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Electrical Maintenance

8-19

TG-VI, MT µP-IV, µP-V, µP-VI, SR-2 or SR-3 Controller

The microprocessor uses relays to operate unit valves and solenoids. Each relay circuit is fuse protected. The relay board also
contains the CYCLE-SENTRY buzzer, 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 board information for
your unit.

Typical Relay Board – SR-2/SR-3

1.

K1: Run Relay

2.

K2: Preheat Relay

3.

K3: High Speed Relay

4.

K4: Damper Relay

5.

K5: D/E

6.

K6: Fuel Solenoid Pull In

7.

K7: Start Relay

8.

K8: Electric Clutch Relay

9.

K9: On/Off Relay

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Содержание SLXi Spectrum

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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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Страница 42: ...QLQJ WR FRRO IURP KHDW F FOH DERYH 5HSODFH UHIULJHUDWLRQ ILOWHU GHK GUDWRU 7KLV VKRXOG DOVR EH SHUIRUPHG ZKHQHYHU V VWHP LV RSHQHG IRU VHUYLFH C CA AU UT TI IO ON N S Se er rv vi ic ce e P Pr ro oc ce...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 74: ...Unit Description 5 30...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 128: ...Controller Operation 7 28...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 156: ...Electrical Maintenance 8 28...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 234: ...Refrigeration Maintenance 10 22...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 316: ...Mechanical Diagnosis 13 8...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

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

Страница 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...

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

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