Thermo King SLXi-100 Maintenance Manual Download Page 4

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TK 61555-2-MM-EN

Safety Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Danger, Warning, Caution, and Notice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Battery Installation and Cable Routing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Battery Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Refrigerant Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Refrigerant Oil Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Electrical Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

High Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Low Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Microprocessor Service Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Welding Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

First Aid. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Belt Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Refrigeration System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Electrical Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Electrical Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Maintenance Inspection Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Unit Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Unit Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Design Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

CYCLE-SENTRY

™

Start-Stop Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Data Logging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
TK BlueBox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
OptiSet

™

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Sequence of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Operating Modes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Engine Compartment Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Unit Protection Devices. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Serial Number Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Electrical Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Alternator Diagnostic Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Table of Contents

Summary of Contents for SLXi-100

Page 1: ...Revision A January 2018 T TK K 6 61 15 55 55 5 2 2 M MM M E EN N Trailer Edition SLXi 100 and SLXi 200 Single Temperature Units Maintenance Manual...

Page 2: ...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 T Th he e p pr ro oc ce ed du ur re es s d de es sc...

Page 3: ...al THERMO KING dealer 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...

Page 4: ...ctrical Control System 17 Electrical Components 17 Maintenance Inspection Schedule 18 Unit Description 21 Unit Overview 21 Design Features 21 CYCLE SENTRY Start Stop Controls 22 Data Logging 22 TK Blu...

Page 5: ...Information 37 How it Works 38 LVD Maintenance 38 Diagnosing the Low Voltage Disconnect LVD 40 Engine Maintenance 41 EMI 3000 41 Engine Lubrication System 41 Engine Oil Change 41 Oil Filter Change 41...

Page 6: ...lass 80 Refrigerant Leaks 81 Checking Compressor Oil 81 High Pressure Cutout Switch HPCO 82 Three Way Valve Condenser Pressure Bypass Check Valve 83 Refrigeration Service Operations 85 Refrigeration S...

Page 7: ...sembly Installation 108 Three Way Valve Condenser Pressure Bypass Check Valve Repair 109 Removal 109 Installation 110 Pilot Solenoid 111 Removal 111 Installation 111 Suction Vibrasorber 111 Removal 11...

Page 8: ...aporator Fan Location 124 Condenser Inlet Orifice Alignment 124 Evaporator Fan Blower Alignment 125 Fan Shaft Assembly 126 Removal 126 Disassembly 126 Reassembly 127 Installation 129 Lower Condenser B...

Page 9: ...s s W WA AR RN NI IN NG G F Fi ir re e H Ha az za ar rd d D Do o n no ot t a at tt ta ac ch h f fu ue el l l li in ne es s t to o b ba at tt te er ry y c ca ab bl le es s o or r e el le ec ct tr ri ic...

Page 10: ...e er r c co on nt ta ai in ne er rs s o ou ut t o of f d di ir re ec ct t s su un nl li ig gh ht t a an nd d a aw wa ay y f fr ro om m i in nt te en ns se e h he ea at t H He ea at t i in nc cr re ea...

Page 11: ...th he e a ai ir r a an ny y l lo on ng ge er r t th ha an n n ne ec ce es ss sa ar ry y S St to or re e r re ef fr ri ig ge er ra an nt t o oi il l i in n a an n a ap pp pr ro ov ve ed d s se ea al le...

Page 12: ...i in n t th he e e ev ve en nt t o of f a an n e el le ec ct tr ri ic ca al l a ac cc ci id de en nt t W WA AR RN NI IN NG G R Ri is sk k o of f I In nj ju ur ry y D Do o n no ot t m ma ak ke e r ra...

Page 13: ...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 14: ...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 15: ...1 7 to 107 2 C or higher Shutdown Engine Coolant Thermostat 71 C Engine Coolant Type N NO OT TI IC CE E S Sy ys st te em m C Co on nt ta am mi in na at ti io on n D Do o n no ot t a ad dd d G GR RE EE...

Page 16: ...at tm mo os sp ph he er re e 4 00 kg R404A 3 73 kg R452A 5 00 kg R404A R452A Compressor Oil Charge X426LSC5 or X430LSC5 4 10 liters litres 6 62 liters litres deep sump Compressor Oil Type Polyol Este...

Page 17: ...to 14 2 volts 25 C Electrical Components Table 5 Note Disconnect components from the unit circuit to check resistance Component Current Draw Amperes at 12 5 Vdc Resistance Ohms Starter Motor 350 to 47...

Page 18: ...ion of the Blue Box Check HMI Controller software revision Upgrades not included Check fuel supply Check and adjust engine oil level Change engine oil hot and oil filter Check and adjust engine coolan...

Page 19: ...of engine vibration mounts Electrical Check alternator connections for corrosion and clean and protect as required Inspect alternator brushes Change alternator brushes and regulator at 6000 hrs Check...

Page 20: ...ect unit for damaged loose or broken parts includes air ducts and bulkheads Check all unit mounting bolts external mounted equipment wiring hoses fuel lines etc Clean micro channel condenser Clean eva...

Page 21: ...ngine operation Model 50 Cooling heating hot gas and defrost hot gas on engine operation and electric standby operation Power is provided by a water cooled direct injection diesel engine The compresso...

Page 22: ...s typically 2 amperes Features of the CYCLE SENTRY system are Offers either CYCLE SENTRY or Continuous Run operation Controller regulated all season temperature control Maintains minimum engine temper...

Page 23: ...on and two way communication A Maintenance Menu feature called Telematics Status is available that allows the user to check for possible telematics status alarms Telematics status alarms differ from s...

Page 24: ...l operate in High Speed Cool until setpoint is reached Unit mode is Null when the engine temperature and battery are satisfied Null mode if setpoint is below Fresh Frozen temperature setting E El le e...

Page 25: ...at setpoint Use a longer defrost interval if defrost is not being initiated on demand Use a shorter defrost interval if defrost is frequently being initiated on demand If the unit is in CYCLE SENTRY N...

Page 26: ...essor discharge manifold If the compressor discharge pressure becomes excessive the switch opens the circuit to the run relay to stop the unit The microprocessor will record Alarm Code 10 H Hi ig gh h...

Page 27: ...e valve cover C Co om mp pr re es ss so or r Stamped between the cylinders on the front end above the oil pump Figure 3 Compressor Serial Number Location 1 Serial Number Location Figure 4 Engine Seria...

Page 28: ...MM EN Figure 5 Unit Serial Number Location Figure 6 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...

Page 29: ...e of accepting a charge Check for a damaged battery correct electrolyte level and loose or corroded connections The alternator charging output will be low if the alternator belt or pulleys are defecti...

Page 30: ...tor from the excitation circuit as required for Prestolite alternators See the specific unit wiring diagram for exact details N No ot te e The F4 fuse must be removed from the base controller on units...

Page 31: ...it th h 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 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...

Page 32: ...icipated voltage regulator setting compare the voltage at the B terminal to the voltage between the battery terminals The voltage at the B terminal should be no more than 1 0 Vdc higher than the volta...

Page 33: ...during scheduled maintenance inspections 2 A dead or low battery can be the cause of an ammeter indicating discharge due to lack of initial excitation of the alternator even after the unit has been b...

Page 34: ...Fuse Size Function Fuse Size Function F2 15A Power to On Off Switch F3 40A Power to Fuel Sol Pull In Starter Solenoid F4 None or 2A No fuse all Bosch and TK alternators Note 1 2A fuse all Prestolite a...

Page 35: ...n the right position control power is routed to the K9 On Off Relay contacts The On Off keys on the HMI Control Panel energize and de energize the K9 On Off Relay When the K9 On Off Relay is energized...

Page 36: ...used for the functions shown in the table Smart FETs halt current flow if an over current condition exists and generate an alarm The Smart FET will resume normal operation when the alarm is cleared an...

Page 37: ...n N NO OT TI IC CE E E Eq qu ui ip pm me en nt t D Da am ma ag ge e D Do o n no ot t c co on nn ne ec ct t o ot th he er r m ma an nu uf fa ac ct tu ur re er r s s e eq qu ui ip pm me en nt t t to o t...

Page 38: ...LVD switch is as follows Disconnects power to external devices when battery voltage drops below 12 1V for longer than 5 7 minutes Automatically resets when system voltage rises above 13V for longer t...

Page 39: ...ered down will result in the LVD switch disconnecting the output after a short period of time within hours depending on total current draw If current draw from all external devices exceeds 14 Amps the...

Page 40: ...t and disconnect LVD harness plug from LVD for 10 seconds and reconnect Alternatively disconnect main battery cable terminals for 10 seconds and reconnect N No ot te e This action performs a power cyc...

Page 41: ...to the Maintenance Inspection Schedule 1 Drain the oil only when the engine is hot to verify that all the oil drains out 2 When changing oil keep unit and trailer level so all the oil can flow from th...

Page 42: ...culating type pressurized cooling system Correct engine temperatures are controlled and maintained by a radiator fan and thermostat The coolant is circulated through the system by a belt driven centri...

Page 43: ...n nv ve en nt ti io on na al l c co oo ol la an nt t i is s a ad dd de ed d t to o E Ex xt te en nd de ed d L Li if fe e C Co oo ol la an nt t t th he e c co oo ol la an nt t m mu us st t b be e c ch...

Page 44: ...allow it to drain out of the block until it is clear b Close the block drain and install a commercially available radiator and block flushing agent and operate the unit in accordance with instruction...

Page 45: ...he engine and monitor the coolant temperature with the unit engine coolant temperature gauge or by using a non contact thermometer pointed at the thermostat housing in the location of the high water t...

Page 46: ...expansion tank until the coolant level is well below the switch level and check continuity of the switch The switch should be open If the tank was removed from the unit accomplish this check with the...

Page 47: ...e fuel tank in the return line Fuel Line Routing The fuel lines from the fuel tank connect to the fittings on the fuel filter Do not change the factory routing of the fuel lines from the fuel filter t...

Page 48: ...procedures can be accomplished under field conditions Bleeding air from the fuel system Fuel tank and filter system maintenance Priming pump hand replacement or repair Fuel transfer pump replacement...

Page 49: ...d Distributor Injection Pump Fuel Return Line Replacement Use the following procedure to replace the fuel return lines and end cap 1 Remove the clamps the end cap the short fuel return lines between t...

Page 50: ...traightest routing for the long return line 5 Be sure all the fittings are tight and check for leaks 6 Write the date and engine hours on the decal Bleeding the Fuel System If the engine runs out of f...

Page 51: ...to the engine A large accumulation of water in the bottom of the fuel tank will stop a diesel engine Water should be drained during scheduled maintenance inspections to prevent breakdowns Drain the wa...

Page 52: ...ed 3 Bleed the air out of the nozzles Check the speed Make the engine speed adjustments with the engine fully warmed up High Speed N No ot te e To achieve proper refrigeration system capacity in High...

Page 53: ...adjustment screw to obtain the correct speed c Tighten the jam nut and recheck the speed 5 Exit the Service Test Mode Injection Pump Timing Use this timing procedure when installing a new injection p...

Page 54: ...ection Pump 2 Existing Index Mark on Gear Case 3 Make New Mark on Gear Case If Needed 2 Clean the area with brake cleaner or something similar Place an injection angle sticker on the gear case so the...

Page 55: ...see Injection Pump Removal p 59 N No ot te e Remove the injection pump gear by removing the nut and lock washer that secure the injection pump gear assembly to the injection pump shaft The injection p...

Page 56: ...p facing the engine The injection angle mark on the pump does not use a decimal point Add a decimal point before the last digit of the injection angle mark to get the injection angle The injection ang...

Page 57: ...on pump 6 Calculate the injection angle difference by subtracting the injection angle of the old injection pump from the injection angle of the new injection pump Examples Injection Angle of New Injec...

Page 58: ...ing marks on the timing gears are aligned as shown below It helps to install the idler gear last when aligning the timing marks Figure 31 Timing Mark Alignment 1 Fuel Injection Pump Gear 2 Idler Gear...

Page 59: ...g the pump the gear must be separated from the pump Using tool P N 204 1011 it will not be necessary to remove the belts crankshaft pulley crankshaft seal or front plate See Figure 35 p 61 1 Note the...

Page 60: ...se the hardware from the cover plate to attach the tool plate with the marked side pointing up and out to the gear case 5 Align the threaded holes in the injection pump gear with the two holes in the...

Page 61: ...Remove hardware holding gear to tool plate then remove tool plate 4 Secure the gear to the injection pump shaft with the lock washer and nut Use a shop rag as before to prevent the lock washer or nut...

Page 62: ...noid Engine Valve Clearance Adjustment The valve clearance should be adjusted every 3 000 hours 1 Remove the rocker arm cover 2 Remove the round cover plug from the timing mark access hole on the fron...

Page 63: ...three cylinder The valve clearance for both the intake valve and the exhaust valve should be 0 15 to 0 25 mm 0 006 to 0 010 in a Check to verify that the valve stem cap is in good condition and is pos...

Page 64: ...breather is located in the valve cover A restrictor is cast into the fitting for the breather hose on the intake manifold The restrictor limits the flow of gases from the crankcase to the intake manif...

Page 65: ...MI 3000 Air Cleaner Assembly Figure 41 EMI 3000 Air Filter Element Belts C CA AU UT TI IO ON N R Ri is sk k o of f I In nj ju ur ry y T Th he e u un ni it t c ca an n s st ta ar rt t a an nd d r ru un...

Page 66: ...rive for the alternator Additionally it has special procedures to facilitate easy belt changes New belts should be tensioned cold and re tensioned cold after 10 hours of unit operation Using Thermo Ki...

Page 67: ...ck 17 Engine to Motor Belt 8 Motor Pulley 18 Compressor Clutch 9 Fanshaft 19 Fan Key 10 Upper Blower 20 Idler Pulley Fan Drive Belt Fan Drive Belt Replacement 1 Place a 17 mm socket wrench over the he...

Page 68: ...nsioner bolt The wrench will rise above the horizontal starting position under the force of the spring 4 Loosen or remove the mounting screws for the upper blower condenser spinning enough to allow th...

Page 69: ...wrench to remove it from the tensioner bolt The belt should be aligned as shown below Figure 48 Final Fan Drive Belt Alignment 10 Check the belt tension with Frequency Gauge P N 2041903 The recommend...

Page 70: ...oner housing Fan Drive Belt Adjustment The sliding idler pulley position is set during factory production for the correct belt tension If required its position can be adjusted in the field to achieve...

Page 71: ...and adjust sliding idler position as required 4 Tighten the sliding idler pulley bolt 5 Perform steps 7 10 of Fan Drive Belt Replacement above reset belt position and measure belt frequency to ensure...

Page 72: ...52 Engine Cross Shaft Belt Arrangement 1 Cross Shaft Electric Motor Pulley 4 Compressor Coupling 30 Models Clutch 50 Models 2 Engine to Motor Cross Shaft Belt 5 Tensioner Clutch 3 Back Idler Pulley E...

Page 73: ...Hole 8 Arm 4 Spring Damper Strut 9 Arm Pivot Bolt 5 Support Bracket Engine Cross Shaft Belt Replacement 1 Loosen the pivot bolt for the eccentric plate The the pivot bolt is located behind the cross s...

Page 74: ...position and install the mounting bolts 10 Use use the 1 2 in drive wrench to slowly raise the eccentric plate its highest position 11 Place the new belt on the cross shaft engine pulley and idler pu...

Page 75: ...f the spring damper strut bolts again to verify the setting is correct 15 Remove the gauge too and check the strut bolts to make sure thy are tight The recommended torque is 20 to 27 to 33 N m 24 ft l...

Page 76: ...ate 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 between the pulley and the cross shaft mounting bracke...

Page 77: ...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 e u un n...

Page 78: ...of refrigerant the unit may not cool properly and the suction and discharge pressure may be high The charge may be determined by inspection of the refrigerant through the receiver tank sight glasses w...

Page 79: ...t overcharged and it is not necessary to complete the rest of the procedure 4 Remove the condenser cover to rapidly reduce discharge pressure 5 Observe the receiver tank sight glass and the unit disch...

Page 80: ...o ou ur r r re ef fr ri ig ge er ra an nt t t ty yp pe e l la ab be el l o on n o ou ut ts si id de e o of f u un ni it t a an nd d m ma ak ke e s su ur re e n no ot t t to o c cr ro os ss s c co on n...

Page 81: ...ined the above conditions for 15 minutes observe the oil level The oil should be 1 4 to 1 2 up in the sight glass C Ch he ec ck k C Co om mp pr re es ss so or r O Oi il l L Le ev ve el l A Am mb bi ie...

Page 82: ...he e d di is sc ch ha ar rg ge e p pr re es ss su ur re e r re ea ac ch he es s 4 47 77 7 p ps si ig g 3 32 2 8 89 9 b ba ar r s sh hu ut t t th he e u un ni it t o of ff f i im mm me ed di ia at te e...

Page 83: ...valve response time when shifting from heat to cool If a three way valve does not shift back to cool immediately after the pilot solenoid closes and finally shifts to cool when the temperature rise p...

Page 84: ...seals properly toward the condenser and the condenser pressure bypass check valve seals properly 9 Back seat condenser pressure bypass check valve stem against the snap ring Both gauges should rise i...

Page 85: ...rformed by a certified technician using approved equipment and complying with all EU and local laws A Service Test mode on these controllers allows technicians to operate the unit under known conditio...

Page 86: ...xchanger 2 Discharge Vibrasorber 10 Expansion Vakve 3 Three Way Valve 11 Evaporator Coil 4 Condenser Coil 12 Accumulator 5 Check Valve 13 Suction Vibrasorber 6 Check Valve 14 Pilot Solenoid R Re ef fr...

Page 87: ...Compressor Flange 17 Service Valve Gasket 3 Compressor Stud 18 Compressor Key 4 Flatwasher 19 Oil Seal 5 Sealing Washer 20 Keyway alignment Tool 6 Valve and cover screw 21 Crankshaft Plate 7 Discharg...

Page 88: ...ring seal adapter 14 HPCO Switch 29 O ring 15 Adapter O Ring 30 Adapter Cap Figure 66 Compressor X430P Components 1 Compressor 17 Discharge Valve 2 Compressor Flange 18 Valve Gasket 3 Compressor Stud...

Page 89: ...r belt guard 7 Support compressor and remove the compressor mounting bolts from flywheel housing 8 Lift the service valves out of the way 9 Slide the compressor to the left until coupling pins are cle...

Page 90: ...inst the tool and it should push the coupling off the crankshaft as you continuing turning the center screw in a counter clockwise direction Using this tool will prevent the coupling from popping off...

Page 91: ...n d dr ro op p t th he e c co ou up pl le er r o on n I If f t th he e t to oo ol l d do oe es s n no ot t f fi it t t th he e k ke ey y w wi il ll l n no ot t f fi it t a an nd d i it t w wi il ll l...

Page 92: ...pling or Clutch 2 Key tapped flush with outside face of coupling Do not tap key any farther into keyway 3 Torque bolt to 122 N m 90 ft lb 4 Washer 5 Spray this area with corrosion inhibitor after asse...

Page 93: ...2 Remove the six mounting flange bolts and remove the mounting flange 3 Remove the three seal plate bolts and use a slide hammer to remove the seal plate N No ot te e Use slide hammer P N 204 638 and...

Page 94: ...pm me en nt t D Da am ma ag ge e D DO O N NO OT T t to ou uc ch h o or r d da am ma ag ge e t th he e p po ol li is sh he ed d s se ea al l f fa ac ce e s su ur rf fa ac ce es s o on n t th he e h ha...

Page 95: ...P N 204 953 5 Internal Lip Seal 12 If damaged replace the internal lip seal by prying the old one out and press the new one into place with the lip facing into the seal plate Verify the lip seal is p...

Page 96: ...e bellows with the hex drive collar and push the bellows firmly against the hex drive collar Leave the protective cap in place during installation If the hex drive does not slide on easily rotate the...

Page 97: ...lip seals and the seal plate gasket from the package number 3 before assembling 15 Install the seal plate and gasket to the compressor body Do not bump the seal hard ring on the end of the crankshaft...

Page 98: ...a micro channel condenser coil Micro channel coils are made of aluminum but have copper stub tubes at the inlet and outlet connections Use a heat sink on the copper stub tubes to prevent damage to the...

Page 99: ...oldered in place to prevent damage to the neoprene seal Figure 79 Cross Section of In line Condenser Check Valve 1 Valve 3 Valve Seat 2 Neoprene Seal 4 Spring Condenser Check Valve Replacement Removal...

Page 100: ...y Position the receiver tank so the sight glass is clearly visible through viewing hole in mounting bracket and the outlet tube lines up 2 Solder the inlet tube to the receiver tank Use a heat sink on...

Page 101: ...eration valves and place the unit in operation 9 Test the unit to see that the expansion valve is properly installed 10 Check refrigerant charge Heat Exchanger Removal 1 Pump down the low side and equ...

Page 102: ...ator access panels 3 Remove the sensors 4 Remove the heat exchanger mounting hardware 5 Remove the feeler bulb from the suction line clamp Note the position of the feeler bulb on the suction line 6 Un...

Page 103: ...NO OT TI IC CE E E Eq qu ui ip pm me en nt t D Da am ma ag ge e U Us se e a a h he ea at t s si in nk k o or r w wr ra ap p E ET TV V w wi it th h w we et t r ra ag gs s t to o p pr re ev ve en nt t...

Page 104: ...way valve to the pilot solenoid N NO OT TI IC CE E E Eq qu ui ip pm me en nt t D Da am ma ag ge e D Do o n no ot t f fo or rc 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...

Page 105: ...tom cap sealing and support area Seat sealing surface End cap sealing and support surface The following parts will be discarded Stem assembly All gaskets Piston seal 10 Remove the screen If any partic...

Page 106: ...ve the condenser pressure bypass check valve snap ring stem spring and piston from the end cap 2 Use a number 43 0 089 in 2 26 mm drill bit to check the size of the hole from the end cap gasket face t...

Page 107: ...snap ring Kit P N 60 163 2 Leave the stem back seated against the snap ring Use a paper clip bent into a 90 degree angle to push the check valve piston back in its bore Verify you can feel the piston...

Page 108: ...n Whenever you disassemble a three way valve you should check that all three of the holes are drilled cleanly Figure 86 Check Seat Orifice 1 Number 66 Drill Bit Assembly Installation After cleaning a...

Page 109: ...Install the bolts and tighten in rotating sequence Torque to 160 in lb 18 N m 9 Install the pilot solenoid line and pressurize the system with refrigerant to check for leaks 10 If there are no leaks...

Page 110: ...p pm me en nt t D Da am ma ag ge e T Th he e p pi is st to on n m mu us st t b be e i in ns se er rt te ed d w wi it th h t th he e f fl la at t s si id de e a ag ga ai in ns st t t th he e v va al lv...

Page 111: ...Us se e a a h he ea at t s si in nk k o or r w wr ra ap p E ET TV V w wi it th h w we et t r ra ag gs s t to o p pr re ev ve en nt t d da am ma ag gi in ng g t th he e E ET TV V 3 Unsolder the other e...

Page 112: ...val 1 Recover the refrigerant charge 2 Unscrew and remove the high pressure relief valve Installation 1 Apply a refrigerant oil to the O ring of the high pressure relief valve 2 Install and tighten th...

Page 113: ...1 Inspect End Cap for wear 2 Inspect Piston for wear 3 Inspect Housing for damage Figure 90 Throttling Valve Piston End Cap 1 Inspect Cap 2 Inspect Spring 3 Shims 5 Break the gasket free and remove t...

Page 114: ...est to outlet opening of the valve body 4 Install the piston and spring Tighten the castle nut until firmly seated against the bottom of the piston 5 Back off the castle nut one full turn only 6 Inser...

Page 115: ...found evacuate the system 5 Open receiver tank outlet valve Place the unit in operation 6 Check refrigerant charge Compressors with Internal Oil Filter In the first quarter of 2014 four cylinder comp...

Page 116: ...mpressor from the unit if needed to access the oil sump 2 Remove the oil sump 3 Remove the nut that fastens the internal oil filter to the stud on the oil pickup tube bracket Figure 94 Remove Nut from...

Page 117: ...edure to check the compressor oil pressure 1 Attach a suitable oil pressure gauge to the oil pressure access port on the compressor oil filter or to the oil pressure access port on the oil pump cover...

Page 118: ...al ll l W Wh hi is sp pe er r a an nd d W Wh hi is sp pe er r P Pr ro o u un ni it t m mo od de el ls s f fi it tt te ed d w wi it th h s so ou un nd d i in ns su ul la at ti io on n b bl la an nk ke...

Page 119: ...a manner similar to the way lint cleans from the lint trap of a household clothes dryer Use a soft bristled brush DO NOT USE A WIRE BRUSH and brush the coil going with the fins across the tubes The c...

Page 120: ...tructions provided by the detergent supplier are followed In case of doubt about the compatibility of the detergent with the type of materials listed above always ask the supplier a written confirmati...

Page 121: ...that hold the unit to the trailer are accessible using an impact wrench with a 25 cm 10 inch extension ball type swivel and a deep well socket N No ot te e The nuts for mounting the unit should be ela...

Page 122: ...st if the controller senses a fault in the damper gear motor operation Alarm Code 30 is set any time the controller tries to move the damper and the damper gear motor draws excessive current for a spe...

Page 123: ...e wires from the connector to the damper gear motor If these wires have good continuity the damper gear motor is probably defective A Al la ar rm m C Co od de e 3 30 0 D De ef fr ro os st t D Da am mp...

Page 124: ...fasten it to the damper gear motor shaft with the two bolts 9 Fasten the damper door to the damper door shaft with the two bolts 10 Replace the evaporator access panels that were removed to access the...

Page 125: ...ce should be approximately 3 8 mm 0 15 in 3 Tighten the hub pinch bolts that hold the blower wheel on the fan shaft to a torque of 18 N m 13 ft lb 4 Center the inlet orifices in the blower orifices Ti...

Page 126: ...hile 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 the shaft against the structure bec...

Page 127: ...her on the evaporator end of the fan shaft 4 Install the other bearing on the evaporator end of the fan shaft with the washers between the two bearings 5 Install the snap ring on the evaporator end of...

Page 128: ...vator to the machined bore inner surface in the evaporator end of the housing and allow it to dry by evaporation Figure 107 Fan Shaft Housing 1 Apply Loctite 7240 Activator to Machined Bore Inner Surf...

Page 129: ...within seconds upon contact N No ot te e Curing time for Loctite 603 is 6 hours when Loctite 7240 activator has been used Do not install the fan shaft in the unit until the Loctite has cured 11 Insta...

Page 130: ...cked when the belt is replaced Spin the lower condenser blower with the belt removed and listen Unusually loud bearing noise indicates the lower condenser blower bearings should be replaced Removal 1...

Page 131: ...n drive belt See Fan Drive Belt in the Engine Maintenance Chapter 2 Remove the engine cross shaft belt See Engine Cross Shaft Belt in the Engine Maintenance Chapter 3 Loosen the pinch bolts on the cro...

Page 132: ...d of the cross shaft 6 Install the snap ring on the engine pulley end of the cross shaft Installation 1 Place the cross shaft in position Make sure with the engine pulley end is located on the engine...

Page 133: ...e Chapter 2 Remove the snap ring and discard it 3 Remove the idler pulley and bearings from the spindle 4 Remove the washers from the spindle and discard them 5 Remove the bearings from the idler pull...

Page 134: ...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 135: ...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 136: ...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 137: ...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 138: ...Unit not heating or defrosting 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 Evaporato...

Page 139: ...TK 61555 2 MM EN 139 Refrigeration Diagrams Cool Cycle...

Page 140: ...21 Accumulator 7 Condenser Coil 22 Suction Line 8 Condenser check valve 23 Suction Vibrasorber 9 High Pressure Relief Valve 24 Suction Service Valve 10 Receiver Tank 25 Throttling Valve 11 Sight Glas...

Page 141: ...55 2 MM EN 141 Heat Defrost Cycle 1 Compressor 16 Expansion Valve 2 Discharge Service Valve 17 Feeler Bulb 3 Discharge Line 18 Equalizer Line R Re ef fr ri ig ge er ra at ti io on n D Di ia ag gr ra a...

Page 142: ...denser check valve 23 Suction Vibrasorber 9 High Pressure Relief Valve 24 Suction Service Valve 10 Receiver Tank 25 Throttling Valve 11 Sight Glass 26 Pilot Solenoid 12 Receiver outlet valve 27 Hot Ga...

Page 143: ...EN 143 Diagram Index The following table lists the diagrams that are relevant to this unit The diagrams are available on EMEA Info Central Drawing No Drawing Title 3E31534 Schematic Diagram 2E98198 W...

Page 144: ...rotect food and perishables and increase industrial productivity and efficiency We are a global business committed to a world of sustainable progress and enduring results ingersollrand com Ingersoll R...

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Thermo King SLXi-100, Maintenance Manual

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