup of salt or debris is present on the condenser coil, the coil should be cleaned using a mild
alkaline cleaner with a pH of 9.5 to 10.5. For example, a 2–3 percent solution of SIMPLE GREEN®
would make a suitable cleaning solution.
78
Apply the solution using a pressure spray/wash type apparatus. Spray the condenser coil thoroughly
from both the inside and outside of the coil. Always thoroughly rinse the coil with a fresh water spray.
CAUTION: Air pressure or water spray pressure must not be too high to prevent
from damage of coil fins.
CAUTION: When using a water spray, isolate the return air plenum to prevent water
spray from entering the passenger compartment.
Condenser Fan and Grille

Use a damp cloth (with mild alkaline cleaner), soft brush, to clean the grille. If necessary, dismantle the
fan assembly and carefully clean the propeller/wings manually.
14.3. Fresh Air Filter Replacement

NOTE: Fresh air filter is optional accessories, not all units are equipped with fresh air filter.
8 7
1
BEA792
2 3 4 5 6
1 Top cover 5 Fresh air grille (internal)

2 Side cover (left) 6 Side cover (right)
3 Holders for fresh air damper cover 7 Top cover fixing bolts
4 Holders for filter medium 8 Fresh air filter (removed from holder)
Figure 43: Fresh air filter (example)
Procedure:
1. Switch OFF the unit/control system.
2. Release all 5 fixing bolts on fresh air damper cover, remove the cover.
3. Remove air filter from filter holders, carefully pull the whole air filter out.
79
4. Clean the internal return air grille, the vacuum cleaner can be also used.
5. Clean the filter or install new filter medium.
6. Put the fresh air damper cover back on its place, tighten the fixing bolts.
IMPORTANT: Used air filter medium waste disposal can be subject to local laws. Never mix
the filter medium with household trash.
14.4. Return Air Filter Replacement

NOTE: Return air filter is optional accessories, not all units are equipped with return air filter.
The internal return air filter (optional) is accessed from inside the bus, generally located on bus ceiling.
Follow the bus manufacturer instructions for exact procedure.
BEA136
Figure 44: Return air filter (example)
Procedure:
1. Use cross-head screwdriver, unscrew all bolts and slowly swing down the return air grille. Release
and remove the clip, remove the return air filter.
NOTE: Use care when removing dirty filters from the unit. Vacuum any loose dirt or debris
from air intake prior to installing new filter.
2. Clean or replace filter as necessary.
3. For cleaning use compressed air, blow in direction opposite normal air flow to remove accumulated
dust. Wash filter material in warm soapy water. Flush water in direction opposite to normal air
flow. Remove excess water and install filter.
4. Install clean or new filter medium, close return air filter grille.
5. Press all bolt heads to fix the return air grille (additional screw not needed).
IMPORTANT: Used air filter medium waste disposal can be subject to local laws. Never mix the
filter medium with household trash.
80
14.5. Coil Air Filter Replacement
1 4
BEA443
1 Evaporator coil 3 Air filter holder

2 Coil sir filter 4 Evaporator blower
Figure 45: Coil Air filter installation (illustrative picture)
Procedure:
2. Carefully open and remove left or right side cover.
3. Locate the coil air filter, remove filter holders and carefully pull the whole air filter out.
4. Clean the filter or install new filter medium.
NOTE: Use care when removing dirty filters from the unit. Vacuum any loose dirt or debris
from air intake prior to installing new filter.
5. Put the filter back on its place.
IMPORTANT: Used air filter medium waste disposal can be subject to local laws. Never mix
the filter medium with household trash.
7. Insert and close side cover, fix the cover with fixing bolts.
81
15.Troubleshooting
15.1. Air Conditioning Diagnosis and Analysis
Analysis Overview
Servicing a system consists of checking system pressures and temperatures. You should be familiar with
the system you are working with.
Diagnosis Procedure
1. Identify components in the system. To identify components, see your unit service manual, parts
manual and the unit itself.
2. Verify that the bus has the proper air flow throughout the system. The air conditioning ducts must
be free from obstructions.
3. Determine that each component is working correctly.
 Are the evaporator blowers running and in the proper range of speed?
 Need the air filters cleaning?
 Are the condenser coils or evaporator coils clean?
 Are the condenser fans running and at proper speed?
 What is the unit thermostat set point and what is the interior temperature of the bus?
 Is there refrigerant in the system in a proper volume?
 If the system does not function, is power supply present? Is there control system switched on
and operating?
 What are the compressor discharge and suction pressures while the unit is operating? (Refer to
Temperature Pressure Table.)
Typical Operating Pressures

The following table shows typical operating pressures when the system is operating at approximately
ambient temperature 25 - 35 °C (77 - 95 °F).
Refrigerant Units Discharge Pressure Suction Pressure
kPa 827 - 1207 207 - 345

psig 120 - 175 30 - 50
R-134a 2
kg/cm 8.4 - 12.3 2.1 - 3.5
bar 8.3 - 12.1 2.1 - 3.4
Figure 46: Typical Operating Pressures
System Analysis
Failure of the system to stay within normal ranges can have several causes. Causes and solutions of
these problems are described in the System Analysis Table on the following pages.
82
15.2. Causes for Failure to Stay Within Temperature Range
Condition / Possible cause Remedy
Excessive load
 Frequent stops 1. Perform structural maintenance inspections
 Long loading stops regularly.
 Open or loose windows and doors 2. Repair leaks.
 Loose body panels
 Poor insulation
 Too many passengers
Blocked filter or dirt on coils
 Dust and lint buildup on evaporator air filter 1. Clean the evaporator air filter by reverse
flushing with warm, soapy water. Recoat the
filter with RP Filter Coat, TK# 203-334 or
equivalent.
 Dirt buildup on condenser or evaporator coils 2. Flush the coils with warm soapy water at
medium pressure.
Excessive oil in circulation
 Restriction in filter-drier causing low suction Remove excess oil. See the “Removing Excess
pressure Oil” procedure in this manual.
NOTE: For accurate results, check the oil when
 Restriction in expansion valve causing low suction
the compressor is warm and the system is
pressure
operating in normal range.
Restriction of liquid line
 Low suction pressure at high speeds Check the filter-drier.
 Temperature change at point of restriction Check the in-line service valves.
 Flashing of refrigerant is occurring Check the expansion valve inlet screen.
See the procedures in this manual for replacing
the filter-drier, in-line service valves, and
expansion valve, and for checking for moisture
content.
Low refrigerant charge
 Low suction pressure Charge the system. See the Charging procedures
in the Refrigeration Maintenance chapter in this
 Hot liquid line
manual.
 Warm suction line
 Hotter than normal compressor discharge
temperatures
 Decreased cooling capacity
High refrigerant charge
 High compressor discharge pressure Evacuate and recharge the system. See the
Evacuation and Charging procedures in this
 Malfunction of loaders manual.
Air in refrigeration system
 Dark oil 1. Test for air in the system. See “Removing
 High compressor discharge temperatures Contaminants” in this manual.
2. Evacuate and recharge the system See the
 High compressor discharge pressure Evacuation and Charging procedures in this
 False refrigerant level indication (air trapped in manual.
receiver tank)
 Erratic action of expansion valve (possibly hissing
noises at expansion valve)
83
Expansion valve set incorrectly
1. Low superheat:
Adjust the expansion valve. See the Expansion
 Flooding at the compressor Valve section in this manual.
 High suction pressures
 Decreased cooling capacity NOTE: The expansion valve is preset and
should not require adjustment. Verify that the
2. High superheat: expansion valve is the problem by rechecking
 Warm suction line temperature all other components before adjusting.
 Low suction pressures
 Decreased cooling capacity
Expansion valve malfunctioning
1. Valve sticks open due to dirt or ice in the valve: Verify that the expansion valve is the cause by
 Excessive sweat on suction line checking all other possible causes (the expansion
valve rarely fails).
 High compressor oil level, indicated by sump being
cool to the touch If the expansion valve is bad, replace it. See the
 Refrigerant charge level appears low Expansion Valve Removal and Installation section
2. Valve sticks closed due to loss of charge in sensor in this manual.
bulb:
 High discharge pressure Check the compressor operating conditions,
 Low suction pressure repair or replace compressor
 No cooling
 Warm suction line and coil
 Low oil level in compressor
3. Valve operation is erratic:
 Low system charge level
 Air in the system
 Moisture frozen in valve
 Dirt in valve inlet screen
 Block in liquid line before expansion valve
 Sensing bulb not in good contact with suction line
Plugged filter-drier
 Restriction of refrigerant at filter-drier
To prevent plugging, perform routine maintenance
 Outlet line cooler than inlet line inspection of the filter
 Frost or sweating on outlet line To replace, see the Filter-Drier Removal and
 Particles in the system caused by breakdown of Installation section in this manual.
filter-drier (extreme cases only)
84
15.3. Compressor suction pressure conditions
LOW compressor suction pressure
Frosty/Cold 1. Normal operation
Suction  Bus is controlling on thermostat with No action.
Line light load and/or at higher speeds
2. Air flow through evaporator is restricted:
 Air filter dirty Clean or replace air filters.
 Evaporator coil dirty Clean or defrost evaporator coil.
3. Evaporator blower motor problem
 Electrical malfunction Check electricity, relays, controller.
 Fan blades broken or damaged Replace condenser fan.
HIGH compressor suction pressure
1. Normal operation
 Heavy load on the evaporator No action.
2. Expansion valve malfunction
 Feeler bulb making poor contact with Fix the feeler bulb in correct operating
suction line position.
 Needle eroded-valve cannot control
Repair/replace expansion valve.
properly
 Adjustment has been incorrectly set
Repair/adjust/replace expansion valve.
(low superheat)
Recover the refrigerant from the system.
See chapter 11 and refer to “Evacuation
3. Overcharge of refrigerant
procedure”. Evacuate and recharge the
system properly.
LOW compressor suction pressure
Recover the refrigerant from the system. See
1. Low refrigerant charge
chapter 11 and refer to “Evacuation
Dry/Warm
procedure”. Evacuate and recharge the
system properly.
Suction
2. Restriction in liquid line Check/replace filter-drier.
Line
3. Expansion valve malfunction:
 Inlet screen plugged
 Sensor bulb lost charge
Repair/adjust/replace expansion valve.
 Adjustment has been incorrectly set
(high superheat)
Recover the refrigerant from the system.
4. Too much oil in system
Clean, evacuate and recharge the system
properly.
5. Restricted suction line Check the piping system. Recover the
refrigerant from the system. Clean,
evacuate and recharge the system properly.
6. Air flow through condenser coil too cold No action.
HIGH compressor suction pressure
1. Compressor malfunction
 Leaking discharge valves
 Leaking piston reeds
Repair or replace compressor.
 Worn piston/sleeve assembly (blow-
by)
2. Heavy load on evaporator No action
3. Compressor turning too slowly Check the compressor operating conditions,
repair or replace compressor.
85
15.4. Compressor discharge pressure conditions
LOW side compressor discharge pressure
Recover the refrigerant from the system. Clean,
1. Low refrigerant charge
Check the compressor operating conditions,
2. Compressor speed low
repair or replace compressor.
3. Air flow through condenser is cold No action.
4. Restrictions to refrigerant flow:
 Liquid line restricted Check/replace filter-drier.
 Suction line blockage Check the piping system. Recover the refrigerant
from the system. Clean, evacuate and recharge
the system properly.
5. Compressor malfunction:
 Leaking discharge valves
 Leaking piston reeds Repair or replace compressor.
 Worn piston/sleeve assembly (blow-by)
HIGH side compressor discharge pressure
1. Air flow into condenser is low or restricted
 Dirty coil Clean condenser coil
 Debris in the coil inlet Clean air grilles
2. Condenser fan or motor problem:
 Motor running on low speed Check fan operating conditions, repair or replace
condenser fan
 Motor not running - electrical malfunction Check electricity, relays, controller.
 Fan blades broken or damaged Replace condenser fan.
3. Restriction on high side of the system:
In-line service valves (shut-off valves) partially Open valves.
closed
4. Non-condensables in the system:
 Air, nitrogen, and other gases (?) Recover the refrigerant from the system. Clean,
5. Hot air entering the condenser coil No action.
6. Overcharge of refrigerant Recover the refrigerant from the system. See
chapter 11 and refer to “Evacuation procedure”.
Evacuate and recharge the system properly.
86
16.Temperature-Pressure Chart
Temperature Pressure Relationship - Vapor Pressure, kPa, psig
Temperature R-22 R-134a R-407C
F C kPa psig kPa psig kPa psig
-50 -45.6 42 6.1 128 18.5 76 11.0
-48 -44.4 33 4.8 120 17.4 68 9.9
-46 -43.3 23 3.4 117 16.9 60 8.7
-44 -42.2 19 2.7 112 16.2 52 7.5
-42 -41.1 14 2.0 106 15.4 43 6.2
-40 -40.0 3 0.5 101 14.7 33 4.8
-38 -38.9 9 1.3 94 13.7 23 3.4
-36 -37.8 15 2.2 88 12.7 13 1.9
-34 -36.7 21 3.0 81 11.7 2 0.3
-32 -35.6 27 3.9 74 10.7 4 0.6
-30 -34.4 33 4.8 68 9.8 10 1.5
-28 -33.3 40 5.8 59 8.6 16 2.3
-26 -32.2 48 6.9 51 7.4 22 3.2
-24 -31.1 54 7.9 43 6.2 29 4.2
-22 -30.0 62 9.0 34 5.0 36 5.2
-20 -28.9 70 10.1 26 3.8 43 6.2
-18 -27.8 78 11.3 15 2.2 50 7.2
-16 -26.7 87 12.6 5 0.7 57 8.3
-14 -25.6 95 13.8 2 0.3 66 9.5
-12 -24.4 104 15.1 7 1.0 74 10.7
-10 -23.3 113 16.4 12 1.8 82 11.9
-8 -22.2 123 17.9 19 2.7 91 13.2
-6 -21.1 134 19.4 25 3.6 100 14.5
-4 -20.0 144 20.9 31 4.5 110 15.9
-2 -18.9 154 22.4 37 5.4 120 17.4
0 -17.8 165 23.9 43 6.3 130 18.9
2 -16.7 177 25.6 50 7.3 141 20.4
4 -15.6 189 27.4 58 8.4 152 22.0
6 -14.4 201 29.1 65 9.4 163 23.7
8 -13.3 213 30.9 72 10.5 175 25.4
10 -12.2 225 32.7 80 11.6 187 27.1
12 -11.1 239 34.7 88 12.8 200 29.0
14 -10.0 254 36.8 97 14.1 212 30.8
16 -8.9 268 38.8 106 15.4 226 32.8
18 -7.8 282 40.9 115 16.7 240 34.8
20 -6.7 296 43.0 124 18.0 254 36.9
22 -5.6 312 45.3 134 19.5 270 39.1
24 -4.4 329 47.7 145 21.0 285 41.3
26 -3.3 345 50.0 155 22.5 301 43.6
28 -2.2 361 52.4 165 24.0 316 45.9
30 -1.1 378 54.8 177 25.6 334 48.4
32 0.0 396 57.5 188 27.3 351 50.9
34 1.1 415 60.2 201 29.1 369 53.5
36 2.2 434 63.0 213 30.9 387 56.1
38 3.3 453 65.7 225 32.7 406 58.9
40 4.4 472 68.5 238 34.5 425 61.7
42 5.6 494 71.6 252 36.5 445 64.6
44 6.7 515 74.7 266 38.6 466 67.6
46 7.8 536 77.8 281 40.7 487 70.7
48 8.9 558 80.9 295 42.8 509 73.8
50 10.0 579 84.0 310 44.9 532 77.1
87
Temperature Pressure Relationship - Vapor Pressure, kPa, psig
Temperature R-22 R-134a R-407C
F C kPa psig kPa psig kPa psig
52 11.1 603 87.5 326 47.3 554 80.4
54 12.2 627 91.0 343 49.7 578 83.9
56 13.3 652 94.5 359 52.1 603 87.4
58 14.4 676 98.0 376 54.5 627 91.0
60 15.6 701 101.6 392 56.9 654 94.8
62 16.7 727 105.5 411 59.6 680 98.6
64 17.8 755 109.5 430 62.4 707 102.5
66 18.9 782 113.4 449 65.1 734 106.5
68 20.0 809 117.4 468 67.9 763 110.7
70 21.1 837 121.4 487 70.7 792 114.9
72 22.2 867 125.8 509 73.8 823 119.3
74 23.3 898 130.2 530 76.9 853 123.7
76 24.4 929 134.7 552 80.1 885 128.3
78 25.6 959 139.1 574 83.2 917 133.0
80 26.7 990 143.6 596 86.4 950 137.8
82 27.8 1024 148.5 620 89.9 984 142.7
84 28.9 1058 153.5 645 93.5 1019 147.8
86 30.0 1092 158.4 669 97.0 1055 153.0
88 31.1 1127 163.4 694 100.6 1091 158.3
90 32.2 1161 168.4 718 104.2 1129 163.7
92 33.3 1199 173.9 746 108.2 1167 169.2
94 34.4 1237 179.4 774 112.2 1206 174.9
96 35.6 1275 184.9 801 116.2 1246 180.7
98 36.7 1313 190.4 829 120.2 1287 186.7
100 37.8 1351 195.9 857 124.3 1329 192.8
102 38.9 1392 201.9 889 128.9 1372 199.0
104 40.0 1434 208.0 919 133.3 1415 205.3
106 41.1 1476 214.1 950 137.8 1461 211.9
108 42.2 1518 220.2 981 142.3 1507 218.5
110 43.3 1560 226.3 1012 146.8 1553 225.3
112 44.4 1606 233.0 1047 151.8 1602 232.3
114 45.6 1653 239.7 1081 156.8 1651 239.4
116 46.7 1699 246.4 1116 161.8 1701 246.7
118 47.8 1745 253.1 1150 166.8 1752 254.1
120 48.9 1792 259.9 1185 171.9 1804 261.7
122 50.0 1842 267.2 1223 177.4 1857 269.4
124 51.1 1893 274.6 1262 183.0 1913 277.4
126 52.2 1944 282.0 1300 188.6 1968 285.5
128 53.3 1995 289.4 1339 194.2 2025 293.7
130 54.4 2046 296.8 1378 199.8 2084 302.2
132 55.6 2102 304.8 1420 205.9 2143 310.8
134 56.7 2157 312.9 1462 212.0 2204 319.6
136 57.8 2213 321.0 1504 218.2 2266 328.6
138 58.9 2269 329.1 1546 224.3 2328 337.7
140 60.0 2325 337.2 1589 230.5 2393 347.1
142 61.1 2386 346.0 1635 237.2 2459 356.7
144 62.2 2447 354.9 1682 244.0 2526 366.4
146 63.3 2508 363.7 1729 250.8 2595 376.4
148 64.4 2569 372.6 1776 257.6 2665 386.5
150 65.6 2630 381.5 1823 264.4 2737 396.9
Shaded Numerals — Inches HG Below 1 ATM
88
17.Index
A digital temperature tester, 49

dimensions, 18
abbreviations, 8
drain pan, 21
acid, 9, 20, 54, 55
driver panel, 14, 29, 30, 31
acid test, 54
air damper, 21, 75 E
air filter, 20, 21, 46, 48, 49, 66, 80-84, 86 economic cool mode, 33
alarm, 30, 43 electrical hazards, 10
alarm code, 43 electronic leak detector, 49
ambient temperature, 15, 60, 83 electronic micron gauge, 49
ambient temperature sensor, 27, 77 evacuation, 49, 52, 53, 54, 55, 57, 58, 60
B evacuation station, 53, 57, 58
evaporator blower, 20, 21, 28, 48, 72, 82, 83,
blower holder, 72
86
C evaporator coil, 19, 20, 21, 24, 28, 48, 64, 79,
82-84, 86
calibration, 34, 37, 58
expansion valve, 20, 21, 27, 28, 54, 64-67, 84,
capillary, 66, 67
85
carbonization, 55
charging, 11, 52, 56, 61, 67, 69, 84 F
charging hose, 56, 57, 61, 62 filter-drier, 20-24, 27, 28, 47, 49, 53, 55, 57, 63,
check valve, 48 64, 84, 85
clamp tester, 49 first aid, 13
cleaning, 65, 79, 83 freeze protection, 44
clutch cycling, 44 fresh air damper, 21, 24
compressor, 14, 17, 22, 25, 46-48, 53, 54, 83- fuse, 16, 70, 71
87 fuse extractor tool, 71
compressor oil, 12, 13, 26, 47, 52, 54-60, 85
G
compressor oil hazards, 12
gas ballast valve, 58, 60
compressor protection, 44
gauge manifold, 9, 47, 49, 53, 55, 56, 57, 62
condenser, 28
condenser coil, 10, 20, 24, 28, 48, 79, 80, 83, H
86, 87
hand tools, 49
condenser fan, 20, 23, 28, 43, 48, 73, 74, 80,
heating capacity, 15
83, 87
heating coil, 20, 21
condenser pressure switch, 48
hourmeter, 42
control system, 14, 19, 20, 22, 29, 79, 83
HPCO, 15, 21, 27, 43, 48, 53, 55, 56, 57, 61,
cooling capacity, 15, 84, 85
68
CPS, 15, 27, 68
CTS, 27, 44 I
D installation drawing, 93
insulation, 65, 84
diagnostic system, 43
digital multimeter, 49
89
L S
leak detector, 53, 56 safety, 9, 52, 61, 62, 70
leak test, 52 safety relief valve, 22, 27, 61, 69
liquid receiver, 20 schematics diagram, 93
liquid recovery, 52, 56 sensor bulb, 65, 66, 67, 85
lock function, 33, 40 serial number, 22
low suction pressure, 84, 85 set point, 83
LPCO, 15, 22, 27, 43, 48, 53-57, 68 sight glass, 20, 27, 47
M solenoid valve, 20
specifications, 15
maintenance, 52
superheat, 66, 85, 86
maintenance intervals, 46
maintenance procedures, 46 T
maintenance records, 46 tank receiver, 24
manual mode, 31, 33 temperature sensor, 43, 77
mode select, 32 temperature tester, 49
moisture, 12, 17, 20, 28, 47, 53-60, 64, 84, 85 theory of operation, 27
N thermometer, 49, 66
threadlocker, 49, 69
nitrogen, 10, 56, 57, 61, 67
TM compressor, 25
normal operating mode, 43
tools, 10, 49, 53
O torque special conditions, 51
off season, 46 torques, 50
oil test kit, 49, 54 U
overvoltage suppressor, 71
unit decals, 22
oxygen, 9, 11, 54, 56
unit protection devices, 20, 21
P V
power supply, 16
vacuum, 49, 53, 54, 57-60, 65, 79
pressure relief valve, 15
vacuum cleaner, 79, 81
pressure rise test, 59
vacuum pump, 49, 54, 57, 60
program number, 36
vapor recovery, 52, 55
R ventilation mode, 43
receiver tank, 20, 21, 27, 28, 84 W
recovery station, 55, 56
warranty, 2, 12, 46
red alarm, 43
water valve, 47
refrigerant hazards, 11
weight, 18
reheat mode, 32
wintertime, 46
relay, 70, 71
wiring diagram, 93
relay test, 36
return air filter, 21 Y
return air grille, 21 yellow alarm, 43
rooftop unit, 14, 19, 20, 22, 79
RTS, 27
90
18.Schemes, Diagrams and Drawings Index
Dwg No. Diagram / Drawing Title Rev. Pages Size
1E64804 Schematics Diagram A 1 A3
1E64805 Wiring Diagram A 2 A3
1E68024 Installation Diagram A 1 A3
1e62001 Installation Drawing X500 W B 5 A3
1e62002 Installation Drawing X500 N B 5 A3
91
19.Appendix
Appendix Title Rev. Pages
Compressor maintenance manual

A 2a 12/03 62
(TM compressors 51068)
92
Compressor
Service
Manual
for
TM-08
TM-13
TM-15
TM-16
TM-21
TM-31
Compressors
INTERNATIONAL
COMPONENTS ENGINEERING
Copyright 2003 • International Components Engineering
Minneapolis, MN, U.S.A. • Printed in U.S.A.
ICE No. 51068 (Rev. 2a, 12/03)
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, International Components Engineering should be consulted.
Sale of product shown in this manual is subject to International Components Engineering terms
and conditions including, but not limited to, the International Components Engineering Limited
Express Warranty. Such terms and conditions are available upon request.
International Components Engineering warranty will not apply to any equipment which has been
“so repaired or altered outside the manufacturer’s plants as, in the manufacturer’s judgment, to
effect its stability.”
No warranties, express or implied, including warranties of fitness for a particular

purpose or merchantability, or warranties arising from course of dealing or usage of
trade, are made regarding the information, recommendations, and descriptions
contained herein. Manufacturer is not responsible and will not be held liable in contract
or in tort (including negligence) for any special, indirect or consequential damages,
including injury or damage caused to vehicles, contents or persons, by reason of the
installation of any product or its mechanical failure.
The compressor is designed for use with R-12 and R-134a for vehicle air conditioning
only. Use with other refrigerants will void any warranty.
The ICE compressor is not intended nor designed for use on aircraft.
2
TM Advantages
Wide Range of Applications

• Single Operator Cabs to Large Trucks, Buses, RVs, and other Specialty Applications.
Smooth Operation
• Balanced Swash Plate design offers low pulsation noise, quiet and smooth operation, less
vibration, and lower horsepower requirements.
High Efficiency
• Cooling capacity is stable throughout the entire RPM operating range.
High Durability
• MoS2 coated steel swash plate provides additional protection during liquid slugging and high load
conditions.
• Ball and shoe design promotes lubrication for better compressor durability.
• Needle bearings insure high durability for long life and high speed operation.
• Lip Shaft Seal insures excellent sealing integrity and extends compressor life.
TM-31 ALSO INCLUDES
TM-31 Compressor with Oil Sight Glass

• Ease of maintenance.
Optimized Lubrication System

• Pressure lubrication system provides superior lubrication to cylinder walls, pistons, bearings, and
shaft seals.
3
Recover Refrigerant
At International Components Engineering, we recognize the need to
preserve the environment and limit 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 responsible use and

handling of CFC/HCFC/HFC refrigerants by using approved recovery
and recycling methods and equipment that limits the loss of
refrigerant into the atmosphere.
4
Table of Contents
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Safety Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
General Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
First Aid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Refrigerant Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Refrigerant Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
First Aid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Leak Detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
R-134a Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Oil Handling Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . 9
Equipment for R-134a Use Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Compressor Identification Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Swash Plate System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Piston Drive System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Compressor System Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Suggested Operating Region . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Clutch Application Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Compressor Clutch and Fitting Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Dimensions and Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
TM-08 Ear Mount Dimensions and Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
TM-08 Alternator Mount Dimensions and Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
TM-08 Ear Mount Pad-Type Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
TM-13 Dimensions and Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
TM-15 Direct Mount Dimensions and Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
TM-31HD Dimensions and Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
TM-08 Exploded View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
TM-13, TM-15, TM-16, TM-21 Exploded View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
TM-31 Exploded View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Tightening Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Compressor Maintenance: TM-08, TM-13, TM-15, TM-16, TM-21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Refrigerant Recovery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Compressor Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Compressor Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Compressor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Operating Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Non-Operating Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Compressor Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Installation Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Installation Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Mounting Compressors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Leak Testing the Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Compressor Oil Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Compressor Oil Caution Statements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Oil Charge Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Oil Type Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Oil Check Interval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Oil Check Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
5
Table of Contents
Compressor Maintenance: TM-08, TM-13, TM-15, TM-16, TM-21 (continued)

Clutch Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Clutch Run-In . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Clutch Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Clutch Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Clutch Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Clutch Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Electrical Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Shaft Seal Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Shaft Seal Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Shaft Seal Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Shaft Seal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Shaft Seal Cover Installation (When Equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Cylinder Head Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Cylinder Head Disassembly–Front and Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Cylinder Head Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Cylinder Head Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Compressor Maintenance: TM-31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Refrigerant Recovery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Compressor Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Compressor Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Compressor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Compressor Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Oil Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Clutch Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Clutch Run-In . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Clutch Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Clutch Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Clutch Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Shaft Seal Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Shaft Seal Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Shaft Seal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Appendix – Tools and Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
6
Safety Precautions
Safety Definitions WARNING: Make sure all mounting bolts

Hazard precautions come in the following levels, are tight and are the correct length for
which you should be familiar with: their particular application. Using an
incorrect length bolt may cut a wire and
DANGER: Denotes the possibility of cause an electrical short or penetrate air
serious injury or death. conditioning components.
WARNING: Denotes the possibility of DANGER: Use caution with a

serious equipment damage or serious refrigeration system in a closed or
personal injury. confined area with a limited air supply (for
example, a bus or garage). Refrigerant
CAUTION: Denotes the possibility of displaces air and can cause oxygen
minor to severe equipment damage or depletion, resulting in suffocation and
personal injury. possible death.
General Safety WARNING: Do not wear jewelry, watches

or rings. These items can short out,
DANGER: Refrigerants in the presence of
causing severe burns to the wearer.
an open flame, spark or electrical short
produce toxic gases that are severe WARNING: Wear eye protection when
respiratory irritants capable of causing handling compressors. Refrigerant liquid
death. and battery acid can permanently damage
the eyes
DANGER: EXPLOSIVE HAZZARD! Do
not close the compressor discharge valve
with the unit in operation. Do not start the
compressor with the discharge valve
closed. This increases internal pressure on
the compressor which will cause the
compressor to explode.
WARNING: Keep your hands, clothing

and tools clear of the fans when the unit is
running. This should also be considered
when opening and closing the compressor
service valves (when equipped).
WARNING: Make sure the gauge

manifold hoses are in good condition.
Keep them away from belts, fan motors,
engine pulleys, and hot surfaces.
WARNING: Do not apply heat to a sealed

refrigeration system or container. This
increases internal pressure and can cause
an explosion.
7
Safety Precautions
Refrigerant DANGER: Never throw or strike service

cans and never handle the packing carton
CAUTION: When removing refrigerant roughly. Do not use service cans which
from a compressor, use a recovery process are damaged or dented. Store service cans
that minimizes refrigerant loss to the out of reach of children.
atmosphere. Although fluorocarbon
refrigerants are classified as safe,
precautions must be observed when
Refrigerant Oil
handling them. DANGER: Avoid refrigeration oil contact
with the eyes. Avoid prolonged or repeated
First Aid contact of refrigeration oil with skin or
Objectives of first aid for frostbite are to protect clothing. Wash thoroughly after handling
the frozen area from further injury, to warm the refrigeration oil to prevent irritation.
affected area rapidly, and to maintain respiration.
First Aid
EYES: For contact with liquid, immediately flush
eyes with large amounts of water and get prompt In case of eye contact, immediately flush with
medical attention. plenty of water for at least 15 minutes. CALL A
PHYSICIAN. Wash skin with soap and water.
SKIN: Flush area with large amounts of
lukewarm water. Do not apply heat. Remove
contaminated clothing and shoes. Wrap burns
Leak Detection
with dry, sterile, bulky dressing to protect from DANGER: Do not use a Halide torch for
infection/injury. Get medical attention. Wash lead detection. When a flame contacts
contaminated clothing before reuse. refrigerant, toxic gases are produced
INHALATION: Move victim to fresh air and use which may cause suffocation or even
CPR or mouth-to-mouth ventilation, if necessary. death.
Stay with victim until arrival of emergency Check manufactures information when using leak
medical personnel. detectors. All leak detectors must detect fluorine.
Leaks can be detected by using soap bubbles and
Refrigerant Handling
with Halogen leak detectors such as G.E. H10G or
a portable leak detector. These are commercially
CAUTION: Never directly heat service
available.
cans or put them in hot water heat ed
above 104 F (40 C) since the can may
explode and cause personal injury. When
it is necessary to heat service cans for
charging in cold weather, use warm water
at a temperature below104 F (40 C).
CAUTION: Do not put the charge valve in

the warm water.
DANGER: Never put service cans on the

engine or the radiator when charging.
DANGER: Never store service cans in

direct sunlight, near flame or where the
temperature exceeds 104 F (40 C). Always
store service cans in a cool dry place.
8
Safety Precautions
Equipment for R-134a Use Only

R-134a Applications
R-134a is a Hydrofluoro-carbon (HFC) because it
CAUTION: Use dedicated equipment for
contains hydrogen, fluorine, and carbon. It does
R-134a to prevent contamination from
not contain chlorine.
other refrigerants and compressor oils. If
Always use recommended procedures when you cannot use dedicated equipment,
servicing equipment: clean, flush, or purge equipment before
using to avoid contamination.
• Do not vent refrigerant to the atmosphere.
• Recover and reclaim all refrigerants. CAUTION: Mixing of refrigerants or oils
in the compressor may damage your
DANGER: Store refrigerants in proper
pump.
containers, out of direct sunlight and away • Gauge Manifold.
from intense heat.
• All service hoses.
DANGER: Do not breathe vapors. Use in • All adaptors and fittings.
well-ventilated areas. Refrigerants cause
oxygen depletion and death. • Micron Gauge optional, but must be used with
refrigerant dedicated hoses.
WARNING: Wear eye protection and • Vacuum pump. (5 cfm size [0.14 meter3/min.]
avoid contact with skin. Refrigerant can or larger recommended).
cause severe frostbite.
• Recovery and recycling equipment.
CAUTION: Use butyl-lined gloves when • Proper storage equipment for refrigerants and
handling refrigerants to prevent frostbite. oils.
• Suction service filter(s) for system clean-up (if
DANGER: Do not use open flame near needed).
refrigerant. Do not burn it as toxic fumes
may be released. NOTE: The larger the size of the vacuum pump,
the faster the evacuation process.
DANGER: Do not use Oxygen (O2) or
compressed air for leak testing. An
explosion may occur.
Compressor Oil
Handling Procedures
CAUTION: Use dedicated equipment for

systems containing R-134a to prevent
contaminating the system with oil from
other systems.
CAUTION: Store oil in sealed containers.
Compressor oil is a hygroscopic

oil, which means it absorbs or attracts moisture
from the air. Therefore, this oil requires special
care and handling procedures.
9
Safety Precautions
Compressor Identification Label
1. ICE Oil Number 4. Compressor Type (Model)

2. Manufactures Serial 5. Compressor Oil Charge
Number
3. ICE Part Number 4
Compressor Identification Label
10
Introduction
Swash Plate System

The driveshaft is supported by two radial bearings
and two thrust bearings. As the swash plate
reciprocates through the rotation of the drive
shaft, the pistons are driven back and forth.
1. Radial Bearing
2. Thrust Bearing
Piston Drive System

The pistons in the cylinders are mounted on the
swash plate through a dive ball and shoe disk.
Each piston has a compression head at each end.
Swash plate rotation results in reciprocating
piston movement parallel to the driveshaft. The
cylinders are arranged at intervals around the
driveshaft, providing 5 front and 5 rear bores.
1. Suction
2. Compression
3. Pistons
4. Ball
5. Shoe Disk
Compressor System Guidelines

• The specified rotation of the TM-08, TM-13,
Item Condition
TM-15, TM-16, and TM-21 is clockwise or
counterclockwise. Ambient Temperature Under 212 F (100 C)
Speed 6000 rpm maximum
• The specified rotation of the TM-31 is
clockwise as viewed from the clutch side. Pressure Max: 284 psig (1960 KPa)
• The compressor must be operated within the

conditions shown below. CAUTION: The A/C system pressure must
not exceed 284 psig (1960 KPa).
11
Introduction
Suggested Operating Region

The figure below shows the suggested operating
region for compressors using R-134a refrigerant:
Figure 1: R-134a Compressor Operation Map
12
Introduction
Clutch Application Guidelines
2
1
3
2
3
4
AEA1878
1. Magnetic Clutch
2. Idle Pulley
3. Drive Pulley
• Ratio of magnetic clutch to drive pulley:

NOTE: Pulley ratio is defined as the ratio of the
magnetic clutch diameter to the drive pulley
diameter.
• To avoid vibration and resonance, avoid
pulley ratio ranges between 1:0.92 and
1:1.08.
• Compressor speed must not exceed the
specified speed.
• Pulley alignment tolerance is less than
0.049 in. (1 mm).
• Belt tension must be adjusted to the specified
tension. See belt manufacturer or system
specifications for tension guidelines.
13
Introduction
14
Compressor Clutch and Fitting Options
Compatible
with
R-134a & R-12
Clutch Options
1. 6 Groove Capacities Available

2. 8 Groove TM-08 (82 cc)
3. 125 mm Double A Groove TM-13 (131 cc)
4. 135 mm Double A Groove TM-15 (147 cc)
5. Variable Grove TM-16 (163 cc)
6. Overhang TM-21 (215 cc)
7. 4 Groove
15
Compressor Clutch and Fitting Options
Compatible
with
R-134a & R-12
Fitting Options Capacities Available

1. 3/4 X 7/8 Horizontal O-ring TM-08 (82 cc)
2. 1 X 14 Horizontal O-ring TM-13 (131 cc)
3. Most ICE Compressors are available with TM-15 (147 cc)
3/4 X 7/8 Monolothic O-ring Configuration TM-16 (163 cc)
4. Vertical Pad TM-21 (215 cc)
5. 3/4 X 7/8 Vertical O-ring (R-12)
6. 3/4 X 7/8 or 1X14 Vertical O-ring
16
Dimensions and Specifications
TM-08 Ear Mount Dimensions and Specifications

NOTE: Sample configuration shown. Some specifications may vary.
Compressor Specifications Magnetic Clutch Specifications
Model TM-08HD Type Electromagnetic Single-Plate

Dry Clutch
Type Swash Plate type
Rated Voltage 12/24 volts DC
Number of 6
Cylinders Belt 2A Type
Bore 36 mm (1.42 in) Current 3.75 amperes (max)
Consumption
Stroke 13.4 mm (0.53 in.)
Static Torque Initial: 35 N•m (3.5 kgfm)
Displacement 82 cm3 (5 cu. in)
After burnishing: 49 N•m
Permissible Speed 700-6000 rpm
(5 kgfm)
Refrigerant R-134a
Rotation CW/CCW
Lubricant Oil see system specification
Weight 2.2 kg (4.9 lbs)

Oil Charge 150+20 cm3
Mass 4.1kg (9.1 lbs) CAUTION: Check system decals and
operation manual for oil type. Mixing
incompatible oils causes system damage.
17
TM-08 Alternator Mount Dimensions and Specifications

Model TM-08HD Type Electromagnetic Single Plate

Dry Clutch
Number of 6
Cylinders Belt Ply “V” 4K type
Consumption
Stroke 13.4 mm (0.53 in)
(5 kgfm)
Refrigerant R-134a
Rotation CW/CCW

Mass 4.1kg (9.1 lbs) CAUTION: Check system decals and
18
TM-08 Ear Mount Pad-Type Fittings


Dry Clutch
Number of 6
Consumption
Permissible Speed 700-6000 rpm (5 kgfm)
Refrigerant R-134a Rotation CW/CCW
Lubricant Oil - see system specification Weight 2.2 kg (4.9 lbs)

Mass 4.1kg (9.1 lbs)
CAUTION: Check system decals and
19
TM-13 Dimensions and Specifications


Dry Clutch
Number of 6
Cylinders Belt 2A type
Consumption
(5 kgfm)
Refrigerant R-134a
Rotation CW/CCW
Lubricant Oil - see system specification

Mass 4.4 kg (9.7 lbs)
20

Magnetic Clutch Specifications

Compressor Specifications
Type Electromagnetic Single-Plate
Model TM-15HD Dry Clutch
Type Swash-Plate type Rated Voltage 12/24 volts DC
Number of 6 Belt Ply “V” 6K type
Cylinders
Current 3.75 amperes (max)
Bore 36 mm (1.42 in) Consumption
Stroke 24 mm (0.94 in) Static Torque Initial: 35 N•m (3.5 kgfm)
Displacement 146 cm3 (8.9 cu. in) After burnishing: 49 N•m
Permissible Speed 700-6000 rpm (5 kgfm)
Refrigerant R-134a Rotation CW/CCW
Lubricant Oil - see system specification Weight 2.28 kg (5 lbs)

150+20 cm3
Mass 4.4 kg (9.7 lbs) operation manual for oil type. Mixing
21
TM-15 Direct Mount Dimensions and Specifications

Model TM-15HD–Direct Mount Type Electromagnetic Single Plate

Dry Clutch
Number of 6
Bore 36 mm (1.42 in) Power Consumption 45 max 45 W @ 25 C (77 F)
Stroke 24.0 mm (0.94 in) Static Torque Initial: 35 N•m (3.5 kgfm)
Displacement 147cm3 (8.97 cu. in) After Burnishing: 49 N•m
(5 kgfm)
Rotation CW/CCW
Refrigerant R-134a
Mass 4.5 kg (9.9 lbs) CAUTION: Check system decals and
22

Compressor Specifications Magnetic Clutch Specification

Dry Clutch
Number of 6
Cylinders Belt Ply “V” 8K
Consumption
Displacement 163 cm3 (9.95 cu. in)
(5 kgfm)
Refrigerant R-134a
Rotation CW/CCW

Oil Charge 150 cm3
Mass 4.9 kg (10.8 lbs) CAUTION: Check system decals and
23

TM-21 Compressor Dimensions Magnetic Clutch

Model TM 21HD Type Electromagnetic,
Type Swash-plate type single-plate dry clutch
Number of Cylinders 10 Rated Voltage 12 or 24 Volts dc
Bore 1.26 in. (32 mm) Current Consumption 3.75 amperes (MAX)
Stroke 1.05 in. (26.7 mm) Stalling Torque 59 N•m (43.5 ft. lb)
Displacement 13 cu. in. (215 cm3) Rotation CW/CCW
Permissible Speed 700 to 6000 rpm Mass 6.8 lbs (3.1 kg)
Refrigerant R-134a
Compressor Oil 1 See note below CAUTION: Check system decals and
Mass 11.3 lbs (3.1 kg) operation manual for oil type. Mixing
1 Depending on application, this compressor can incompatible oils causes system damage.
be used with different and non-compatible compressor
oils. See unit labels for proper oil. The initial installer is
responsible for proper labeling.
24
TM-31HD Dimensions and Specifications
1. Drive Shaft
2. Radial Bearing
3. Piston
4. Radial Bearing
5. Thrust Bearing
6. Swash Plate
TM-31 Internal Components
25
Figure 2: TM-31
26
Model TM-31
Type Swash Plate
Number of Cylinders 10
Bore 36 mm (1.42 in.)
Stroke 30.7 mm (1.21 in.)
Displacement 313 cm3 (19.1 cu. in.)
Maximum Speed 6000 rpm
Direction of Rotation Clockwise, viewed from clutch
Lubrication System Gear Driven Positive Pressure
Lubricant Oil - I see system specification
Oil Charge 500 cc (16.9 fl. oz.)
Refrigerant R-134a
Shaft Seal Shaft Seal Lip Seal Type
Weight 9.5 kg (21 lbs)
TM-31 Compressor Specifications
Type Electro Magnetic Single Plate Dry Clutch

Rated Voltage 12 V DC/ 24 V DC
Current Consumption 46 Watts @ 25 C
Static Torque 78.1 N• m (8.0 kgf-m, 58 ft-lb)
Direction of Rotation Clockwise, viewed from clutch
Weight Approximate 4.7 kg (10 lbs)
TM-31 Magnetic Clutch Specifications

27
TM-08 Exploded View
1. Armature Bolt 15. O-ring Body

2. Armature Plate 16. Rear Gasket
3. Shim 17. Rear Valve Plate
4. Snap Ring 18. Rear Suction Valve
5. Cover 19. Cylinder Shaft Assembly
6. Pulley Assembly 20. Pressure Relief Valve
7. Coil Screw 21. Front Suction Valve
8. Coil 22. Front Valve Plate
9. Discharge Fitting 23. Front Gasket
10. Gasket Fitting 24. Front Cylinder Head
11. Suction Fitting 25. Shaft Seal
12. Oil Fill Plug 26. Washer
13. O-ring 27. Body Bolt
14. Rear Cylinder Head
28
TM-13, TM-15, TM-16, TM-21 Exploded View
1. Bolt, Armature 16. Front Valve Plates

2. Armature Plate 17. Front Suction Valve
3. Shim 18. Cylinder Shaft Assembly
4. Snap Ring 19. Rear Suction Valve
5. Cover 20. Rear Valve Plate
6. Pulley Assembly 21. Rear Gasket
7. Screw, Coil 22. O-ring, Body
8. Coil 23. Rear Cylinder Head
9. Body Bolt 24. O-ring, Drain Plug
10. Washer 25. Drain Plug
11. Snap Ring 26. Pressure Relief Valve
12. Shaft Seal 27. Pressure Relief Valve
13. Front Cylinder Head 28. Pin, Alignment
14. O-ring, Body 29. O-ring, Oil Fill Plug (TM16)
15. Front Gasket 30. Oil Fill Plug (TM16)
29
TM-31 Exploded View
20 16
19
20 2
21 3
19
17
12
21
6 10 13
8
11
9
4 1
15
14
15
14
7
18 5
23
1. Compressor Body 13. Rear Gasket

2. Oil Fill Plug 14. Body Bolt
3. Oil Plug O-ring 15. Body Bolt Washer
4. Front Cylinder Head 16. Suction Screen
5. Front Gasket 17. Oil Pump
6. Body O-ring 18 Shaft Seal
7. Front Valve Plate 19. Manifold
8. Front Valves 20. Manifold Bolt
9. Rear Valves 21. Manifold O-ring
10. Alignment Pin 22. Sight Glass
11. Rear Valve Plate 23. Body Center O-ring
30
Tightening Torques
6
1
TM-08–TM-21 Thread Size and Torque Specifications

Part Thread Size Tightening Torque
1. Armature Bolt M6 x 1.0 8.7 to 10.1 ft-lb (12 to 14 N•m)
2. Field Coil Screw M5 x 0.8 2.9 to 4.3 ft-lb (4 to 6 N•m)
3. Body Bolt M8 x 1.25 12.5 to 15.5 ft-lb (17 to 21 N•m)
4. Oil Drain Plug M8 x 1.25 9.4 to 10.8 ft-lb (13 to 15 N•m)
5. Manifold Bolt M8 x 1.25 14.5 to 17.3 ft-lb (20 to 24 N•m)
6. Pressure Relief Valve 3/8-24 UNF 5.9 to 7.4 ft-lb (8 to 10 N•m)
TM-31 Thread Size and Torque Specifications

Part Thread Size Tightening Torque
1. Armature Bolt M10 x 1.5 14.8 to 16.2 ft-lb (20 to 22 N•m)
2. Field Coil Screws M6 x 1 5.9 to 7.4 ft-lb (8 to 10 N•m)
3. Body Bolts M10 x 1.5 18.4 to 22.1 ft-lb (25 to 30 N•m)
4. Oil Fill Plug M8 x 1.25 10.3 to 11.8 ft-lb (14 to 16 N•m)
5. Manifold Bolts M8 x 1.25 14.8 to 16.2 ft-lb (20 to 22 N•m)
31
32
Compressor Maintenance: TM-08, TM-13,
TM-15, TM-16, TM-21
Safety Refrigerant Recovery

DANGER: Explosion Hazard! Do not Avoid releasing refrigerant into the atmosphere. If
throw or strike service cans. Do not handle you are removing refrigerant from an air
the packing carton roughly. Do not use conditioning system, use a refrigerant recovery
damaged or dented service cans. Store unit.
service cans out of reach of children. Consult your recovery unit operators manual for
hookup and operating procedures.
DANGER: Explosion Hazard! Do not
directly heat service cans or put them in
water above 104 F (40 C). Do not put
service cans on the engine or radiator
when charging.
If is necessary to heat service cans for
charging in cold weather, use water below
104 F (40 C).

store service cans in direct sunlight, near
flame, or where temperature exceeds 104
F (40 C).

the warm water.
Figure 3: Recovery Unit – ICE No. 2590119
33
Compressor Maintenance: TM-08, TM-13, TM-15, TM-16, TM-21
Compressor Handling Compressor Removal

CAUTION: Do not strike or turn the Operating Compressor
compressor upside down. If the 1. Perform the Oil Return Operation. See
compressor is turned upside down, rotate “Returning Oil to the Compressor” on
it 5 to 6 times to circulate oil. page 37).
2. Recover the refrigerant. (See “Refrigerant
Recovery” on page 33 and your system
manual).
3. Remove the compressor from the system
Consult system manual if necessary.
Non-Operating Compressor
1. Perform the Refrigerant Recovery” (For more
information, see “Refrigerant Recovery” on
page 33.)
2. Remove the compressor from the system.
1. Rotate Compressor Drive Shaft Several

Compressor Installation
Times
Installation Precautions
Compressor Storage The new compressor has a specified quantity of
compressor oil and nitrogen gas (N2). When
Store new and rebuilt compressors: mounting the compressor, take the following
• With the correct oil charge. steps:
• Within the orientation range shown in Figure • Loosen the discharge side connector cap.
4 on page 35. If the compressor sits outside Gently release N2 from compressor.
that orientation for more than one minute, turn
NOTE: This may be applicable to new
compressor manually (slowly) to clear oil
compressors only.
from the cylinders.
• With a holding charge of refrigerant or
nitrogen to a pressure of 7 to 21 psig (48 to
145 kPa). This protects internal parts from
moisture and corrosion.
34
Mounting Compressors
CAUTION: Do not let oil escape.
1. Range of Motion. Verify the range of motion
positioning at both extremes of the belt
• Manually rotate the drive shaft several times adjustment. Figure 4 shows the range of
to distribute oil that has settled in the motion for the compressor.
cylinders. 2. Clearance. Clearance between the
compressor mounting supports and bracket
must be less than 0.004 inches (0.10 mm). Use
shims as necessary to adjust this clearance
(Shim Kit ICE No. 2570101). This reduces
stress on the compressor.
3. Pulley alignment. Maintain correct pulley
alignment for the drive belt.
• Check and adjust the oil quantity before

replacing the compressor. (see “Returning Oil
to the Compressor” on page 37.) Follow
system specifications.
Installation Position
Install the compressor within the range shown in
Figure 4 below.
1. Bracket
NOTE: The compressor has a pressure-feed
2. Shim ICE No. 257101
lubrication system that cannot function if the
compressor is installed outside this range. 3. Compressor
When the compressor is mounted in its final Figure 5: Shim Installation

position, turn it over manually approximately 10
revolutions before hooking the drive belt up to the
pulley. If you do not do this, damage to the
compressor valves can result from oil slugging.
This is not covered under warranty!
Figure 4: Compressor Installation Range
35
Leak Testing the Compressor

CAUTION: Do not store PAG oil in
After repairs and before installation, check a plastic containers. PAG oil absorbs
compressor for refrigerant leaks: moisture through the plastic container.
1. Install the discharge and suction caps on the
connector. Oil Charge Considerations
Most compressors come with a factory oil charge,
which is listed on the rear label. This oil charge is
for an average system that is already “wet.” The
actual oil charge needed is application-specific,
and may be different than the factory oil charge.
Consult your application manual for the specific
oil charge needed.
If you are replacing the compressor in an already
“wet” system which has had no leaks, follow the
procedure “Returning Oil to the Compressor” on
page 37 to determine the oil charge needed for the
new compressor.
If you are placing the compressor in a new,
“un-wet” installation, use the amount of oil
specified in the application manual. If no amount
is specified, you will have to determine the
2. Fill the compressor with refrigerant gas (same
amount experimentally. New systems require an
type used in the system) through the connector
additional oil charge to “wet” system components.
suction port. Raise the pressure to at least
70 psig (483 Kpa).
CAUTION: Not using the correct oil
3. Check the compressor for leaks using a charge will damage your system.
reliable leak detector.
NOTE: Use a leak tester being capable of Oil Type Considerations
detecting fluorine-based refrigerants.
Your compressor comes with an oil charge that
may not be compatible with your system. Check
Compressor Oil Procedures system decals and operation manual for correct oil
type.
Compressor Oil Caution Statements
If the oil charge in a new compressor is not
compatible with your air conditioning system,
CAUTION: Do not leave a system or oil
remove and replace the oil.
containers open to the air longer than
necessary. Compressor oils (POE and
PAG) absorb moisture. Moisture-
contaminated oil will damage system
components. CAUTION: Mixing incompatible oils will
damage your system.
CAUTION: Do not open refrigeration
system unnecessarily. Doing so increases
chances of contamination.
CAUTION: Discard used oil containers.

These containers are hazardous.
36
Oil Check Interval 3. Compressor Removal

Check and replenish or replace the compressor 4. Inspect the Oil
oil: Figure 6: Oil Check Procedure
• At the start of the season
Returning Oil to the Compressor
• Every 3,200 miles (5000 km) or every 5
months for commercial vehicles and vehicles During operation, oil circulates with refrigerant in
that are in constant use a system. Before checking the oil, you must return
as much as possible to the compressor. Not doing
• When the compressor, evaporator, condenser, so will result in an incorrect measurement.
or receiver-drier is replaced
To return oil to the compressor:
• When refrigerant has leaked from the system
(for example, high pressure relief valve 1. Open the vehicles doors and windows to raise
discharges) the interior air temperature to 75 to 80 degrees
[25 to 27 C]. (The ambient air temperature
• When gas or refrigerant leaks from the should be above 85 degrees F (29 C). If not,
compressor partially block the condenser air flow to raise
• When oil-related problems occur in the the compressor discharge pressure above
cooling cycle. 170 psig (1172 kPa).)
2. Run the A/C system at idle or high idle (800
Oil Check Procedure and 1500 rpm) for approximately 20 minutes.
To check the compressor oil on an operating 3. Turn the A/C system off.
compressor, follow these steps:
4. Recover the refrigerant. See your system and
• Return oil to the compressor recovery unit manuals for this procedure.
• Recover the refrigerant 5. Remove the compressor from the system. See
• Remove the compressor “Compressor Removal” on page 34.
• Drain and inspect the oil. 6. Drain the oil as described below.
Oil return, draining, and inspection procedures are Draining the Oil
described in this section. For compressor removal,
see “Compressor Removal” on page 34. For 1. Perform the “Returning Oil to the
refrigerant recovery, consult your system and Compressor” procedure above.
recovery unit manuals. 2. Remove the drain plug from the compressor.
3. Drain oil from the compressor drain plug and
all other ports.
4. Remove remaining oil through the discharge
side connector by manually rotating the drive
plate until all oil is removed.
5. Measure oil in a measuring cylinder.
NOTE: See your application specifications
for the correct oil amount.
6. Inspect oil for contamination (see “Checking
1. Return Oil to Compressor Compressor Oil for Contamination” on
2. Recover Refrigerant
page 38).
Figure 6: Oil Check Procedure
37
7. Replace the oil drain plug and tighten it per 2. Verify the correct oil amount in your system
specifications (see “Tightening Torques” on specifications.
page 31).
3. If oil is contaminated, replace old oil with new
8. If necessary add oil. See “Adding Compressor oil.
Oil” on page 38.
4. Add oil to the compressor through the suction
9. Install the compressor (see “Compressor port as shown in Figure 8.
Installation” on page 34). Tighten bolts to the
5. Turn the shaft manually several times while
specified torque (see “Tightening Torques” on
adding oil to distribute oil evenly.
page 31).
NOTE: Replace oil with fresh oil taken only
from a sealed metal container.
Figure 7: Draining Oil
Checking Compressor Oil for

Contamination
Figure 8: Typical Compressor Oil Fill Procedure
Inspect extracted oil for the following:
• Dirt
• Color changed to red or black
• Presence of foreign substances, metal
shavings, etc. in the oil.
Black oil indicates a severely contaminated
system. To determine the extent of contamination,
remove the filter-drier, then check if the black
colored oil is present there. If so, flush the system.
If flushing is required, use industry approved
materials.
If the oil is clean at the filter-drier, install a new
filter-drier and replace the oil with new oil. See
“Adding Compressor Oil” below.
Adding Compressor Oil

To add oil:
1. Verify the correct oil type on the compressor
label.
38
Clutch Procedures
For application guidelines, see “Clutch
Application Guidelines” on page 13.
Clutch Run-In
Use this procedure to break in a new magnetic
clutch.
1. Install the clutch on the compressor. For more
information, see “Clutch Installation” on page
41.
2. Install the compressor on the engine. Charge
the system. Operate the compressor by
running the system. 1. Holder
3. Maintain the compressor speed at idle. Figure 9: Remove Center Bolt
Operate the A/C Switch through the on/off
cycle at least 10 times (on for 10 seconds, off 2. Remove the armature plate using the armature
for 10 seconds). plate puller. Remove the shims from the
armature shaft or the armature plate.
Clutch Test
If the field coil lead wire is broken, replace the
field coil. Check the amperage and voltage. The
amperage range should be:
System Amperage
12 Volt System 3.6 to 4.2
24 Volt System 1.8 to 2.1
Amperage indications:
• A very high amperage reading indicates a
short within the field coil.
Figure 10: Remove Drive Plate
• No amperage reading indicates an open circuit
in the winding. 3. Remove the snap ring using external snap ring
pliers. Remove the cover (if equipped).
• An intermittent or poor system ground results
in lower voltage at the clutch. Check for a
tight fit on the coil retaining snap ring, or for
good ground at the coil retaining screws.
Clutch Removal
NOTE: See the Appendix for correct tools.
Contact your local International Components
Engineering Dealer for more information.
1. Remove the center armature bolt.
39
NOTE: Do not hold the coil by the lead wire.
1. Snap Ring Figure 13: Remove Coil

2. Cover (If Equipped)
Clutch Inspection
Figure 11: Remove Snap Ring and Cover
• Armature Plate
4. Remove the pulley assembly using the pulley
remover and the spacer positioned on the If the contact surface is scorched, replace the
cylinder head hub. armature plate and pulley.
• Pulley Assembly
CAUTION: To avoid damaging the pulley
Inspect the appearance of the pulley assembly.
groove, hook the puller claws into, not
If the pulley contact surface is excessively
under, the pulley groove.
grooved due to slippage, replace the coil,
pulley assembly, and armature plate. There
should also be no foreign matter, such as oil or
grit, lodged between the clutch plate and
pulley. Clean these contact surfaces and the
drive plate with a suitable solvent before
installation.
• Coil
Inspect the coil for a loose connector or
cracked insulation. If the insulation is cracked,
replace the coil. Repair or replace the wire or
the connector if either is loose or damaged.
Figure 12: Remove Pulley
5. Remove the coil lead wire from the holder on

the top of the compressor.
6. Remove the three screws that attach the coil to 1. Drive Plate
the compressor. Remove the coil. 2. Pulley Assemble
3. Coil
Figure 14: Inspect Components
40
Clutch Installation
See “Clutch Inspection” before installing the
clutch.
1. Install the coil on the compressor with the lead
wire on top. Tighten the mounting screws to
the specified torque. See “Tightening
Torques” on page 31.
2. Install the lead wire in the wire holder on the
compressor.
1. Snap Ring
Figure 17: Install Cover and Snap Ring (1)
NOTE: Install the snap ring with the chamfered

inner edge outward (facing away from seal).
Figure 15: Install Coil
3. Install the pulley assembly using the Installer

(ICE No. 2590118) and a hand press.
1. Snap Ring
Figure 18: Install Cover and Snap Ring (2)
5. Install the driver plate on the drive shaft,

together with the original shim(s). Press the
Figure 16: Install Pulley
drive plate down by hand.
4. Install the cover and the snap ring using
NOTE: If replacement or additional shims
external ring pliers.
are required, a clutch hardware kit is
available (ICE No. 2530109).
6. Tighten the bolt to the specified torque using
the Arbor puller (ICE No. 2590113) to prevent
drive-plate rotation. See “Tightening Torques”
on page 31.
41
After tightening the bolt, ensure that the Shaft Seal Procedures
pulley rotates smoothly.
Shaft Seal Removal
1. Remove the magnetic clutch assembly See
“Clutch Removal” on page 39.
2. Use the seal remover (from the shaft seal kit
ICE No. 2590114) to remove the shaft seal
cover. Turn the seal remover to engage the
hook on the seal remover with the hook on the
shaft seal cover, then slowly pull the shaft seal
cover out of the cylinder head (some models).
3. Remove the snap ring using internal snap ring
pliers.
1. Shims
Figure 19: Install Shims and Drive Plate
7. Ensure that the clutch clearance is as
specified. If necessary, adjust the clearance
using shims.
NOTE: Adjusting shims are available in the
clutch Hardware kit ICE No. 2530109.
NOTE: Specified clearance: 0.012 to 0.024
in. (0.3 to 0.6 mm).
1. Snap Ring
2. Cover (When equipped)
NOTE: Do not reuse the shaft seal cover.

Use a new shaft seal cover when
reassembling a compressor.
Figure 20: Check Clearance
Electrical Connection
1. Connect the lead wire to the electrical circuit.
NOTE: The stationary field is grounded at
the factory. Connect the hot (lead) wire only.
2. Engage and disengage the clutch several times
to check the engagement. The disc should
snap firmly against the pulley. 1. Shaft Seal Cover (Some Models)
Figure 21: Remove Shaft Seal Cover
42
4. Use the seal remover (from the shaft seal kit dry the clean surfaces, and apply clean
(ICE No. 259114) to remove the shaft seal. compressor oil. Use the same oil in the
Turn the seal remover to engage the hook on system.
the seal remover with the hook on the shaft
3. Place the seal guide (from the shaft seal kit
seal, then slowly pull the shaft seal housing
ICE No. 2590114) on the end of the spline
out of the cylinder head.
shaft.
1. Shaft Seal
Figure 22: Remove Shaft Seal 1. Seal Guide
Figure 24: Place Guide on Shaft

Shaft Seal Inspection
Use a new shaft seal when reassembling the 4. Place the shaft seal over the seal guide. Slide
compressor. Inspect the lip of the new shaft seal the seal into the front cylinder head.
for scratches and other damage. Make sure the
shaft seal is free from lint and dirt.
Figure 23: Inspect Shaft Seal
Shaft Seal Installation

1. Seal Guide
Before installing a shaft seal inspect it carefully
2. Shaft Seal
(see “Shaft Seal Inspection” above).
Figure 25: Place Shaft Seal on Guide
1. Clean the seal section of the front cylinder
head that holds shaft seal. 5. Use the seal installer (from the shaft seal kit
2. Apply clean compressor oil to the new shaft ICE No. 2590116) to press the shaft seal into
seal and front cylinder head. If the slip the cylinder head as far as possible.
surfaces are dirty, clean them with thinners, 6. Remove the seal guide from the spline shaft.
43
Figure 26: Press Seal Into Cylinder Head Figure 27: Shaft Seal Cover (When equipped)
7. Install the snap ring using internal snap ring 3. Use the seal installer (from the shaft seal kit
pliers. Press the snap ring using the installing ICE No. 2590114) to press the shaft seal cover
end of the remover until you hear a “click.” into the cylinder.
4. Remove the seal guide from the spline shaft.
NOTE: Position the shaft seal cover as shown in
the illustration.
1. Shaft Seal
2. Guide
3. Snap Ring
NOTE: Install the snap ring with the chamfered

edge facing upward.
1. Top
Shaft Seal Cover Installation (When 2. Shaft Seal Cover
Equipped) 3. Bottom
1. Place the seal guide (from the shaft seal kit Figure 28: Shaft Seal Cover Position
ICE No. 2590116) on the end of the shaft.
2. Place the shaft seal cover on the seal guide Cylinder Head Procedures
and slide the shaft seal cover into the cylinder
head. Cylinder Head Disassembly–Front
and Rear
1. Remove the magnetic clutch assembly, as
outlined in “Clutch Removal” on page 39.
2. Remove the connector caps and the drain
Drain the oil. See “Draining the Oil” on
page 37.
44
3. Remove the shaft seal cover and shaft seal.

See “Shaft Seal Removal” on page 42.
4. Remove the six body bolts securing the head
using a socket wrench.
1. O-ring
2. Gasket
3. Front Cylinder Head
7. Remove the valve plate and suction valve

5. To remove the front cylinder head, alternately from the cylinder shaft assembly. Remove the
tap the two projections on the circumference gasket material from the valve plate.
of the front cylinder head with a screwdriver
and a plastic mallet.
1. Valve Plate
6. Remove the O-ring from the front cylinder 2. Suction Valve
head. Remove the gasket material from the
front cylinder head. 8. To remove the rear cylinder head, alternately
tap the projections on the circumference of the
rear head with a screwdriver and a plastic
mallet.
45
9. Remove the O-ring from the rear cylinder 1. Valve Plate

head. Remove the gasket material from the
2. Suction Valve
rear cylinder head.
Cylinder Head Inspection

• Check the front and rear valve plates for
scratched, bent, or damaged parts.
• Inspect both cylinder heads and both valve
plate assemblies for nicks and burrs on the
sealing surfaces. Clean or replace them if
damaged.
• Ensure that all passages in the valve plate are
unobstructed. If the cylinder head or valve
plate is cracked, replace it.
1. O-ring
2. Gasket
10. Remove the valve plate and suction valve

from the cylinder shaft assembly. Remove the
gasket material from the valve plate.
1. Front Cylinder
2. Valve Plate
46
1. Escape Groove 2. Install the rear suction valve so that it aligns

2. Suction Valve with the alignment pin.
3. Piston
CAUTION: Ensure that the valve is
aligned with the valve escape groove of
each cylinder.

2. O-ring
1. Escape Groove
3. Gasket
2. Suction Valve
4. Valve Plate
3. Piston
5. Suction Valve
3. Install the rear valve plate on the rear suction

Cylinder Head Reassembly valve.
Rear Cylinder Head
CAUTION: Do not mistake the front valve
1. Place the cylinder shaft assembly on the bench plate for the rear valve plate.
with the rear side up.
4. Coat the new gasket with clean compressor
oil. Install it on the rear valve plate. Use the
same oil used in the system.
47
5. Thinly coat the new O-ring with clean

compressor oil (same type of oil that is used in
the system). Install it on the rear cylinder
head.
6. Install the rear cylinder head. If the rear
cylinder head is difficult to install, tap the
cylinder head lightly with a mallet.
1. Escape Groove
2. Suction Valve
3. Piston
CAUTION: Ensure that the valve is

aligned with the valve escape groove of
1. Rear Cylinder Head each cylinder.
2. O-ring 3. Install the front valve plate on the front
3. Gasket suction valve.
4. Valve Plate
CAUTION: Do not to mistake the rear
5. Suction Valve
valve plate for the front valve plate.
Front Cylinder Head 4. Coat the new gasket with clean compressor oil
1. Place the cylinder shaft assembly on the bench (same oil used in the system). Install it on the
with the front side up. front valve plate.
2. Install the front suction valve so that it aligns 5. Thinly coat the new O-ring with clean
with alignment pin. compressor oil (same oil used in the system).
Install it on the front cylinder head.
6. Install the front cylinder head. If the front
cylinder head lightly with a plastic mallet.
48
NOTE: Air Gap—An incorrect air gap could

cause erratic engagement or disengagement
and/or clutch rattle. Check the air gap with a
feeler gauge (0.012 to 0.024 in. [0.3 to
0.6 mm]). Adjust based on “Clutch
Installation” on page 41.
1. Front Cylinder Head

2. Valve Plate
3. Suction Valve
4. Gasket
5. O-ring
Figure 29: Tightening Sequence
7. Install new gaskets on the body bolts. Insert
the six body bolts from the front cylinder head
side and tighten them to the specified torque.
TIghten each bolt gradually in three or more
stages to ensure the specified torque (see
“Tightening Torques” on page 31). Tighten
bolts in the order shown in Figure 29 on page
49.
Turn the drive shaft 2 to 3 times manually to
ensure that the shaft rotates smoothly.
8. Install the oil drain plug with a new O-ring,
thinly coated with clean compressor oil, and
tighten it to the specified torque. See
“Tightening Torques” on page 31.
1. Drain Plug
9. Fill the compressor with the specified amount
of clean compressor oil. See “Adding
Compressor Oil” on page 38.
CAUTION: Check label to verify you are

using the correct oil for the system.
10. Install the magnetic clutch (see “Clutch

Installation” on page 41).
11. :Leak test the system. See “Leak Testing the
Compressor” on page 36.
49
50
Compressor Maintenance: TM-31
Safety Refrigerant Recovery

DANGER: Explosion Hazard! Do not Avoid the release of refrigerant into the
throw or strike service cans. Do not handle atmosphere. If releasing refrigerant from an air
the packing carton roughly. Do not use conditioning system, use a refrigerant recovery
damaged or dented service cans. Store unit to recover the refrigerant.
service cans out of reach of children. Consult your recovery unit operators manual for
hookup and operating procedures.
directly heat service cans or put them in
water above 104 F (40 C). Do not put
service cans on the engine or radiator
when charging.
If is necessary to heat service cans for
charging in cold weather, use water below
104 F (40 C).

store service cans in direct sunlight, near
flame, or where temperature exceeds 104
F (40 C).

the warm water.
Figure 30: Recovery Unit – ICE No. 2590119
51
Compressor Handling Compressor Installation

CAUTION: Do not strike or turn the
compressor upside down. If the
compressor is turned upside down, rotate
it 5 to 6 times to circulate oil.
1. Compressor Oil Sight Glass
1. Rotate Compressor’s Magnetic Clutch 5 to

6 Times
Compressor Storage
Store new and rebuilt compressors:
• With the correct oil charge.
• Within the orientation range shown in Figure
31 on page 52. If the compressor sits outside
that orientation for more than one minute, turn
compressor manually (slowly) to clear oil
from the cylinders. Figure 31: Inclination Limit
• With a holding charge of refrigerant or NOTE: Inclination limit at installation must
nitrogen to a pressure of 7 to 21 psig (48 to be within the range shown above.
145 kPa). This protects internal parts from
moisture and corrosion. NOTE: If mounting shims are required for
installation, use Shim Kit (ICE No.
2570101).
Compressor Removal
See “Compressor Removal” on page 34.
52
Oil Procedures Clutch Removal

NOTE: For Compressor Oil Caution Statements, 1
Compressor Oil Charge Considerations,
Compressor Oil Type Considerations, Oil Check
Interval, Draining the Oil, and all Oil Check
procedures, see “Compressor Oil Procedures”
on page 36 in this manual.
To check oil level:
1. Return the oil to the compressor. See
“Returning Oil to the Compressor” on
page 37)
2. Use a flashlight to observe the compressor oil AEA1879
sight glass. Oil level should be approximately
in the middle of the sight glass. 1. Drive Plate Holder -Typical
CAUTION: If compressor installation 1. Remove the center bolt using a drive plate
does not permit easy viewing, use a mirror holder to prevent armature assembly rotation.
to view the sight glass. Be careful of
moving belts and pulleys. 1
1
AEA1742
AEA1880
1. Compressor Oil Sight Glass 1. Drive Plate Puller
2. Remove the armature assembly using the

Clutch Procedures drive plate puller. Remove the shims from the
NOTE: See “Clutch Application Guidelines” on compressor driveshaft or armature assembly.
page 13 for application information.
Clutch Run-In
See“Clutch Run-In” on page 39.
53
1 2
5. Remove the field coil by releasing the lead

wire grommet from the compressor, then
removing the three screws that secure the coil.
AEA1881
CAUTION: Do not hold the field coil by
1. Snap Ring Pliers ICE No. the harness.
2590117
2. Snap Ring Clutch Inspection
3. Remove the snap ring using external snap ring 1 2 3
pliers.
AEA1884
1. Armature Assembly
2. Pulley Assembly
3. Field Coil
1. If the contact surface has been damaged by

excessive heat, replace the armature and
AEA1882
pulley.
2. Check the appearance of the pulley assembly.
1. Pulley Puller Center If the contact surface of the pulley is
ICE No. 2590115 excessively grooved due to slippage, replace
4. Position the pulley puller center on the end of both the pulley and armature. Clean the
the driveshaft. Remove the pulley assembly contact surfaces of the pulley assembly with a
using a suitable pulley puller. suitable solvent before reinstallation.
3. Check the field coil for a loose connector or
CAUTION: Clip the puller claws into the cracked insulation.
pulley groove to prevent pulley groove
damage.
54
Clutch Installation
AEA1885
1. Install the field coil on the compressor (with

the harness on top). Tighten the mounting
screws to the specified torque.
Specified Torque: 6 to 7 ft-lbs (8 to 10 N•m) AEA1887
2. Install the wire harness/strain relief. 1. Shim(s)
5. Install the armature assembly on the driveshaft

1 together with the original shim(s). Press the
armature assembly down by hand.
NOTE: If required, additional shims are
available. Use clutch hardware kit ICE No.
2530109.
6. Install the armature bolt and tighten the bolt to
the specified torque using the drive plate
holder to prevent armature assembly rotation.
AEA1886
Specified Torque: 14 to 16 ft-lbs (20 to 22 N•m)
1. Pulley Installer
3. Install the pulley assembly using the pulley CAUTION: After tightening the center
installer and a hand press. bolt, check that the pulley rotates smoothly
4. Install the snap ring using external snap ring 1

pliers. Install the snap ring with the chamfered
inner edge outward (facing away from the
seal).
AEA1888
Clutch Clearance: 0.012 t 0.024 in. (0.3 to 0.6 mm)
55
7. Check that the clutch clearance is as specified.

If necessary, adjust the clearance using
1
shim(s).
NOTE: Clutch hardware kit is available
(ICE No. 2530109).
2
Shaft Seal Procedures

Shaft Seal Removal
AEA1891
1. Remover - Shaft Seal Kit ICE No.

3 2590114
1
2. Shaft Seal
5. Remove the shaft seal, pushing the remover

5 until the shaft seal is pushed out the back of
4 the head.
2 Shaft Seal Installation

AEA1889
1
Figure 32: Torque Sequence
1. Remove the magnetic clutch assembly See

“Clutch Removal” on page 53.
2. Remove the connector caps and oil drain plug.
Drain the oil. See “Draining the Oil” on AEA1892
page 37.
2
3. Remove the five through-bolts securing the
head using a hexagon wrench.
1. Installer- ICE No. 2590117
2. Shaft Seal
1. Clean the sealed section of the front cylinder

head.
2. Apply clean compressor oil to the new shaft
seal.
AEA1890
CAUTION: Use same oil type in the
4. Remove the front cylinder head by tapping the system.
three projections on the circumference of the
front cylinder head with a screwdriver (flat 3. Insert the shaft seal as far as possible into the
head) and a plastic or rubber mallet. front cylinder head using the installer.
56
6. Mount the new gaskets on the through-bolts.

7. Insert the five through-bolts from the front
cylinder head side and tighten them to the
specified torque.
4 NOTE: Tighten the bolts in the order shown
1 in the torque sequence photo. See “Torque
Sequence” on page 56..
3 2 Specified Torque: 18.4-22.1 ft-lbs (25 to 30 N•m)
AEA1893
1. Guide
2. Shaft
3. Gasket
4. O-ring
AEA1895
4. Thinly coat the new O-ring and gasket with
clean compressor oil. Use the same oil used in 1. Handle
the system.
8. Turn the drive shaft two or three times
5. Fit the guide onto the end of the drive shaft. manually to ensure that the shaft rotates
Install the front cylinder head. If the front smoothly.
cylinder head lightly with a plastic or rubber 9. Fill the compressor with the specified amount
mallet. of clean compressor oil through the oil filler.
Tighten the oil filler plug to the specified
torque.
Specified Torque: 10-12 ft-lbs (14 to 16 N•m)
10. Install the magnetic clutch. See “Clutch

Installation” on page 55.
11. Do a clutch run-in (see “Clutch Run-In” on
page 39) and leak test (see “Leak Testing the
Compressor” on page 36).
AEA1894
57
58
Appendix – Tools and Kits
Clutch Remover – ICE No. 2590115
Compressor Holder – ICE No. 2590116
59
Clutch Installation Kit – ICE No. 2590118 Shaft Seal Kit – ICE No. 2590114
60
Snap Ring Pliers – ICE No. 2590117
Clutch Hardware Kit – ICE No. 2530109 Shim Kit – ICE No. 2570101
61
Customer Service: Phone 952-886-6088

Visit our Web site at www.intl-comp.com
or contact our Customer Service at
952-886-6088
Fax: 952-886-6099
62

TK 60690-3-MM X500 Rev.0.1 Print Date 2011-02-28

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

TK 60690-3-MM X500 Rev.0.1 Print Date 2011-02-28

Uploaded by

Copyright:

Available Formats

X-series HVAC System

TK 60690-3-MM Revision 0.1 (Print Date: February 28, 2011)

Copyright © 2011 Ingersoll Rand Corporation, Thermo King

For further information, refer to:

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

Before you call Thermo King Service

3. List of Figures ..........................................................................................................................................7

8. Rooftop Unit Description .......................................................................................................................19

10. Operating Instructions ........................................................................................................................27

11. Refrigeration System Maintenance.....................................................................................................52

12. Refrigeration/Heating Repairs ............................................................................................................63

13. Electrical Maintenance & Repairs.......................................................................................................70

14. Mechanical Maintenance & Repairs ...................................................................................................78

16. Temperature-Pressure Chart ..............................................................................................................87

17. Index ....................................................................................................................................................89

18. Schemes, Diagrams and Drawings Index...........................................................................................91

19. Appendix .............................................................................................................................................92

A/C Air Conditioning HTS HTS: Heating water temperature

The exclamation symbol appears next to a point that is particularly important.

DANGER: Denotes the possibility of serious injury or death.

WARNING: Denotes the possibility of serious equipment damage or serious personal

CAUTION: Denotes the possibility of minor to severe equipment damage or personal

5.1. General Practices

DANGER: Never apply heat to a sealed refrigeration system or container. Heat

DANGER: Refrigerant in the presence of an open flame, spark or electrical short

WARNING: Be careful when using ladders or scaffolding to install or service air

5.2. Electrical Hazards

CAUTION: When working with electrical circuits that contain microprocessors,

CAUTION: Certain service procedures on air conditioning equipment require that

5.3. Refrigerant Hazards

CAUTION: When recovering or transferring refrigerant, use a process that prevents

CAUTION: Refrigerant in a liquid state evaporates rapidly when exposed to the

5.4. Compressor Oil Hazards

CAUTION: When servicing TK units, do not use equipment that might be

CAUTION: Store compressor oil in an approved sealed container to avoid moisture

Parts of system SR 380

Figure 1: X500 Unit dimensions

8.2.1. Condenser Coil

8.2.2. Condenser Fan

8.2.4. Evaporator/Heating Coil Assemblies

8.2.5. Evaporator Blowers

8.2.6. Fresh Air Damper (optional)

8.2.7. Air Filters (optional)

8.2.8. Unit Protection Devices

High Pressure Switch (HPCO)

Low Pressure (LPCO) Switch

Safety Relief Valve (SRV)

8.2.9. Structural Frame and Cover

1 Unit front - condenser section 5 ABS right side cover

Figure 3: X500 Outside view

1 Unit frame 9 Electrical circuit connection

Figure 4: X500 Inside view

Figure 5: TM compressors (Illustration photo)

CAUTION: Type of oil R-134a is TK No. 203-515.

ATS Ambient temperature sensor FD Filter-drier

Figure 6: A/C refrigeration system (example)

Figure 7: Application diagram

10.4. ClimaAIRE ID controller

1 ON/OFF key 8 Temperature icons

10.4.1. Operating elements

ON/OFF key Press the key to turn the unit ON

Yellow alarm indicator

Mode select key Reheat/Auto mode