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TK 61555-2-MM-EN

Injection Pump Timing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Injection Pump Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Injection Pump Reinstallation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Fuel Solenoid Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

Engine Valve Clearance Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

Crankcase Breather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

EMI 3000 Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

Belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

Fan Drive Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Engine/Cross Shaft Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Water Pump Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

Refrigeration Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

Refrigerant Charge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

Testing The Refrigerant Charge With An Empty Trailer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Testing the Refrigerant Charge with a Loaded Trailer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Testing for an Overcharge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

Moisture Indicating Sight Glass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

Refrigerant Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

Checking Compressor Oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

High Pressure Cutout Switch (HPCO) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

Three-Way Valve Condenser Pressure Bypass Check Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

Refrigeration Service Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

Refrigeration System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Compressor Coupling Removal (Standard Units) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Compressor Coupling Installation (Standard Units) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Compressors with Pressurized Seal Cavity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Hex Drive Compressor Seal Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

Condenser Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98

Discharge Vibrasorber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98

Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98

In-Line Condenser Check Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

Condenser Check Valve Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

Bypass Check Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100

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Содержание SLXi-100

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

Страница 2: ...ti io on n r re ec co om mm me en nd da at ti io on ns s o or r d de es sc cr ri ip pt ti io on ns s c co on nt ta ai in ne ed d h he er re ei in n T Th he e p pr ro oc ce ed du ur re es s d de es sc...

Страница 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...

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

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

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

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

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

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

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

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

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

Страница 13: ...their antistatic packing materials until you re ready to use them After servicing any electronic components check the wiring for possible errors before restoring power to the unit Never use a battery...

Страница 14: ...S Sk ki in n Remove contaminated clothing Wash thoroughly with soap and water Get medical attention if irritation persists I In ng ge es st ti io on n Do not induce vomiting Immediately contact local...

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

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

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

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

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

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

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

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

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

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

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

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

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

Страница 28: ...MM EN Figure 5 Unit Serial Number Location Figure 6 Laminated Serial Number Plate Located Where Shown Above 1 Unit Serial Number 2 Unit Model 3 Bill of Material Number U Un ni it t D De es sc cr ri ip...

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

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

Страница 31: ...it th h t th he e r re es si is st to or r b by yp pa as ss s f fu us se e i in ns st ta al ll le ed d w wi il ll l d da am ma ag ge e T Th he er rm mo o K Ki in ng g a al lt te er rn na at to or rs s...

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Страница 76: ...ate bolts they will be tighten when the belt is installed 5 Install the cross shaft engine pulley Position pulley axially using block P N 2042435 between the pulley and the cross shaft mounting bracke...

Страница 77: ...sw wi it tc ch h i in n t th he e O Of ff f p po os si it ti io on n b be ef fo or re e i in ns sp pe ec ct ti in ng g o or r s se er rv vi ic ci in ng g a an ny y p pa ar rt t o of f t th he e u un n...

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Страница 104: ...way valve to the pilot solenoid N NO OT TI IC CE E E Eq qu ui ip pm me en nt t D Da am ma ag ge e D Do o n no ot t f fo or rc ce e t th he e t to oo ol l i in nt to o t th he e b br ra as ss s o or r...

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Страница 126: ...hile sliding the evaporator blower off the end of the fan shaft Make sure to remove and keep the key N No ot te e Make sure to avoid hitting the machined surface of the shaft against the structure bec...

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

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

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

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

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

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

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

Страница 134: ...he correct engine Refer to appropriate Microprocessor Diagnostic Manual Fuel solenoid defective or stuck Replace Fuel injection pump defective Replace pump Air heater defective Replace No fuel or wron...

Страница 135: ...ve Replace pump Engine knocks heavily Air in system Bleed fuel system Wrong fuel Change fuel Injection pump not timed Retime injection pump Injection nozzles fouled or opening pressure too low Clean r...

Страница 136: ...lace seals on valve stem Worn valve stem Replace valves Broken piston rings or cylinder bore worn or scored Have engine repaired and rebored Replace broken piston rings Clogged air cleaner system Uncl...

Страница 137: ...ient Air flow through condenser restricted Air through condenser too cold ambient Air in refrigerant system Condenser fan blades bent or broken Air short cycling around evaporator coil Air through eva...

Страница 138: ...Unit not heating or defrosting SYMPTOM POSSIBLE CAUSES Restricted line on the low side Restricted line on the high side Restricted drier Defrost damper stays open Defrost damper stuck closed Evaporato...

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

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

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

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

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

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

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