Thermo King SLXi Spectrum Maintenance Manual Download Page 197

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Engine Maintenance

9-41

NOTE: Can be used on tensioner service p/n: 78-1904.

Tensioner tool cannot be used on tensioner assembly service p/n: 77-3192 (implemented in October 2016).

For SLXi units, please use a size 17mm spanner wrench.

Tensioner Tool – SL, SLX, SLXe and Spectrum Units

Tensioner Tool

Tool Fixing Bolt

Tensioner Base

Tensioner Assembly

Tensioner Pivot Bolt

Tensioner Tool Nut

Pawl Release Mechanism

Tensioner Tool Socket

Summary of Contents for SLXi Spectrum

Page 1: ...SL 300 SL 400 SL TCI SL 100e SL 200e SL 400e SPECTRUM SL SLX 100 SLX 200 SLX 300 SLX 400 SLX SPECTRUM SLX Whisper SLX Ferry SLXe 100 SLXe 200 SLXe 300 SLXe 400 SLXe SPECTRUM SLXe Whisper SLXe 300 Whi...

Page 2: ...s as in the manufacturer s judgment to effect its stability No warranties express or implied including warranties of fitness for a particular purpose or merchantability or warranties arising from cour...

Page 3: ...st Aid 2 4 Unit Decals 2 4 Specifications 3 1 Engine 3 2 Drive System 3 4 Refrigeration System 3 5 R 404A R 452A 3 5 Heat and Defrost System 3 6 Controller 3 7 Electrical Control System 3 8 Electrical...

Page 4: ...roller 5 10 SL 300 P IV or P V Controller 5 11 SL 400 SLe 400 SLX SLXe SLXi and SLX SLXe SLXi Spectrum P VI SR 2 and SR 3 Controller 5 13 Thermo King SR basic operational sequence Diesel Mode 5 16 Ope...

Page 5: ...Entering Setpoint Temperature 7 3 Selecting CYCLE SENTRY or Continuous Run Mode Multi Temp MT P IV and P V ONLY 7 3 Initiating Manual Defrost 7 3 Viewing Information Display Screens 7 4 Checking the...

Page 6: ...moval 8 15 Battery 8 15 Unit Wiring 8 16 12 Vdc Charging System 8 16 Fuse Link 8 16 Fuses 8 17 Fuses Units with TG VI MT P IV P V P VI SR 2 or SR 3 8 17 Relay Board 8 18 TG VI MT P IV P V P VI SR 2 or...

Page 7: ...31 SL Belt Adjustments 9 32 SLe SLX SLXe SLXi and Spectrum Belt Adjustments 9 36 Blower Belts Upper and Lower Poly V Groove Belt Replacement on SL Units and Upper Belt Only on SLX SLXe SLXi 9 37 SLX S...

Page 8: ...Zone Refrigeration Control Components 10 21 Refrigeration Service Operations 11 1 Refrigeration System Components 11 2 Low Side Pump Down 11 2 Compressor 11 2 High Pressure Cutout Switch or High Pres...

Page 9: ...12 42 Jackshaft Cross Shaft Assembly 12 43 SL 12 43 SLe and SPECTRUM 12 45 SLXi SLXe SLX Cross Shaft Assembly 12 49 Remote Evaporator Unit 12 50 Unit Inspection 12 50 Defrost Drains 12 50 Evaporator C...

Page 10: ...on Cool Zone 2 on Cool and Zone 3 on Cool 16 4 Zone 1 on Cool Zone 2 on Cool and Zone 3 on Heat 16 5 SLX SLXe SLXI Spectrum 16 6 Zone 1 on Cool Zone 2 on Heat 16 6 Wiring Diagrams and Wiring Schemati...

Page 11: ...TCI 3 049118 w 049122 SL 300 50 TCI 2 049115 SL 300 50 HC TCI 2 049115 w 049121 SL 300 50 TCI 3 049106 SL 300 50 HC TCI 3 049106 w 049121 TLE 2 918060 TLE 3 918061 SLe SL 100e SL 200e SL 400e Spectrum...

Page 12: ...s Manual TK51516 SL 400e SR 2 Parts Manual TK 51881 SL 400e SR2 w Tier2 Engine Parts Manual TK 53553 SL TCI Parts Manual TK 50252 Spectrum SL Multi Temp Parts Manual TK 51486 Spectrum SL Multi Temp w...

Page 13: ...rect length for their particular application 8 Use extreme caution when drilling holes in the unit The holes may weaken structural components and holes drilled into electrical wiring can cause fire or...

Page 14: ...ectives of First Aid are to protect the frozen area from additional injury to warm the affected area rapidly and to maintain respiration EYES For contact with liquid immediately flush eyes with large...

Page 15: ...ontrol unit truck or truck chassis when the temperature control unit is attached it is necessary to ensure that welding currents are NOT allowed to flow through the electronic circuits of the unit The...

Page 16: ...d an electrical shock Obtain immediate medical assistance if available The source of shock must be immediately removed by either shutting down the power or removing the victim from the source If it is...

Page 17: ...Safety Precautions 2 5 Warning Decals...

Page 18: ...Safety Precautions 2 6 Warning Decals Information Decals...

Page 19: ...tion System 3 5 Controller 3 6 Electrical Control System 3 6 Heat Defrost System 3 6 Electrical Components 3 8 Evaporator Fan Motors 3 9 Electric Standby 3 10 Electric Drive Motor 3 10 Standby Power R...

Page 20: ...1450 25 RPM Low Speed SL 300 SL 400 and SL 400e 2200 25 RPM High Speed 1450 25 RPM Low Speed SL TCI SPECTRUM SL 2200 25 RPM High Speed 1450 25 RPM Low Speed SLX Whisper 1450 25 RPM High Speed 1250 25...

Page 21: ...ollowing equivalents Texaco ELC 7997 7998 16445 16447 Havoline Dex Cool 7994 7995 Havoline XLC for Europe 30379 33013 Shell Dexcool 94040 Shell Rotella 94041 Saturn General Motors Dex Cool Caterpillar...

Page 22: ...et Frequency Hz SLX SLXe SLXi and SLX SLXe SLXi SPECTRUM Direct Drive to Compressor Model 30 Electric Motor Compressor Drive Units fitted with original SLX clutch tensioner up until build date 13th Au...

Page 23: ...SLX 200 SLX 300 and SLX 400 7 50 kg SLX SPECTRUM SLXe Spectrum 6 5 kg approx For correct charge procedure for a SPECTRUM system see section in Trailer Install manual SLXe SLXi 100 4 00 kg SLXe SLXi 4...

Page 24: ...ine Operation Hot gas Electric Operation Hot gas electric heater strips Model 50 Electronic Defrost Termination Switch All models with TG VI P IV P V P VI SR 2 or SR 3 Coil must be below 7 C for defro...

Page 25: ...00e SLX all models Smart Reefer 2 SR 2 or Smart Reefer 3 SR 3 SLXe SLXi all models Smart Reefer 3 SR 3 Setpoint Range TG VI P IV P V P VI and SR 2 28 0 to 28 0 C optional range to 32 0 C Digital Tempe...

Page 26: ...37 ampere brush type optional 65 ampere brush type SL TCI and SPECTRUM 120 ampere brush type Voltage Regulator Setting All models 13 8 to 14 2 25 C Alternator Regulator LED Diode Used when replacing...

Page 27: ...August 2000 SLX SLXe SLXi 3 1 to 4 2 2 5 to 3 1 3 0 to 4 0 4 0 to 5 0 Receiver Tank Pressure Solenoid TCI and SPECTRUM models 0 7 17 Liquid Line Solenoid Front and Rear TCI and SPECTRUM models 1 3 9 6...

Page 28: ...Specifications 3 10 Number 2 or 3 Voltage 12 Vdc Full Load Amps 7 amperes SPECTRUM Remote Evaporator Fan Motor S 2 after Jan 2012 Number 2 Voltage 12 Vdc Full Load Amps 6 amperes EVAPORATOR FAN MOTORS...

Page 29: ...4 RPM 1450 1450 1450 1755 1755 Full Load Amps 19 0 19 0 38 0 18 9 37 8 Overload Relay Setting Amps 20 20 40 20 40 SLX Ferry 400 3 50 380 3 50 190 3 50 460 3 60 230 3 60 Horsepower 11 7 11 7 11 7 Kilow...

Page 30: ...evaporator states PTC remote Liquid line solenoid pulsing current draw remains the same Resistance 9 6 ohms Remote Hot Gas Solenoid Current Draw 1 5 amps Resistance 8 3 ohms Remote Suction Line Soleno...

Page 31: ...le SL and SLe 4 2 Remote Evaporators ECT ELT EW SPECTRUM and TLE 4 4 All SLX SLXe and Spectrum Models Host Unit 4 6 All SLX SLXe Spectrum Models 4 9 All SLXi Single Temperature Spectrum Host Unit Mode...

Page 32: ...hever comes first Inspect compressor fan drive water pump belts for condition and tension Adjust if necessary Inspect all belt tension devises belt idler pulley for condition correct operation Inspect...

Page 33: ...n Inspect battery terminals and electrolyte level If EON battery only inspect terminals Check battery fixture Remove clean and protect battery terminals Wet cell batteries check electrolyte specific g...

Page 34: ...rnal mounted equipment wiring hoses fuel lines etc Clean copper tube and fin condenser Clean evaporator coil and defrost drains of debris Miscellaneous Check accuracy of return and discharge sensors a...

Page 35: ...4500 hours Or every 48 Months whichever comes first EDAC Labour standard 1 5 hr 2 5 hrs 7 5 hrs For SPECTRUM 8 0 hrs REMOTE EVAPORATOR S Electrical Inspect wire harness for damaged wires or connectio...

Page 36: ...60 months whichever comes first Inspect compressor fan drive water pump belts for condition and tension Adjust if necessary Replace all belts Inspect all belt tension devises belt idler pulley for con...

Page 37: ...ns Pay particular attention to interconnecting harnesses Check electric motor or cross shaft bearings Check operating modes on electric standby 50 models Refrigeration Visually inspect condenser radia...

Page 38: ...s whichevercomes first EDAC Labour standard 1 5 hr 2 5 hrs 7 5 hrs For SPECTRUM 8 0 hrs Replace compressor oil filter when compressor drive belt is replaced Structural Trailer Body Check all doors ope...

Page 39: ...urs Or every 48 Months whichever comes first EDAC Labour standard 1 5 hr 2 5 hrs 7 5 hrs For SPECTRUM 8 0 hrs REMOTE EVAPORATOR S Electrical Inspect wire harness for damaged wires or connections Check...

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Page 43: ...lectrolyte N No ot te e If no drain plug is available in the fuel tank the tank manufacturer should provide clear instructions for fuel cleaning For fuel supplies taken from the truck tank the truck m...

Page 44: ...e Maintenance Schedule Check fuel supply Check adjust engine oil level Perform Automatic Pre Trip Listen for unusual noises vibrations etc Visually inspect unit for fluid leaks coolant oil refrigerant...

Page 45: ...m DAS Option 5 6 Remote Control Options TG V P IV Multi Temp P V and P VI Controllers 5 6 Sequence of Operation 5 6 SL 100 SL 100e SL 200 and SL 200e TG VI Controller 5 10 SL 300 P IV or P V Controlle...

Page 46: ...st hot gas on engine operation and electric standby operation Power is provided by a water cooled direct injection diesel engine The compressor is connected directly to the engine on the Model 30 A ce...

Page 47: ...d service procedures Electric Standby Motors SL SLe SLXe and SLXi model 50 units feature a 9 3 kW 60 50 Hz electric drive motor SLX and SLX Ferry units feature a 14 7 kW 60 50 Hz electric drive motor...

Page 48: ...d graph or table trip reports can then be created and printed Sleep Mode Option Option on P IV and P V Controllers Standard on P VI SR 2 and SR 3 Controllers P IV or P V controllers are available with...

Page 49: ...rs only places the unit on Continuous Run operation when cargo requires continuous air circulation CSFR operation is determined by a programmable setpoint temperature range that locks out CYCLE SENTRY...

Page 50: ...track temperature management against setpoint The DAS option can interface with TG VI P V P VI and multi temperature P IV controllers Remote Control Options SR 3 SR 2 TG V P IV Multi Temp P V and P VI...

Page 51: ...aver II or TG V controller Exceptions Initial unit start up 4 Null if setpoint is below 9 5 C Defrost The Defrost mode can be initiated any time the evaporator coil temperature is below 6 C 3 C on uni...

Page 52: ...rost The unit remains on Defrost until the evaporator coil temperature increases to 14 C at which time the unit shifts back to the operating mode required by controller demand NOTE If the controller c...

Page 53: ...perate The host unit will stay in Null until one or both of the controllers calls for High Speed or until Defrost is initiated by one of the compartment control systems The mode of operation charts on...

Page 54: ...9 C earlier software versions were programmable to 4 C During Defrost mode unit operates in Low Speed Heat only When the unit is in Null on electric standby operation the drive motor and compressor d...

Page 55: ...contactor and Defrost icon The controller maintains the In range signal during defrost The unit remains in defrost until the evaporator coil temperature increases to 14 C If the evaporator coil tempe...

Page 56: ...within 8 minutes the unit will operate in High Speed Cool until setpoint is reached 4 Unit mode is Null when the engine temperature and battery are satisfied 5 Null mode if setpoint is below Fresh Fro...

Page 57: ...on based on controller demand SL 400 SLe 400 SLX SLXe SLXi and SLX SLXe SLXi Spectrum P VI SR 2 and SR 3 Controller Operating Characteristics of P VI SR 2 and SR 3 Software P VI SR 2 and SR 3 software...

Page 58: ...eat are locked out if controller setpoint is below Fresh Frozen temperature setting CYCLE SENTRY Mode1 2 High Speed Cool3 Low Speed Cool3 Null4 Low Speed Heat5 High Speed Heat5 Defrost 1 ETV operation...

Page 59: ...set to 4 C or 9 C the modulation mode is completely disabled The Modulation mode is disabled when the controller setpoint is above or below the modulation temperature range when the unit is in Defros...

Page 60: ...is energised The Run relay energises and feeds power to the hold in coil of the Fuel Solenoid The Run Relay also makes ready other unit circuits for operation 3 After proper Pre Heat time and approxim...

Page 61: ...ing SR basic operational sequence Diesel Mode Note The Unit will remain running in Cycle Sentry until the following occurs 1 Box temperature is satified 2 Engine temperature is warm 3 Unit is not in d...

Page 62: ...electric ready input was not initiated 4 Once the ER signal is received by the Microprocessor the Pre Heat Buzzer is energised to warn the operator the Electric motor is about to start 5 After the Bu...

Page 63: ...hermo King SR basic operational sequence Electric Standby Mode Note The unit will remain running in Cycle Sentry until the following occurs 1 Box temperature is satisfied 2 Unit is not in defrost 3 Th...

Page 64: ...bar 400 psi the condenser inlet solenoid is de energised until the discharge pressure drops below 1380 kPa 13 80 bar 200 psi The receiver tank pressure solenoid and the purge valve are energised open...

Page 65: ...Simple Zone Control mode the controller sees Zone 2 as switched on so modulation will not be available Typical SLX SLXe SLXi Spectrum Zone 1 on Cool Zone 2 on Cool Z 1 Zone 1 Evaporator Host Unit COO...

Page 66: ...ccurs when the difference between the return air temperature discharge air temperature and evaporator coil temperature becomes excessive Defrost can be initiated any time the evaporator coil temperatu...

Page 67: ...MI displays PRECISION TEMPERATURE ZONE 2 or 3 below picture shows PTC active for zone 2 Only one zone can be activated in the Mode menu the other zone will control as normal Main Features Available PT...

Page 68: ...ext 20 second period this could be half a second or up to the full 20 seconds and this will continue until the zone reaches set point Once at set point and the return air rises to 1 1 C return air abo...

Page 69: ...Unit Description 5 25 1 Expansion Module 2 Base Controller Interface Board Assembly 3 High Voltage Tray 4 HMI Control Panel Typical Components Inside Control Box...

Page 70: ...WARNING The unit can start at any time without warning Press the Off key on the HMI control panel and place the microprocessor On Off switch in the Off position before inspecting any part of the unit...

Page 71: ...inal Board Markstrip 2 Hot Gas Solenoid 7 Blower Housing 12 Drain Heater Resistance Wire 3 Liquid Solenoid 8 Blower Cover 13 Return Air Sensor Graded 4 Suction Line Solenoid 9 Terminal Board Bracket 1...

Page 72: ...trailer s compartment s at the setpoint The operating modes include Cool Null Heat and Defrost Power to run the direct current fan motors is supplied by the alternator in the host unit When cooling i...

Page 73: ...d Solenoid Circuit Fuse in Remote Evaporator Control Circuits TCI and SPECTRUM Models Fuse in Remote Evaporator Fan Motor Circuits TCI and SPECTRUM Models Fuse in Modulation Valve Circuit Option Fuse...

Page 74: ...Unit Description 5 30...

Page 75: ...12 Standard Display 6 13 Operating The Unit In Single Zone Control Mode 6 14 Standard Display Variations 6 15 Alarm Display 6 15 Temperature Watch Display 6 16 Other Unit Controls 6 16 Unit Instrumen...

Page 76: ...Units equipped with TG VI controllers and equipped with CYCLE SENTRY OFF position The electric control system is de energised and the unit will not operate SLEEP position optional with MT P IV P V and...

Page 77: ...nit will defrost NOTE The following units do not have a Manual Defrost switch Units equipped with a Multi Temp MT P IV P V P VI or TG VI controller Typical Multi Temp MT P IV P V or P VI Controller 1...

Page 78: ...the ON position the unit may start at any time without prior warning Diesel Operation CONTINUOUS RUN Modulation Cool option is activated at setpoints above 5 C 9 C or 4 C on some units The unit operat...

Page 79: ...ion option is disabled unless the CYCLE SENTRY Fresh CSFR feature is active and the setpoint is within the programmed lockout range The unit operates on Cool and Null except when CSFR is active CONTRO...

Page 80: ...Interface Control Panel which is used to operate the unit The CargoWatch and Printer ports are used to retrieve data from the data logging system Microprocessor On Off Switch This switch supplies or r...

Page 81: ...el has a display and eight touch sensitive keys The display is capable of showing both text and graphics The keys on the left and right sides of the display are dedicated or single function keys These...

Page 82: ...ne 2 has a setpoint of 2 C and a return air box temperature of 2 1 C The absence of an arrow indicates that this zone is in null Zone 3 has a setpoint of 10 C and a return air temperature of 9 3 C The...

Page 83: ...Wait Press On to Resume and then Off will appear momentarily When the power down sequence is complete the display will be blank For more information See page 7 20 Defrost Key Press this key to initiat...

Page 84: ...he expansion tank Note If the cooling system is low and Extended Life coolant ELC has been used previously The system can only be topped up with ELC or de ionised water Battery The terminals must be c...

Page 85: ...Zone 1 is turned on any time the host unit is turned on Zone 1 is turned off when the host unit is turned off 2 The display briefly shows a Thermo King Logo as the display initializes NOTE With extre...

Page 86: ...en will appear instead if the unit is connected to standby power 6 The Standard Display showing box temperatures and setpoints reappears when the unit is running Turning Unit Off Single or Multi Temp...

Page 87: ...erature for Zone 2 is 2 1 C with a 2 C setpoint The down pointing arrow indicates that Zone 2 is also cooling The return air temperature for Zone 3 is 9 3 C with a 10 C setpoint The up pointing arrow...

Page 88: ...ill control to the same setpoint The Zone 1 sensors are used to determine box temperature NOTE Using Method 2 it is recommended that all bulkheads should be taken down to create one large compartment...

Page 89: ...curs the large Alarm Icon will appear on the Standard Display as shown below If an alarm specific to a zone occurs then a small zone alarm icon will appear next to the affected zone as well Both Alarm...

Page 90: ...curs while the Temperature Watch Display is present the display will return to the Standard Display If the Defrost or Cycle Sentry keys are pressed the display will return to the Temperature Watch Dis...

Page 91: ...menu display HEAD PRESSURE CONTROL SWITCH HPCS On SPECTRUM models with a Multi Temp MT P IV controller this switch confirms the operation of the receiver tank pressure solenoid and purge valve to con...

Page 92: ...bol Multi Temp MT P IV DATA INTERFACE A serial port on the front of the MT P IV P V SR 2 SR 3 and P VI controllers can be connected to a computer with Thermo King Wintrac software to download data OIL...

Page 93: ...Operating Instructions 6 19 COMBO DISPLAY Option SLX SLXe SLXi Allows viewing of unit status and alarms directly from the driver s cab including operating mode box temperature and fuel level...

Page 94: ...refrigerant pressure exceeds 34 48 3 45 bar 500 50 psi The valve will reset when the pressure drops to 27 58 bar 400 psi The valve could possibly leak refrigerant after it has relieved excess pressure...

Page 95: ...could overheat BATTERY The terminals must be clean and tight and that the battery is mounted securely BELTS The belts must be in good condition and adjusted to proper tension ELECTRICAL The electrica...

Page 96: ...try Fish Dairy products Candy Chemicals Film All non edible products Examples of Products Normally Requiring Continuous Run Operation for Air Flow Fresh fruits and vegetables especially asparagus bana...

Page 97: ...controller display ON 3 Place the unit or Zone 1 On Off switch in ON position The CYCLE SENTRY symbol should appear TG VI MT P IV P V P VI SR 2 and SR 3 controllers 4 Set the compartment Zone 1 setpo...

Page 98: ...tion 6 Set the compartment Zone 1 setpoint at the desired temperature DO NOT adjust the setpoint lower than required lowering the setpoint does not make the unit cool faster 7 If the controller is dem...

Page 99: ...s being performed The amps check continues for several minutes Then the unit starts automatically and the controller performs the operating tests d Press the ENTER key while PRE TRIP or USC is display...

Page 100: ...units with a TG IV controller the unit will defrost The defrost cycle should terminate automatically TG VI MT P V AND P VI NOTE A manual defrost function is built into the controller Press SELECT key...

Page 101: ...Multi Temp Remote Control Panel 7 11 Displaying Operating Data 7 12 Entering Setpoint Temperature 7 12 Thermoguard P VI Controller 7 13 Entering Setpoint Temperature 7 14 Selecting CYCLE SENTRY or Co...

Page 102: ...Manual for complete operation and diagnosis information Unit operational information appears on liquid crystal display LCD During normal operation the Standard Display appears on the screen Return ai...

Page 103: ...controller press and release the SELECT key until CYCLS appears in the upper display 2 Press the UP or DOWN arrow key until the desired setting shows in the lower display Yes CYCLE SENTRY mode No Con...

Page 104: ...to display additional information screens Information screens that may appear on a controller NOTE The information and organization of screens displayed by a controller depend on the controller type...

Page 105: ...ndicates that a condition requires corrective action before an abnormal condition becomes severe The ALARM symbol appears and remains ON Shutdown Alarms This alarm indicates that a condition may damag...

Page 106: ...the MT P IV display indicating the amps check is being performed The amps check continues for several minutes Then the unit starts automatically and the controller performs the operating tests 4 With...

Page 107: ...ay START automatically AT ANY TIME when the On Off switch is in the ON position and the CYCLE SENTRY icon APPEARS in the TG VI display CYCLS screen in menu display set to YES Make sure to turn the On...

Page 108: ...T change and the display will return to the Standard Display in about 10 seconds Selecting CYCLE SENTRY or Continuous Run Mode 1 With the Standard Display on the controller press and release the SELEC...

Page 109: ...it The controller stops the unit the ALARM symbol appears and the entire display flashes ON and OFF 1 To display the alarm code press and release the SELECT key until the alarm screen is displayed NOT...

Page 110: ...ld PASS before being released for service Self Check Tests The controller performs the following checks Operator attention is not required after the programmable settings have been displayed Preheat a...

Page 111: ...rol panel connects to the Multi Temp MT P IV controller so the unit can be operated from a remote location The remote control panel provides the following functions Start and stop the host unit Zone 1...

Page 112: ...ator to program the setpoint temperature for each zone Entering Setpoint Temperature The setpoint temperature of the unit can be easily changed To adjust the setpoint begin from the Standard Display 1...

Page 113: ...e sensors unit hourmeters oil pressure water temperature gauge ammeter voltmeter tachometer suction pressure discharge pressure ETV position counter mode indicators and temperature control system cont...

Page 114: ...ill NOT change and the display will return to the Standard Display in about 10 seconds Selecting CYCLE SENTRY or Continuous Run Mode 1 With the Standard Display on the controller press and release the...

Page 115: ...the lower display Yes CYCLE SENTRY mode No Continuous Run mode NOTE If OptiSet has been programmed to determine the Economy mode setting the arrow keys will not change the screen setting 3 When the c...

Page 116: ...the first screen to appear will be the DIS A screen 2 Repeatedly press the SELECT key to display additional information screens Prompt TLHR ENHR ELHR HRM4 HRM5 HRM6 Display Total Hours Engine Hours E...

Page 117: ...nutes if no other key is pressed Checking the Software Version NOTE The software version is important to know when servicing the unit 1 With the unit operating press and hold the TK LOGO key until PrE...

Page 118: ...Pre trip Test automatically performs a functional check of unit operation The test must be performed with the unit in Diesel mode and no alarms present If necessary turn electric power supply OFF and...

Page 119: ...ted that they were detected during a Unit Self Check test FAIL Shutdown alarm conditions were detected during the test and the controller stopped the unit to prevent possible damage The Unit Self Chec...

Page 120: ...the unit The unit may START automatically AT ANY TIME when the On Off switch is in the ON position CAUTION The Controller On Off switch MUST be in the OFF position before disconnecting or connecting t...

Page 121: ...en briefly appears The Standard Display appears and the bar on top of screen reads the new mode Press the Mode key again to change the unit back to the previous mode Initiating a Manual Defrost Cycle...

Page 122: ...UAGE PLEASE WAIT Screen briefly appears 7 The LANGUAGE SELECTED IS XXX Screen briefly appears 8 Press the Exit soft key to return to the Standard Display Alarms Menu Alarms are viewed and cleared usin...

Page 123: ...to restart in normal operation Press the Yes soft key to confirm the day 9 The display will now prompt you for the hour the unit is to restart in normal operation In this example 18 00 hours has been...

Page 124: ...andard Display 2 Press the Back and Next soft keys as required to show the the Adjust Brightness Menu 3 Press the or soft keys to select the desired brightness 4 Press the Yes soft key to enter the ne...

Page 125: ...et Time Limit 20 Engine Vapor Motor CR Failed to Start 73 Maintenance Hourmeter 6 Exceeds Set Time Limit 21 Cooling Cycle Check 74 Controller Reset to Defaults 22 Heating Cycle Check 75 Controller RAM...

Page 126: ...Total Unit Run Time Maintenance Reminder 2 134 Power On Hours 135 Spare Digital Inputs 136 Spare Digital Outputs 137 Check Damper Motor Heater Output 138 Log DAS Real Time Clock Battery Failure DAS 1...

Page 127: ...k using your SR 3 maintenance menu Please refer to your SR 3 diagnostic s manual for more information T1 SIM not inserted T8 Data delayed to TracKing T2 Check SIM PIN T9 CAN communication issue T3 Che...

Page 128: ...Controller Operation 7 28...

Page 129: ...Fuses Units with TG VI MT P IV P V P VI SR 2 or SR 3 8 17 Relay Board 8 18 TG VI MT P IV P V P VI SR 2 or SR 3 Controller 8 19 Air Heater 8 20 Low Oil Level Switch 8 21 Switch Test 8 21 Switch Removal...

Page 130: ...ng to full field the alternator by applying battery voltage to terminal F2 will cause voltage regulator failure Complete the following checkout procedure before replacing the voltage regulator or the...

Page 131: ...nit for CONTINUOUS operation and place the main On Off switch in the ON position 6 Check the voltage at pin A and pin B in the two pin connector on the alternator harness a The A pin is the battery se...

Page 132: ...voltage at the B terminal should be 13 to 18 volts and the amperage in the 2A wire should be at least as high as the rated output of the alternator Amperage in 2A Voltage at B Problem Solution At or...

Page 133: ...the alternator 2 Connect a jumper wire between the F2 terminal on the alternator and a chassis ground and note the ammeter reading 3 The ammeter reading indicates field current The following chart sh...

Page 134: ...housing a Remove the nut lock washer flat washer and isolation washer from the B terminal on the alternator b Remove the four screws on the front of the alternator that surround the rotor shaft c Remo...

Page 135: ...r and remove CAUTION Note the position of the isolation washer and the isolation spacer on the B terminal 7 Separate stator windings from the diode plate only if necessary Unsolder the three leads of...

Page 136: ...e O ring in the bearing bore of the rear housing if needed 2 Inspect the rear housing for a cracked or broken casting stripped threads or evidence of severe wear in the bearing bore due to a worn rear...

Page 137: ...hmmeter across the rotor body and the slip rings Should be no continuity 6 Check condition of slip rings a Clean the brush contacting surfaces with a fine crocus cloth wipe dust and residue away b If...

Page 138: ...ows 1 Place the negative lead of the meter on G Place the positive lead of the meter on A B and C There should be continuity from G to A B and C 2 Place the positive lead of the meter on G Place the n...

Page 139: ...using labelled B and slide the diode plate rotor assembly into the rear housing d Insert the three screws into the diode plate and secure it to the rear housing 3 Install the rotor Slide the small bea...

Page 140: ...ngs or brushes b Attach the field green wire to field terminal on alternator 6 Install the insulator on the B terminal Install the insulating washer flat washer lock washer and nut on the B terminal 7...

Page 141: ...t procedure before replacing the voltage regulator or the alternator When testing alternators use accurate equipment such as a Thermo King FLUKE 23 digital multimeter and a Thermo King amp clamp or an...

Page 142: ...agnostic s Manual for specific Information on Service Test Mode 6 Check the voltage at pin A and pin B in the two pin connector on the alternator harness a The A pin is the battery sense circuit and s...

Page 143: ...m the alternator terminals 3 Remove the mounting bolts and remove the alternator Battery CAUTION Before connecting or disconnecting the unit battery Place the Unit On Off switch in OFF position On uni...

Page 144: ...CHARGING SYSTEM Immediately after start up the ammeter may show a discharge condition on systems with brush type alternators This is due to a light film build up on the alternator slip rings The film...

Page 145: ...0e models 15 amp fuses protect the damper motor or solenoid high speed solenoid and various control relays and components Several 2 or 3 amp fuses protect microprocessor circuits control relay circuit...

Page 146: ...ll in Relay 2 K2 High Speed Relay 3 K3 Damper Relay 4 K4 Preheat Relay 5 K5 Starter Relay 6 K7 Run Relay Typical Relay Board Multi Temp MT P IV 1 K2 High Speed Relay 2 K3 Damper Relay Zone 1 3 K4 Preh...

Page 147: ...zzer remote light fuses ammeter shunt and jumpers to configure the relay board for proper operation NOTE Refer to the appropriate Controller Operation and Diagnosis Manual for more specific relay boar...

Page 148: ...ance of the air 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 1 to 0 2 ohms Ch...

Page 149: ...Removal and Installation 1 Disconnect the switch wires from the main wire harness before removing the switch 2 Remove the push in style switch by carefully prying it out of the oil pan with a pry bar...

Page 150: ...no continuity from the switch to ground 3 If the engine becomes overheated and reaches 104 C the switch should have continuity to ground 4 Replace a defective switch CONDENSER AND EVAPORATOR FAN ROTA...

Page 151: ...on when the phase of the power supply is incorrect Incorrect phase causes the electric motor to spin backwards which causes the unit s fans to spin backwards MT P IV P V P VI SR 2 and SR 3 have autom...

Page 152: ...f the electric motor operates backwards unit airflow incorrect Turn the electric power supply OFF Refer to the appropriate diagnostic s manuals and wiring schematics diagrams If the electric motor doe...

Page 153: ...Electrical Maintenance 8 25 Typical High Voltage Tray SLX SLXe SLXi with SR 2 SR 3 Controller 1 Overload Relay 2 Heaters Contactor 3 Phase Selector 4 Drive Motor Contactors...

Page 154: ...cycle can be initiated by the manual defrost switch the defrost air switch or the automatic defrost timer when the defrost termination thermostat is closed The initiation of the Defrost cycle energis...

Page 155: ...rvals See the appropriate Controller Operations and Diagnostic manual for more specific information about programmable defrost intervals TG VI NOTE The in range defrost interval is automatically deter...

Page 156: ...Electrical Maintenance 8 28...

Page 157: ...lacement 9 16 TK 482 TK 486 and TK 486V Engines 9 17 Integral Fuel Solenoid TK 482 TK 486 and TK 486V 9 17 Diagnosing the Integral Fuel Solenoid System 9 18 Fuel Solenoid Replacement 9 22 Injection Pu...

Page 158: ...check the oil level Add oil as necessary to reach the full mark Oil Filter Change The oil filter should be changed when you change engine oil Spin on Filter 1 Remove the filter 2 Apply oil to rubber r...

Page 159: ...ke system affects horsepower fuel consumption and engine life 1 Air Heater 2 Air Restriction Indicator 3 Intake Manifold 4 Restrictor in Breather Hose 5 Crankcase Breather Crankcase Breather System TK...

Page 160: ...ance 9 4 Typical Dry Air Cleaner System SL SLX SLXe SLXi and Spectrum Models TK 482 or TK 486 Engine 1 Dry Air Cleaner with Air Cleaner Hose 2 Dry Air Cleaner with Reasonator Tube LDB Option 3 Air Res...

Page 161: ...nt at 3000 hours or 2 years whichever occurs first It cannot be interchanged with air filters used on previous Thermo King trailer units however it can be retrofit on previous units by using the Cyclo...

Page 162: ...ents freezing down to 34 0 C 2 Retards rust and mineral scale that can cause the engine to overheat 3 Retards corrosion acid that can an attack accumulator tank water tubes radiator and engine block p...

Page 163: ...k and make the cooling system appear to be full when it is not The unit will overheat if the cooling system is not full Make sure that there are no low spots in the expansion tank vent tube between th...

Page 164: ...intenance 9 8 Engine Cooling System SLX SLXe SLXi 1 Expansion Tank Cap 2 Expansion Tank 3 Coolant Level Sensor 4 Radiator 5 Engine Coolant INLET 6 Engine Coolant OUTLET 7 Vent Tube 8 Engine Thermostat...

Page 165: ...free premixed 50 50 concentrate Shell Dexcool 94040 Shell Rotella 94041 Havoline XLC 30379 Europe 100 concentrate Havoline XLC 33013 Europe premixed 50 50 concentrate Saturn General Motors Dex Cool Ca...

Page 166: ...ine block drain to drain water and flushing solution 3 Pour clear water into the radiator Allow it to drain out of the block and accumulator until it is clear 4 Inspect all the hoses for deterioration...

Page 167: ...rained from the system Check Specifications section for Coolant System Capacity on page 3 3 6 Start and operate the unit for a minute Then stop the unit 7 Check the coolant level and add coolant if ne...

Page 168: ...mp 7 Injection pump 8 Injection nozzles The hand fuel pump is used to manually draw fuel from the tank up to the transfer pump if the unit should run out of fuel Fuel is drawn from the fuel tank throu...

Page 169: ...injection pressure atomizes the fuel more efficiently which reduces the emissions The injection pump camshaft is driven at one end by the engine timing gears The cam lobes actuate the plungers forcing...

Page 170: ...lowing procedures can be done under field conditions Bleeding air from the fuel system Fuel tank and filter system maintenance Prime pump hand replacement or repair TK 482 TK 486 and TK 486V engines T...

Page 171: ...off during scheduled maintenance inspections Let the tank set idle for an hour before removing the drain plug from fuel tank Let water and fuel drain into a container until only fuel is draining from...

Page 172: ...filter and properly dispose of fuel and filter 2 Fill the new filter with clean fuel through one of the small openings in the top of the filter body Do not use the center hole to add fuel to the filte...

Page 173: ...aller increments Low Speed 1 Loosen the jam nut on the low speed adjustment screw 2 Operate the unit in low speed Adjust the screw to obtain the correct speed 3 Tighten the jam nut and recheck the spe...

Page 174: ...s enough power to crank the engine over it has enough power to energise the fuel solenoid pull in coil If you suspect that the engine does not operate because the fuel solenoid is not operating correc...

Page 175: ...ted components for a fault b If battery voltage is present on the 8D circuit go to step 6 5 Check CH circuit in the main wire harness at the fuel solenoid connector for continuity to a good chassis gr...

Page 176: ...een the 8DP circuit in the connector to the fuel solenoid and terminal 2 at the fuse link The fuel solenoid should make a definite click when the pull in coil is energised but should not click when th...

Page 177: ...Engine Maintenance 9 21 Integral Fuel Solenoid Components 1 Integral Fuel Solenoid 2 O ring 3 Fuel Injection Pump Groove...

Page 178: ...otation clockwise from the front Rotate the engine until both push rods on the No 1 cylinder are loose and the injection timing mark on the flywheel lines up with the pointer in the bell housing An al...

Page 179: ...or shows a figure larger than 0 5 mm rotate the top of the pump away from the engine until the dial indicator reads the correct value A figure less than 0 5 mm requires the pump be turned in towards t...

Page 180: ...r cover 4 Remove the front crankshaft bolt 5 Remove the crankshaft pulley by using a suitable puller 6 Remove the timing gear cover and sound shield 7 Remove the injection pump gear nut and lock washe...

Page 181: ...k on the injection pump gear The C mark on the idler gear should line up with the C mark on the camshaft gear 7 Install the timing gear cover and sound shield Tighten the mounting bolts 8 Install the...

Page 182: ...l are used to check the injection pump timing WARNING Loosen all of the injection lines at the injection nozzles to prevent the possibility of the engine firing while it is being rotated 3 Remove the...

Page 183: ...g mark is positioned in the bottom of the timing mark access hole The injection timing mark is a horizontal line stamped on the flywheel approximately 30 mm 1 2 in before the top dead center mark 8 Pu...

Page 184: ...ngle mark on the pump does not use a decimal point Add a decimal point before the last digit of the injection angle mark sample number 67 equals an injection angle of 6 7 degrees 5 Record the injectio...

Page 185: ...uge The clearance for both the intake and exhaust valve should be 0 15 to 0 25 mm NOTE Check to make sure that the valve stem cap is in good condition and is positioned squarely on the top of the valv...

Page 186: ...both valves for the number four cylinder 12 Place the engine at top dead center of the compression stroke for the number two cylinder a Rotate the engine again in the normal direction of rotation unt...

Page 187: ...arings causing premature belt and bearing failures New belts should be tensioned cold and re tensioned cold after 10 hours of unit operation NOTE DO NOT attempt to remove or install belts without loos...

Page 188: ...lot to obtain a reading of 30 on the belt tension gauge 4 Tighten the adjusting arm bolt and the alternator pivot bolt Water Pump Belt Replacement and Adjustment The water pump belt tension should rea...

Page 189: ...ten the jackshaft to the jackshaft angle until the threaded ends of these bolts are flush with the nuts welded on the jackshaft angle These bolts must be loosened so the jackshaft can be moved enough...

Page 190: ...l washers if required for correct belt alignment 11 Tighten the bolts that fasten the jackshaft to the jackshaft angle 12 Move the idler toward the back of the unit until any slack is taken out of bot...

Page 191: ...he belts on the clutch pulley through the gap between the clutch and the flywheel 2 Place the compressor in position and install the mounting bolts 3 Insert a pry bar into the access hole in the unit...

Page 192: ...ctrum SL units only 1 Remove the bolts on the water pump pulley Refer to Belt Arrangement SL 30 Models or Belt Arrangement SL 50 Models for illustrations of the adjustable water pump pulley 2 Remove t...

Page 193: ...ecured tightly in position 2 With a 19 mm wrench turn the tool until belt tension is released engage tool pawl to lock the tool with the belt tension in a loose position and the belt is slack enough t...

Page 194: ...Polygroove Belt 6 Alternator 7 Fanshaft Bearing Assembly Control Box Side 8 Fanshaft Pulley 9 Upper Polygroove Belt 10 Alternator Pulley 11 Jackshaft Pulley Upper Belt 12 Jackshaft 13 Electric Motor 1...

Page 195: ...changes Belt Arrangement SLX SLXe SLXi 1 Blower Belt 2 Alternator Pulley 3 37 Amp Alternator 4 Belt Tensioner 5 Grooved Idler 6 Smooth Idler 7 Slider Block 8 Spindle Bracket 9 Shaft Assembly 10 Blower...

Page 196: ...wer air inlet cowl reverse of step 4 7 With the new belt correctly installed in it s Poly V Grooves pull the sliding pulley 5 to apply tension to the belt Tighten and lock the sliding pulley into posi...

Page 197: ...p n 77 3192 implemented in October 2016 For SLXi units please use a size 17mm spanner wrench Tensioner Tool SL SLX SLXe and Spectrum Units 1 Tensioner Tool 2 Tool Fixing Bolt 3 Tensioner Base 4 Tensio...

Page 198: ...The spanner will rise above the horizontal starting position under the force of the spring NOTE It is important to place the spanner in the correct starting position as indicated in step 1 4 With a su...

Page 199: ...d guidelines the sliding idler pulley position can be adjusted to increase decrease belt tension NOTE 1 The sliding idler pulley position is set during factory production for correct belt tension If r...

Page 200: ...g idler bolt Perform steps 6 9 reset belt position and measure belt frequency to ensure correct belt tension 10 Tighten the upper condenser fan inlet hardware reverse of step 4 11 Monitor belt tension...

Page 201: ...t the compressor and unbolt the compressor from the flywheel housing leave the refrigeration lines connected 7 Slide the compressor assembly away from the flywheel housing 8 Remove the belt through th...

Page 202: ...justing bolt as necessary to obtain the correct belt tension 4 Tighten the adjusting bolt lock nut 5 Tighten the six electric motor mounting bolts Compressor Drive Belt SLe and Spectrum 50 Models 1 Cl...

Page 203: ...Remove the loosened belt from the tensioner pulley and electric motor cross shaft pulley N B Complete removal of the belt will require the compressor to be removed To refit and Set Belt Tension 4 Fit...

Page 204: ...e belt tension it is recommended 1 Ensure that the distance between the motor pulley and the motor bracket is 42mm or the distance between the motor pulley and the eccentric plate is 14 8 mm 2 A 1 2 b...

Page 205: ...o a dimension of 139 mm is 78 81 Hz with a new belt This frquency should reduce to a tension of 69 73 Hz after 15 to 20 minutes running time 5 Once the clutch tensioner has been installed on the unit...

Page 206: ...ng Centre to centre dimension between tensioning element screws checking using checking gauge 139 0mm tensioning gauge tool P N 2042436 Description of SLXe and SLXi tensioning system Warning Only use...

Page 207: ...system 1 System Belt 2 Tensioning System 3 Eccentric plate 4 Square hole For 1 2 standard Socket Wrench 5 Tensioner Element 6 Bracket Support 7 Arm 8 Idler grooved 9 Idler Flat 10 Pivot screw M14 l 10...

Page 208: ...oning system just make sure the plate screws are in contact with the plate 2 Fit the electric engine pulley Position pulley axially using block P N 2042435 eccentric bracket to pulley 16 6 mm from mot...

Page 209: ...ng holding hardware 5 Once the gauge tool fits perfectly and freely on the screw heads of the tensioner element remove it and tighten the plate screws S2 and S3 to lock the eccentric plate in that pos...

Page 210: ...Engine Maintenance 9 54 Clutch Assembly SL SLe 1 Bearing 2 Spring 3 Friction Shoe 4 6 Pin Coupling see Parts Catalogue for P N 5 8 Pin Coupling see Parts Catalogue for P N...

Page 211: ...that are 180 degrees apart 10 Reconnect the suction and discharge valves to the compressor if they were removed Evacuate the compressor Then backseat the discharge service valve 11 Reinstall the comp...

Page 212: ...on shoes to the hub with the mounting bolt plate the mounting bolts and the lock nuts Torque the lock nuts to 41 to 47 Nm 15 To replace the bearing a Remove the snap ring and press the bearing out of...

Page 213: ...e Indicating Sight Glass 10 7 Refrigerant Leaks 10 10 Evacuating and Charging Smart Reefer Multi Temp Systems 10 10 Set up Unit 10 10 System Evacuation 10 10 Evacuation is Important and Critical to Sy...

Page 214: ...452A Because polyol ester oil has an affinity for moisture keep it in a closed container and add it as the last step in system repair Wear rubber gloves when handling polyol ester oil to prevent possi...

Page 215: ...ct the Hot Gas Bypass valve solenoid wires from the main wire harness for applicable Spectrum units c Keep Zone 1 setpoint adjusted to require COOL and turn the front compartment On Off switch ON d Ad...

Page 216: ...moved for service or replacement To check compressor oil level Operate the unit and all remote evaporators through a complete heat cycle and raise the box temperature to 15C At 15C operate the unit on...

Page 217: ...glass should be floating under the conditions below For category B SLX open doors to view the sight glass and close again Discharge pressure reading R404A The discharge pressure gauge should read 19 0...

Page 218: ...nd the unit s discharge pressure When the discharge pressure decreases approximately 3 45 bar 50 psi the ball in the sight glass should move and the liquid level should decline When the discharge pres...

Page 219: ...nk Allow the level to stabilise 1 to 2 minutes If the refrigerant level is now high remove refrigerant see above If the refrigerant level is still low repeat steps 4 through 6 If the refrigerant level...

Page 220: ...e equipped with mechanical throttling valves and fin tube condensers Category B SLX SPECTRUM units manufactured between the 14th of November 2011 and the 30th of April 2012 These units are fitted with...

Page 221: ...pressure to approximately 325psig to 350psig 22 Bar to 23 Bar gauge Ball in receiver sight glass should be between and full if the ball is not floating add charge at 0 25kg increments until the ball...

Page 222: ...ual for complete information about the microprocessor SYSTEM EVACUATION NOTE Use the Service Test mode to operate units with a TG VI P IV P V P VI SR 2 or SR 3 controller See the appropriate Controlle...

Page 223: ...Refrigeration Maintenance 10 11 Vacuum Gauge 1 100 Microns 2 500 Microns 3 1000 Microns 4 2500 Microns 5 5000 Microns 6 20 000 Microns 7 Atmospheric Pressure...

Page 224: ...e The leak must then be located and eliminated 2 Time 3 Pressure Vacuum 4 Atmospheric Pressure Pressure Rise Levels Off After Evacuation Indicates Moisture in System 1 Close the vacuum valve and watch...

Page 225: ...battery charger Make sure that the battery voltage is sufficient to keep the solenoids energised when in evacuation mode NOTE The evacuation line to Evacuation pump should be larger than the other 3...

Page 226: ...hose to the evacuation pump should be larger than the other three hoses to the unit This will speed up evacuation time Unit Evacuation 1 Vacuum Gauge 2 Isolation Valve Open 3 Vacuum Valve 4 Gauge Mani...

Page 227: ...stem caps on all three service valves Do not remove them unit unit is charged 4 Open the vacuum valve at the vacuum pump and start the pump 5 Evacuate the system for 5 minutes Then open the isolation...

Page 228: ...3 Check the unit data plate for the required weight of refrigerant charge Then subtract the amount of the charge to be input to your unit from the total weight of the tank of refrigerant This provide...

Page 229: ...the low side through the suction service valve f Add refrigerant until the correct charge is attained NOTE If you are charging a partially charged unit make sure the liquid level does not rise above t...

Page 230: ...ature units only The condenser pressure bypass check valve is built into the three way valve This check valve controls the bypass flow of refrigerant gas between the condenser inlet line and compresso...

Page 231: ...check valve NOTE Valve stem MUST be back seated during normal unit operation 11 Back seat the receiver tank outlet valve remove the gauges and return the unit to normal operation MODULATION VALVE The...

Page 232: ...nt of the stepper motor and piston assembly or the entire valve and body HOT GAS BYPASS VALVE The hot gas bypass valve is used in conjunction with the modulation valve or Electronic Throttling valve t...

Page 233: ...s if a DE unit are located in the host unit The Zone 2 valves and Zone 3 valves if present are located in the remote evaporator s for each zone Liquid Line Solenoid LLS This valve is energized open an...

Page 234: ...Refrigeration Maintenance 10 22...

Page 235: ...Valve 11 10 Hot Gas Bypass Solenoid Valve 11 10 Throttling Valve non ETV units 11 11 Three Way Valve Condenser Pressure Bypass Check Valve Repair 11 14 Three Way Valve Repair 11 15 Compressor Oil Filt...

Page 236: ...allows the refrigerant in the condenser to flow into the accumulator undoing the low side pump down c Place the unit in the Evacuation Test Refer to the appropriate Microprocessor Diagnostic Manual Th...

Page 237: ...SLX SLXe and SLXi units 8 Back seat the suction and discharge service valves 9 Operate the unit at least 30 minutes and then inspect the oil level in the compressor Add or remove oil if necessary 10 C...

Page 238: ...k and add correct coolant solution to fill the cooling system to the top of the filler neck if required Make sure there are no low spots in the vent tube that will trap air in the expansion tank SLX S...

Page 239: ...es which might adhere to the seat and would damage the new seat If damaged replace the entire check valve assembly Replacement 1 If the seat in the check valve is damaged unsolder the inlet and outlet...

Page 240: ...ght glass is clearly visible through viewing hole in mounting bracket and the outlet tube lines up 3 Solder the inlet tube to the receiver tank 4 Connect filter drier outlet tube and bypass check valv...

Page 241: ...l the new drier and tighten the mounting bracket screws and nuts 3 Install and tighten the inlet nut to the receiver tank outlet valve line inlet end of drier is labelled IN Hold the drier with a back...

Page 242: ...lating tape and feeler bulb from suction line clamp Note the position of the feeler bulb on the suction line 6 Unsolder the suction line and hot gas line from the evaporator coil 7 Disconnect the elec...

Page 243: ...utlet line connections on the condenser side of the bulkhead Seal openings through bulkhead with putty when refrigerant lines have cooled off 4 Tighten the heat exchanger mounting hardware securely 5...

Page 244: ...3 Disconnect the wires and remove coil from modulation valve 4 Unsolder two elbows that connect the modulation valve between the evaporator outlet and heat exchanger Remove the valve CAUTION Use a he...

Page 245: ...nd check compressor oil level Throttling Valve non ETV Units Removal 1 Pump down the low side and equalise pressure to 0 psig 0 bar g 2 Front seat the discharge and suction service valves 3 Remove the...

Page 246: ...oil Install gasket on the valve body Place shims in end cap use same number as removed Tighten end cap in place with vent hole closest to outlet opening of the valve body 4 Install the piston and spr...

Page 247: ...sher 2 Bellows End Plate 3 End Plate Gasket 4 Adjusting Washers Shims 5 Bellows Spring 6 Bellows and Shaft 7 O ring 8 Housing 9 O ring Valve to Compressor 10 Piston Housing Gasket 11 Piston 12 Piston...

Page 248: ...f replacement parts are needed a 60 163 kit must be used which includes the Teflon valve spring O ring valve stem and circlip Installation 1 Coat the O ring with compressor oil and install it on the c...

Page 249: ...ION Do not force the tool into the brass or against the bolts 5 Remove the 4 bolts from the valve 6 Remove the top cap and spring 7 Remove the spring clip Observe the slot in the spool shaft and slide...

Page 250: ...Cap 4 Check Valve Assembly 5 Spring 6 Piston Valves built before 11 97 7 Clip 8 Teflon Seal Valves built before 11 97 9 O ring Valves built before 11 97 10 Gasket 11 Seat 12 Gasket 13 Stem Assembly 1...

Page 251: ...ke sure that the stem assembly is located correctly into the hole in the bottom cap 8 Solder pilot solenoid line and pressurise system with refrigerant to check for leaks 9 Replace Drier 10 If there a...

Page 252: ...the unit off Some microprocessors close the ETV when the unit is turned off Refer to the appropriate Diagnostic Manual for information about the Evacuation Mode Test WARNING If the ETV is stuck in th...

Page 253: ...nstallation of Service Kit NOTE Do not connect the main unified wire harness to the ETV and turn the unit on before the stepper motor and piston assembly is installed in the valve body The controller...

Page 254: ...e applicable for ETV standard from October 2016 only Align Arrowhead Marks 4 For latest version ETV released in October 2016 Install the four screws and torque them to 4 4 0 4 ft lb 6 0 0 5 N m For pr...

Page 255: ...d one or if retrofitted to SLX SLXe units built prior to October 2016 NOTE Do not disassemble the new ETV to solder it in place Installing Complete ETV Assembly 3 Use a heat sink or wrap the valve bod...

Page 256: ...and check the compressor oil level Liquid Line Solenoid Valve LLS LLS2 LLS3 RLLS or CLLS or Suction Line Solenoid Valve SLS SLS2 SLS3 RSLS or CSLS NOTE Valves that have nylon seats must be disassemble...

Page 257: ...heck valve NOTE An in line check valve see Parts Catalogue for P N does not have a bonnet nut and is not repairable An in line check valve must be replaced if it fails Place a heat sink on the valve b...

Page 258: ...leaks are found evacuate the system 7 Recharge unit with correct refrigerant Check the compressor oil level Purge Valve PV NOTE Valves that have nylon seats must be disassembled before soldering Remov...

Page 259: ...ng Holes SLX SLXe SLXi 12 7 Defrost Damper 12 8 SL Defrost Damper 12 8 Damper Door Motor with Current Sensing Blade Position Control SLXi SLXe SLX SLe and Late Model SL Units 12 22 Fan Shaft Assembly...

Page 260: ...ting bolts to 81 3 N m Torque the engine mounting bolts to 203 N m Typical Engine Mounting Bolt Location 1 Check and tighten four 4 engine mounting bolts Typical Unit Mounting Bolt Location 1 All Mode...

Page 261: ...pray nozzle should be kept between 1 inch and 3 inches 25 to 75 millimetres from the coil surface 4 If necessary to use a chemical cleaner or detergent use a cleaner that does not contain any hydroflu...

Page 262: ...Structural Maintenance 12 4 Coil Before Cleaning Coil after Wiping Right Hand Side with Cloth Source Angle for Cleaning with Air or Water...

Page 263: ...ugh the hinged condenser grille 2 SL and SLe Reach the top center nut by opening the control panel side condenser grille and removing the blower access panel 3 Reach this top nut through the hinged co...

Page 264: ...moved NOTE to trailer manufacturer Not all trailer configurations will permit adding the top center unit mounting bracket assembly 9154C10G01 The top center mounting bolt can be permanently mounted to...

Page 265: ...d side access door 5 The lower mounting hole on the compressor side is accessible through the front access door near the compressor 6 Access the top mounting hole on the compressor side through the ro...

Page 266: ...er motor assembly are the electric motor gear case cams and micro switches Two micro switches are activated by cams on the motor end of the output shaft The outer cam leads the inner cam by 20 degrees...

Page 267: ...e from the outer switch and the blue wire from the inner switch are connected to the 29A or 29B circuit at the connector on the damper motor assembly The red wires from both switches are connected to...

Page 268: ...relay K3 or D3 is energised The 29 circuit is then energised by the 2AA or 2A or 8VF circuit through the damper fuse F3 and the normally open contacts in the damper relay Damper Motor Assembly Motor E...

Page 269: ...cro switch is now providing power to the damper motor see Outer Micro Switch Circuit Still Closing Damper illustration The damper motor continues to rotate until the outer cam leaves the outer micro s...

Page 270: ...29A circuit is 29B on TCI models Micro Switch Circuits When Damper Is Closed SL DM Damper Motor IMS Inner Micro Switch OMS Outer Micro Switch K3 Damper Relay NOTE 29A circuit is 29B on TCI models Two...

Page 271: ...Outer Micro Switch K3 Damper Relay NOTE 29A circuit is 29B on TCI models Micro Switch Circuits When Damper Is Open SL DM Damper Motor IMS Inner Micro Switch OMS Outer Micro Switch K3 Damper Relay NOT...

Page 272: ...he damper is now in the open position Open circuits stop the damper motor in the open position see Micro Switch Circuits When Damper Is Open illustration Damper Motor Installation and Damper Adjustmen...

Page 273: ...in the unit NOTE If the damper motor assembly does not function properly it should not be installed Damper Motor Installation 1 Make sure that the flat is on the left side of the damper motor output s...

Page 274: ...the damper motor bracket in place but do not completely tighten the mounting hardware 5 Push the damper motor and bracket assembly up so it is positioned as high as possible in the evaporator blower h...

Page 275: ...stainless steel screw lock washer and two flat washers The flat washers should be placed between the ball joint link and the damper link Check to make sure that the ball joint link is approximately v...

Page 276: ...makes contact with the top of the evaporator blower housing 5 Energise the 29A or 29B circuit to open the damper and check to make sure that the rubber strip on the damper door is barely making contac...

Page 277: ...ght enough the cam may remain stationary while the output shaft turns Therefore the cam will not actuate the switch NOTE Do not overtighten the set screw or the threads in the cam may be stripped If t...

Page 278: ...switch opens when the temperature rises to 1 0 3 C The heater is connected to the 7K circuit and the chassis ground CH 8F and CL circuits on units with TG VI P IV P V or P VI When the unit is operatin...

Page 279: ...d be approximately 12 ohms If not check the switch and the resistance wire separately 3 To check the switch and resistance wire separately cut the splice connector that connects the switch wire to the...

Page 280: ...ent sensing motor controller is located in the control box Gear Motor Controller The gear motor controller is located in the unit control box It is wired as shown below Wiring See the schematic below...

Page 281: ...r Measure the resistance of the gear motor from the GM wire to the Y terminal of the controller If the motor resistance is not approx 6 0 ohms the motor or motor harness is defective and must be repai...

Page 282: ...ose and reopen and observe the operation 7 The motor bracket should not noticeably move and the damper blade should lightly touch the air discharge anti ice strip 8 This will set the damper blade to t...

Page 283: ...Structural Maintenance 12 25 Figure 2 1 Spacer Washers 2 Damper Bracket 3 Ball Joint Link Figure 3 KEEP VERTICAL CLOSED POSITION...

Page 284: ...paragraphs on Damper Door Logic and Operation this is the same principle on the SLXe SLX Figure 4 Defrost Damper Closed SLXi SLXe SLX 1 Evaporator Grille 2 Damper Door 3 Evaporator Blower 4 Evaporato...

Page 285: ...ls during pre trip inspections If a seal is leaking remove and repair that bearing assembly Fan Shaft Assembly Overhaul Disassembly This procedure details the complete disassembly of the fan shaft 1 R...

Page 286: ...pulley screws 10 Remove the end shaft screw item 14 from the control box side end of the fan shaft 11 Remove the fan shaft pulley item 12 and the Woodruff key item 17 from the fan shaft 12 Loosen the...

Page 287: ...bly 7 Compressor Side Evaporator Orifice 8 Control Box Side Evaporator Orifice 9 Evaporator Blower 10 Seal Plate 2 11 Control Box Side Bearing Assembly 12 Fan shaft Pulley 13 Evaporator Shaft Seal Col...

Page 288: ...eed to be adjusted 2 Bolt the seal plates item 10 loosely in place Make sure to spray dry film lubricant item 22 on the outer surfaces of the seal plates the sides with THIS FACE UP stamped on them ar...

Page 289: ...e fan shaft enters the evaporator section slide the evaporator shaft seal collar item 13 over the compressor side end of the fan shaft The rubber gasket on the collar should face toward the control bo...

Page 290: ...stened to the inside blower side of the evaporator blower housing item 19 8 Slide the fan shaft through the compressor side bearing assembly item 6 The compressor side bearing is self aligning and doe...

Page 291: ...mpressor side condenser blower and the shoulder on the fan shaft This keeps the inner bearing race from turning on the fan shaft 14 Torque the compressor side condenser blower mounting screws item 15...

Page 292: ...ween the fan shaft pulley and the shoulder on the fan shaft This keeps the inner bearing race from turning on the fan shaft 18 Torque the two M8 fan shaft pulley mounting screws to 25 N m 19 Torque th...

Page 293: ...ny farther to the compressor side of the fan shaft 23 Hold the control box side condenser blower firmly in this position against the bulkhead and torque the control box side condenser blower mounting...

Page 294: ...key item 18 into the keyway 29 Remove the evaporator shaft seal gauge after tightening the set screw in the shaft seal collar 30 Slide the evaporator blower back into the evaporator blower housing an...

Page 295: ...vaporator orifice in this position 36 Check the radial clearance of the evaporator blower by passing a 2 3 mm wire completely around the circumferences of the evaporator orifices and the evaporator bl...

Page 296: ...l SL and SLe NOTE The fan shaft bearing assemblies require a special oil see Parts Catalogue for P N Compressor Side Bearing Disassembly 1 Remove the compressor side bearing assembly from the unit 2 R...

Page 297: ...sher 5 Coat the outer edge of the oil seal with gasket sealant and press it into end cap 6 Lubricate the gasket with light oil and position it on the bearing housing 7 Install the bearing end cap on t...

Page 298: ...e 11 Clean the parts thoroughly with clean solvent Reassembly 1 Coat the outer edges of the oil seals with gasket sealant and press them into the bearing housing and the bearing end cap 2 Press the be...

Page 299: ...e Assembly 1 Install the bearing on the shaft 2 Install the flat washers x2 to Fanshaft 3 Install wave washer onto bearing ontop of the flatwasher 4 Add the second bearing onto wavewasher and flatwash...

Page 300: ...ting Screws x3 3 Remove Front mounting Bracket Bolts x3 and Screw caps x2 4 With the Front mounting Plate removed remove the remaining Cap screws x2 holding the blower spindle onto the rear mounting B...

Page 301: ...e unit Disassembly With the jackshaft assembly removed from the unit 1 Position the jackshaft in a vise with protective jaws or use two pieces of wood to protect the jackshaft housing from damage Vise...

Page 302: ...s the bearings 5 Using a suitable tool slightly larger than the bearing shaft tap bearings onto the shaft until the bearings are seated on the bearing shaft 6 Install the shaft into the housing and as...

Page 303: ...usually loud bearing noise indicates the jackshaft bearings should be replaced See the following procedures and illustrations for removal of Jackshaft for SLe and Spectrum Removal 1 Remove the polygro...

Page 304: ...mmer 4 Remove the bearing from the jackshaft by supporting the bearing and tapping on the end of the jackshaft 5 Remove the bearing from the jackshaft housing with a hammer and punch 6 Clean and inspe...

Page 305: ...in lower mounting bolt tab end of the jackshaft housing 6 Install the snap ring on the large end of the jackshaft 7 Install the key and pulley on the small end of the jackshaft Make sure the pulley h...

Page 306: ...ructural Maintenance 12 48 Jackshaft Assembly SLe 1 Snap Ring 2 Bearing 3 Wave Washer 4 Large End of Jackshaft 5 Lower Mounting Bolt Tab 6 Jackshaft Housing 7 Small End of Jackshaft 1 2 3 3 4 5 6 7 1...

Page 307: ...Cross Shaft Assembly Cross Shaft Jackshaft Assembly SLXi SLXe SLX 1 Cross Shaft Housing 2 Wave Washer 3 Bearing 4 Shaft 5 Snap Ring 6 Key CrossShaft Assembly SLXi SLXe SLX 1 Cross Shaft Housing 2 Wave...

Page 308: ...quire repair or replacement of parts Defrost Drains Clean the defrost drains during scheduled maintenance inspections to make sure the lines remain open Evaporator Coil Clean the evaporator coil durin...

Page 309: ...13 Mechanical Diagnosis TK 482 TK 486 and TK 486V Engines 13 2...

Page 310: ...ded battery cable connections Clean and tighten Fuse link blown Check for short circuit and replace fuse link Fuse F12 blown F10 on DE TC TCI and SPECTRUM models Check for short circuit and replace fu...

Page 311: ...ergised Check 8D 8DP circuits and fuel relay Check for correct YAN screen setting in Super Guarded menu of P IV P V and P VI controllers Fuel solenoid valve defective or stuck Replace Injection nozzle...

Page 312: ...intake system clean or replace air filter Fuel tank vent clogged Unclog vent Clogged fuel tank or fuel lines Clean fuel tank and fuel lines Speed adjustment wrong Adjust speed Insufficient fuel volum...

Page 313: ...too low Clean repair or replace injection nozzles Delivery valve spring broken Replace spring or repair injection pump Valve out of adjustment Adjust valves Fuel return line plugged Remove return lin...

Page 314: ...maged valve seals Replace 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 ai...

Page 315: ...onsumption Repair as necessary Engine is sooting heavily emits thick black clouds of smoke excessive fuel to air ratio Cold engine Allow engine to warm up Wrong fuel Drain and refill with correct fuel...

Page 316: ...Mechanical Diagnosis 13 8...

Page 317: ...14 Refrigeration System Diagnosis All Models Except TCI and SPECTRUM 14 2 TCI and SPECTRUM Models 14 4 Remote Evaporator System Diagnosis 14 5...

Page 318: ...arge of refrigerant Shortage of refrigerant No refrigerant Air through condenser too hot ambient Air flow through condenser restricted Air through condenser too cold ambient Air in refrigerant system...

Page 319: ...ondenser pressure bypass check valve Modulation or ETV valve stuck closed Hot gas bypass valve stuck open or leaking ALL MODELS EXCEPT TCI AND SPECTRUM Continued Unit operating with reduced heating ca...

Page 320: ...id HGS Closed front hot gas solenoid HGS Leaky front liquid line solenoid LLS Closed front liquid line solenoid LLS Leaky suction line check valve SLCV Leaky rear hot gas solenoid RHGS or HGS3 Closed...

Page 321: ...aporator coil Defrost or clean evaporator coil Expansion valve open too much Replace or adjust valve Poor fitting trailer doors Repair or replace doors Liquid line solenoid partially closed or defecti...

Page 322: ...Refrigeration System Diagnosis 14 6...

Page 323: ...15 5 Heat and Defrost Cycles with Modulation 15 5 SL SLe 200 and 300 15 4 Cooling Cycle with Modulation 15 4 Heat and Defrost Cycles with Modulation 15 5 SL 400 and SL 400e 15 6 Cooling Cycle with Mo...

Page 324: ...lve 7 Condenser Coil 8 Condenser Check Valve 9 High Pressure Relief Valve 10 Receiver Tank 11 Sight Glass 12 Receiver Outlet Valve 13 Liquid Line 14 Drier 15 Heat Exchanger 16 Expansion Valve 17 Feele...

Page 325: ...ndenser Check Valve 9 High Pressure Relief Valve 10 Receiver Tank 11 Sight Glass 12 Receiver Outlet Valve 13 Liquid Line 14 Drier 15 Heat Exchanger 16 Expansion Valve 17 Feeler Bulb 18 Equaliser Line...

Page 326: ...eck Valve 9 High Pressure Relief Valve 10 Receiver Tank 11 Sight Glass 12 Receiver Outlet Valve 13 Liquid Line 14 Drier 15 Heat Exchanger 16 Expansion Valve 17 Feeler Bulb 18 Equaliser Line 19 Distrib...

Page 327: ...Valve 9 High Pressure Relief Valve 10 Receiver Tank 11 Sight Glass 12 Receiver Outlet Valve 13 Liquid Line 14 Drier 15 Heat Exchanger 16 Expansion Valve 17 Feeler Bulb 18 Equaliser Line 19 Distributor...

Page 328: ...Valve 10 Receiver Tank 11 Sight Glass 12 Receiver Outlet Valve 13 Liquid Line 14 Drier 15 Heat Exchanger 16 Expansion Valve 17 Feeler Bulb 18 Equaliser Line 19 Distributor 20 Evaporator Coil 21 Accumu...

Page 329: ...e 10 Receiver Tank 11 Sight Glass 12 Receiver Outlet Valve 13 Liquid Line 14 Drier 15 Heat Exchanger 16 Expansion Valve 17 Feeler Bulb 18 Equaliser Line 19 Distributor 20 Evaporator Coil 21 Accumulato...

Page 330: ...e Relief Valve 10 Receiver Tank 11 Sight Glass 12 Receiver Outlet Valve 13 Liquid Line 14 Drier 15 Heat Exchanger 16 Expansion Valve 17 Feeler Bulb 18 Equaliser Line 19 Distributor 20 Evaporator Coil...

Page 331: ...ceiver Tank 11 Sight Glass 12 Receiver Outlet Valve 13 Liquid Line 14 Drier 15 Heat Exchanger 16 Expansion Valve 17 Feeler Bulb 18 Equaliser Line 19 Distributor 20 Evaporator Coil 21 Accumulator 22 Su...

Page 332: ...Single Temperature Refrigeration System Diagrams 15 10...

Page 333: ...PECTRUM 16 2 Zone 1 on Cool and Zone 2 on Cool 16 2 Zone 1 on Cool and Zone 2 on Heat 16 3 Zone 1 on Cool Zone 2 on Cool and Zone 3 on Cool 16 4 Zone 1 on Cool Zone 2 on Cool and Zone 3 on Heat 16 5 S...

Page 334: ...let Check Valve CICV Open 8 Receiver Tank Pressure Solenoid RTPS Closed 9 Condenser Check Valve CCV Open 10 Bypass Hand Valve 11 Purge Valve PV Closed 12 Purge Check Valve PCV Closed Z 2 Zone 2 Evapor...

Page 335: ...k Valve CICV Closed 8 Receiver Tank Pressure Solenoid RTPS Open 9 Condenser Check Valve CCV Closed 10 Bypass Hand Valve 11 Purge Valve PV Open 12 Purge Check Valve PCV Open Z 2 Zone 2 Evaporator HEAT...

Page 336: ...CV Open 10 Bypass Hand Valve 11 Purge Valve PV Closed 12 Purge Check Valve PCV Closed Z 2 Zone 2 Evaporator COOL 1C Zone 2 Liquid Line Solenoid LLS2 Open 2C Zone 2 Liquid Return Check Valve LRCV2 Clos...

Page 337: ...PV Open 12 12 Purge Check Valve PCV Open Z 2 Zone 2 Evaporator COOL 1C Zone 2 Liquid Line Solenoid LLS2 Open 2C Zone 2 Liquid Return Check Valve LRCV2 Closed 3C Zone 2 Suction Line Check Valve SLCV2 O...

Page 338: ...olenoid LLS Open 2 Liquid Return Check Valve LRCV Closed 3 Suction Line Check Valve SLCV Open 4 Suction Line Solenoid SLS Open 5 Hot Gas Solenoid HGS Closed 6 Condenser Inlet Solenoid CIS Closed 7 Con...

Page 339: ...Multi Temperature Refrigeration System Diagrams 16 7...

Page 340: ...Multi Temperature Refrigeration System Diagrams 16 8...

Page 341: ...ems SL 300 30 TCI 2 3 5D50980 5D50981 SL 300 30 HC TCI 2 3 5D50980 5D50981 SL 300 50 TCI 2 3 5D50115 5D50114 SL 300 50 HC TCI 2 3 5D50115 5D50114 SLe Single Temperature Systems SL 100e 30 5D50976 5D50...

Page 342: ...Wiring Diagrams and Wiring Schematics 17 2...

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