Thermo King X214 Manuale utente

Distributed by:

Ingersoll Rand’s Climate Solutions sector delivers energy-efﬁ cient HVACR solutions for

customers globally. Its world class brands include Thermo King, the leader in transport

temperature control and Trane, a provider of energy efﬁ cient heating, ventilating and air

conditioning systems, building and contracting services, parts support and advanced controls

for commercial buildings and homes.

SB-210+

Additional text information

to be placed here

TK 5XXXX-X-PL

TK 6875-8-OM

Printed in U.S.A.

314 West 90th Street

Minneapolis, MN 55420

Direct (952) 887-2200

Thermo King Corporate

Distributed by:

SB-210+

Additional text information

to be placed here

TK 5XXXX-X-PL

314 West 90th Street

Minneapolis, MN 55420

Direct (952) 887-2200

Thermo King Corporate

SB-210+

Additional text information

to be placed here

TK 5XXXX-X-PL

Distributed by:

314 West 90th Street

Minneapolis, MN 55420

Direct (952) 887-2200

Thermo King Corporate

Distributed by:

X214, X418, X426 &

X430 Compressor

TK 6875-8-OM (Rev. 9, 02/14)

314 West 90th Street

Minneapolis, MN 55420

Direct (952) 887-2200

Thermo King Corporate

Overhaul ManualOverhaul Manual

Overhaul ManualOverhaul ManualOverhaul Manual

Overhaul Manual

X214, X418,

X426 & X430

Compressor

TK 6875-8-OM (Rev. 9, 02/14)

U.S.A.

Overhaul Manual

Revision History

Rev. 9 – TK 6875-8-OM (Rev. 9, 02/14) Update for Oil Collection Container, Pressurized Seal

Cavity, and Internal Oil Filter.

This manual is published for informational purposes only and the information so provided should

not be considered as all-inclusive or covering all contingencies. If further information is required,

Thermo King Corporation should be consulted.

Sale of product shown in this manual is subject to Thermo King’s terms and conditions

including, but not limited to, the Thermo King Limited Express Warranty. Such terms and

conditions are available upon request. Thermo King’s warranty will not apply to any

equipment which has been “so repaired or altered outside the 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.

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.

CHANGES, COMMENTS and SUGGESTIONS

You are invited to comment on this manual so it can be updated and improved to better meet you

needs. Any corrections, comments or suggestions are welcome. Please complete the following

information:

Manual Form Number _____________________________________________________

Section and Page # _______________________________________________________

Your Name ______________________________________________________________

Company Name __________________________________________________________

Phone Number ___________________________________________________________

Corrections, Comments and Suggestions _____________________________________

________________________________________________________________________

Return to:

NORTH AMERICA

THERMO KING CORPORATION

314 West 90th Street

Mail Stop 38

Minneapolis, MN 55420

Attn: Service Department

EUROPEAN SERVED AREA

THERMO KING CORPORATION

Ingersoll Rand Climate Control Technologies

Monivea Road

Mervue, Galway, Ireland

Attn: Service Department

Table of Contents

Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

General Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Battery Installation and Cable Routing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Battery Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Refrigerant Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Refrigerant Oil Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Electrical Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

High Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Low Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

First Aid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

First Aid, Refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

First Aid, Refrigerant Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

First Aid, Engine Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

First Aid, Electrical Shock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Compressor Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Compressor Model Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Two Cylinder Compressors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Four Cylinder Compressors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Oil Collection Container . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

General Compressor Repair Techniques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Dirt and Moisture can Easily Ruin Compressors! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Compressor Oil Indications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Compressor Oil Color Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Disassembly and Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Disassembly Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Reassembly Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Fastener Torque Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Cleaning Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Drive Coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Discharge Valve Plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Two-piece Compressor Seal Plate and Mounting Flange Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Seal Plate Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Installation of Spring Loaded Neoprene Bellows Type Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Installation of Metal Bellows Seal With Set Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Installation of Metal Bellows Seal With Drive Tangs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Installation of Metal Bellows Seal With Hex Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Oil Sump and Oil Pickup Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Table of Contents

Internal Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46

Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47

Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48

Pre-Lubrication of Oil Pump Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49

Connecting Rod, Piston and Sleeve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51

Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53

Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54

Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57

Compressor Crankshaft Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59

Removal and Installing Crankshaft Counterweights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60

Compressor Body Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61

Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62

Check Valve Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62

Unloader Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63

Check Out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63

Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64

Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64

Leak Testing, Storage, and Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65

Leak Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65

Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65

Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65

Compressor History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67

Compressor History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67

Released . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67

Two-piece Compressor Seal Plate and Mounting Flange Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67

Metal Bellows Crankshaft Seal with Set Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67

Polyol Ester (POE) Compressor Oil for HFC Refrigerants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67

Groove Top Pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67

Teflon Seal Type Drive End Ball Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67

New Coupling Mounting Washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67

Large Shaft Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67

Metal Bellows Crankshaft Seal with Drive Tangs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67

8 Pin Coupling and Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67

Fins Eliminated from Crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67

Seven Quart Oil Sump on Four Cylinder Compressors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67

Deep Oil Sump on Two Cylinder Compressors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67

Increase Bronze Bearing Bore Diameter in Oil Pump Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68

Improve Heat Treating on Oil Pump Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68

HPCO Switch with Straight Threads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68

C5 Crankshaft Drive End Bearing and Cast Iron Oil Pump Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68

Oil Collection Container . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68

Check Valve in Oil Collection Container . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68

Pressurized Seal Cavity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68

Internal Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68

Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .69

Safety Precautions

Thermo King recommends that all service be

performed by a Thermo King dealer. However,

you should be aware of several general safety

practices:

The symbol appears next to a point that is

particularly important

General Practices

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.

DANGER: Do not operate the compressor

with the discharge service valve closed.

This condition increases internal pressure,

which can cause an explosion.

DANGER: Never apply heat to a sealed

refrigeration system or container. Heat

increases internal pressure, which might

cause an explosion.

DANGER: Refrigerant in the presence of

an open flame, spark or electrical short

produces toxic gases that are severe

respiratory irritants.

DANGER: Keep your hands, clothing and

tools clear of fans when working on a unit

that is running. Loose clothing might

entangle moving 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

cargo area or garage. Refrigerant

displaces air and can cause oxygen

depletion, resulting in suffocation and

possible death.

DANGER: Avoid engine operation in

confined spaces and areas or

circumstances where fumes from the

engine could become trapped and cause

serious injury or death.

WARNING: Make sure your gauge

manifold hoses are in good condition

before using them. Never let them come in

contact with moving belts, fans, pulleys or

hot surfaces. Defective gauge equipment

can damage components or cause serious

injury.

WARNING: Always wear goggles or safety

glasses when working on a unit.

Refrigerant liquid, oil and battery acid can

permanently damage your eyes. See “First

Aid” on page 10.

WARNING: Use extreme caution when

drilling holes in a unit. Holes might

weaken structural components. Holes

drilled into electrical wiring can cause a

fire or explosion.

WARNING: Exposed coil fins can cause

lacerations. Service work on the

evaporator or condenser coils is best left to

a certified Thermo King technician.

WARNING: Do not apply heat to a closed

cooling system. Before applying heat to a

cooling system, drain it. Then flush it with

water and drain the water. Antifreeze

contains water and ethylene glycol. The

ethylene glycol is flammable and can

ignite if the antifreeze is heated enough to

boil off the water.

WARNING: Be careful when using

ladders or scaffolding to install or service

a unit. Observe the manufacture’s 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.

Safety Precautions

NOTE: In the USA, EPA Section 608

Certification is required to work on refrigeration

systems.

Battery Installation and Cable

Routing

Battery Removal

This order is important because the frame is

grounded to the negative battery terminal. If the

negative terminal is still connected, a complete

circuit exists from the positive terminal of the

battery to the frame. Metal objects contacting the

positive side and the frame simultaneously will

cause sparks or arcing. If there are sufficient

hydrogen gases emitted from the battery, an

explosion might occur, causing equipment

damage, serious injury, even death.

Refrigerant Hazards

WARNING: Improperly installed battery

could result in a fire or explosion! A

Thermo King approved battery must be

installed and properly secured to the

battery tray.

WARNING: Improperly installed battery

cables could result in fire or explosion!

Battery cables must be installed, routed

and secured properly to prevent them from

rubbing, chaffing or making contact with

hot, sharp or rotating components.

WARNING: Do not attach fuel lines or

any additional wiring harnesses to the

battery cables as this could cause an

electrical fire!

CAUTION: Do not connect other

manufacturer’s equipment or accessories

to the Thermo King unit. This could result

in severe damage to equipment and void

the warranty!

CAUTION: Set all unit electrical controls

to the OFF position before connecting

battery cables to the battery to prevent unit

from starting unexpectedly and causing

personal injury.

CAUTION: Always wear protective

clothing, gloves and eye wear when

handling and installing batteries. Battery

acid can cause serious burns when

exposed to eyes or skin. If battery acid

contacts skin or clothing, wash

immediately with soap and water. If acid

enters your eye, immediately flood it with

running cold water for at least twenty

minutes and get medical attention

immediately.

CAUTION: Always cover battery

terminals to prevent them from making

contact with metal components during

battery installation. Battery terminals

grounding against metal could cause the

battery to explode.

DANGER: Disconnect the negative

battery terminal (-) first when removing a

battery. Connect the positive terminal (+)

first when installing a battery.

DANGER: Do not use a Halide torch.

When a flame comes in contact with

refrigerant, toxic gases are produced.

These gases can 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 can cause

them to burst.

DANGER: Do not use oxygen (O2 ) or

compressed air for leak testing. Oxygen

mixed with refrigerant is combustible.

WARNING: Wear butyl lined gloves when

handling refrigerant to help prevent

frostbite.

Safety Precautions

Refrigerant Oil Hazards

Electrical Hazards

High Voltage

Low Voltage

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.

CAUTION: When being transferred,

refrigerant must be in liquid state to avoid

possible equipment damage.

CAUTION: When transferring

refrigerant, use a process that prevents or

greatly restricts refrigerant from escaping

into the atmosphere. Refrigerant damages

the earth’s upper ozone layer.

WARNING: Protect your eyes from

contact with refrigerant oil. The oil can

cause serious eye injuries. Avoid

prolonged or repeated contact with

refrigerant oil. To prevent irritation, wash

your hands and clothing thoroughly after

handling the oil.

CAUTION: Use the correct oil in Thermo

King systems to avoid damaging

equipment and invalidating its warranty.

CAUTION: Do not mix refrigerant oils

because that can cause system damage.

CAUTION: Use dedicated equipment to

prevent contaminating systems with the

wrong type of oil.

CAUTION: Store refrigerant oil in an

approved sealed container to avoid

moisture contamination.

CAUTION: Do not expose the refrigerant

oil to the air any longer than necessary.

The oil will absorb moisture, which results

in much longer evacuation times and

possible system contamination.

CAUTION: Wipe up spills immediately.

Refrigerant oil can damage paints and

rubber materials.

DANGER: Lethal amounts of voltage are

present in some electrical circuits. Use

extreme care when working on an

operating refrigeration unit.

WARNING: Do not make rapid moves

when working on high voltage circuits in

refrigeration units. Do not grab for falling

tools because you might accidentally touch

a high voltage source.

WARNING: Use tools with well insulated

handles. Never hold uninsulated metal

tools near exposed, energized conductors.

WARNING: Treat all wires and

connections as if they were high voltage

until a meter and wiring diagram indicate

otherwise.

WARNING: Never work alone on high

voltage circuits in the refrigeration unit.

Another person should be nearby to shut

off the unit and provide aid in the event of

an accident.

WARNING: Safety glasses, rubber-

insulated gloves and cable cutters should

be near your work area, in the event of an

electrical accident.

WARNING: Use caution when working

with electrical circuits that contain

capacitors. Some capacitors hold a

significant charge that might cause burns

or shocks if accidentally discharged. Make

sure capacitors are discharged before

working on electrical circuits.

WARNING: Control circuits used in

refrigeration units are low voltage (12 to

24 volts dc). This voltage is not dangerous,

but the large amount of amperage

available from the alternator can cause

severe burns if accidentally shorted to

ground with metal objects, such as tools.

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