Thermo King Rail Edition SLXi-DRC Maintenance Manual Download

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Revision B

August 2018

K 5

3--5

5--M

M--E

Rail Edition
SLXi-DRC

Single Temperature Units

Maintenance Manual

Summary of Contents for Rail Edition SLXi-DRC

Page 1: ...Revision B August 2018 T TK K 5 56 64 43 33 3 5 5 M MM M E EN N Rail Edition SLXi DRC Single Temperature Units Maintenance Manual...

Page 2: ...n nu ua al l o or r a an ny y i in nf fo or rm ma at ti io on n r re ec co om mm me en nd da at ti io on ns s o or r d de es sc cr ri ip pt ti io on ns s c co on nt ta ai in ne ed d h he er re ei in n...

Page 3: ...ler S Se er rv vi ic ce e T To oo ol ls s Use the proper service tools Gauge manifold sets should include appropriate shutoff valves or disconnects near the end of each service line R Re ec co ov ve e...

Page 4: ...CargoLink 20 OptiSet Plus 21 FreshSet 21 Sequence of Operation 21 Operating Modes 21 Defrost 21 Engine Compartment Components 22 Unit Protection Devices 22 Serial Number Locations 22 E El le ec ct tr...

Page 5: ...Fan Drive Belt 52 Fan Drive Belt Replacement 52 Fan Drive Belt Adjustment 54 Engine Cross Shaft Belt 55 Assembly of Tensioner Clutch 56 Engine Cross Shaft Belt Replacement 56 Water Pump Belt 58 R Re e...

Page 6: ...ief Valve 78 Removal 78 Installation 78 Discharge Pressure Transducer 78 Removal 78 Installation 78 Suction Pressure Transducer 78 Removal 78 Installation 78 Electronic Throttling Valve ETV 79 Removal...

Page 7: ...bly 91 Reassembly 92 Installation 92 Idler Assemblies 92 Disassembly 92 Reassembly 93 M Me ec ch ha an ni ic ca al l D Di ia ag gn no os si is s 9 94 4 R Re ef fr ri ig ge er ra at ti io on n D Di ia...

Page 8: ...ir r s su up pp pl ly y R Re ef fr ri ig ge er ra an nt t d di is sp pl la ac ce es s a ai ir r a an nd d c ca an n c ca au us se e o ox xy yg ge en n d de ep pl le et ti io on n r re es su ul lt ti i...

Page 9: ...s a a f fl la am mm ma ab bl le e g ga as s t th ha at t c ca an n i ig gn ni it te e o or r e ex xp pl lo od de e A A b ba at tt te er ry y s st to or re es s e en no ou ug gh h e el le ec ct tr ri i...

Page 10: ...er r h ha an nd dl li in ng g t th he e o oi il l R Ru ub bb be er r g gl lo ov ve es s a ar re e r re ec co om mm me en nd de ed d N NO OT TI IC CE E E Eq qu ui ip pm me en nt t D Da am ma ag ge e U...

Page 11: ...their antistatic packing materials until you re ready to use them After servicing any electronic components check the wiring for possible errors before restoring power to the unit Never use a battery...

Page 12: ...S Sk ki in n Remove contaminated clothing Wash thoroughly with soap and water Get medical attention if irritation persists I In ng ge es st ti io on n Do not induce vomiting Immediately contact local...

Page 13: ...sig 127 kPa minimum in low speed 45 to 57 psig 310 to 390 kPa in high speed Intake Valve Clearance 0 006 to 0 010 in 0 15 to 0 25 mm Exhaust Valve Clearance 0 006 to 0 010 in 0 15 to 0 25 mm Valve Set...

Page 14: ...9 Use service tool P N 204 2436 to set belt tension Distance of 139 0 mm as set by service tool equates to 95 Hz for a new belt Fan Drive Belt TK Belt Tension Tool 204 3185 106 118 Hz 95 106 Hz Water...

Page 15: ...o 29 High Speed Throttle Solenoid 2 9 4 3 Air Heater 60 to 70 0 14 Damper Gear Motor 2 5 to 3 1 4 0 to 5 0 Pilot Solenoid 0 7 17 0 Electronic Throttling Valve Coil A Red EVA and Blue EVB Wires 20 to 3...

Page 16: ...er element Dependent on operating conditions assess fitness to continue to next service Check engine mounts for wear Replace EMI 3000 air cleaner element see EMI 3000 Air Cleaner at 3 000 hours or two...

Page 17: ...r efficiency and pump down refrigeration system Replace dehydrator and check discharge and suction pressure every two 2 years or 3 000 hours Structural Visually inspect unit for fluid leaks Visually i...

Page 18: ...Series four cylinder reciprocating compressor with 30 0 cu in 492 cm3 displacement Electronic Throttling Valve The Electronic Throttling Valve ETV is a variable position valve operated by a stepper m...

Page 19: ...Diagnostic Manual TK 56487 for complete operation and service information about the SR 3 Control System and the related components Refer to the Operator s Manual for information about basic unit opera...

Page 20: ...ures must be enabled using WinTrac software Using a properly configured and enabled flash drive the following functions may be available Download the ServiceWatch Data Logger Download the CargoWatch D...

Page 21: ...hot refrigerant to defrost the evaporator coils Hot refrigerant gas passes through the evaporator coil and melts the frost The water flows through collection drain tubes onto the ground The methods o...

Page 22: ...the positive battery cable The fuse link protects the electric system from a short If the fuse link burns out replace it by replacing the positive battery cable F Fu us se es s Various fuses are loca...

Page 23: ...Serial Number Location 1 Serial Number Location Figure 6 Engine Serial Number Location 1 Serial Number Location Figure 7 Unit Serial Number Location RAJ724 1 1 On Frame In Engine Compartment U Un ni...

Page 24: ...24 TK 56433 5 MM EN Figure 8 Laminated Serial Number Plate Located Where Shown Above 1 Unit Serial Number 2 Unit Model 3 Bill of Material Number U Un ni it t D De es sc cr ri ip pt ti io on n...

Page 25: ...y a defective voltage regulator Alternator Identification These units use Thermo King Alternators Figure 9 p 25 which are painted black Figure 9 Thermo King Alternator Terminal and Component Locations...

Page 26: ...s se e i in ns st ta al ll le ed d w wi il ll l d da am ma ag ge e T Th he er rm mo o K Ki in ng g a al lt te er rn na at to or rs s T Th he e r re es si is st to or r b by yp pa as ss s f fu us se e...

Page 27: ...e if there are no problems in the wiring Recheck the wiring before replacing the alternator 19 A Al lt te er rn na at to or r D Di io od de e Q Qu ui ic ck k C Ch he ec ck k N No ot te e This check co...

Page 28: ...is designed for use with the engine air pre heater Always replace the fuse with the TK specified fuse Service Parts Base Controllers are shipped without the F5 fuse 3 The device identified as F15 is...

Page 29: ...ent 2 ETV LEDs are illuminated when the respective ETV output is energized On applications without ETV the LEDs may be illuminated Smart FET Outputs A Smart FET is a self protecting output device used...

Page 30: ...intake heater with an ohmmeter between the M6 terminal on the front of the heater and the screw on the back of the heater or the heater case The resistance should be 0 14 0 02 ohms Check the current d...

Page 31: ...unit and trailer level so all the oil can flow from the oil pan N No ot te e It is important to get as much of the oil out as possible because most of the dirt particles are contained in the last few...

Page 32: ...hermostat mounted in the coolant outlet line from the cylinder head to the radiator automatically maintains coolant temperature within the specified temperature range All water cooled engines are ship...

Page 33: ...he unit C CA AU UT TI IO ON N R Ri is sk k o of f I In nj ju ur ry y A Av vo oi id d d di ir re ec ct t c co on nt ta ac ct t w wi it th h h ho ot t c co oo ol la an nt t 2 Open the engine block drain...

Page 34: ...speed a Remove the cap from the expansion tank and slowly pour coolant into expansion tank until it is full then reinstall the expansion tank cap 8 Repeat steps 6 and 7 until the coolant level stabili...

Page 35: ...tem by allowing a certain amount of fuel to return to the tank One orifice is located in the center of the filter head It bleeds off water The other orifice is located off center on the filter head It...

Page 36: ...nance Priming pump hand replacement or repair Fuel transfer pump replacement or repair Injection line replacement Engine speed adjustments Injection pump timing Nozzle spray pattern testing and adjust...

Page 37: ...rger clamp 4 Install the fuel return lines and clamps It may be necessary to adjust the banjo fitting slightly to obtain the straightest routing for the long return line 5 Be sure all the fittings are...

Page 38: ...until no water is visible in the fuel draining from the tank a If the water and fuel do not drain freely the vent may be plugged If so clean or replace the vent 4 Install the drain plug Fuel Pre Stra...

Page 39: ...system capacity in High Speed engine operation it is important to ensure the engine high speed throttle is set properly 1 Shut the unit off 2 Remove the ball socket from the throttle bracket ball 3 En...

Page 40: ...gned with the index mark on the gear case If not make a mark on gear case in line with the index mark on the injection pump see Figure 25 p 40 Figure 23 Index Mark Location 1 Index Marks Figure 24 Ind...

Page 41: ...n angle marked on the old injection pump see the following photographs The injection angle mark is located on the side of the pump facing the engine The injection angle mark on the pump does not use a...

Page 42: ...Mark at 1 8 Degrees 8 Install the injection pump gear lock washer and nut Torque the nut to 58 to 65 ft lb 78 to 88 N m N No ot te e If the timing gear cover was removed to remove the injection pump g...

Page 43: ...Use a shop rag to prevent the lock washer or nut from falling into the gear case N No ot te e The injection pump gear assembly is made of three pieces the flange the gear and the transfer pump cam Do...

Page 44: ...t Use a shop rag as before to prevent the lock washer or nut from falling into the gear case Torque the nut to 58 to 65 ft lb 78 to 88 N m 5 Fasten cover plate to gear case and reinstall all component...

Page 45: ...hms 100 F 38 C 23 2 Ohms 28 3 Ohms 125 F 52 C 24 4 Ohms 29 8 Ohms 150 F 66 C 25 6 Ohms 31 2 Ohms d If the resistance is out of specifications proceed to Fuel Solenoid Replacement below If the resistan...

Page 46: ...ted until you de energize the circuit c If the fuel solenoid plunger fails to actuate or hold during this test check that the circuit is OK If it appears normal proceed to Fuel Solenoid Replacement be...

Page 47: ...n head screws and Hex head bolts to prevent leaks 6 to 7 ft lb 8 to 10 N m Trochoid Feed Pump Replacement Use the following procedure to replace the trochoid feed pump 1 Remove the four hex head screw...

Page 48: ...ss the ON Key to turn the unit on 2 Enter the Gauges Menu before the engine starts and check the coolant temperature to make sure it is below 32 F 0 C 3 Let the engine start then check the engine rpm...

Page 49: ...he engine in the normal direction of rotation clockwise viewed from the water pump end until the 1 4 timing mark on the flywheel lines up with the index mark in the timing mark access hole Figure 48 T...

Page 50: ...arrangement E I E I E I E I Piston in No 1 cylinder is at TDC on compression stroke Piston in No 4 cylinder is at TDC on compression stroke Crankcase Breather Gases formed in the crankcase are direct...

Page 51: ...ere duty air cleaner is similar to the EMI 3000 air cleaner but allows the air cleaner element to be replaced at 4 000 hour intervals under normal operating conditions Figure 51 EMI 3000 Air Cleaner A...

Page 52: ...Belt Tensioner Clutch 7 Lower Condenser Blower 16 Compressor Clutch Belt 8 Cross Shaft Engine Pulley 17 Compressor Coupling 9 Cross Shaft Jackshaft Fan Drive Belt Replacement 1 Place a 17 mm socket wr...

Page 53: ...m the upper blower and the belt to be passed between the upper blower and its condenser spinning 5 Remove the old belt 6 Slide the new belt between the upper blower and its condenser spinning and inst...

Page 54: ...n in the mark on the tensioner arm should rest between the two marks on the tensioner housing Fan Drive Belt Adjustment The sliding idler pulley position is set during factory production for the corre...

Page 55: ...ion is set at all times I Im mp po or rt ta an nt t When checking the alignment of the pulleys the service tool 2042435 Pulley Alignment Tool must be used to verify the correct positioning of theCross...

Page 56: ...4 ft lb 144 to 155 N m Do not tighten the eccentric plate bolts they will be tighten when the belt is installed 5 Install the cross shaft engine pulley Position pulley axially using block P N 2042435...

Page 57: ...ower the eccentric plate against the belt pressure until the Gauge Tool P N 2042436 fits over the heads of the spring damper strut bolts I Im mp po or rt ta an nt t Care must be taken when installing...

Page 58: ...f ff f s sw wi it tc ch h i in n t th he e O Of ff f p po os si it ti io on n b be ef fo or re e i in ns sp pe ec ct ti in ng g o or r s se er rv vi ic ci in ng g a an ny y p pa ar rt t o of f t th he...

Page 59: ...on refrigerant Testing the Refrigerant Charge with a Loaded Trailer 1 Install a gauge manifold 2 Use the Service Test Mode to run the unit in high speed cool Refer to the appropriate Diagnostic Manual...

Page 60: ...em has been changed For example evacuating a system to remove the moisture will not change the color of the indicator ring until the system has been recharged and then operated for at least 15 minutes...

Page 61: ...ll lo ow w t th he e d di is sc ch ha ar rg ge e p pr re es ss su ur re e t to o e ex xc ce ee ed d 4 47 77 7 p ps si ig g 3 32 28 89 9 k kP Pa a 3 Raise the discharge pressure of the compressor by bl...

Page 62: ...e Electronic Throttling Valve ETV is standard on the these units The ETV is a variable position valve operated by a stepper motor The ETV is located in the suction line between the accumulator and the...

Page 63: ...ypass Valve The hot gas bypass valve is used in conjunction with the electronic throttling valve to reduce the capacity of the unit during modulation This normally closed solenoid valve is located in...

Page 64: ...d by Federal and in some cases by State and Local laws In the USA all regulated refrigeration service procedures must be performed by an EPA certified technician using approved equipment and complying...

Page 65: ...The compressor drive coupling will only slide onto the coupling pins in either of two positions which are 180 degrees apart 3 Install the service valves using new gaskets soaked in compressor oil Con...

Page 66: ...Inspect both mating surfaces for burrs oxidation and other surface imperfections Dress with crocus cloth if necessary and re clean as required N NO OT TI IC CE E E Eq qu ui ip pm me en nt t D Da am ma...

Page 67: ...Compressor Coupling or Clutch 2 Key tapped flush with outside face of coupling Do not tap key any farther into keyway 3 Torque bolt to 90 ft lb 122 N m 4 Washer 5 Spray this area with corrosion inhibi...

Page 68: ...lip seal in the seal plate with the lip side facing out and the flat side facing toward the compressor Figure 79 Lip Seal Installation 1 Lip Side Facing Out 2 Flat Side Toward Compressor N NO OT TI IC...

Page 69: ...82 Internal Lip Seal Installation 1 Lip Facing Into Seal Plate 13 Apply clean compressor oil to the O ring inside the bellows Slide the bellows on the crankshaft align the hex drive on the bellows wit...

Page 70: ...prevent corrosion between the copper and aluminum 4 Remove the condenser coil mounting bolts and remove the coil from the unit Figure 85 Top View of Curbside Condenser Coil 1 Copper Stub Tube 2 Unise...

Page 71: ...w through the valve 3 Place a heat sink on the check valve 4 Solder the inlet and outlet connections 5 Pressurize the refrigeration system and test for leaks 6 If no leaks are found evacuate the syste...

Page 72: ...r bulb from the clamp Note the position of the feeler bulb on the suction line 4 Unsolder the equalizer line inlet liquid line and distributor from the expansion valve 5 Remove the expansion valve mou...

Page 73: ...ction line from the evaporator coil 8 Remove the mounting bolts and remove the coil from the evaporator housing Installation 1 Place the evaporator coil assembly in position and install the mounting b...

Page 74: ...c ce e t th he e t to oo ol l i in nt to o t th he e b br ra as ss s o or r a ag ga ai in ns st t t th he e b bo ol lt ts s 4 Loosen the four 1 4 inch Allen head screws DO NOT REMOVE OR CAP MAY POP OF...

Page 75: ...Number 43 Drill Bit Piston Bleed Orifice Check 1 Use a number 66 0 033 in 0 84 mm drill bit to check the orifice in the bleed hole from the gasket surface to the groove in the bottom of the piston bo...

Page 76: ...ng and inspecting all parts reassemble the valve as follows 1 Install the screen in the bottom cap 2 Install the new stem in the bottom cap 3 Install new gaskets on both sides of the seat Oil the gask...

Page 77: ...sor oil and install the assembly into the check valve seat in the three way valve 4 Screw the check valve stem into the three way valve until the snap ring can be installed 5 Install the snap ring 6 U...

Page 78: ...connector installed Use the old connector and just install new wire terminals or install a new connector and wire terminals Refer to the appropriate Parts Manual for the correct connector and termina...

Page 79: ...on n l lo ow w s si id de e p pr re es ss su ur re e o on n t th he e g ga au ug ge e m ma an ni if fo ol ld d I If f t th he e s su uc ct ti io on n p pr re es ss su ur re e h ha as s i in nc cr re e...

Page 80: ...he open position In the open position the bottom edge of the piston is 0 3 to 0 7 in 8 to 18 mm from the bottom edge of the piston housing The piston retracts to open and extends to close Figure 98 St...

Page 81: ...e the unit in operation Hot Gas Bypass Valve Removal 1 Recover the refrigerant charge 2 Disconnect the wires and remove the coil for the valve 3 Unsolder the refrigeration lines 4 Remove the mounting...

Page 82: ...was removed Checking Compressor Oil Pressure The oil pressure at the oil pressure access port varies with the suction pressure in the compressor Therefore we need to calculate the net oil pressure to...

Page 83: ...low Throttling Valve Net Oil Pressure 5 The net oil pressure should be at least 20 psig 138 kPa If the net oil pressure is low first check the compressor oil level then check the compressor oil pump a...

Page 84: ...be inspected and cleaned if needed The coil should be cleaned if there are visible accumulations that obstruct the view of the fins or tubes of the coil The coils should be cleaned if there is debris...

Page 85: ...r nozzle or any other tool This will damage the tubes of the coil N NO OT TI IC CE E E Eq qu ui ip pm me en nt t D Da am ma ag ge e F Fa ai il lu ur re e t to o c co om mp pl ly y w wi it th h a ab bo...

Page 86: ...ing the current draw should not exceed 0 8 amps A technician must visually verify the damper will move Troubleshooting Defrost Damper A problem with a damper will usually generate Alarm Code 29 or Ala...

Page 87: ...asten the damper door to the damper door shaft with the two bolts 10 Replace the evaporator access panels that were removed to access the damper gear motor and damper door Condenser and Evaporator Fan...

Page 88: ...ing bolts 6 Remove the fan shaft while sliding the evaporator blower off the end of the fan shaft Make sure to remove and keep the key N No ot te e Make sure to avoid hitting the machined surface of t...

Page 89: ...r The cleaner needs to be sprayed on wiped down and then allowed to evaporate dry I Im mp po or rt ta an nt t The cleaner must be allowed to evaporate before the next step Figure 116 Fan Shaft and Hou...

Page 90: ...of the fan shaft 6 Place the upper condenser blower on the fan shaft and slide it into position to where its pulley is aligned correctly with the other pulleys and tighten the hub pinch bolts 7 Instal...

Page 91: ...se indicates the cross shaft bearings should be replaced Removal 1 Remove the fan drive belt See Fan Drive Belt in the Engine Maintenance Chapter 2 Remove the engine cross shaft belt See Engine Cross...

Page 92: ...n the cross shaft Position it axially using block P N 2042435 between the pulley and the cross shaft mounting bracket and tighten the pinch bolts 5 Make sure the key is in place in the fan pulley end...

Page 93: ...t To prevent damage to the bearings use bearing drivers or other suitable tools on the bearing races when installing the bearings 1 Install the bearings in the idler pulley 2 Place new washers on the...

Page 94: ...he correct engine Refer to appropriate Microprocessor Diagnostic Manual Fuel solenoid defective or stuck Replace Fuel injection pump defective Replace pump Air heater defective Replace No fuel or wron...

Page 95: ...ve Replace pump Engine knocks heavily Air in system Bleed fuel system Wrong fuel Change fuel Injection pump not timed Retime injection pump Injection nozzles fouled or opening pressure too low Clean r...

Page 96: ...lace seals on valve stem Worn valve stem Replace valves Broken piston rings or cylinder bore worn or scored Have engine repaired and rebored Replace broken piston rings Clogged air cleaner system Uncl...

Page 97: ...ient 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 eva...

Page 98: ...ing SYMPTOM POSSIBLE CAUSES Restricted line on the low side Restricted line on the high side Restricted drier Defrost damper stays open Defrost damper stuck closed Evaporator fans stay running Evapora...

Page 99: ...TK 56433 5 MM EN 99 Refrigeration Diagrams Cool Cycle...

Page 100: ...Suction Service Valve 8 Condenser check valve 25 Hot Gas Bypass Solenoid 9 High Pressure Relief Valve 26 Pilot Solenoid 10 Receiver Tank 27 Hot Gas Line 11 Sight Glass 28 Defrost Pan Heater 12 Receive...

Page 101: ...TK 56433 5 MM EN 101 Heat Defrost Cycle R Re ef fr ri ig ge er ra at ti io on n D Di ia ag gr ra am ms s...

Page 102: ...Suction Service Valve 8 Condenser check valve 25 Hot Gas Bypass Solenoid 9 High Pressure Relief Valve 26 Pilot Solenoid 10 Receiver Tank 27 Hot Gas Line 11 Sight Glass 28 Defrost Pan Heater 12 Receive...

Page 103: ...The following table lists the diagrams that are relevant to this unit The diagrams are available on TSA Info Central and in the SLXi DRC Diagrams Manual TK 56504 Drawing No Drawing Title 3E31534 Schem...

Page 104: ...ers truck bodies buses air shipboard containers and railway cars since 1938 For more information visit www thermoking com or www tranetechnologies com Thermo King has a policy of continuous product an...

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Thermo King Rail Edition SLXi-DRC, Maintenance Manual

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Summary of Contents for Rail Edition SLXi-DRC

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