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Thermo King SLXi-300, Maintenance Manual

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Thermo King SLXi-300 Maintenance Manual Download Page 97

TK 61552-2-MM-EN

97

Figure 70.

Refrigeration System Components

1.

Evaporator Coil

11.

Suction Pressure Transducer

2.

Heat Exchanger

12.

Suction Vibrasorber

3.

Expansion Valve

13.

ETV

4.

Condenser Coil

14.

Accumulator

5.

Discharge Pressure Transducer

15.

Filter-Drier

6.

Three-Way Valve

16.

Receiver Tank

7.

Discharge Vibrasorber

17.

Condenser Check Valve

8.

Pulsing Hot Gas Bypass Valve

18.

High Pressure Relief Valve

9.

Pilot Solenoid

19.

Bypass Check Valve

10.

Compressor

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Summary of Contents for SLXi-300

Page 1: ...Revision A January 2018 T TK K 6 61 15 55 52 2 2 2 M MM M E EN N Trailer Edition SLXi 300 and SLXi 400 Single Temperature Units Maintenance Manual...

Page 2: ...a 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 cr ri ib be ed d h he er re ei in n s...

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: ...n 19 Refrigeration System 19 Electrical Control System 20 Electrical Components 20 Maintenance Inspection Schedule 21 Unit Description 24 Unit Overview 24 Design Features 24 Electronic Throttling Valv...

Page 5: ...ter 42 Unit Wiring 42 Wire Harness Routing 42 Low Voltage Disconnect Switch LVD 43 General Information 43 How it Works 43 LVD Maintenance 44 Diagnosing the Low Voltage Disconnect LVD 45 Engine Mainten...

Page 6: ...Charge with a Loaded Trailer 87 Testing for an Overcharge 88 Moisture Indicating Sight Glass 89 Refrigerant Leaks 90 Checking Compressor Oil 90 High Pressure Cutout Switch HPCO 91 Three Way Valve Con...

Page 7: ...n 111 Heat Exchanger 112 Removal 112 Installation 112 Evaporator Coil Assembly 112 Removal 112 Installation 113 Accumulator 113 Removal 113 Installation 113 Three Way Valve Repair 113 Removal Disassem...

Page 8: ...ressor Oil Pressure 129 Structural Maintenance 130 Unit and Engine Mounting Bolts 130 Unit Inspection 130 Condenser Evaporator and Radiator Coils 131 Micro Channel Coil Cleaning Recommendations 131 De...

Page 9: ...sembly 143 Reassembly 144 Installation 144 Idler Assemblies 145 Disassembly 145 Reassembly 145 Mechanical Diagnosis 146 Refrigeration Diagnosis 149 Refrigeration Diagrams 151 Cool Cycle 151 Heat Defro...

Page 10: ...nj ju ur ry y o or r p po os ss si ib bl le e d de ea at th h D DA AN NG GE ER R R Ri is sk k o of f I In nj ju ur ry y K Ke ee ep p y yo ou ur r h ha an nd ds s c cl lo ot th hi in ng g a an nd d t...

Page 11: ...e ed d i in nt to o h hi ig gh h v vo ol lt ta ag ge e c ca ab bl le es s c co ou ul ld d c ca au us se e a an n e el le ec ct tr ri ic ca al l f fi ir re e s se ev ve er re e p pe er rs so on na al l...

Page 12: ...r rd d o of f E Ex xp pl lo os si io on n A Al lw wa ay ys s c co ov ve er r b ba at tt te er ry y t te er rm mi in na al ls s t to o p pr re ev ve en nt t t th he em m f fr ro om m m ma ak ki in ng g...

Page 13: ...e ed d g gl lo ov ve es s a an nd d o ot th he er r c cl lo ot th hi in ng g a an nd d e ey ye e w we ea ar r w wh he en n h ha an nd dl li in ng g r re ef fr ri ig ge er ra an nt t t to o h he el lp...

Page 14: ...n ne ev ve er r t th he e u un ni it t i is s c co on nn ne ec ct te ed d t to o a a s so ou ur rc ce e o of f e ex xt te er rn na al l s st ta an nd db by y p po ow we er r V Vo ol lt ta ag ge es s o...

Page 15: ...n nt ts s C Co on nt tr ro ol l c ci ir rc cu ui it ts s u us se ed d i in n r re ef fr ri ig ge er ra at ti io on n u un ni it ts s a ar re e l lo ow w v vo ol lt ta ag ge e 1 12 2 t to o 2 24 4 v vo...

Page 16: ...cting the battery Disconnect power to the unit Disconnect all wire harnesses from the microprocessor Disconnect the ECU and the battery charger if so equipped If there are any electrical circuit break...

Page 17: ...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 18: ...ump 12 1 BTDC timed on No 1 cylinder flywheel side Low Oil Pressure Switch Normally Closed 0 55 to 0 83 bar 8 to 12 psi High Coolant Temperature Switch Sensor 101 7 to 107 2 C or higher Shutdown Engin...

Page 19: ...uates to 95 Hz for a new belt Fan Drive Belt SLX SLXe SLXi 106 118 95 106 Water Pump Belt Tension Number on TK Gauge 204 427 Field Reset 35 40 Refrigeration System Table 3 Compressor Thermo King X430P...

Page 20: ...el on outside of unit and do not to cross contaminate Electrical Control System Table 4 Voltage 12 5 Vdc nominal Battery Wet Cell 12 volt AHr Rating 92AHrs 760 Cold Cranking Amps at 18 C EON 12 volt A...

Page 21: ...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 22: ...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 23: ...lkheads Check all unit mounting bolts external mounted equipment wiring hoses fuel lines etc Clean micro channel condenser Clean evaporator coil and defrost drains of debris Miscellaneous Check calibr...

Page 24: ...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 compressor is c...

Page 25: ...tem pressures did not respond as expected during the test This may be caused by a malfunction of the ETV or by a refrigeration system problem such as low refrigerant level a frozen expansion valve or...

Page 26: ...ain setpoint and provide constant airflow N No ot te e The SR 3 Controller provides a wide range of control and programming flexibility However pre programming of the unit controller may prohibit oper...

Page 27: ...erly configured and the desired features must be enabled using WinTrac software Using a properly configured and enabled flash drive the following functions may be available Download the ServiceWatch D...

Page 28: ...d The unit will Defrost in low speed only Heat and Defrost consists of hot gas delivered to the evaporator coil distributor E En ng gi in ne e O Op pe er ra at ti io on n The microprocessor will selec...

Page 29: ...ure discharge air temperature and coil temperature exceed certain limits The unit can enter defrost cycles as often as every 30 minutes if required M Ma an nu ua al l D De ef fr ro os st t In Manual D...

Page 30: ...h ht t G Gl la as ss s Use this sight glass to check the level of refrigerant in the receiver tank See the Refrigeration Maintenance section for the correct procedure Figure 4 Engine Compartment Compo...

Page 31: ...reseat properly recover the refrigerant charge and replace the valve L Lo ow w O Oi il l L Le ev ve el l S Sw wi it tc ch h The low oil level switch closes if the oil drops below an acceptable level...

Page 32: ...32 TK 61552 2 MM EN Figure 6 Engine Serial Number Location 1 Serial Number Location Figure 7 Unit Serial Number Location U Un ni it t D De es sc cr ri ip pt ti io on n...

Page 33: ...TK 61552 2 MM EN 33 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 34: ...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 35: ...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 36: ...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 37: ...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 38: ...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 39: ...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 40: ...rd When fuse F10 is installed in 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 t...

Page 41: ...y The Status LED flashes several times per second during a flash load The Status LED is on without flashing during reboot and when the Base Controller is under test The Status LED flashes twice within...

Page 42: ...e link by replacing the positive battery cable Air Heater The air heater is mounted on the open end of the intake manifold It heats the intake air to help the engine start in cold weather The air heat...

Page 43: ...This new LVD switch replaces the previous optional aftermarket solution the battery safeguard Example of external devices which are required to be powered through the LVD switch connection points inc...

Page 44: ...nstallation instructions Actual LVD switch is located attached to the frame below the alternator External device connection point consists of an 8 pin Deutsch connector located inside the control box...

Page 45: ...power output to external devices once again N No ot te e Typical power output from alternator in normal unit running operation is 13 8 14 2V Once unit is running for 10 seconds perform step 1 again t...

Page 46: ...ress it will likely require replacement of LVD N No ot te e If unit is within warranty and LVD is requested back under warranty claim Thermo King recommend to seal the LVD in a air water tight plastic...

Page 47: ...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 48: ...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 49: ...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 50: ...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 51: ...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 52: ...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 53: ...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 54: ...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 55: ...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 56: ...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 57: ...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 58: ...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 59: ...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 60: ...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 61: ...see Injection Pump Removal p 65 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 62: ...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 63: ...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 64: ...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 33 Timing Mark Alignment 1 Fuel Injection Pump Gear 2 Idler Gear...

Page 65: ...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 37 p 67 1 Note the...

Page 66: ...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 67: ...l 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 from falling into the gear case Torque the nut to 78 to 88...

Page 68: ...ur meter leads first Subtract these values from the resistance values you measure b Check the hold in coil resistance between pins A and C as shown Figure 39 p 69 c The resistance of the hold in coil...

Page 69: ...a af ft te er r 2 2 s se ec co on nd ds s I If f t th hi is s c co oi il l c co on nt ti in nu ue es s d dr ra aw wi in ng g c cu ur rr re en nt t f fo or r m mo or re e t th ha an n 3 3 s se ec co on...

Page 70: ...o the main unified wire harness 3 Press the ON Key to turn the unit on 4 Use the microprocessor keypad to enter the Interface Board Test Mode Refer to the appropriate Microprocessor Diagnostic Manual...

Page 71: ...2 Top Dead Center Mark for 1 and 4 b Check the rocker arms on the number one cylinder to see if they are loose c If the rocker arms are loose the engine is at top dead center of the compression strok...

Page 72: ...ines when finished Valve Adjustments and Cylinder Configurations Rear Flywheel End Front Pulley End Cylinder Number 1 2 3 4 Valve arrangement E I E I E I E I Piston in No 1 cylinder is at TDC on compr...

Page 73: ...ose should be inspected when the air cleaner element is replaced to verify they are not plugged or damaged Inspect the insulation to verify it is in place and undamaged The insulation is used to preve...

Page 74: ...inspections for wear scuffing or cracking Belt tension should also be checked during scheduled maintenance inspections Correct belt tension is critical for correct unit operation Belts that are too l...

Page 75: ...1903 1 Probe 2 Metal Tab N No ot te e Do not attempt to remove or install belts without loosening adjustments Belts that are installed by prying over pulleys will fail prematurely due to internal cord...

Page 76: ...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 77: ...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 78: ...wrench to remove it from the tensioner bolt The belt should be aligned as shown below Figure 52 Final Fan Drive Belt Alignment 10 Check the belt tension with Frequency Gauge P N 2041903 The recommend...

Page 79: ...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 80: ...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 81: ...56 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 82: ...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 83: ...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 84: ...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 85: ...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 86: ...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 87: ...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 88: ...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 89: ...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 90: ...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 91: ...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 92: ...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 93: ...n vibrasorber The ETV system also uses discharge and suction pressure transducers and a hot gas bypass valve The ETV has two internal coils The microprocessor operates the valve by energizing the coil...

Page 94: ...g them to the readings on a gauge manifold set attached to the compressor Refer to the appropriate Diagnostic Manual for more information about the testing and operation of the pressure transducers Ho...

Page 95: ...valve is de energized closed when modulation is discontinued Refer to the for information about testing the hot gas solenoid See Refrigeration Service Operations for removal and installation procedure...

Page 96: ...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 97: ...TV 4 Condenser Coil 14 Accumulator 5 Discharge Pressure Transducer 15 Filter Drier 6 Three Way Valve 16 Receiver Tank 7 Discharge Vibrasorber 17 Condenser Check Valve 8 Pulsing Hot Gas Bypass Valve 18...

Page 98: ...20 Oil Seal 5 Flare Cap 21 Keyway alignment Tool 6 Valve and cover screw 22 Restriction Fitting 7 Flatwasher 23 Discharge Manifold 8 Suction valve 24 Manifold Screw 9 Valve Cap 25 Pipe Plug 10 Gasket...

Page 99: ...it N No ot te e When the compressor is removed from the unit note the oil level or measure the oil removed from the compressor Add the same amount of oil to the replacement compressor 11 Remove clutch...

Page 100: ...will prevent the coupling from popping off because the center bolt and flat washer will hold it in place Compressor Coupling Installation Standard Units In a tapered fit joint the entire twisting load...

Page 101: ...co oa at te ed d w wi it th h f fi in ne e l la ap pp pi in ng g c co om mp po ou un nd d a an nd d u us se ed d a as s a a l la ap pp pi in ng g t to oo ol l t to o c cl le ea an n t th he e k ke ey...

Page 102: ...ture from wicking into the joint and causing corrosion Compressors with Pressurized Seal Cavity Starting in the first quarter of 2017 the pressurized seal cavity was phased into use on large shaft fou...

Page 103: ...t 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 an...

Page 104: ...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 105: ...l 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...

Page 106: ...he 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 107: ...e 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 crankshaf...

Page 108: ...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 109: ...oldered in place to prevent damage to the neoprene seal Figure 84 Cross Section of In line Condenser Check Valve 1 Valve 3 Valve Seat 2 Neoprene Seal 4 Spring Condenser Check Valve Replacement Removal...

Page 110: ...le 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 the bypass check valve 3 Tighten the receiver tank mounting har...

Page 111: ...emove the expansion valve from the unit Installation 1 Install and bolt the expansion valve assembly in the unit 2 Solder 95 5 Solder the inlet liquid line and the distributor to the expansion valve 3...

Page 112: ...e to the suction line and the liquid outlet line to the expansion valve 6 Tighten the heat exchanger mounting hardware securely 7 Pressurize the low side and test for leaks If no leaks are found evacu...

Page 113: ...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 d da am ma ag g...

Page 114: ...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 115: ...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 116: ...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 117: ...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 118: ...n Whenever you disassemble a three way valve you should check that all three of the holes are drilled cleanly Figure 91 Check Seat Orifice 1 Number 66 Drill Bit Assembly Installation After cleaning a...

Page 119: ...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 120: ...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 121: ...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 122: ...in operation High Pressure Relief Valve Removal 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 pr...

Page 123: ...in operation Electronic Throttling Valve ETV Removal 1 Pump down the low side and equalize the pressure to slightly positive 2 The ETV must be open to remove the stepper motor and piston assembly Ope...

Page 124: ...e er ry y d de ev vi ic ce e t to o t th he e s se er rv vi ic ce e p po or rt t o on n t th he e r re ec ce ei iv ve er r t ta an nk k o ou ut tl le et t v va al lv ve e M Mi id ds se ea at t t th he...

Page 125: ...Housing 2 Bottom Edge of Piston 2 Lubricate the O rings with refrigeration oil Place one on the stepper motor and piston assembly and place the other in the valve body Figure 97 Install O Ring on Ste...

Page 126: ...8 Open the refrigeration valves and place the unit in operation Installation of Complete ETV Assembly 1 Clean the tubes for soldering 2 Place the new complete ETV assembly and any tubes that were rem...

Page 127: ...om the valve 3 Place the valve in the unit and install the mounting bolts The arrow on the valve indicates the direction of flow through the valve Verify that the arrow points in the proper direction...

Page 128: ...Oil Filter 1 Oil Discharge Tube 4 Pressure Relief Valve 2 O Ring 5 Oil Pickup Tube 3 Internal Oil Filter 6 Stud On Oil Pickup Tube Bracket 1 Remove the compressor from the unit if needed to access the...

Page 129: ...elow the throttling valve Use the following procedure 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...

Page 130: ...a 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 k...

Page 131: ...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 132: ...ructions 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 confirmatio...

Page 133: ...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 el...

Page 134: ...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 135: ...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 136: ...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 137: ...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 138: ...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 139: ...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 140: ...vator to the machined bore inner surface in the evaporator end of the housing and allow it to dry by evaporation Figure 115 Fan Shaft Housing 1 Apply Loctite 7240 Activator to Machined Bore Inner Surf...

Page 141: ...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 142: ...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 143: ...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 144: ...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 145: ...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 146: ...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 147: ...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 148: ...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 149: ...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 150: ...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 151: ...TK 61552 2 MM EN 151 Refrigeration Diagrams Cool Cycle...

Page 152: ...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 153: ...TK 61552 2 MM EN 153 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 154: ...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 155: ...EN 155 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 156: ...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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