TPW5 TRAINING 2007

LeTourneau Inc.
 Program
Section 1 – Specifications
Section 2 – Parts Identification (General)
Section 3 – Parts Identification (Hydraulic Manifold)
Section 4 – Hydraulic Manifold Adjustment
Section 5– Compressor Assembly
Section 6 – Water Valve Conversion
Section 7 – Electrical
Section 8 – Troubleshooting
Section 9 – Preventive Maintenance

TPW5
 Section 1

Specifications

TPW5
 SPECIFICATIONS

Cooling Capacity: 18,000 Btu/hr (5kw) at 100°F and 81°FDB/67°FW (38°C and 27/19°C) Return air.

Heating Capacity: At 180°F (81°C) water is 40,000 BUT/hr.

Air Flow: 450 cfm max.

Evaporator: A double inlet double wheel blower blows Air thru the evaporator and heater
coils. Motor is totally enclosed, ball bearing.

Casing: Heavy gauge stainless steel to resist corrosion and provide superior strength and protection.

Mounting: Unit mounted using wall-mounted plenum, provided. Plenum also serves as
Cut out template. Refer to drawing T9078053

Control Console: Easy to install control pad makes all unit functions controllable from
Inside the cab.

Controls: Cooling is thermostatically controlled by either a De-ice thermostat or by return air

temperature.

Refrigerant Charge – 3 LBS R-134a

TPW5
 Section 2

Parts Identification
General

TPW5
 Parts Identification
424-1529

424-1529

Condenser Fan Assembly

TPW5
 Parts Identification
H

FRESH AIR
INLET FROM
BLOWER
HYDRAULIC
CONNECTIONS

TPW5
 Parts Identification
424-1521

424-1521

TPW5
 Parts Identification
424-3891
424-1554
424-3893
424-1553

424-1553

424-3893
424-1554

TPW5
 Parts Identification
424-3889

424-3889

TPW5
 Parts Identification

TPW5
 Parts Identification
424-1542

424-1542

TPW5
 Parts Identification
424-1541

424-1541

Condenser Coil
TPW5
 Parts Identification
424-3890

424-3890

TPW5
 Parts Identification
424-3885
423-9143

424-3885

423-9143

TPW5
 Parts Identification
424-3892
424-1522
424-1520

424-1522

424-3892

424-1520

TPW5
 Parts Identification
424-1532
424-1526
424-3888

424-1526

424-1532

424-3888

TPW5
 Parts Identification
424-1533
424-3886/424-3887

424-1523
424-1524

424-1533

424-1524

424-1523

424-
3886/424-
3887

WATER
VALVE KIT
424-8928

Evaporator Section

TPW5
 Section 3

Parts Identification
Hydraulic Manifold

TPW5
 Parts Identification

Solenoid Valve

Pressure
Reducing Valve

Flow Control

TPW5
 Parts Identification

Relief Valve

TPW5
 Parts Identification

Manifold Body

Check Valve

TPW5
 Section 4
Hydraulic Manifold Adjustment

TPW5
 Manifold Adjustment
Notes:

Gauge kit, Sigma part number 831-C031, is necessary to set the manifold. Included in the kit
are gauge assembly 831-C032 and #8 hose fittings 831-C035 male, and 831-C036 female.

All bold letters given below are inscribed on the manifold.

“G”, “B”, and “A” are all connection points on the manifold.

TPW5
 Manifold Adjustment

“RV” indicates the pressure relief

valve on the manifold. “RV” is used
as a safety and can be adjusted to
set the maximum operating pressure
for the manifold. When pressure
exceeds the maximum operating
pressure then the oil is routed back
to the tank without going through the
rest of the system.

Relief Valve (RV)

TPW5
 Manifold Adjustment

“PR” indicates the pressure

reducing valve on the
manifold. “PR” is used to
reduce the system pressure
beyond the valve resulting in
less pressure being delivered
to the compressor.

Pressure reducing Valve

TPW5
 Manifold Adjustment

“FC” indicates flow control on the

manifold. “FC” is used to adjust the
flow of oil to the compressor.
Adjusting “FC” will increase or
decrease the compressor RPM.

Flow Control

TPW5
HYDRAULIC MANIFOLD SCHEMATIC (830-C019)

Solenoid Valve

Flow Control

Check Valve
Pressure Reducing
Valve

Relief Valve

SUPPLIED BY:
ACC. PUMPL-1850
TPW5 BLOWER PUMP L-1350
 Manifold Adjustment

Setup
Gauge Port
With the hydraulic supply on
verify that the pressure is
close to 2000 PSI and the
flow of oil is close to 7
gallons per minute.
Turn the hydraulic supply off.
Connect the gauge to “G”
and tighten to prevent leaks.
Loosen locking nuts on “RV”
and “PR”.

TPW5
 Manifold Adjustment

Setting the relief valve

Bring “RV” and “FC” all the way in

(clockwise, but do not over tighten).
Turn the hydraulic supply on.
Bring “RV” out (counter clockwise)
until a squealing noise is heard then
turn counter clockwise 3/8 turns
(same thing as 145 degrees). The
squealing noise should not be heard
now.
Tighten the “RV” locking nut. 2300
PSI has now been set at the
maximum operating pressure.
Flow Control Relief Valve (RV)

TPW5
 Manifold Adjustment
Setting the pressure reducing valve
Turn the hydraulic supply off.
Hose “B” will need to be removed from the
manifold inlet. The recommended method
for this is to first remove hose “A” at the
manifold to gain access then to remove
hose “B” at the manifold. Note that there
will still be some oil left in the hoses and it
is recommended to have towels and a drain
bucket to prevent making a mess.
Cap both hose “B” and the manifold inlet
“B” using #8 hose fittings and tighten to
prevent leaks.
Re-connect hose “A” and tighten to prevent
leaks. It is recommended to apply Loctite
242 to the hose fitting threads before re-
connecting to prevent the hose from
loosening over time.

TPW5 Hose “B”

 Manifold Adjustment “PR”
Setting the pressure reducing valve
Bring “FC” out (counter clockwise) 2 or 3
turns.
Turn on both the hydraulic supply and air
conditioning unit. It is strongly
recommended to increase the pressure
slowly and to check for leaks before
proceeding.
Write down the pressure going to the unit.
Also, notice the pressure reading at the “G”
port gauge. Bring “PR” in or out as
necessary to get the “G” gauge to read 50
PSI less than the pressure going to the unit.
Do not allow the “G” port gauge to read the
same as the pressure going to the unit! It
must read slightly less.
Tighten the “PR” locking nut. Approximately
2000 PSI has now been set as the maximum
pressure that the compressor will see.

TPW5
 Manifold Adjustment
Setting the flow control
Turn both the hydraulic supply and air
conditioning unit off.
Re-connect hose inlet “B” to the hydraulic
motor and tighten to prevent leaks. It is
recommended to apply Loctite 242 to the
hose fitting threads before re-connecting to
prevent the hose from loosening over time.
Turn on both the hydraulic supply and air
conditioning unit. It is strongly
recommended to increase the pressure
slowly and to check for leaks before
proceeding.
Find the current compressor RPM using a
stroboscope.
Bring “FC” in or out as necessary to get the
compressor to 2000 RPM.
The manifold is now completely adjusted.

TPW5
 Section 5

Compressor Assembly

TPW5
 Compressor Assembly

TPW5
 Compressor Assembly
Step 1

TPW5
 Compressor Assembly
Step 2

TPW5
 Compressor Assembly
Step 3

TPW5
 Compressor Assembly
Step 4

TPW5
 Compressor Assembly
Step 5

TPW5
 Compressor Assembly
Step 6

TPW5
 Compressor Assembly

Step 7

1/8 “ ------------

TPW5
 Compressor Assembly
Step 8

Make sure the stud is to

the back side of the slot

TPW5
 Compressor Assembly
Step 9

TPW5
 Compressor Assembly
Step 10

TPW5
 Section 6

Water Valve Conversion

TPW5
 Water Valve Conversion

Single Valve Replacement Assembly

TPW5
 Water Valve Conversion

Flow Arrow

Be Aware of The Direction Of Flow

TPW5
 Water Valve Conversion

Apply
Thread
Seal

TPW5
 Water Valve Conversion

Make Sure To Use Two Wrenches When Tightening The Bulkhead

TPW5
 Water Valve Conversion

Remove the stage 2 heat relay

TPW5
 Water Valve Conversion

Remove the stage 2 fuse

TPW5
 Water Valve Conversion

Cut the terminals on both ends of wire 27 and bury into the loom

TPW5
 Section 7

Electrical

TPW5
 Electrical 2 Valve System

TPW5
 Electrical 1 Valve System

TPW5
 Control Board

TPW5
 Control Board
Load Output Indicator Relay Fuse Rating

Control Circuit --- --- --- F5 2A

Remote relay coil WP1&4 CR2 --- F5 2A
Auxiliary Output WP2 CR3 K1 F1 20A
Fan Low WP8 CR9 --- F4 30A
Fan Med WP9 CR10 K4 F4 30A
Fan High WP10 CR12 K5 F4 30A
Condenser WP3 CR4 K2 F2 30A
Cool Fan WP5 CR5 K3 F3 15A
Heater #1 WP13 CR16 K7 F7 5A
Heater #2 WP12 CR14 K6 F6 5A

TPW5
 Cab Display
Defog Mode

Heat Mode

Auto Mode
Fan Speed

Cool Mode

Cab Temperature
Unit ON/OFF
Raise Temperature Lower Temperature

TPW5
 Cab Display

LED INDICATORS

SET -The set point temperature is currently being displayed on the three digit LED readout.
ACTUAL - The actual temperature is currently being displayed on the three digit LED readout.
LOW - The fan is running at low speed.
MED - The fan is running at medium speed.
HIGH - The fan is running at high speed.

The three digit LED display indicates a two digit temperature and C or F.

OPERATION - The control parameters and set points are stored in EEPROM on the control board and are
sent to the unit on startup or when the operator makes a change to one of the settings. The control
communicates using RS485 on the five wire harness that connects it to the unit. The control remembers
the last settings and will restart at those settings when power is reapplied or the system is turned on.

TPW5
 Cab Display

DISPLAY CODES

--- The unit is off

LC or LF The temperature is less than 0.
HC or HF The temperature is more than 100

TPW5
 Section 8

Troubleshooting

TPW5
 Troubleshooting
Inadequate Air Flow

Check supply voltage to unit

Check supply voltage to evaporator blower motor
Check evaporator motor brushes
Check dip switch, 1 and 2 should be in the off positions
Clean filters
Check blower motor rotation
Check condenser fan rotation
Check grounding

TPW5
 Troubleshooting
Inadequate Cooling

Check compressor is cycling on and off

If cycling on high pressure check condenser fans, motors, check for over charge and dirty coils, check for over
charge by measuring temperature of liquid out of condenser, it should be 10°F to 15°F cooler than the
condensing temperature.

Check refrigerant charge, sight glass should be full

Check compressor speed, should be 2000 rpm

Check Hydraulic flow, should be 7.5 gpm @ 2000 psi

Check head pressure

If ambient is 70°F head pressure should be 125-175 psi.
If ambient is 80°F head pressure should be 140-180 psi
If ambient is 90°F head pressure should be 150-220 psi
If ambient is 100°F head pressure should be 180-250 psi
If ambient is 110°F head pressure should be 200-270 psi
If ambient is 120°F head pressure should be 220-300 psi

Check airflow

Check low pressure cycling. If not enough refrigerant is passing thru the system, there could be blockage.

If TX-valve is blocked head pressures will be very high and suction pressure very low.

TPW5
 Troubleshooting
Inadequate Heating

Check that the solenoid valve is opening and closing properly

(This can be done by feeling both sides of the lines coming in to the valve)

Purge heater core to remove air

Check for consistent temperature across the coil. If they are not equal,
there may be a blockage.

TPW5
 Section 9

Preventive Maintenance

TPW5
 Preventive Maintenance
Bi-Weekly
Check unit lids to ensure latches are properly closed.
Discard lower filter, stage one of return air filter assembly and replace.

Monthly
All bi-weekly checks
Flush out drains
Check seals
Flush out condenser area and coil
Check all heating, refrigeration and hydraulic connections, inside and outside the unit.

Annually
Total unit clean out
Check all motors, repair or replace
Flush out evaporator and condenser coils
Check cover seals, replace if necessary
Check fan blades for damage, replace if necessary

TPW5
 Preventive Maintenance

Cleaning The High Efficiency Filter

The high efficient filters are washable. They can be Cleaned by using a low-pressure water
hose and a soft brush. As much dust as possible should be knocked out of the filter while
the filter is still dry. Water can then be applied using a Low pressure water hose ( use of a
high pressure hose will damage the filter media. Apply the water while lightly scrubbing
the filter media. This should remove any particles that have impregnated the media. This
should be followed by a final rinse of water. The filter should be allowed to dry
completely before returning it to the unit.

TPW5