If the Thermo King SLXi-300 engine is not starting and shows an ALARM 1/2, a possible issue could be a discharged battery. This can happen if the unit has not been used for a while or if aftermarket devices are drawing power. A discharged battery may prevent the engine from cranking and trigger alarm codes like ALARM 1/2.

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Summary of Contents for Thermo King SLXi-300

Page 1 Maintenance Manual Trailer Edition SLXi-300 and SLXi-400 Single Temperature Units Revision A T T K K 6 6 1 1 5 5 5 5 2 2 - - 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.
Page 4: Table Of Contents
Table of Contents Safety Precautions................10 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 Test Equipment for Checking Voltage and Current ..........35 Alternator Load 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 Draining Water from Fuel Tank ............. . 57 Fuel Filter/Water Separator.
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................. . 108 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 High Pressure Relief Valve ..............122 Removal.
Page 9 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 Installation ................143 Cross Shaft Assembly .
Page 10: 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 11: Battery Installation And Cable Routing
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 f f E E x x p p l l o o s s i i o o n n ! ! N N e e v v e e r r c c l l o o s s e e t t h h e e c c o o m m p p r r e e s s s s o o r r d d i i s s c c h h a a r r g g e e s s e e r r v v i i c c e e v v a a l l v v e e w w h h e e n n 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 .
Page 12: 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 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 f f E E x x p p l l o o s s i i o o n n ! ! I I m m p p r r o o p p e e r r l l y y i i n n s s t t a a l l l l e e d d 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 c c o o u u l l d d r r e e s s u u l l t t i i n n a a f f i i r r e e , , e e x x p p l l o o s s i i o o n n , , o o r r i i n n j j u u r r y y .
Page 13: 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 Refrigerant Hazards D D A A N N G G E E R R H H a a z z a a r r d d o o u u s s P P r r e e s s s s u u r r e e s s ! ! A A l l w w a a y y s s s s t t o o r r e e r r e e f f r r i i g g e e r r a a n n t t i i n n p p r r o o p p e e r r c c o o n n t t a a i i n n e e r r s s , , o o u u t t o o f f d d i i r r e e c c t t s s u u n n l l i i g g h h t t a a n n d d a a w w a a y y f f r r o o m m i i n n t t e e n n s s e e h h e e a a t t .
Page 14: Electrical 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 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 d d e e d d i i c c a a t t e e d d 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 e e q q u u i i p p m m e e n n t t t t o o p p r r e e v v e e n n t t c c o o n n t t a a m m i i n n a a t t i i n n g g 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 y y s s t t e e m m s s w w i i t t h h t t h h e e w w r r o o n n g g t t y y p p e e o o f f o o i i l l o o r r r r e e f f r r i i g g e e r r a a n n t t .
Page 15: 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 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 ! ! S S a a f f e e t t y y g g l l a a s s s s e e s s , , r r u u b b b b e e r r - - i i n n s s u u l l a a t t e e d d g g l l o o v v e e s s , , a a n n d d c c a a b b l l e e c c u u t t t t e e r r s s s s h h o o u u l l d d b b e e n n e e a a r r y y o o u u r r w w o o r r k k a a r r e e a a i i n n t t h h e e e e v v e e n n t t o o f f a a n n e e l l e e c c t t r r i i c c a a l l a a c c c c i i d d e e n n t t .
Page 16: Welding 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 Welding Precautions Take precautions before electrically welding any portion of the unit or the vehicle to which it is attached.
Page 17: 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 18: Specifications
-25°C to +40°C: SAE 10W-40 -15°C to +40°C (or -10°C to +50°C): SAE 15W-40 Engine RPM SLXi-300 and Whisper 1450 +/- 25 RPM High Speed, 1200 +/- 25 RPM Low Speed SLXi-300 Whisper Pro 2000 +/- 25 RPM High Speed, 1250 +/- 25 RPM Low Speed...
Page 19: Belt Tension
Refrigeration System Table 3. Compressor Thermo King X430P® Refrigerant Charge - Type SLXi-300, SLXi-300 Whisper Pro 5.00 kg - R404A/R452A* SLXi-400 5.70 kg - R404A/R452A* 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 ! ! F F l l u u o o r r i i n n a a t t e e d d R R e e f f r r i i g g e e r r a a n n t t g g a a s s e e s s s s h h o o u u l l d d n n o o t t b b e e v v e e n n t t i i l l a a t t e e d d t t o o t t h h e e a a t t m m o o s s p p h h e e r r e e .
Page 20: 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 Table 3. (continued) Electronic Defrost Coil must be below 7°C for defrost Termination Switch initiation Coil must be above 14°C for defrost...
Page 21: 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 22 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 23 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 •...
Page 24: Unit Description
SMART REEFER 3 (SR-3) programmable microprocessor controller. 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 reciprocating compressor. •...
Page 25: Electronic Throttling Valve (Etv)
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 • Electronic Throttling Valve (ETV) • EMI-3000 • TK Bluebox Electronic Throttling Valve (ETV) The Electronic Throttling Valve (ETV) is standard on the these units.
Page 26: Cycle-Sentry™ Start-Stop Controls
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 3. New Style ETV Inlet Valve Body Stepper Motor Outlet CYCLE-SENTRY™...
Page 27: Tk Bluebox
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 28: Optiset
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 Check GPS Antenna TT99 Telematics System Issue No GPS Fix OptiSet™...
Page 29 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 • Null • Modulated Heat (Continuous operation only) • Hot Gas Heat •...
Page 30: 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 Components The following maintenance items can be checked visually. 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 ! ! T T h h e e u u n n i i t t c c a a n n s s t t a a r r t t a a t t a a n n y y t t i i m m e e w w i i t t h h o o u u t t w w a a r r n n i i n n g g .
Page 31: Serial Number Locations
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 H H i i g g h h P P r r e e s s s s u u r r e e C C u u t t o o u u t t S S w w i i t t c c h h : : The high pressure cutout switch is located on the compressor discharge manifold.
Page 32 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 6. Engine Serial Number Location Serial Number Location Figure 7. Unit Serial Number Location TK 61552-2-MM-EN...
Page 33 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 Where Shown Above) Unit Serial Number Unit Model Bill of Material Number...
Page 34: 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 9, p. 35), which are painted black. TK 61552-2-MM-EN...
Page 35: 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 36: 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 37: 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 38: 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 39: 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 10.
Page 40: 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 41: Led Functions
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 LED Functions The LED is illuminated when the associated circuit output is energized.
Page 42: Smart Reefer 3 (Sr-3) Microprocessor Controller
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 43: Low Voltage Disconnect Switch (Lvd)
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 Low Voltage Disconnect Switch (LVD) General Information N N O O T T I I C C E E...
Page 44: Lvd Maintenance
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 LVD Maintenance For information regarding installation instructions of the LVD retrofit kit, or installation of external devices to LVD, please refer to TK 61516-11-2.
Page 45: Diagnosing The Low Voltage Disconnect (Lvd)
Figure 13. 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 46 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 –...
Page 47: 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 48: 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 49: Extended Life Coolant (Elc)
GREEN or BLUE-GREEN colored coolants. Figure 15. 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 50: 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 51: 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 52 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. Plastic Expansion Tank Float Coolant Level Switch N N o o t t e e : : Figure 17, p.
Page 53: 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 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 Any major injection pump or nozzle repairs should be done by a quality diesel injection service shop.
Page 55: 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 18. Fuel System SLXi Relief Valve Fuel Transfer Pump Filter Head Priming Pump...
Page 56: 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 19. Fuel Return Line Replacement End Cap Short Fuel Return Lines Larger Clamp...
Page 57: 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 20. Injection Pump Bleed Screw Priming Pump 2.
Page 58: Fuel Filter/Water Separator 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 Filter/Water Separator Replacement Replace the fuel filter/water separator at intervals according to the Maintenance Inspection Schedule.
Page 59: 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 22. Engine Speed Adjustments High Speed Solenoid Throttle Bracket Ball Linkage Rod Low Speed Adjustment...
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 23. Index Mark Location Index Marks Figure 24.
Page 61 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. Place Injection Angle Sticker on Gear Case Index Mark on Injection Pump Injection Angle Sticker Figure 27.
Page 62 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 28. Removing Injection Pump Gear Do Not Loosen or Remove These Four Bolts Remove Nut and Lock Washer 4.
Page 63 Figure 30. 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 64 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. 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.
Page 65: 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 34. Align Flat Sides of Crankshaft Gear with Flat Sides of Inner Rotor in Timing Gear Cover Crankshaft Gear Oil Pump Cover...
Page 66 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 36. Index Mark Alignment Index Mark on Injection Pump Index Mark on Gear Case 2.
Page 67: 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 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 be de-energized after a few seconds to keep it from being damaged. The pull-in coil is controlled by the microprocessor through the fuel solenoid pull in relay (K6).
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 39. Fuel Solenoid Connector Pin Identification Red (8D) White (8DP) Black (CH)
Page 70: 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 8. Visual functionality check (no measurements required). 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 f f u u e e l l s s o o l l e e n n o o i i d d c c a a s s i i n n g g m m a a y y g g e e t t h h o o t t d d u u r r i i n n g g t t h h i i s s r r a a p p i i d d c c y y c c l l i i n n g g , , u u s s e e c c a a u u t t i i o o n n w w h h e e n n...
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 Remove the rocker arm cover. Remove the round cover (plug) from the timing mark access hole on the front of the bell housing.
Page 72: 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 42. Adjusting the Valve Clearance Hold the adjustment screw in place and tighten the locknut.
Page 73: 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 Figure 43. Crankcase Breather Breather Hose Baffle Breather Insulation Baffle Plate...
Page 74: Belts
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.
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 46. Using Frequency Gauge P/N 204-1903 Probe Metal Tab N N o o t t e e : : Do not attempt to remove or install belts without loosening adjustments.
Page 76: 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 47. Belt Arrangement Blowers Belt Lower Blower Alternator Pulley Condenser Spinning...
Page 77 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 78 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. Stage 2 Figure 51. Stage 3 7.
Page 79 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 80 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 54. Sliding Idler Pulley Position 2.
Page 81: 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 56. Engine/Cross Shaft Belt Arrangement Cross Shaft / Electric Compressor Coupling Motor Pulley...
Page 82 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 57. Tensioner Clutch Components Plate Adjustment Bolt Grooved Idler Eccentric Plate Flat Idler...
Page 83 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 84 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 60. Gauge Tool on Strut Bolts Gauge Tool P/N 2042436 13.
Page 85 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.
Page 86: 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 87: 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 88: 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 89: 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 90: 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 91: 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 92: 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 93: 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 Operate the unit on cool and pump down the low side to 20 in.
Page 94: 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 Figure 68.
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 M M a a i i n n t t e e n n a a n n c c e e energized (opened) at full modulation.
Page 96: 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 97 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 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 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 71.
Page 99: 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 Suction Transducer O-ring seal adapter Suction Valve adapter...
Page 100: 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 Compressor Coupling Removal (Standard Units) After the compressor has been removed from the unit, use the appropriate Allen tool provided with removal tool P/N 204-991 to loosen the center bolt which holds the coupling to...
Page 101 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 10 mm Allen Tool (for large shaft compressor) Long Spacers (supplied with tool)
Page 102: 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 Figure 74.
Page 103: 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 75.
Page 104 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 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 78.
Page 106 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 80.
Page 107: 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 82.
Page 108: 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 109: 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 110: 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 111: Expansion Valve 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 (depending on manufacture date of the unit) fitting.
Page 112: Heat Exchanger
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 Heat Exchanger Removal Pump down the low side and equalize the pressure to slightly positive.
Page 113: 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 1.
Page 114: 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 86.
Page 115 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 116: 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 88.
Page 117 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 89.
Page 118: 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 119: 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 92.
Page 120: 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 93.
Page 121: 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 122: 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 123: Suction Pressure Transducer
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 Suction Pressure Transducer Removal Pump down the low side and equalize pressure to slightly positive.
Page 124: 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 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 ! ! I I f f t t h h e e E E T T V V i i s s s s t t u u c c k k i i n n t t h h e e c c l l o o s s e e d d p p o o s s i i t t i i o o n n , , m m u u c c h h o o f f t t h h e e r r e e f f r r i i g g e e r r a a n n t t c c h h a a r r g g e e m m a a y y b b e e t t r r a a p p p p e e d d...
Page 125 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 96.
Page 126: Installation Of Complete Etv 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 Figure 98.
Page 127: Hot Gas Bypass Solenoid 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 Figure 100.
Page 128: Internal Oil Filter 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 Internal Oil Filter Replacement The internal oil filter should be replaced in the same situations in which the external oil filter was replaced, such as when the drier is replaced or the compressor oil is changed.
Page 129: 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 Stud On Oil Pickup Tube Bracket 4.
Page 130: 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 104.
Page 131: 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 132 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.
Page 133: 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 106.
Page 134: 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 108.
Page 135: 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 136: 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 137: 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 110.
Page 138: 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 139: 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 112.
Page 140 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.
Page 141: 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 116.
Page 142: 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 143: 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 144: 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 119.
Page 145: 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 146: 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 147 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 148 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 149: 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 150 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 151: Refrigeration Diagrams
Refrigeration Diagrams Cool Cycle TK 61552-2-MM-EN...
Page 152 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 153: 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 61552-2-MM-EN...
Page 154 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 155: 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 61552-2-MM-EN...
Page 156 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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