Truck Open Drive

Scroll Compressor
Diagnostic Manual
TK 51205-1-OM (Rev. 1, 08/02)

Copyright© 2001 Thermo King Corp., Minneapolis, MN, U.S.A.

Printed in U.S.A.
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.
Table of Contents
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
General Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
First Aid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Refrigeration Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
First Aid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Electrical Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
High Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
First Aid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Low Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Unit Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Maintenance Inspection Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Scroll Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Axial and Radial Compliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Component Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Scroll Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Fixed Scroll . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Orbiting Scroll . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Oldham Coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Unloader . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Floating Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Dynamic Discharge Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
Liquid Injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
Oil Pump and Lubrication System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
Refrigeration Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
Set Up and Test of Evacuation Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
Unit Evacuation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
Unit Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
Remove Refrigerant Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
Refrigerant Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
Refrigerant Charge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
Checking Compressor Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
High Pressure Cutout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
Low Pressure Cutout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
High Temperature Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
Diagnosing the Scroll Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
Symptoms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
Pump Down Test Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
Compressor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
Compressor Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
Shaft Seal Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
Oil Filter Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
Compressor Oil Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
High Temperature Cutout Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
µP-T Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
Scroll Compressor Component Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41

5
Table of Contents

6
Safety Precautions
General Practices
1. ALWAYS WEAR GOGGLES OR SAFETY
GLASSES. Refrigerant liquid, refrigeration
oil, and battery acid can permanently damage
the eyes (see First Aid).
2. Never close the compressor discharge service
valve with the unit operating.
3. Never operate the unit with the compressor
discharge valve closed.
4. Keep your hands, clothing and tools clear of
the fans and belts when the unit is running.
This should also be considered when opening
and closing the compressor service valves.
5. Make sure gauge manifold hoses are in good
condition. Never let them come in contact
with a belt, fan motor pulley, or any hot
surface.
6. Never apply heat to a sealed refrigeration
system or container.
7. Fluorocarbon refrigerants in the presence of
an open flame produce toxic gases that are
severe respiratory irritants capable of causing
death.
8. Make sure all mounting bolts are tight and
are of correct length for their particular
application.
9. Use extreme caution when drilling holes in
the unit. The holes may weaken structural
components, and holes drilled into electrical
wiring can cause fire or explosion. Holes
drilled into the refrigeration system will
release refrigerant.
10. Use caution when working around exposed
coil fins. The fins can cause painful
lacerations.
11. Use caution when working with a refrigerant
or refrigeration system in any closed or
confined area with a limited air supply (for
example, a truck body or garage). Refrigerant
tends to displace air and can cause oxygen
depletion resulting in suffocation and
possible death.
12. When using ladder or scaffolding, use
caution and follow manufacturer
recommendations.
Auto Start/Stop
CAUTION: The unit may start
automatically and at any time when
the unit On-Off switch is in the ON
position. Units with the
CYCLE-SENTRY option start
automatically in both CYCLE-SENTRY
mode and Continuous mode. Be sure
to turn the On-Off switch OFF before
opening doors or inspecting or
working on any part of the unit.
Refrigerant
When removing refrigerant from a unit, a
recovery process that prevents or minimizes
refrigerant loss to the atmosphere is required by
law.
When a refrigerant is exposed to the atmosphere
in the liquid state, it evaporates rapidly, freezing
anything it contacts. If refrigerant contacts the
skin, severe frostbite can result.
First Aid
In the event of frost bite, the objectives of First
Aid are to protect the frozen area from further
injury, to warm the affected area rapidly and to
maintain respiration.
• EYES: For contact with liquid, immediately
flush eyes with large amounts of water and
get prompt medical attention.
• SKIN: Flush area with large amounts of
lukewarm water. Do not apply heat. Remove
contaminated clothing and shoes. Wrap burns
with dry, sterile, bulky dressing to protect
from infection/injury. Get medical attention.
Wash contaminated clothing before reuse.
INHALATION: Move victim to fresh air and use
cardiopulmonary resuscitation (CPR) or
mouth-to-mouth ventilation if necessary. Stay
with victim until arrival of emergency medical
personnel
7
Safety Precautions
Refrigeration Oil
Observe the following precautions when working
with or around synthetic or polyol ester refrigerant
oil:
• Do not allow refrigerant oil to contact your
eyes.
• Do not allow prolonged or repeated contact
with skin or clothing.
• To prevent irritation, you should wash
thoroughly immediately after handling
refrigerant oil. Rubber gloves are
recommended when handling polyol ester oil.
First Aid
• EYES: Immediately flush eyes with large
amounts of water for at least 15 minutes while
holding the eyelids open. Get prompt medical
attention.
• SKIN: Remove contaminated clothing. Wash
thoroughly with soap and water. Get medical
attention if irritation persists.
• INHALATION: Move victim to fresh air and
restore breathing necessary. Stay with victim
until arrival of emergency personnel.
• INGESTION: do not induce vomiting.
Contact a local poison control center or
physician immediately.
Electrical Hazards
Microprocessor Service
Precautions must be taken to prevent electrostatic
discharge when servicing the microprocessor
controller and related components. Potential
differences considerably lower than those which
produce a small spark from a finger to a door
knob can severely damage or destroy solid-state
integrated circuit components.
The following procedures must be rigidly adhered
to when servicing units to avoid microprocessor
damage or destruction.
1. Disconnect all power to the unit.
2. Avoid wearing clothing that generates static
electricity (wool, nylon, polyester, etc.).
8
3. Do wear a static discharge wrist strap (TK P/N
204-622) with the lead end connected to the
microprocessor’s ground terminal. These
straps are available at most electronic
equipment distributors. DO NOT wear these
straps with power applied to the unit.
4. Refer to the THERMOGUARD µP-IV
Microprocessor Controller Operations and
Diagnosis Manual (TK 41087) (T.I.P.
Procedure #P41AA12B) and the Electrostatic
Discharge Training Guide (TK 40282) for
additional information.
5. Avoid contacting the electronic components
on the circuit boards of the unit being
serviced.
6. Leave the circuit boards in their static proof
packing materials until ready for installation.
7. If a defective controller is to be returned for
repair, it should be returned in the same static
protective packing materials from which the
replacement component was removed.
8. After servicing the controller or any other
circuits, the wiring should be checked for
possible errors before restoring power.
9. Never use testers consisting of a battery and a
light bulb to test circuits on any
microprocessor based equipment.
10. Before connecting or disconnecting the
battery, the microprocessor switch must be
turned OFF.
Welding of Units or Truck Bodies
When electric welding is to be performed on any
portion of the temperature control unit, truck or
truck chassis when the temperature control unit is
attached, it is necessary to ensure that welding
currents are NOT allowed to flow through the
electronic circuits of the unit.These procedures
must be rigidly adhered to when servicing units to
avoid damage or destruction of the controller.
1. Disconnect all power to the unit.
2. Disconnect all wire harnesses from the
controller.
3. Switch all of the electrical circuit breakers in
the control box to the OFF position.
Safety Precautions
4. Weld unit and/or container per normal
welding procedures. Keep ground return
electrode as close to the area to be welded as
practical. This will reduce the likelihood of
stray welding currents passing through any
electrical or electronic circuits.
5. When the welding operation is completed, the
unit power cables, wiring and circuit breakers
must be restored to their normal condition.
High Voltage
When servicing or repairing a temperature control
unit, the possibility of serious or even fatal injury
from electrical shock exists. Extreme care must be
used when working with a refrigeration unit that
is connected to a source of operating power, even
if the unit is not operating. Lethal voltage
potentials can exist at the unit power cord, inside
the control box, at the motors and within the
wiring harnesses.
Precautions
1. Be certain the unit On/Off switch is turned
OFF before connecting or disconnecting the
standby power plug. Never attempt to stop the
unit by disconnecting the power plug.
2. Be certain the unit power plug is clean and dry
before connecting it to a power source.
3. When working on high voltage circuits on the
temperature control unit, do not make any
rapid moves. If a tool drops, do not grab for it.
People do not contact high voltage wires on
purpose. It occurs from an unplanned
movement.
4. Use tools with insulated handles that are in
good condition. Never hold metal tools in
your hand if exposed, energized conductors
are within reach.
5. Treat all wires and connections as high
voltage until a meter and wiring diagram show
otherwise.
6. Never work alone on high voltage circuits on
the temperature control unit. Another person
should always be present to shut off the
temperature control unit and to provide aid in
the event of an accident.
7. Have electrically insulated gloves, cable
cutters and safety glasses available in the
immediate vicinity in the event of an accident.
First Aid
IMMEDIATE action must be initiated after a
person has received an electrical shock. Obtain
immediate medical assistance if available.
The source of shock must be immediately
removed by either shutting down the power or
removing the victim from the source. If it is not
possible to shut off the power, the wire should be
cut with either an insulated instrument (e.g., a
wooden handled axe or cable cutters with heavy
insulated handles) or by a rescuer wearing
electrically insulated gloves and safety glasses.
Whichever method is used do not look at the wire
while it is being cut. The ensuing flash can cause
burns and blindness.
If the victim must be removed from a live circuit,
pull the victim off with a non-conductive material.
Use the victim’s coat, a rope, wood, or loop your
belt around the victim’s leg or arm and pull the
victim off. DO NOT TOUCH the victim. You can
receive a shock from current flowing through the
victim’s body. After separating the victim from
the power source, check immediately for the
presence of a pulse and respiration. If a pulse is
not present, start CPR (Cardiopulmonary
Resuscitation) and call for emergency medical
assistance. If a pulse is present, respiration may be
restored by using mouth-to-mouth resuscitation,
but call for emergency medical assistance.
Low Voltage
Control circuits used in the temperature control
unit are low voltage (24 volts ac and 12 volts dc).
This voltage potential is not considered
dangerous, but the large amount of current
available (over 30 amperes) can cause severe
burns if shorted or ground.
Do not wear jewelry, watch or rings when
working on the unit. If these items contact an
electrical circuit, severe burns may result.
9
Safety Precautions

Unit Decals
Serial number decals, refrigerant type decals and
warning decals appear on all Thermo King
equipment. These decals provide information that 1
may be needed to service or repair the unit.
Service technicians should especially read and
follow the instructions on all warning decals.

AAD62

1. Below the fuel filters, inside the engine access 1. Serial Plate Location on Side of Compressor
door.
2. On the evaporator beside the expansion valve. Figure 3: Compliant Scroll Compressor
3. Beside the serial number plate on top of the
unit frame above the switch panel.
4. On the top of the condenser coil.
Figure 1: Refrigerant Decal Locations

AEA1635

Figure 2: Refrigerant Decal

10
Specifications

Models Models
Scroll Compressor Specifications TS-200 & TS-300 TS-500 & TS-600
XDS & UTS

Compressor Model TF15 TF22

Displacement 4.096 cubic inch 5.982 cubic inch

*Compressor Oil Charge 1.6 qt (1.5 liters)

Compressor Oil Type: (R404A) Mobil EAL-22C

(203-516 Ester Base)

Max / Min Speed 4200 / 2300 RPM

Maximum Discharge Pressure 450 psig (3102 kPa)

Minimum Operating Suction Pressure 5 psig (34.5 kPa)

Minimum Pump down Pressure 10” Hg

Maximum Compression Ratio 24: 1

Maximum Discharge Temperature 302 F (150 C)

(measured at thermostat well in end cap)

Direction of Rotation CCW (viewed from shaft end of compressor)

NOT REVERSIBLE
(Note arrows on compressor body)
Liquid Injection Valve:
Closed Below 250 F (121 C)
Begins to Open 250 F (121 C)
Fully Open 270 F (132 C)

Compressor High Temperature Cutout Switch:

Opens 293 ± 9 F (145 ± 5 C)
Closes 142 ± 27 F (61 ± 15 C)

*When the compressor is removed from the unit, oil level should be noted or the oil removed from the
compressor should be measured so that the same amount of oil can be added before placing the
replacement compressor in the unit.

11
Specifications

12
Maintenance Inspection Schedule

Every Annual/
2,000* 3,000 REFRIGERATION SYSTEM
Pre-trip Hours Hours
• • Check refrigerant level.
• • Check compressor oil level.
Check suction pressure regulator/throttling valve operation on
• • defrost or heat.
• Check discharge and suction pressures.
• Check compressor efficiency.
— Replace dehydrator and compressor oil filter every two years.

13
Maintenance Inspection Schedule

14
Scroll Operation

This manual was written to help the service These compressors are the latest in compliant
technician better understand the operation and scroll design and technology and when combined
service procedures of the Thermo King TF15 and with a routine preventive maintenance program,
TF22 Compliant Scroll compressors. will provide many hours of satisfactory service.

AAD61

Figure 4: Compliant Scroll Compressor

15
Scroll Operation

The scroll compressor is designed around two
identical spirals or scrolls that, when inserted
together, form crescent-shaped pockets.
During a compression cycle, one scroll remains
stationary while the other orbits around the first.
As this motion occur, gas is drawn into the scrolls
and moved in increasingly smaller pockets
towards the center.
At this point, the gas, now compressed to a high
pressure, is discharged from the port in the center
of the fixed scroll.
During each orbit, several pockets of gas are
compressed simultaneously, creating smooth,
nearly continuous compression.

1. 2. 3.

4. 5.

1. Compression in the scroll is created by the mating of an orbiting spiral vane and a
stationary spiral vane. Gas enters an outer opening as one of the spiral vane orbits.
2. The open passage is sealed off as gas is drawn into the spiral vane.
3. As the spiral vane continues to orbit, the gas is compressed into a decreasingly smaller
pocket.
4. By the time the gas arrives at the center port, discharge pressure has been reached.
5. Actually, during operation, all six gas pockets are in various stages of compression at all
times, resulting in nearly continuous suction and discharge.
Figure 5: Scroll Operation

16
Scroll Operation

Axial and Radial Compliance Reliability and Durability

The scroll compressors are called “compliant” The scroll compressor has fewer moving
scrolls due to the method in which the two scroll components then a reciprocating compressor.
vanes interact both in the axial and radial direction Its axial and radial compliance make the scroll
to achieve high efficiency and durability compressor more tolerant to liquid refrigerant and
simultaneously. debris - two of the most common causes of system
Compliance scroll compressor also provide the failure.
following advantages:
Component Description
• Minimized gas leakage and maximized
performance efficiency through continuous
Scroll Set
scroll vane contact, maintained by radial
compliance. The scroll set is comprised of two matching scrolls
- the fixed scroll and the orbiting scroll. Each
• Improved durability from radial scroll has a scroll vane and a base plate. When the
compliance that allows spiral vane two scrolls are brought together, the tips of each
members to separate in the presence of scroll vane contact the base plate of the other
liquid refrigerant and debris. resulting in tip sealing.
• Improved efficiency ensured through axial
compliance, which keeps scroll vane tips Fixed Scroll
and base in continuous contact without the The mounting of the “fixed” scroll to the main
use of tip seals. bearing housing is designed to allow some axial
• Axial and radial compliance provide movement in order to provide the appropriate
improved liquid tolerance. sealing pressure at the scroll tips at all times. This
Improved Starting Ability axial compliance characteristic also allows the
scrolls to separate axially in order to pass debris at
Due to the design of the compliant scroll
the scroll tips. Discharge from the scroll set passes
compressor, the spiral vanes always start unloaded
through the discharge port at the center of the
even if the system pressures ares not balanced. In
fixed scroll. Cooling liquid refrigerant is injected
addition, since internal compressor pressures are
into the scroll set via holes machined into the body
always balanced at start-up, electric standby
of the fixed scroll. The fixed scroll houses the
starting characteristics are excellent for compliant
floating seal and the dynamic discharge check
scroll compressors.
valve.
Efficiency
Unlike reciprocating compressors, the suction and 1
discharge process of a scroll compressor are
physically separated. This reduces heat transfer 4
that can reduce overall efficiency.
The scroll compression and discharge process is
smooth and nearly continuous. This process occurs
during a full 540 degrees of rotation in the scroll 2
compressor compared to 180 degrees of rotation in
a reciprocating compressor.
Reciprocating compressors require both discharge
and suction valves, while the scroll design does
3
not require a valve plate or piston reeds.

1. Discharge Port 3. Liquid Injection

2. Bleed Port for Line
Floating Seal 4. Liquid Injection
Ports
Figure 6: Fixed Scroll
17
Scroll Operation
Orbiting Scroll
This half of the scroll set is driven by the
crankshaft via the drive unloader. It does not
rotate, but moves in a circular motion. This motion
allows for a rolling contact between vanes of the
orbiting and fixed scrolls. This rolling contact
provides sealing along the scroll flanks.
The combination of tip and flank sealing results in
pockets being formed between the two scrolls.
With the motion of the orbiting scroll, gas pockets
are continuously pushed from larger volumes at
the outer circumference of the scroll set into
smaller volumes at the center of the scroll set,
resulting in gas compression.
1
1. Scroll Tips
Figure 7: Orbiting Scroll
Oldham Coupling
This coupling is sandwiched between the orbiting
scrolls and the thrust plate of the main bearing
housing. It has four keys, two that mesh with tabs
on the fixed scroll and two that mesh with tabs on
the orbiting scroll. The Oldham coupling controls
the motion of the orbiting scroll relative to the
fixed scroll by preventing the orbiting scroll from
rotating and ensuring that the orbiting scroll
moves in a perfect circle within the fixed scroll.
Figure 8: Oldham Coupling
18
Unloader
The unloader is a unique bushing that couples the
crankshaft to the orbiting scroll hub. It translates
the rotation of the crankshaft into the orbiting
motion necessary to drive the orbiting scroll and is
designed to ensure that optimum sealing is
maintained at the scroll flanks. The loose fit of the
unloader on the crankshaft’s drive flat allows the
orbiting scroll to separate radially from the fixed
scroll, if required, in order to pass debris or liquid -
this is called radial compliance.
Figure 9: Unloader
Floating Seal
The floating seal is press fit into the fixed scroll
and forms a cavity with the walls of the fixed
scroll. During compressor operation this cavity is
pressurized by partially compressed gas bled from
the scroll set. This pressure acts on the back of the
floating seal and pushes it axially until it seats
against the sealing face on the end cap, thus
sealing the discharge from the suction gas. The
cavity pressure also acts on the fixed scroll to
force it against the orbiting scroll, thereby
maintaining the seal between the tips of the scrolls.
When the compressor is not running there is no
pressure in the cavity and no sealing occurs - this
leads to unloaded compressor starts.
1
1. Floating Seal 2. Pressure Cavity
Figure 10: Floating Seal and
Pressure Cavity
Scroll Operation
Dynamic Discharge Valve
The dynamic discharge valve is located at the
discharge port of the fixed scroll and is held in
position by a retaining nut. This reed check valve
prevents the back flow and re-expansion of
discharge gas and results in higher compressor
efficiencies.
Figure 11: Dynamic Discharge Valve
Assembly
Liquid Injection
The liquid injection valves purpose is to cool the
compressor scroll set if the temperatures get too
high. It is sometimes called a de-superheater
valve. The valve operates similarly to a
thermostatic expansion valve and is controlled by
a feeler bulb fixed to the compressor discharge
line. At approximately 250 F (121 C) the valve
starts to open and inject liquid refrigerant directly
into the scroll set through a fitting on the side of
the compressor body. The liquid refrigerant is
drawn from the liquid line near the drier or from
the outlet of the compressor. The valve is fully
open at 270 F (132 C).
Oil Pump and Lubrication System
The oil pump is a low pressure (5-9 psi) high
volume pump. It has no pressure regulator and is
sized to the porting and bearing surfaces. It is a
sliding vane type pump and is mounted directly
on the crankshaft.
Suction Side
1. The scroll compressor oil capacity is 50 fluid
ounces and is stored in area (A).
2. Oil is drawn to the oil pump through the
pick-up tube and screen (B). This 100 x 90
micron screen filters 100% of the flow and is a
field serviceable item.
3. Oil moves vertically then horizontally through
an oil gallery machined into the compressor
body (C).
4. Oil flows into the suction passage of the
stationary oil pump housing (D) to the oil
pump suction port.
Discharge Side
1. The rotary oil pump (E) comprises of the
rotating oil pump impeller, 4 spring loaded
vanes and the stationary eccentric oil pump
cover. This pump can deliver 2 ounces per
second at a speed of 4000 rpm.
2. Oil is pumped through the discharge port (F),
which is 180 degrees from the suction port,
and flows into the discharge passage of the
stationary oil pump housing (G).
3. Oil flow is split in two at a junction machined
into the compressor body (H). 20% of the oil
flow is directed vertically through a machined
oil gallery (I) towards the discharge oil filter
(J). 80% of the flow is directed into the cavity
surrounding the mechanical shaft seal (K).
4. Oil filling the oil filter cavity passes radially
through the 5 micron discharge oil filter
(serviceable item), is bled back into the main
compressor cavity (L) and drip flows to the
compressor sump.
5. Oil filling the cavity surrounding the
mechanical shaft seal lubricates the seal (M),
flows by the outer edges of the ball bearing
cover (N), and also flows into the eccentric oil
gallery machined into the crankshaft (O).
6. Oil delivered to the ball bearing flows back to
the sump via a machined hole through the oil
pump housing and eccentric oil pump cover
(not shown).
7. Oil entering the crankshaft oil gallery flows to
the main bearing (P) and the drive bearing of
the orbiting scroll hub (Q).
8. Oil flows to the main bearing via a hole
machined on a small flat on the outside
diameter of the crank journal. Excess oil from
the main bearing can escape to the cavity
between the orbiting scroll hub and the main
bearing housing.
19
Scroll Operation

9. Oil from the drive bearing is squeezed around 11. Oil can be drained from the oil sump by
the unloader into the cavity between the removing the oil drain plug (U) or by
orbiting scroll hub and the main bearing removing the oil pick-up tube plate (V).
housing. From there it flows between the
12. Lubrication of the scroll tips and flanks is
thrust surface of the main bearing housing and
solely dependant on the oil carried in the
the back plate of the orbiting scroll hub (S).
refrigerant flow. Oil in the refrigerant flow
Oil then flows to the Oldham coupling,
also contributes to Oldham key and thrust
Oldham keys, and scroll set tabs.
surface lubrication. This oil is returned to the
10. Excess oil from the thrust surface can return to compressor through the suction baffle (W).
the compressor sump through a slot machined The oil will separate from the return gas and
in the compressor body (T). Excess oil in the drain back over the main bearing housing to
cavity between the orbiting scroll hub and the sump.
main bearing housing has a route back to the
sump via a hole machined in one arm of main
bearing housing (R) and the above mentioned
machined slot in the compressor body.

20
Scroll Operation

J W

L G F P
I
N

K H

O
Q

E
M D

C S

V R
A

B
U

A. Oil Sump M. Mechanical Shaft Seal

B. Pick-up Tube and Screen N. Ball Bearing Cover
C. Oil Gallery O. Crankshaft Oil Cavity
D. Oil Pump Housing (Suction) P. Main Bearing
E. Rotary Oil Pump Q. Orbiting Scroll Drive Bearing
F. Discharge Port R. Oil Return Cavity
G. Stationary Oil Pump (Discharge) S. Orbiting Scroll Back Plate
H. Oil Gallery Junction T. Oil Return Slot
I. Machined Oil Gallery U. Oil Drain Plug
J. Discharge Oil Filter V. Oil Pickup Tube Plate
K. Oil Cavity for Mechanical Shaft Seal W. Baffle
L. Oil Return Bleed Hole
Figure 12: Scroll Lubrication System

21
Scroll Operation

22
Refrigeration Maintenance

NOTE: Evacuation is important and is critical NOTE: The attached evacuation procedures
to System Performance! have been written to be used with the
Thermo King Evacuation System (Tool No.
It has been determined through testing and
204-725). However, the principles of 3-point
system analysis that refrigeration systems which
evacuation and the use of a micron gauge
contain non-condensable gases such as nitrogen
during evacuation should always be
and/or air can be overcharged with refrigerant
practiced.
when charged using the sight glass method. An
overcharge of refrigerant will cause compressor Refer to the diagram of the Thermo King
damage. evacuation station (Tool No. 204-725) and note
the location of the valves.
Therefore, Thermo King recommends that all
repairs to the refrigeration system include the Valve #1 (V-1): Is in the open position when the
removal and reclamation (cleaning) of the pump is running to evacuate the hoses and/or the
refrigerant, followed by a thorough evacuation unit. When V-1 is closed, the pump has been
using the proper tools and procedures. (See isolated from the hoses and/or the unit.
attached tool list and evacuation procedures.)
Valve #2 (V-2): Is in the open position during
The primary objective of evacuation is to bring unit evacuation. In the closed position, V-2
the system’s pressure to a low micron level to isolates the micron gauge and thermistor
ensure the removal of moisture and assembly from the hoses and/or the unit.
non-condensable gases. There are however,
Valve #3 (V-3): Is in the open position during
certain other principles which must be observed.
unit evacuation. When closed, V-3 isolates the
These are:
micron gauge and the vacuum pump from the
Evacuate from 3-points to access both sides of other evacuation hoses.
check valves and solenoids. Energize solenoids
Valve #4 (V-4): Is in the open position during
during evacuation to prevent trapping of
unit evacuation. When closed, V-4 isolates the
refrigerant or non-condensable gases.
evacuation hoses and the unit from the
Always leave stem caps on during evacuation evacuation system.
and do not exercise the valve stems while the unit
is in a deep vacuum. Packing glands on older
valves are prone to leak.
Never attempt evacuation without a micron or
vacuum gauge. The micron gauge will help
determine:
• If the pump is capable of pulling a deep
vacuum.
• When the vacuum pump oil is contaminated.
• If the vacuum hoses and valves are leak free.
• If the unit is leak free.
• How long you should evacuate the unit.
• That the unit is still in a deep vacuum before
any lines are disconnected or refrigerant is
added.

23
Refrigeration Maintenance

1. Calibration Standard 6. V-2

2. Vacuum or Micron Gauge 7. V-1
3. V-4 8. Two Stage Vacuum Pump
4. V-3 9. To 110 Vac Power
5. Thermistor
Figure 13: Evacuation Station

24
Refrigeration Maintenance

1. 100 Microns
2. 500 Microns
3. 1000 Microns
4. 2500 Microns
5. 5000 Microns
6. 20,000 Microns
7. Atmospheric Pressure
8. Calibration Adjustment Screw
9. Example: Meter needle shown at calibration position
when Calibration Standard specifies 0.15 mm Hg.
Figure 14: Vacuum Gauge

25
Refrigeration Maintenance
Set Up and Test of Evacuation
Equipment
NOTE: Refer to the previous two pages for the
following discussion.
1. Connect the evacuation system to a 110 Vac
power supply. Connect a gauge manifold and
refrigerant supply to the fitting above valve
V-4. Turn the micron gauge ON.
2. Close valves V-1, V-3 and V-4. Valve V-2 is
open.
3. Turn the vacuum pump ON.
4. Open valve V-1 at the pump. The micron
gauge needle will move to the left. (Refer to
micron gauge scale diagram—previous page.)
LEAK
Isolate the pump from the system by closing the
proper valve. Watch the movement of the vacuum
gauge needle. If the needle continues to rise, this
is an indication that a leak exists in the unit or the
connecting line. The leak must then be located
and eliminated.
26
NOTE: If the vacuum pump is okay, and there
are no leaks between V-1 and V-3, the micron
gauge should show less than 500 microns. If
not, locate and correct the problem.
5. With the pump still operating, open valve V-3.
If the micron reading does not return to a level
of less than 500 microns, locate and correct
the problem before continuing.
6. With the vacuum pump still operating, open
valve V-4. The micron level will rise
momentarily. If the micron reading does not
return to a level of less than 500 microns,
locate and correct the problem before
continuing.
MOISTURE
Should the needle show a pressure rise but finally
level off to practically a constant mark, this is an
indication that the system is vacuum tight but is
still too wet, requiring additional dehydration and
pumping time.
Refrigeration Maintenance

7. Evacuate hoses to 100 microns or lowest
achievable level below 500 microns.
8. Once 100 microns is reached, close valve V-1
at the pump. Turn the vacuum pump OFF.
9. Observe the micron gauge reading. The
vacuum rise should not exceed 1500 microns
in 5 minutes.
10. If the rise is above 1500 microns in 5 minutes,
check all hoses and connections for leaks.
Hoses with moisture present will require
additional evacuation time to achieve
satisfactory results.
NOTE: Dirty vacuum pump oil or a defective
vacuum pump will prevent a low micron
reading. Hoses and fittings can be isolated
individually to identify leaks.
Unit Evacuation
NOTE: Do not attempt to evacuate the unit
until the evacuation equipment has been
tested and its performance has been verified.
1. Prepare the unit for evacuation. Recover
refrigerant to 0 psig (0 kPa).
NOTE: New Federal Regulations may require
your recovery machine to pull the system’s
pressures lower than 0 psig [0 kPa].
NOTE: The presence of refrigerant in the
compressor oil may prevent a low micron
reading from being achieved. The oil can
continue to “outgas” for long periods of time.
If the micron level appears to stall after 1/2
hour or 45 minutes between 1000 and 1500
microns, back seat the suction service valve
and observe the micron gauge. A sharp drop
in the micron reading (300 to 500 microns)
would indicate that refrigerant is present in
the oil or a leak exists in the compressor area.
6. When the desired micron level has been
achieved (500 to 1000 microns), close valve
V-1 at the pump. Turn the pump to OFF.
7. Observe the reading on the micron gauge after
5 minutes have elapsed. The vacuum rise
should not exceed 2000 microns. If the
vacuum level exceeds 2000 microns after 5
minutes, a leak is present or additional
evacuation time is required.
8. If the vacuum level is acceptable, start the
pump and open valve V-1 to evacuate the
pressure rise (5 minutes).
9. Close valve V-1 and stop the pump. Observe
the micron gauge to confirm that the system
remains in a deep vacuum. Close valve V-4.
The unit is ready to charge.

CAUTION: Do not attempt to evacuate a

unit until you are certain that the unit is
leak free. A unit with less than a full
refrigerant charge should be thoroughly
leak checked and all leaks must be
repaired.

2. Install hoses on the receiver tank suction

service valve and discharge ports of the
compressor.
3. Install a charge line from the spare access port
on valve V-4 to a refrigerant supply. Bottle
valve closed.
4. Start the vacuum pump and open valves V-1,
V-2, V-3, V-4.
5. Evacuate the system to 500 microns or the
lowest achievable level between 500 and 1000
microns.

27
Refrigeration Maintenance
Unit Charging
NOTE: Before charging, make sure that the
refrigerant lines from the gauge manifold to
the refrigerant supply bottle have been
evacuated or purged.
1. Close valve V-4.
2. Set the refrigerant supply bottle for liquid.
Open the gauge manifold hand valve, and
charge liquid refrigerant until the system has
the proper charge or until the system will take
no more liquid. The remainder of the charge
will be added as a liquid through the suction
service valve if more refrigerant is required.
3. After the liquid refrigerant is added, close the
gauge manifold hand valve.
4. Back seat (close) the receiver outlet valve.
Remove the evacuation station hoses.
5. If the unit is not fully charged, install a gauge
manifold set on the suction service valve and
the discharge port of the compressor.
6. Open the refrigerant supply valve for liquid.
Open the low side gauge manifold hand valve.
7. Start and operate the unit with the thermostat
set for cool. Add liquid through the suction
service valve until the correct charge is
attained. Make sure that at the liquid level
does not rise above the sight glass. Refer to
the unit serial plate for the correct amount of
charge.
8. When the correct amount of charge has been
added, close the gauge manifold hand valve.
Remove Refrigerant Hoses
1. A low leak fitting must be used on hoses when
Schrader port fittings are encountered on units
(unit OFF).
2. With a low leak fitting on the discharge gauge
line, remove this line from the unit.
3. Front seat the receiver tank service valve. Run
the unit until a 3 to 5 psig [21 to 35 kPa]
reading is obtained on the suction gauge.
Stop the unit.
4. Back seat the suction service valve and
remove all remaining hoses.
5. Install and tighten service port and valve stem
caps.
28
6. Backseat the receiver outlet.
7. Unit is ready for a functional check out.
Refrigerant Leaks
Use a reliable leak detector (e.g., electronic
detector) to leak test the refrigeration system.
Inspect for signs of oil leakage which is the first
sign of a leak in the refrigeration system.
NOTE: It is normal for compressor shaft seals
to have a slightly oily film.
Refrigerant Charge
Testing the Refrigerant Charge with an
Empty Box
If the unit has an insufficient charge of refrigerant,
the evaporator will be “starved” and the box
temperature may rise even though the unit is
operating. The suction pressure will drop as the
refrigerant charge decreases. The charge may be
determined by inspection of the refrigeration
through the receiver tank sight glass with the
following conditions established:
1. Place a test box over the evaporator.
2. Place a thermometer (TK No. 204-135) test
lead in the box near the evaporator return air
opening.
3. Install the gauge manifold.
4. Run the unit on Cool until the air in the box
indicates 0 F (-18 C). By allowing the box to
leak a small amount, you will be able to
maintain 0 F (-18 C).
5. R-404A Systems—The discharge or head
pressure gauge should read 275 psig (1896
kPa).
If the pressure is below this, it can be raised by
covering a portion of the condenser coil with a
piece of cardboard.
6. R-404A Systems—The compound gauge
should be indicating 13 to 18 psig (90 to 124
kPa) gauge pressure.
If there is any doubt about the unit gauge,
check the calibration.
7. Under these conditions, the ball in the receiver
tank sight glass should be floating.
Refrigeration Maintenance

Testing the Refrigerant Charge with a

Loaded Box
1. Install a gauge manifold (optional).
2. Run the unit on the Cool cycle.
3. Cover at least three quarters of the condenser
to drive any excess refrigerant from the
condenser into the receiver tank.
4. As the head pressure is rising, check the
AAC21
receiver tank sight glass. The ball should be
floating. If there is no indication of refrigerant 1
in the receiver tank sight glass, the unit is low
2
on refrigerant.
NOTE: If the ball floats, there is sufficient
refrigerant in the unit for that load at that 1. Compressor Oil Sight Glass location
particular box temperature. This test does not (after 9/98)
determine if the unit contains a full charge of (location opposite side before 10/98)
refrigerant. 2. Oil Drain Plug and O-Ring

Checking Compressor Oil Figure 15: Scroll Compressor

The compressor oil should be checked when there
is evidence of oil loss (oil leaks) or when
components in the refrigeration system have bee
removed for service or replacement. The oil level
in the compressor oil sight glass should be 1/2 to
3/4 full.
To check compressor oil level with an ambient air
temperature above 50 F (10 C):
Install a gauge manifold on the compressor.
R-404A Systems—Operate the unit on Cool with
a 10 psig (69 kPa) minimum suction pressure and
185 psig (1275 kPa) minimum discharge pressure
for 15 minutes or more.
After the unit has maintained the above conditions
for 15 minutes, observe the oil level. The oil
should be 1/4 to 1/2 up in the sight glass.
CAUTION: Oil is under pressure. See
instructions for adding oil
Checking compressor oil level at ambient
air temperatures below 50 F (10 C)
Run the unit through a complete DEFROST
CYCLE. After completing the defrost cycle, run
the unit on COOLING for ten minutes. Observe
the oil level. The oil should be 1/4 to 1/2 up in the
sight glass.
If the evaporator temperature is above 45 F (7 C),
it will be necessary to force defrost. To force
defrost, use the relay board test.
If the box is empty, you can run the unit on the
heat cycle instead of the defrost cycle.
NOTE: Use refrigeration compressor oil ONLY.
R-404A systems use a special Ester oil TK No.
203-516. Required for Scroll compressors.
To add oil to the compressor, pump down
compressor. (see “Compressor Pump Down and
Checkout.”

29
Refrigeration Maintenance
High Pressure Cutout
The high pressure cutout is located on the
discharge line. If the discharge pressure rises
above 450 psig (3102 kPa) on R-404A units, the
switch opens the 8 circuit, de-energizing the fuel
solenoid or electrical motor contactor. To test the
switch, rework a gauge manifold per illustration.
1. Relief Valve (66-6543)
2. O-Ring (33-1015)
3. Adapter Tee (Weather Head No. 552X3)
Figure 16: High Pressure Cutout Manifold
1. Connect the gauge manifold to the compressor
discharge service port with a heavy duty, black
jacketed thick wall #HCA 144 hose with a 900
psig (6204 kPa) working pressure rating.
2. Set the thermostat well below the box
temperature so that the unit will be in High
Speed Cool.
3. Raise the discharge pressure of the
compressor by blocking the condenser coil air
flow by covering the roadside condenser grille
with a piece of cardboard.
NOTE: The discharge pressure should never
be allowed to exceed a pressure of 450 psig
(3103 kPa) on R-404A systems.
4. Failure of the HPCO system to stop
compressor operation should be investigated
first by checking the control circuit operation
and secondly by HPCO switch replacement.
30
Low Pressure Cutout
NOTE: Not all units are equipped with a low
pressure cutout switch.
The low pressure cutout is located on the suction
line. If the low pressure falls below 5-7” of
vacuum, the switch opens the 8 circuit
de-energizing the fuel solenoid or the electrical
motor contactor.
1. Connect the gauge manifold to the compressor
suction service port.
2. Start the unit and perform a pump down on the
low side.
3. Note the pressure reading when the unit stops.
Failure of the switch to stop the unit should be
investigated.
High Temperature Switch
The compressor high temperature switch is
located in the top cap of the compressor. It is
wired in series with the high pressure cutout.
This switch opens the 8 circuit, de-energizing the
fuel solenoid or electric motor contactor. There
should be continuity through the switch under
normal operation. The switch opens at 293 ± 9 F
(145 C) and closes at 142 ± 27 F (61 C).
Continuity can be checked with an Ohm meter, a
test light, or a relay coil in series with the switch.
The switch is rated for 15 amps at 12 Vdc.
To test the switch use a non contact thermometer
and measure the top cap temperature. This method
is not perfect, as the switch is in a well pocket of
the top cap, however if the top cap near the switch
is less than 250 F (121 C), the compressor is
operating in a normal mode and the compressor
high temperature switch should be closed.
Diagnosing the Scroll Compressor

Symptoms Loss of Capacity

There are three categories of symptoms to
investigate when diagnosing the truck scroll
compressors:
• Leaks
• Compressor Noise
• Loss of Capacity
External Leaks
Oil leakage can occur from worn or damaged
components such as:
• Front Shaft Seal - replaceable
• Oil Filter Cover - replaceable
• Front Seal Cover - replaceable
• Oil Pickup Screen Cover - replaceable
• Temperature Switch - replaceable
The scroll compressor has no discharge or
suction valve plates. It does have a discharge
check valve in the outlet fitting where the
discharge line solders on. This check valve will
enable the technician to pump down the
compressor. To check capacity, run a compressor
efficiency test as outlined below.
Compressor Efficiency Test
1. To check for gross capacity, install manifold
gauges at the compressor.
2
3
4

Compressor Noise
The scroll compressor is a relatively quiet
compressor. Any unusual noises should be
investigated.
NOTE: When rotating the compressor by
hand, the Oldham coupler and scroll set will
make a clicking noise. This is normal. 1

If the compressor is noisy while running on

electric standby, look at the following:
a. Is the compressor rotating in the right
direction? (CW front of unit).
b. Is the phase reverse correct?
c. Are codes 10 and 38 present?
d. Does the PC board have jumpers 500 and
501 in the correct locations?
(See TK 41087-6 Diagnostic Manual).
e. Check the oil level.
f. Check the refrigerant charge.
If the compressor is noisy while running on
diesel and electric, check the following:
a. Perform capacity test.
b. Perform pump down test.
NOTE: If the unit fails one of these tests,
replace the compressor.
1. Discharge Service Port
2. Compound Gauge
3. High Pressure Gauge (0 to 500 psig)
4. Suction Service Valve
Figure 17: Gauge Manifold Installation
2. Run the unit for several minutes in the cool
mode and note the pressure readings, and for
refrigerant visible in the sight glass.
3. Cover the condenser and see if the discharge
pressure goes up at least 100 psig over the
previous (or normal run) pressures. This
should occur within 1-2 minutes.
4. If the pressure won’t come up to 100 psig or
more, or it takes a long time (several minutes)
to rise, perform a pump down test.
31
Diagnosing the Scroll Compressor
Pump Down Test Procedure
1. Run the unit in low speed cool.
2. Front seat the ROV (receiver outlet valve).
3. The compressor should be able to pump to a
10 inch vacuum in 1 minute.
4. After 1 minute of operation or 10 inches of
vacuum, stop the unit.
5. The low side gauge may come up a few
pounds on shut off, then should hold
approximately 0 psig.
If the compressor pumps down to a 10 inch
vacuum it is okay.
If it leaks back, it is the end cap check valve.
This is not a critical component for
compressor operation - it is only there for high
pressure cut-out operation or pump downs.
The compressor will work fine without a
outlet discharge check valve.
NOTE: If the compressor will not pump down
to a 10 inch vacuum or pass the capacity test,
replace the compressor.
Compressor Removal
NOTE: It is generally good practice to replace
the filter drier whenever the high side is
opened or when the low side is opened for an
extended period of time.
1. Remove the refrigerant from the unit using
approved methods.
2. Loosen and remove the compressor/electric
motor belt from the compressor pulley.
3. Unsolder the discharge line and unbolt the
suction valve from the compressor.
4. Disconnect the pilot valve line, and unsolder
liquid injection line.
5. Remove the compressor mounting bolts.
6. Lift the compressor out of the unit. Keep the
compressor ports covered to prevent dust, dirt,
etc., from falling into the compressor.
32
NOTE: When the compressor is removed from
the unit, the oil level should be noted, or the
oil removed from the compressor should be
measured so that the same amount of oil can
be added before placing the replacement
compressor in the unit.
Compressor Installation
1. Lift the compressor into the unit and install
the mounting bolts.
2. Install the service valve using a new gasket
soaked in refrigeration oil. Connect the high
temperature cutout switch.
3. Reconnect the pilot valve line, liquid injection
line and solder the discharge line.
4. Pressurize the compressor and test for
refrigerant leaks.
5. If no leaks are found, evacuate the system.
Replace the compressor/electric motor belt
and adjust the tension.
6. Charge the system with refrigerant.
7. Operate the unit at least 30 minutes and then
inspect the oil level in the compressor. Add or
remove oil if necessary.
8. Check the refrigerant charge and add
refrigerant if needed.
Shaft Seal Replacement
Thermo King recommends changing the
compressor shaft seal when there is a major
system interruption, such as component
replacement or total loss of refrigerant charge.
When the shaft seal is changed, Thermo King also
recommends changing the oil and oil filter.
The steps for changing the shaft seal are as
follows:
1. Remove the compressor as outlined in
Compressor Removal above.
2. Remove drive pulley and woodruff key from
shaft.
3. Clean shaft seal cover of excess dirt.
4. Remove four Torx head screws from shaft seal
cover.
Diagnosing the Scroll Compressor

5. Carefully pry the shaft seal cover out of

compressor body using flats at top and bottom
of shaft seal cover. 2
1
6. Loosen the set screws on the rotating member 3
and remove it from the shaft, being careful not
to loose the spacer on the shaft.
7. Ensure the spacer is properly located on the
shaft flat.
5
8. Lubricate the O-ring in new rotating member 4
with compressor oil TK No. 203-516 and slide
onto shaft, being careful not to touch leaded 1. Set Screw
bronze surface with fingers. 2. Seal Faces
9. Torque set screws to 48 to 42 in-lb. (5.4 to 4.8 3. O-Ring
N•m). 4. Hard Ring
10. Remove stationary member, dust shield from 5. Bellows
shaft seal cover, and O-ring.
Figure 19: Set Screw Type Bellows Seal
11. Install new dust shield in shaft seal cover.
12. Lubricate O-ring on new stationary member
and press into shaft seal cover, being careful Replacement Parts List
not to touch the sealing surface with fingers. (Required)
13. Lubricate new O-ring with compressor oil TK O-Ring 33-2998
No. 203-516 and install on the shaft seal
cover. Seal Kit 22-1100
14. Push shaft seal cover into body and torque
screws to 100 to 110 in-lb. (11.2 to 12.4 N•m) Replacement Parts List
15. Torque front pulley bolt to 8-22 ft.-lb. (As Needed)
(24-30 N•m). Torx Screws 55-9020

Oil Filter Replacement

Thermo King recommends changing the
compressor oil filter when there is a major system
interruption, such as component replacement or
1 total loss of refrigerant charge. When the oil filter
is changed, Thermo King also recommends
changing the oil.
2
1. Remove refrigerant. Equalize pressure to
slightly positive.
2. Clean oil filter cover plate area of excess dirt.
1. Clamp Ring
3. Remove cover plate and spring, noting the
2. Orange Protective Cap location of hex studs for proper installation.
Figure 18: Cross Section of Set Screw 4. Scrape gasket off compressor body and cover
Type Bellows plate.
5. Remove oil filter and O-ring.
6. Clean oil filter cavity of any noticeable debris.

33
Diagnosing the Scroll Compressor

7. Lubricate new O-ring with compressor oil TK Compressor Oil Change

No. 203-516.
1. Remove refrigerant. Equalize pressure to
8. Press oil filter and O-ring over stem in slightly positive.
compressor body until seated.
2. Clean oil drain area (bottom and bottom rear
9. Lubricate new gasket with compressor oil TK of compressor) of excess dirt.
No. 203-516.
3. Remove SAE plug from rear bottom of
10. Install spring, new gasket, and cover plate compressor to drain oil.
using hex studs and torque head screws,
4. Remove two screws and end plate from
torquing to 290 to 310 in-lb. (34 to 36 N•m).
bottom rear of compressor.
Be certain to install hex studs in their original
location. 5. Scrape gasket from plate and body.
1
6. Remove spring, pickup screen and pickup
2
tube from body.
7. Clean pickup screen and pickup cover.
3
8. Replace pickup screen and pickup tube,
4
ensuring notch in cover is aligned with notch
in body.
5 9. Lubricate new gasket with compressor oil TK
6
No. 203-516.
10. Replace pickup screen, spring, gasket, end
plate and screws.
11. Torque screws to 290 to 310 in-lb. (34 to 36
N•m).
12. Lubricate O-ring on SAE plug with
compressor oil TK No. 203-516.
AAC22 13. Replace SAE plug in rear bottom of body,
torquing to 100 to 110 in-lb. (11.2 to 12.4
N•m).
14. Measure oil removed and add an equal amount
1. Hex Studs 4. Gasket or add 40 oz. (1.2 liters) of compressor oil TK
2. Cover Plate 5. Oil Filter No. 203-516, using Schrader fitting at oil filter
3. Spring 6. O-Ring cavity.
Figure 20: Oil Filter Replacement NOTE: The gasket must be replaced. Use TK
No. 33-2997

Replacement Parts List (Required)

Oil Filter & O-ring 22-1030
Gasket 33-2996
Parts List (As Needed)
Cover Plate 22-1031
Spring 22-1032
Hex Studs 55-9019
Torx Screws 55-9020

34
Diagnosing the Scroll Compressor

.
1. Cut through silicone sealant surrounding
1 9
2 plastic cap.
3 2. Pry plastic cap out of top cap.
4
3. Remove cutout switch by pulling it out of top
cap well.
4. Clean all debris out of top cap well and off of
5
top cap surface.
6 5. Apply 0.25 to 0.50 cubic centimeters of
AAC21 dielectric compound into thermal well.
6. Apply 0.25 to 0.50 cubic centimeters of
7
dielectric compound between cutout switch
8 element and kapton sleeve.
7. Fold kapton sleeve over, fully protecting
1. Mounting Bolts 6. Oil Pickup cutout switch element.
Tube 8. Firmly press cutout switch element into
2. End Plate 7. O-Ring thermal well by rubber boot.
3. Gasket 8. SAE Drain 9. Completely fill remaining void in thermal well
Plug with silicone to protect against water
4. Spring 9. Schrader infiltration.
Fitting 10. Press new protective plastic cap in place with
(opposite side) wire channel pointed down. Cap will snap into
5. Oil Pickup place when in proper location.
Screen

Figure 21: Compressor Oil Change

1
Other Parts Which May Be Used
(As Needed) 2
SAE Plug 55-9021
AAC23
Torx Head Screws 55-9022
End Plate 22-1033
Spring 22-1034 1. High Temperature Cutout Switch
Oil Pickup Screen 22-1035 2. Switch Cover
Oil Pickup Cover 22-1036 Figure 22: High Temperature Cutout
Switch
High Temperature Cutout Switch
NOTE: Thermo King recommends changing Parts List
the high temperature cutout switch whenever (As Needed)
the insulation on the leads has been broken or High Temperature 41-2467
there is other reason to suspect a defective Cutout Switch
thermostat. Plastic Cap 22-1040
The steps for changing the high temperature Dielectric Compound 203-454
cutout switch are as follows: Silicone Sealant N/A

35
Diagnosing the Scroll Compressor
Liquid Injection Fitting
The steps for changing the liquid injection fitting
are as follows:
1. Remove refrigerant. Equalize pressure to
slightly positive.
2. Clean compressor body in area of liquid
injection fitting.
3. Sweat tubing out of liquid injection fitting.
4. Visually inspect screen in liquid injection
fitting.
5. If plugged, carefully remove liquid injection
fitting from compressor body.
6. Install new O-ring on new liquid injection
fitting.
7. Lubricate new O-ring with compressor oil TK
203-516.
8. Carefully thread new liquid injection fitting
through compressor body into steel block on
the inside. Make sure the fitting is not
cross-threaded in the steel block.
9. Torque liquid injection fitting to 100 to 120
in-lb. (11.2 to 13.6 N•m).
10. Re-attach tubing to liquid injection fitting.
11. Pressurize the unit and check for leaks.
12. Evacuate the unit and recharge system.
. switch.
2
1
AAC24
1. Liquid Injection 2. O-Ring 33-2995
Fitting 66-9056
Figure 23: Liquid Injection Fitting
36
µP-T Alarms
Alarm codes will help direct a service technician
to the source of a problem.
To view the complete list of alarm codes and their
definitions, refer to Section 4 in the Operation and
Diagnosis Manual (TK 41087).
CODE 10 - High Discharge Pressure or
Compressor Temperature
High Discharge Pressure
Check for high compressor discharge pressure.
The switch setting is cut-out 470 ± 7 psi (3240 ±
48 kPa) and cut-in 375 ± 38 psi (2585 ± 262 kPa).
Follow good diagnosing procedures for high
discharge pressure.
High Compressor Discharge Temperature
Check for high compressor discharge temperature.
The scroll compressor has a discharge refrigerant
gas temperature switch located in a well of the top
cap. It is installed with heat sink compound in the
well. It is not in the refrigerant flow, but measures
the temperature through the top cap. Switch
setting is “open” at 293 ± 9° F (145 ± -16 C) and
“closes” at 142 ± 27° F (61 ± -3 C).
a. Verify top cap temperature with a
non-contact thermometer. If the
temperature of the top cap is around 200 F
(93 C) check for a possible defective
b. If the temperature is close to the switch
setting check the following:
• refrigerant charge level
• suction pressure
• discharge pressure
• compressor rotation in electric
c. If the suction pressure is low or in a
vacuum or discharge pressure is very high
(abnormal) then the compressor will run
hot. Correct low charge or other
conditions that are causing abnormal
readings.
Diagnosing the Scroll Compressor

d. If the refrigerant pressures appear normal CODE 32 - Refrigeration Capacity Low

for the box temperature and ambient, then
a. Check for proper refrigeration charge.
check to see if the liquid injection valve is
working. The valve should start to inject b. Check compressor capacity.
liquid refrigerant into the scroll set at
c. Air flow may be restricted. Check rotation
250 F (121 C) or higher discharge line
of evaporator fans, wrong fans,
temperatures. To check, raise the
misadjusted fans, etc.
discharge pressure to 400 psi (2757 kPa)
in the cool cycle. The discharge line d. Check for the electric motor running in
should warm up to at least 250 F (121 C) reverse rotation (test for phase reversal).
or higher. The liquid injection line into the
compressor should get cold. If not, replace CODE 38 - Electric Phase Reversed or
the liquid injection valve. Motor Overload Tripped
Low Suction Pressure a. Check for electric motor overload setting
and electric motor amp draw.
Some units may be equipped with a low
refrigerant pressure switch. Check for low suction b. Check for compressor lockup.
pressure and correct.
c. Check for high suction pressure regulator
Electric Standby Only or throttle valve setting.
If the unit is shutting down when the motor
contactor pulls in, check for possible low voltage
to the unit and correct.
Defective Compressor
a. Verify with a capacity check and a low
side pump down.
b. Check for the compressor running in
reverse rotation.

37
Diagnosing the Scroll Compressor

Rapid cycling between cool and heat

Unit cools in heat and defrost cycle

Unable to hold vacuum in low side

Unable to pull vacuum in low side
Unit heats in refrigeration cycle

Unable to pump down system

Unit not heating or defrosting

Receiver sight glass empty
Unit operating in a vacuum

SYMPTOM
Suction line frosting back
High suction pressure
Low suction pressure

Unit not refrigerating

No suction pressure
High head pressure
Low head pressure

Noisy compressor
No head pressure

POSSIBLE CAUSES
• • • • Overcharge of refrigerant
• • • • • • Shortage of refrigerant
• • • • • No refrigerant
• Air through condenser too hot (ambient)
• Air flow through condenser restricted
• • • Air through condenser too cold (ambient)
• • • Air in refrigerant system
• Condenser fan blades bent or broken
• Air short cycling around evaporator coil
• Air through evaporator restricted
• • • • Evaporator needs defrosting
• • Compressor discharge valves leaking
• • Scroll compressor seals leaking
• Too much compressor oil in system
• Faulty oil pump in compressor
• Loose compressor pulley
• Compressor bearing loose or burned out
• • • • • Broken discharge check valve in compressor
• • Expansion valve power element lost its charge
• • Expansion valve feeler bulb improperly mounted

38
Diagnosing the Scroll Compressor

Rapid cycling between cool and heat

Unit cools in heat and defrost cycle

Unable to hold vacuum in low side

Unable to pull vacuum in low side
Unit heats in refrigeration cycle

Unable to pump down system

Unit not heating or defrosting

Receiver sight glass empty
Unit operating in a vacuum

SYMPTOM
Suction line frosting back
High suction pressure
Low suction pressure

Unit not refrigerating

No suction pressure
High head pressure
Low head pressure

Noisy compressor
No head pressure

POSSIBLE CAUSES
• • • Expansion valve feeler bulb making poor contact
• • Expansion valve open too much
• • Expansion valve closed too much
• • Expansion valve needle eroded or leaking
• • • Expansion valve partially closed by ice, dirt or wax
• • • Liquid refrigerant entering compressor
• • Restricted line on the low side
• • • • Restricted line on the high side
• • • • Restricted drier
• Evaporator shutter open
• • • Evaporator shutter stuck closed
• Suction service valve back seated
• • • • • • • Faulty three-way valve
• • • • • Faulty pilot solenoid
• • Loose or broken electrical connections
• • • • • Thermostat or thermometer out of calibration
• • • • Suction pressure gauge out of calibration
• Leaky receiver tank outlet valve
• Leaky bypass check valve

39
Diagnosing the Scroll Compressor

Compliant Scroll Components

1. Oil Splash Guard 36. Mounting Bolts (2)
2. Mounting Screws 37. Gasket
3. Oil Pickup Tube 38. Liquid Injection Fitting
4. Oil Pickup Screen 39. Gasket
5. Spring 40. Top Cap & Muffler Plate Assy.
6. Gasket 41. Mounting Bolts (12)
7. End Plate 42. High Temperature Switch
8. Mounting Bolts 43. Switch Cover
9. Crankshaft 44. Discharge Tube / Check Valve
10. Ball Bearing 45. Mechanical Shaft Seal Assy.
11. Retaining Clip 46. O-Ring
12. Bearing Cover 47. O-Ring
13. Belleville Washer 48. Shaft Seal Housing
14. Gasket 49. Dust Cover
15. Oil Pump Body 50. Mounting Bolts (4)
16 Mounting Bolts (2) 51. Mounting Bolts
17. Oil Pump Impeller 52. Schrader Valve Assy.
18. Oil Pump Vane (4) 53. Suction Baffle
19. Vane Springs 54. Screen
20. Oil Pump Eccentric Cover 55. O-Ring
21. Counter Weight Assy. 56. Oil Filter
22. Baffle Plate 57. Gasket
23. Unloader 58. Spring
24. Unloader Bushing 59. Oil Filter Cover
25. Main Bearing Housing 60. Mounting Studs (4)
26. Main Bearing 61. Mounting Bolts (2)
27 Oldham Coupling 62. Oil Drain Plug
28. Orbiting Scroll 63. O-Ring
29. Sleeve Guides 64. O-Ring
30 Fixed Scroll 65. Sight Glass
31. Scroll Bolts 66. Serial Plate
32. Dynamic Discharge Valve Assy. 67. Compressor Body
33. Retaining Nut 68. O-Ring
34. Floating Seal 69. O-Ring
35. Internal Liquid Injection Line

40
Scroll Compressor Component Diagram

41