Related Manuals for Thermo King Rail Edition SLXi-DRC
Summary of Contents for Thermo King Rail Edition SLXi-DRC
- Page 1 Maintenance Manual Rail Edition SLXi-DRC Single Temperature Units Revision B T T K K 5 5 6 6 4 4 3 3 3 3 - - 5 5 - - M M M M - - E E N N August 2018...
- Page 2 TK 56403 TK482 and TK486 Engine Overhaul Manual TK 50136 X214, X418, X426 and X430 Compressor Overhaul Manual TK 6875 Diagnosing Thermo King Truck and Trailer Refrigeration Systems TK 5984 Tool Catalog TK 5955 Evacuation Station Operation and Field Application...
- Page 3 C C o o m m p p o o n n e e n n t t s s u u n n a a b b l l e e t t o o b b e e i i s s o o l l a a t t e e d d for service must be repaired only after refrigerant is properly recovered. At Thermo King®, we recognize the need to preserve the environment and limit the potential harm to the...
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Page 4: Table Of Contents
Diesel Engine ......18 Thermo King X430 Series Air Heater ....... 30 Reciprocating Compressor. - Page 5 T T a a b b l l e e o o f f C C o o n n t t e e n n t t s s Antifreeze Maintenance Assembly of Tensioner Clutch ..56 Engine/Cross Shaft Belt Procedure .
- Page 6 T T a a b b l l e e o o f f C C o o n n t t e e n n t t s s Condenser Check Valve High Pressure Relief Valve....78 Removal .
- Page 7 T T a a b b l l e e o o f f C C o o n n t t e e n n t t s s Fan Shaft Assembly..... . 88 Installation .
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Page 8: Danger, Warning, Caution, And Notice
Thermo King dealer and to be aware of i i n n a a n n y y c c o o n n f f i i n n e e d d a a r r e e a a w w i i t t h h a a l l i i m m i i t t e e d d a a i i r r s s u u p p p p l l y y . -
Page 9: Battery Installation And Cable
S S a a f f e e t t y y P P r r e e c c a a u u t t i i o o n n s s W W A A R R N N I I N N G G W W A A R R N N I I N N G G R R i i s s k k o o f f I I n n j j u u r r y y ! ! P P e e r r s s o o n n a a l l P P r r o o t t e e c c t t i i v v e e E E q q u u i i p p m m e e n n t t ( ( P P P P E E ) ) -
Page 10: Refrigerant Hazards
S S a a f f e e t t y y P P r r e e c c a a u u t t i i o o n n s s battery, an explosion might occur, causing equipment N N O O T T I I C C E E damage, serious injury, even death. -
Page 11: Microprocessor Service Precautions
S S a a f f e e t t y y P P r r e e c c a a u u t t i i o o n n s s Microprocessor Service • Never use a battery and a light bulb to test circuits on any microprocessor-based equipment. -
Page 12: First Aid
S S a a f f e e t t y y P P r r e e c c a a u u t t i i o o n n s s First Aid • S S k k i i n n : : Remove contaminated clothing. Wash thoroughly with soap and water. -
Page 13: Engine
Specifications Engine Model TK486V25X (Tier 4) Number of Cylinders Cylinder Arrangement In-line vertical, number 1 on flywheel end Firing Order 1-3-4-2 Direction of Rotation Counterclockwise viewed from flywheel end Fuel Type No. 2 diesel fuel under normal conditions No. 1 diesel fuel is acceptable cold weather fuel Oil Capacity 13 quarts (12.3 liters/litres) crankcase and oil filter Fill to full mark on dipstick... -
Page 14: Belt Tension
95-106 Hz Water Pump Belt Tension Number on TK Gauge 204-0427 Field Reset: 35-40 Refrigeration System Compressor Thermo King X430P® Refrigerant Charge - Type 12.5 lb (5.7 kg) – R452A Compressor Oil Charge 4.3 qt (4.1 liters/litres)* Compressor Oil Type... -
Page 15: Electrical Components
S S p p e e c c i i f f i i c c a a t t i i o o n n s s Electrical Components Note: Disconnect components from the unit circuit to check resistance. Component Current Draw (Amps) at 12.5 Resistance —... - Page 16 Maintenance Inspection Schedule Every Every Pretrip Annual/ Inspect/Service These Items 1,500 3,000 4,500 Hours Hours* Hours Microprocessor • Run Pretrip Test. Engine • Check fuel supply. • • • • Check engine oil level. • • • • Inspect belts for condition and proper tension. •...
- Page 17 M M a a i i n n t t e e n n a a n n c c e e I I n n s s p p e e c c t t i i o o n n S S c c h h e e d d u u l l e e Every Every Pretrip...
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Page 18: Unit Overview
TK486V25X engine, and the Thermo King X430P reciprocating compressor. Figure 1. Front View Thermo King X430 Series Reciprocating Compressor The unit is equipped with a Thermo King X430 Series four cylinder reciprocating compressor with 30.0 cu. in. (492 cm ) displacement. Electronic Throttling Valve The Electronic Throttling Valve (ETV) is a variable position valve operated by a stepper motor. -
Page 19: System
U U n n i i t t D D e e s s c c r r i i p p t t i i o o n n CYCLE-SENTRY™ Start-Stop Controls allowing continued operation of the unit at a temporarily reduced refrigeration capacity. -
Page 20: Tk Bluebox
SR-4 Controller that offers fleet owners the ability to monitor their refrigerated units. Cellular, GPS, and be preformed before contacting the Thermo King Service Department for Bluetooth capabilities communicate with Thermo King’s web-based TracKing™ application, and assistance in diagnosing a problem. Refer to the SR-3 Trailer Single Temperature SL- Bluetooth with the TK Reefer App. -
Page 21: Optiset Plus
U U n n i i t t D D e e s s c c r r i i p p t t i i o o n n OptiSet Plus™ Defrost Frost gradually builds-up on evaporator coils as a OptiSet Plus is a group of programmable functions that result of normal operation. -
Page 22: Engine Compartment Components
U U n n i i t t D D e e s s c c r r i i p p t t i i o o n n Engine Compartment acceptable level, the microprocessor records Alarm Code 41 and possibly 18. The microprocessor might Components also shut the unit down. - Page 23 U U n n i i t t D D e e s s c c r r i i p p t t i i o o n n Figure 5. Compressor Serial Number Location Figure 7. Unit Serial Number Location Serial Number Location Figure 6.
- Page 24 U U n n i i t t D D e e s s c c r r i i p p t t i i o o n n Figure 8. Laminated Serial Number Plate (Located Unit Serial Number Where Shown Above) Unit Model Bill of Material Number...
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Page 25: Alternator Diagnostic Procedures
Removing the resistor bypass fuse places the 300 ohm resistor in the Alternator Identification excitation circuit as required for Thermo King These units use Thermo King Alternators (Figure 9, p. alternators (and Australian Bosch alternators). -
Page 26: Alternator Load Test
(F4) removed. Alternator Load Test Check and note the battery voltage at the battery Thermo King no longer recommends a full field test for with the unit turned off. determining the alternator current output. Full fielding... -
Page 27: Field Current Test
Regulator voltage can vary from approximately 15.2 Vdc at -40 F (-40 C) to 2. Energize the field on the Thermo King alternator by approximately 13.2 Vdc at 176 F (80 C). connecting a jumper wire between the F2 terminal and the B+ terminal. -
Page 28: Battery Load Test
Fuse F4 must be in place for Prestolite alternators to charge. Fuse F4 must be removed for Bosch and Thermo King alternators. Service Parts Base Controllers are shipped without the F4 fuse. The F5 preheat fuse is a “slow blow” type fuse. It is designed for use with the engine air pre-heater. -
Page 29: Fuse F15
ETV-C (Note 2) problem. A ServiceWatch download must be preformed before contacting the Notes: Thermo King Service Department for The Status LED flashes once per second when the assistance in diagnosing a problem. Refer Base Controller is powered and operating normally. -
Page 30: Air Heater
E E l l e e c c t t r r i i c c a a l l M M a a i i n n t t e e n n a a n n c c e e grounded 2 wire before replacing the fuse link. -
Page 31: Emi 3000
The oil filter should be changed along with the engine N N o o t t e e : : Units equipped with the EMI 3000 package do oil. Use a genuine Thermo King extended maintenance require regular inspection in accordance with oil filter. -
Page 32: Engine Cooling System
E E n n g g i i n n e e M M a a i i n n t t e e n n a a n n c c e e Figure 12. Low Oil Pressure Flow Chart Engine Cooling System All water cooled engines are shipped from the factory with a 50 percent permanent type antifreeze... -
Page 33: Extended Life Coolant (Elc)
Chevron/Delo XLC is currently the only Extended Life Otherwise proceed to step 3. Coolant approved by Thermo King for use in these Run clear water into the radiator and allow it to units for five years or 12,000 hours: drain out of the block until it is clear. -
Page 34: Engine Thermostat
E E n n g g i i n n e e M M a a i i n n t t e e n n a a n n c c e e N N o o t t e e : : If an engine runs with air trapped in the block, Repeat steps 6 and 7 until the coolant level the engine may be damaged. -
Page 35: Checking The Float
E E n n g g i i n n e e M M a a i i n n t t e e n n a a n n c c e e Operation accomplish this check with the tank right side up. Replace the switch if it is does not close in step 3 Fuel is drawn from the fuel tank and through the fuel and does not open in step 4. - Page 36 E E n n g g i i n n e e M M a a i i n n t t e e n n a a n n c c e e Any major injection pump or nozzle repairs should be •...
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Page 37: Fuel Return Line Replacement
E E n n g g i i n n e e M M a a i i n n t t e e n n a a n n c c e e Fuel Return Line Replacement the larger clamp. 4. -
Page 38: Draining Water From Fuel Tank
E E n n g g i i n n e e M M a a i i n n t t e e n n a a n n c c e e few minutes. If the engine fails to start, or starts but Figure 19. -
Page 39: Fuel Filter/Water Separator
E E n n g g i i n n e e M M a a i i n n t t e e n n a a n n c c e e Fuel Filter/Water Separator High Speed N N o o t t e e : : To achieve proper refrigeration system capacity The fuel filter/water separator filters the fuel, and in High Speed engine operation, it is important removes water from the fuel and returns it to the fuel... -
Page 40: Injection Pump Timing
E E n n g g i i n n e e M M a a i i n n t t e e n n a a n n c c e e Adjustments” above). Index Mark on Injection Pump b. - Page 41 Injection Angle Mark N N o o t t e e : : If you cannot read the injection angle mark, contact the Thermo King Service Department with the injection pump serial number or the engine serial number and they will provide Do Not Loosen or Remove These Four Bolts the injection angle.
- Page 42 E E n n g g i i n n e e M M a a i i n n t t e e n n a a n n c c e e new injection pump. Figure 33. Timing Mark Alignment 6.
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Page 43: Injection Pump Removal
E E n n g g i i n n e e M M a a i i n n t t e e n n a a n n c c e e Injection Pump Removal Index Mark on Injection Pump The injection pump drive gear will not fit through the Index Mark on Gear Case gear housing when removing the pump, the gear must... -
Page 44: Injection Pump Reinstallation
E E n n g g i i n n e e M M a a i i n n t t e e n n a a n n c c e e Figure 37. Injection Pump Gear Tool Injection Pump Adapter (Tool) Gear Case... -
Page 45: Testing The Fuel Solenoid
E E n n g g i i n n e e M M a a i i n n t t e e n n a a n n c c e e Figure 38. Fuel Solenoid Location 125 F 52 C 24.4 Ohms 29.8 Ohms... -
Page 46: Fuel Solenoid Replacement
E E n n g g i i n n e e M M a a i i n n t t e e n n a a n n c c e e I I f f t t h h i i s s c c o o i i l l c c o o n n t t i i n n u u e e s s d d r r a a w w i i n n g g c c u u r r r r e e n n t t f f o o r r fuel solenoid. -
Page 47: Trochoid Feed Pump Leaks
E E n n g g i i n n e e M M a a i i n n t t e e n n a a n n c c e e Figure 42. Trochoid Feed Pump Removal Trochoid Feed Pump Outlet Pressure Cranking 15-30 psi (103-206 kPa) -
Page 48: Cold Start Device
E E n n g g i i n n e e M M a a i i n n t t e e n n a a n n c c e e Cold Start Device Replacement 6. Install and tighten four hex head screws that attach the trochoid feed pump to the injection pump. -
Page 49: Engine Valve Clearance Adjustment
E E n n g g i i n n e e M M a a i i n n t t e e n n a a n n c c e e Figure 47. Clean Piston Figure 48. Top Dead Center One and Four Index Mark Top Dead Center Mark for 1 and 4... -
Page 50: Crankcase Breather
E E n n g g i i n n e e M M a a i i n n t t e e n n a a n n c c e e Figure 49. Adjusting the Valve Clearance Hold the adjustment screw in place and tighten the locknut. -
Page 51: Emi 3000 Air Cleaner
E E n n g g i i n n e e M M a a i i n n t t e e n n a a n n c c e e Belts will increase as the air cleaner gets dirty and becomes more restrictive. -
Page 52: Fan Drive Belt
E E n n g g i i n n e e M M a a i i n n t t e e n n a a n n c c e e Fan Drive Belt Figure 54. Belt Arrangement Fan Shaft Fan Drive Belt Tensioner Upper Condenser Blower... - Page 53 E E n n g g i i n n e e M M a a i i n n t t e e n n a a n n c c e e W W A A R R N N I I N N G G Figure 57.
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Page 54: Fan Drive Belt Adjustment
E E n n g g i i n n e e M M a a i i n n t t e e n n a a n n c c e e Fan Drive Belt Adjustment Figure 59. Final Fan Drive Belt Alignment The sliding idler pulley position is set during factory production for the correct belt tension. -
Page 55: Engine/Cross Shaft Belt
E E n n g g i i n n e e M M a a i i n n t t e e n n a a n n c c e e Figure 62. Sliding Idler Pulley Adjustment Figure 63. -
Page 56: Assembly Of Tensioner Clutch
E E n n g g i i n n e e M M a a i i n n t t e e n n a a n n c c e e Figure 64. Tensioner Clutch Components place the pulley 0.65 in. (16.6 mm)from the end of the cross shaft housing). - Page 57 E E n n g g i i n n e e M M a a i i n n t t e e n n a a n n c c e e Figure 66. Place Gauge Tool on Strut Bolts Adjustment Bolt Pivot Bolt 2.
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Page 58: Water Pump Belt
E E n n g g i i n n e e M M a a i i n n t t e e n n a a n n c c e e Water Pump Belt C C A A U U T T I I O O N N The water pump pulley is a split type. -
Page 59: Refrigerant Charge
If the unit has an overcharge of refrigerant, the unit may not cool properly and the suction and discharge Use the following procedure to identify a Thermo King pressure may be high. The charge may be determined unit with an excessive refrigerant charge: by inspection of the refrigerant through the receiver 1. -
Page 60: Moisture Indicating Sight Glass
R R e e f f r r i i g g e e r r a a t t i i o o n n M M a a i i n n t t e e n n a a n n c c e e 1. -
Page 61: High Pressure Cutout Switch
R R e e f f r r i i g g e e r r a a t t i i o o n n M M a a i i n n t t e e n n a a n n c c e e 3. -
Page 62: Electronic Throttling Valve (Etv)
R R e e f f r r i i g g e e r r a a t t i i o o n n M M a a i i n n t t e e n n a a n n c c e e check valve as follows: pressure bypass check valve seals properly. -
Page 63: Pressure Transducers
R R e e f f r r i i g g e e r r a a t t i i o o n n M M a a i i n n t t e e n n a a n n c c e e Pressure Transducers Figure 72. -
Page 64: Refrigeration System Components
Refrigeration Service Operations Refrigeration System N N o o t t e e : : The following procedures involve servicing the refrigeration system. Some of these service Components procedures are regulated by Federal, and in some cases, by State and Local laws. The following figure shows various refrigeration system components. -
Page 65: Compressor
R R e e f f r r i i g g e e r r a a t t i i o o n n S S e e r r v v i i c c e e O O p p e e r r a a t t i i o o n n s s Evaporator Coil Suction Pressure Transducer Heat Exchanger... -
Page 66: Compressor Coupling Installation
R R e e f f r r i i g g e e r r a a t t i i o o n n S S e e r r v v i i c c e e O O p p e e r r a a t t i i o o n n s s coupling off the crankshaft as you continuing Figure 74. -
Page 67: Compressors With Pressurized Seal
R R e e f f r r i i g g e e r r a a t t i i o o n n S S e e r r v v i i c c e e O O p p e e r r a a t t i i o o n n s s Figure 75. -
Page 68: Hex Drive Compressor Seal
R R e e f f r r i i g g e e r r a a t t i i o o n n S S e e r r v v i i c c e e O O p p e e r r a a t t i i o o n n s s Figure 78. - Page 69 R R e e f f r r i i g g e e r r a a t t i i o o n n S S e e r r v v i i c c e e O O p p e e r r a a t t i i o o n n s s Figure 81.
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Page 70: Condenser Coil
R R e e f f r r i i g g e e r r a a t t i i o o n n S S e e r r v v i i c c e e O O p p e e r r a a t t i i o o n n s s N N O O T T I I C C E E Figure 85. -
Page 71: In-Line Condenser Check Valve
R R e e f f r r i i g g e e r r a a t t i i o o n n S S e e r r v v i i c c e e O O p p e e r r a a t t i i o o n n s s cleaning thoroughly. -
Page 72: Filter-Drier
R R e e f f r r i i g g e e r r a a t t i i o o n n S S e e r r v v i i c c e e O O p p e e r r a a t t i i o o n n s s Installation tank. -
Page 73: Installation
R R e e f f r r i i g g e e r r a a t t i i o o n n S S e e r r v v i i c c e e O O p p e e r r a a t t i i o o n n s s bulb from the suction tube. -
Page 74: Three-Way Valve Repair
R R e e f f r r i i g g e e r r a a t t i i o o n n S S e e r r v v i i c c e e O O p p e e r r a a t t i i o o n n s s leaks. -
Page 75: End Cap Checks
R R e e f f r r i i g g e e r r a a t t i i o o n n S S e e r r v v i i c c e e O O p p e e r r a a t t i i o o n n s s Figure 90. -
Page 76: Assembly/Installation
R R e e f f r r i i g g e e r r a a t t i i o o n n S S e e r r v v i i c c e e O O p p e e r r a a t t i i o o n n s s determine how much of the end of the hole is damaged. -
Page 77: Three-Way Valve Condenser Pressure Bypass Check Valve Repair
R R e e f f r r i i g g e e r r a a t t i i o o n n S S e e r r v v i i c c e e O O p p e e r r a a t t i i o o n n s s Three-Way Valve Condenser N N O O T T I I C C E E Pressure Bypass Check Valve... -
Page 78: Installation
R R e e f f r r i i g g e e r r a a t t i i o o n n S S e e r r v v i i c c e e O O p p e e r r a a t t i i o o n n s s N N O O T T I I C C E E to 20 ±... -
Page 79: Electronic Throttling Valve (Etv)
R R e e f f r r i i g g e e r r a a t t i i o o n n S S e e r r v v i i c c e e O O p p e e r r a a t t i i o o n n s s and reconnect the wires. -
Page 80: Installation Of Service Kit
R R e e f f r r i i g g e e r r a a t t i i o o n n S S e e r r v v i i c c e e O O p p e e r r a a t t i i o o n n s s Installation of Service Kit Figure 99. -
Page 81: Assembly
R R e e f f r r i i g g e e r r a a t t i i o o n n S S e e r r v v i i c c e e O O p p e e r r a a t t i i o o n n s s Hot Gas Bypass Valve 4. -
Page 82: Checking Compressor Oil Pressure
R R e e f f r r i i g g e e r r a a t t i i o o n n S S e e r r v v i i c c e e O O p p e e r r a a t t i i o o n n s s Figure 103. - Page 83 R R e e f f r r i i g g e e r r a a t t i i o o n n S S e e r r v v i i c c e e O O p p e e r r a a t t i i o o n n s s port to get the net oil pressure.
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Page 84: Unit And Engine Mounting Bolts
Structural Maintenance Unit and Engine Mounting Bolts Condenser, Evaporator, and Radiator Coils Check and tighten all unit and engine mounting bolts during scheduled maintenance inspections.Torque the Clean the coils during scheduled maintenance unit mounting bolts to 60 ft-lb (81 N•m). Torque the inspections. -
Page 85: Defrost Drains
S S t t r r u u c c t t u u r r a a l l M M a a i i n n t t e e n n a a n n c c e e •... -
Page 86: Testing Defrost Damper
S S t t r r u u c c t t u u r r a a l l M M a a i i n n t t e e n n a a n n c c e e Figure 110. -
Page 87: Replacing Damper Gear Motor
S S t t r r u u c c t t u u r r a a l l M M a a i i n n t t e e n n a a n n c c e e connector to the damper gear motor. -
Page 88: Evaporator Fan Blower
S S t t r r u u c c t t u u r r a a l l M M a a i i n n t t e e n n a a n n c c e e wheel on the fan shaft to a torque of 13 ft-lb (18 N N o o t t e e : : Make sure to avoid hitting the machined N•m). - Page 89 S S t t r r u u c c t t u u r r a a l l M M a a i i n n t t e e n n a a n n c c e e 2.
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Page 90: Installation
S S t t r r u u c c t t u u r r a a l l M M a a i i n n t t e e n n a a n n c c e e Figure 119. -
Page 91: Reassembly
S S t t r r u u c c t t u u r r a a l l M M a a i i n n t t e e n n a a n n c c e e Removal Figure 120. -
Page 92: Reassembly
S S t t r r u u c c t t u u r r a a l l M M a a i i n n t t e e n n a a n n c c e e Figure 121. -
Page 93: Reassembly
S S t t r r u u c c t t u u r r a a l l M M a a i i n n t t e e n n a a n n c c e e 5. - Page 94 Mechanical Diagnosis CONDITION POSSIBLE CAUSE REMEDY Engine will not crank Electrical problem Check and repair electrical system Defective starter solenoid Replace solenoid Defective starter Repair starter Water in cylinders Check for hydrostatic lock. Remove injectors and turn engine slowly Starter motor turns but engine does Starter clutch defective Replace not crank...
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Page 95: M M E E C C H H A A N N I I C C A A L L D D I I A A G G N N O O S S I I S
M M e e c c h h a a n n i i c c a a l l D D i i a a g g n n o o s s i i s s CONDITION POSSIBLE CAUSE REMEDY Engine does not develop full power Air intake system clogged... - Page 96 M M e e c c h h a a n n i i c c a a l l D D i i a a g g n n o o s s i i s s CONDITION POSSIBLE CAUSE REMEDY High oil consumption 10 hour engine break in running was not...
- Page 97 Refrigeration Diagnosis POSSIBLE CAUSES Overcharge of refrigerant • • • • Shortage of refrigerant • • • • • • No refrigerant • • • • • Air through condenser too hot (ambient) • Air flow through condenser restricted • Air through condenser too cold (ambient) •...
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Page 98: R R E E F F R R I I G G E E R R A A T T I I O O N N D D I I A A G G N N O O S S I I S
R R e e f f r r i i g g e e r r a a t t i i o o n n D D i i a a g g n n o o s s i i s s POSSIBLE CAUSES •... -
Page 99: Cool Cycle
Refrigeration Diagrams Cool Cycle TK 56433-5-MM-EN... - Page 100 R R e e f f r r i i g g e e r r a a t t i i o o n n D D i i a a g g r r a a m m s s Compressor Equalizer Line Discharge Service Valve...
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Page 101: Heat/Defrost Cycle
R R e e f f r r i i g g e e r r a a t t i i o o n n D D i i a a g g r r a a m m s s Heat/Defrost Cycle TK 56433-5-MM-EN... - Page 102 R R e e f f r r i i g g e e r r a a t t i i o o n n D D i i a a g g r r a a m m s s Compressor Equalizer Line Discharge Service Valve...
- Page 103 Diagram Index The following table lists the diagrams that are relevant The diagrams are available on TSA Info Central and in to this unit. the SLXi-DRC Diagrams Manual TK 56504. Drawing No. Drawing Title 3E31534 Schematic Diagram 2E98198 Wiring Diagram TK 56433-5-MM-EN...
- Page 104 1938. For more information, visit www.thermoking.com or www.tranetechnologies.com. Thermo King has a policy of continuous product and product data improvements and reserves the right to change design and specifications without notice. We are committed to using environmentally conscious print practices.
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