Thermo King SLXi-100 Maintenance Manual
Trailer edition; single temperature units
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- Manual (96 pages) ,
- Operator's manual (68 pages) ,
- Maintenance manual (342 pages)
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Summary of Contents for Thermo King SLXi-100
- Page 1 Maintenance Manual Trailer Edition SLXi-100 and SLXi-200 Single Temperature Units Revision A T T K K 6 6 1 1 5 5 5 5 5 5 - - 2 2 - - M M M M - - E E N N...
- Page 2 This manual is published for informational purposes only. Thermo King® makes no representations warranties express or implied, with respect to the information recommendations and descriptions contained herein. Information provided should not be regarded as all-inclusive or covering all contingencies. If further information is required, Thermo King Corporation Service Department should be consulted.
- Page 3 Regulations must be observed when working on refrigeration systems. At Thermo King®, we recognize the need to preserve the environment and limit the potential harm to the ozone layer that can result from allowing refrigerant to escape into the atmosphere.
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Page 4: Table Of Contents
Table of Contents Safety Precautions................9 Danger, Warning, Caution, and Notice . - 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 General Diagnostic and Warranty Evaluation Procedure ........31 Field Current Test .
- 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 Injection Pump Timing..............53 Injection Pump 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 Removal................. . 100 Installation .
- Page 8 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 Checking Compressor Oil Pressure ............. 117 Structural Maintenance .
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Page 9: Safety Precautions
Safety Precautions Danger, Warning, Caution, and Notice Thermo King® recommends that all service be performed by a Thermo King dealer and to be aware of several general safety practices. Safety advisories appear throughout this manual as required. Your personal safety and the proper operation of this unit depend upon the strict observance of these precautions. -
Page 10: Battery Removal
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 C C A A U U T T I I O O N N H H a a z z a a r r d d o o u u s s S S e e r r v v i i c c e e P P r r o o c c e e d d u u r r e e s s ! ! S S e e t t a a l l l l u u n n i i t t e e l l e e c c t t r r i i c c a a l l c c o o n n t t r r o o l l s s t t o o t t h h e e O O F F F F p p o o s s i i t t i i o o n n b b e e f f o o r r e e c c o o n n n n e e c c t t i i n n g g b b a a t t t t e e r r y y c c a a b b l l e e s s t t o o t t h h e e b b a a t t t t e e r r y y t t o o p p r r e e v v e e n n t t u u n n i i t t f f r r o o m m s s t t a a r r t t i i n n g g u u n n e e x x p p e e c c t t e e d d l l y y a a n n d d c c a a u u s s i i n n g g p p e e r r s s o o n n a a l l i i n n j j u u r r y y . -
Page 11: Refrigerant Oil 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 Refrigerant Oil Hazards W W A A R R N N I I N N G G 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 ) ) R R e e q q u u i i r r e e d d ! ! P P r r o o t t e e c c t t y y o o u u r r e e y y e e s s f f r r o o m m c c o o n n t t a a c c t t w w i i t t h h r r e e f f r r i i g g e e r r a a n n t t o o i i l l . -
Page 12: Low Voltage
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 H H a a z z a a r r d d o o u u s s V V o o l l t t a a g g e e ! ! U U n n i i t t s s f f e e a a t t u u r r i i n n g g o o p p t t i i o o n n a a l l E E l l e e c c t t r r i i c c S S t t a a n n d d b b y y u u t t i i l l i i z z e e 4 4 6 6 0 0 , , 4 4 0 0 0 0 , , o o r r 2 2 3 3 0 0 v v o o l l t t 3 3 p p h h a a s s e e A A C C e e l l e e c c t t r r i i c c a a l l p p o o w w e e r r a a n n y y t t i i m m e e t t h h e e u u n n i i t t i i s s o o p p e e r r a a t t i i n n g g i i n n E E l l e e c c t t r r i i c c M M o o d d e e . -
Page 13: 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 Precautions Take precautions to prevent electrostatic discharge when servicing the microprocessor and its related components. -
Page 14: 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 R R E E F F R R I I G G E E R R A A N N T T •... -
Page 15: Specifications
Specifications Engine Table 1. Model TK486V Fuel Type Diesel fuel must conform to EN590 Oil Capacity 12.3 liters/litres crankcase and oil filter Fill to full mark on dipstick Oil Type Petroleum Multi-grade Oil API Type CI-4, ACEA Class E3 Synthetic Multi-grade Oil API Type CI-4, ACEA Class E3 (after first 500 hours) Oil Viscosity -30°C to +0°C: SAE 5W-30... -
Page 16: Belt Tension
95-106 Water Pump Belt Tension Number on TK Gauge 204–427 Field Reset: 35-40 Refrigeration System Table 3. Compressor SLXi-100 Thermo King X426P® SLXi-200 Thermo King X430P® Refrigerant Charge - Type SLXi-100 4.00 kg - R404A, 3.73 kg - R452A* SLXi-200 5.00 kg - R404A/R452A*... -
Page 17: Electrical Control System
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 Control System Table 4. Voltage 12.5 Vdc (nominal) Battery Wet Cell: 12 volt, AHr Rating - 92AHrs, 760 Cold Cranking Amps at -18°C EON: 12 volt, AHr Rating - 64AHrs, 880 Cold Cranking Amps at -18°C Battery Charging (Alternator) 37 ampere brush type (optional: 65 ampere brush type) -
Page 18: Maintenance Inspection Schedule
Maintenance Inspection Schedule N N o o t t e e : : Please refer to your SLXi Operator Manual TK 61452-2-OP for Operator Weekly Checks The service technician is responsible for assessing the condition of all parts & components found during any service operation to be in a condition suitable for further operation up to the next scheduled service. - Page 19 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 The service technician is responsible for assessing the condition of all parts &...
- Page 20 Check calibration of return and discharge sensors as per customers HACCP or • • • annually. Check operation of all unit attached accessories Thermo King and non Thermo • • • King items. Check service records and ensure all service and warranty modifications have •...
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Page 21: Unit Description
The unit mounts on the front of the container with the evaporator extending through an opening in the front wall. The unit features the quiet running Thermo King TK486V engine, and the Thermo King X430P or X426CSLS reciprocating compressor. -
Page 22: Cycle-Sentry™ Start-Stop Controls
SR-3 Controller. Therefore, it is recommended that a ServiceWatch download be performed to help diagnose a problem. A ServiceWatch download must be preformed before contacting the Thermo King Service Department for assistance in diagnosing a problem. Refer to the for information about downloading the ServiceWatch Data Logger and viewing the data. -
Page 23: Tk Bluebox
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 U U S S B B P P o o r r t t : : A Universal Serial Bus (USB) port is provided on all units. If installed, it is located next to the HMI. -
Page 24: Operating Modes
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 Operating Modes The microprocessor uses a complex program to determine which operating mode the unit should be in. -
Page 25: 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 A A u u t t o o m m a a t t i i c c D D e e f f r r o o s s t t : : The controller is programmed to automatically initiate timed or demand defrost cycles. -
Page 26: Unit Protection Devices
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 2. Engine Compartment Components Compressor Sight Glass Engine Oil Filter Engine Oil Dipstick Unit Protection Devices C C o o o o l l a a n n t t L L e e v v e e l l S S w w i i t t c c h h : : The coolant level switch closes if the coolant level drops below an... - Page 27 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 E E n n g g i i n n e e : : Engine identification plate is located on the engine valve cover. C C o o m m p p r r e e s s s s o o r r : : Stamped between the cylinders on the front end above the oil pump.
- Page 28 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. Unit Serial Number Location Figure 6. Laminated Serial Number Plate (Located Where Shown Above) Unit Serial Number Unit Model Bill of Material Number...
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Page 29: Electrical Maintenance
The unit control circuits or installed accessories may be drawing excessive current. • An overcharged battery is usually caused by a defective voltage regulator. Alternator Identification These units use Thermo King Alternators (Figure 7, p. 30), which are painted black. TK 61555-2-MM-EN... -
Page 30: Base Controller Fuse F4
N N o o t t e e : : The F4 fuse must be removed from the base controller on units equipped with Thermo King alternators. The voltage regulator on the Thermo King alternators will be damaged if the unit is turned On with the F4 fuse in place on the base controller. -
Page 31: Alternator Load Test
This damage may not be readily apparent. To test the alternator under load, Thermo King recommends the use of a clamp-on ammeter to monitor output current, both on initial startup and under full unit load conditions. For example, on multi-temp units, all remote evaporators should be turned on. -
Page 32: Field Current Test
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 14. -
Page 33: Battery
Attach a clamp-on ammeter to the 2A wire near the B+ terminal on the alternator. Energize the field on the Thermo King alternator by connecting a jumper wire between the F2 terminal and the B+ terminal. Do not connect the F2 terminal to ground or the alternator will be damaged. -
Page 34: Base Controller
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 Base Controller Figure 8. -
Page 35: Fuse F10
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 36: Led Functions
SR-3 Controller. Therefore, it is recommended that a ServiceWatch download be preformed to help diagnose a problem. A ServiceWatch download must be preformed before contacting the Thermo King Service Department for assistance in diagnosing a problem. Refer to the SR-3 Trailer Single Temperature SL-400e, SLX/ SLXe/SLXi Series Diagnostic Manual TK 56487 for information about downloading the ServiceWatch Data Logger and viewing the data. -
Page 37: 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 Air Heater The air heater is mounted on the open end of the intake manifold. -
Page 38: How It Works
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 I I m m p p o o r r t t a a n n t t : : All external device connections must be connected through the LVD switch as per instructions detailed below. - Page 39 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 Figure 10.
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Page 40: Diagnosing The Low Voltage Disconnect (Lvd)
Figure 11. Cycle Power to Reset Diagnosing the Low Voltage Disconnect (LVD) If there is no power output from the LVD connection harness to external devices, Thermo King recommends performing the following diagnostic steps: 1. Use multimeter/voltmeter to measure voltage output from LVD harness positive and negative terminals (located in control box). -
Page 41: Engine Maintenance
Never overfill. See Specifications for correct type of oil. Oil Filter Change The oil filter should be changed along with the engine oil. Use a genuine Thermo King extended maintenance oil filter. 1. Remove the filter. 2. Fill the new oil filter with clean engine oil. -
Page 42: 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 • Low oil pressure can usually be traced to the lack of oil, a faulty oil pressure regulating valve, or worn bearings. -
Page 43: Extended Life Coolant (Elc)
GREEN or BLUE-GREEN colored coolants. Figure 13. ELC Nameplate Located Near Expansion Tank The following are the Extended Life Coolants currently approved by Thermo King for use in ELC units for five years or 12,000 hours: • Chevron Dex-Cool •... -
Page 44: Antifreeze Maintenance Procedure
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 Antifreeze Maintenance Procedure As with all equipment containing antifreeze, periodic inspection on a regular basis is required to verify the condition of the antifreeze. -
Page 45: 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 I I C C E E E E q q u u i i p p m m e e n n t t D D a a m m a a g g e e ! ! D D o o n n o o t t s s t t a a r r t t t t h h e e e e n n g g i i n n e e w w i i t t h h o o u u t t b b l l e e e e d d i i n n g g t t h h e e a a i i r r o o u u t t o o f f t t h h e e b b l l o o c c k k . - Page 46 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 15. Plastic Expansion Tank Float Coolant Level Switch N N o o t t e e : : Figure 15, p.
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Page 47: Engine Fuel 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 Pull the coolant level switch straight up to remove it from the tank. It may be necessary to use a small pry bar or screwdriver. - Page 48 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 done by a quality diesel injection service shop.
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Page 49: 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 Figure 16. Fuel System SLXi Relief Valve Fuel Transfer Pump Filter Head Priming Pump... -
Page 50: Bleeding The Fuel 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 17. Fuel Return Line Replacement End Cap Short Fuel Return Lines Larger Clamp... -
Page 51: 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 Figure 18. Injection Pump Bleed Screw Priming Pump 2. -
Page 52: Engine Speed Adjustments
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 Replacement Replace the fuel filter/water separator at intervals according to the Maintenance Inspection Schedule. -
Page 53: 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 Figure 20. Engine Speed Adjustments High Speed Solenoid Throttle Bracket Ball Linkage Rod Low Speed Adjustment... - Page 54 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 21. Index Mark Location Index Marks Figure 22.
- Page 55 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 24. Place Injection Angle Sticker on Gear Case Index Mark on Injection Pump Injection Angle Sticker Figure 25.
- Page 56 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 26. Removing Injection Pump Gear Do Not Loosen or Remove These Four Bolts Remove Nut and Lock Washer 4.
- Page 57 Figure 28. Injection Angle Mark 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 the injection angle.
- Page 58 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 30. Examples of Injection Pump Index Mark Alignment with Injection Angle Sticker Injection Pump Index Mark at –0.6 Degrees Injection Pump Index Mark at +1.8 Degrees 8.
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Page 59: 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 Figure 32. Align Flat Sides of Crankshaft Gear with Flat Sides of Inner Rotor in Timing Gear Cover Crankshaft Gear Oil Pump Cover... - Page 60 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 34. Index Mark Alignment Index Mark on Injection Pump Index Mark on Gear Case 2.
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Page 61: 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 35. Injection Pump Gear Tool Injection Pump Adapter (Tool) Gear Case... -
Page 62: 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 Board Test Mode. 5. Perform a visual functionality check per step 8 in “Testing the Fuel Solenoid” above to verify the fuel solenoid operates correctly. - Page 63 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. Top Dead Center One and Four Index Mark Top Dead Center Mark for 1 and 4 b.
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Page 64: 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 Check and adjust the exhaust valve for the number two cylinder, the intake valve for the number three cylinder, and both valves for the number four cylinder. -
Page 65: 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 The crankcase breather and the breather hose should be inspected when the air cleaner element is replaced to verify they are not plugged or damaged. - Page 66 New belts should be tensioned cold and re-tensioned cold after 10 hours of unit operation. Using Thermo King Frequency Gauge (See Tool Catalog) is the best method to check belt tension. Other commercially available tension gauges that measure the frequency or the tension in pounds are also acceptable.
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Page 67: 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 Figure 43. Belt Arrangement Blowers Belt Lower Blower Alternator Pulley Condenser Spinning... - Page 68 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 R R i i s s k k o o f f I I n n j j u u r r y y ! ! D D o o n n o o t t p p u u t t f f i i n n g g e e r r s s b b e e t t w w e e e e n n t t h h e e b b e e l l t t a a n n d d t t h h e e t t e e n n s s i i o o n n e e r r p p u u l l l l e e y y .
- Page 69 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 46. Stage 2 Figure 47. Stage 3 7.
- Page 70 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 : : The belt tension frequency measurement should be the primary method used to determine the correct belt tension.
- Page 71 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 50. Sliding Idler Pulley Position 2.
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Page 72: 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 Engine/Cross Shaft Belt Figure 52. Engine/Cross Shaft Belt Arrangement Cross Shaft / Electric Compressor Coupling Motor Pulley... - Page 73 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 53. Tensioner Clutch Components Plate Adjustment Bolt Grooved Idler Eccentric Plate Flat Idler...
- Page 74 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 2. Place a 1/2 in. drive wrench in the 1/2 in. square hole in the eccentric plate use it to hold the eccentric plate when the adjustment bolt is loosened in the next step.
- Page 75 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 56. Gauge Tool on Strut Bolts Gauge Tool P/N 2042436 13.
- Page 76 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 3. Install the arm pivot bolt, and the eccentric plate adjustment and pivot bolts, and tighten them finger tight.
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Page 77: 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 The water pump pulley is a split type. Adjust the tension by adding or removing shims between the pulley sheaves. -
Page 78: Refrigeration Maintenance
Operating and Diagnostic manual for instructions on how to use the Service Test mode. N N o o t t e e : : The following procedures can be found in the Thermo King Truck and Trailer Diagnosing Manual TK 60201-8-OD 1. -
Page 79: Testing For An Overcharge
Testing for an Overcharge Use the following procedure to identify a Thermo King unit with an excessive refrigerant charge: 1. Install a calibrated gauge manifold on the compressor. 2. Operate the host unit in high speed with all zones in cool long enough to stabilize system pressures and reduce the compartment temperatures to approximately 16 C (60 F)or colder. -
Page 80: 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 2. -
Page 81: Refrigerant Leaks
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 Refrigerant Leaks Use a reliable leak detector that is suitable for R-404A and R-452A to leak test the refrigeration system. -
Page 82: High Pressure Cutout Switch (Hpco)
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 High Pressure Cutout Switch (HPCO) The High Pressure Cutout Switch (HPCO) is located on the compressor discharge manifold. -
Page 83: Three-Way Valve Condenser Pressure Bypass 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 M M a a i i n n t t e e n n a a n n c c e e Three-Way Valve Condenser Pressure Bypass Check Valve A three-way valve condenser pressure bypass check valve is used in this unit. - Page 84 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 Operate the unit on cool and pump down the low side to 20 in.
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Page 85: Refrigeration Service Operations
Refrigeration Service Operations N N o o t t e e : : Some of the following involve servicing the refrigeration system and are regulated by EU regulation known as "F-Gas" and /or local laws. All regulated refrigeration service procedures must be performed by a certified technician, using approved equipment and complying with all EU and local laws. - Page 86 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 64.
- Page 87 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 Receiver Tank High Pressure Relief Valve Dehydrator...
- Page 88 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 Service Valve Cap Pipe Plug Gasket...
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Page 89: 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 Valve and cover screw Restriction Fitting Flatwasher... -
Page 90: Compressor Coupling Removal (Standard Units)
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 adjust the tension). - Page 91 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 67.
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Page 92: Compressors With Pressurized Seal Cavity
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 keyway with a light press fit requiring only a minimum of light tapping. -
Page 93: Hex Drive Compressor Seal Replacement
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 70. - Page 94 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 plate.
- Page 95 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 73.
- Page 96 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.
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Page 97: 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 Figure 77. -
Page 98: 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 I I m m p p o o r r t t a a n n t t : : This unit uses a micro-channel condenser coil. -
Page 99: 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 N N O O T T I I C C E E E E q q u u i i p p m m e e n n t t D D a a m m a a g g e e ! ! U U s s e e a a h h e e a a t t s s i i n n k k , , P P / / N N 2 2 0 0 4 4 - - 5 5 8 8 4 4 , , o o r r w w r r a a p p t t h h e e v v i i b b r r a a s s o o r r b b e e r r w w i i t t h h w w e e t t r r a a g g s s t t o o p p r r e e v v e e n n t t d d a a m m a a g g i i n n g g... -
Page 100: Bypass 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 Bypass Check Valve Removal Pump down the low side and equalise the pressure to 0 psig (0 bar g). -
Page 101: 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 Installation Install and bolt the expansion valve assembly in the unit. -
Page 102: 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 Installation Clean the tubes for soldering. -
Page 103: Accumulator
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 12. -
Page 104: Removal/Disassembly
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. - Page 105 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 82.
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Page 106: 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 83. - Page 107 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 84.
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Page 108: 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 Seat (Center Section) Orifice Check There are three 0.84 mm (0.033 in.)holes located in the three-way valve seat (center section). -
Page 109: 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 Figure 87. -
Page 110: 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 Figure 88. -
Page 111: Pilot Solenoid
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 Pilot Solenoid Removal Recover the refrigerant charge. -
Page 112: 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 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 High Pressure Cutout Switch Removal Pump down the low side and equalize the pressure to slightly positive. - Page 113 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 C C A A U U T T I I O O N N R R i i s s k k o o f f I I n n j j u u r r y y ! ! T T h h e e e e n n d d c c a a p p i i s s u u n n d d e e r r s s l l i i g g h h t t s s p p r r i i n n g g p p r r e e s s s s u u r r e e .
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Page 114: 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 b. -
Page 115: 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 Figure 92. - Page 116 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 93.
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Page 117: 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 95. -
Page 118: Structural Maintenance
Structural Maintenance Unit and Engine Mounting Bolts Check and tighten all unit and engine mounting bolts during scheduled maintenance inspections. Torque the unit mounting bolts to 81 N•m (60 ft-lb). Torque the engine mounting bolts to 203 N•m (150 ft-lb). Figure 96. -
Page 119: Condenser, Evaporator, And Radiator Coils
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 Condenser, Evaporator, and Radiator Coils Clean the coils during scheduled maintenance inspections. - Page 120 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 N N o o t t e e s s : : 1.
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Page 121: 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 Figure 98. -
Page 122: 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 100. -
Page 123: Troubleshooting 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 •... -
Page 124: Condenser And Evaporator Fan Location
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 Remove Bolts from Damper Door Shaft Remove Bolts from Damper Gear Motor Shaft Remove Screws from Damper Gear Motor (one not... -
Page 125: Evaporator Fan Blower Alignment
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 102. -
Page 126: Fan Shaft Assembly
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 Fan Shaft Assembly The unit is equipped with a fan shaft assembly that contains special sealed bearings. -
Page 127: 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 104. - Page 128 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 I I m m p p o o r r t t a a n n t t : : The cleaner must be allowed to evaporate before the next step.
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Page 129: 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 108. -
Page 130: Lower Condenser Blower Assembly
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 4. -
Page 131: 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 Reassembly I I m m p p o o r r t t a a n n t t : : To prevent damage to the bearings, use bearing drivers (or other suitable tools) on the bearing races when installing the bearings. -
Page 132: 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 111. -
Page 133: Idler Assemblies
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 Idler Assemblies The idler assemblies contains special sealed bearings. -
Page 134: Mechanical Diagnosis
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... - Page 135 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 136 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...
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Page 137: Refrigeration Diagnosis
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) •... - Page 138 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 •...
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Page 139: Refrigeration Diagrams
Refrigeration Diagrams Cool Cycle TK 61555-2-MM-EN... - Page 140 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 Expansion Valve Discharge Service Valve...
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Page 141: 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 Compressor Expansion Valve... - Page 142 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 Discharge Vibrasorber Distributor Three-Way Valve...
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Page 143: Diagram Index
Diagram Index The following table lists the diagrams that are relevant to this unit. The diagrams are available on EMEA Info Central.. Drawing No. Drawing Title 3E31534 Schematic Diagram 2E98198 Wiring Diagram TK 61555-2-MM-EN... - Page 144 Our people and our family of brands — including Club Car ® , Ingersoll Rand ® , Thermo King ® Trane ® — work together to enhance the quality and comfort of air in homes and buildings; transport and protect food and perishables;...
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