Thermo King SL-100 Maintenance Manual
  1. Manuals
  2. Brands
  3. Thermo King Manuals
  4. Refrigerator
  5. SL-100
  6. Maintenance manual

Thermo King SL-100 Maintenance Manual

Trailer units
Hide thumbs
Table of Contents

Advertisement

Quick Links

Download this manual
Maintenance Manual
Trailer Units
SL-100
SL-200
SL-300
SL-400
SL-TCI
SL-100e
SL-200e
SL-400e
SPECTRUM SL
SLX-100
SLX-200
SLX-300
SLX-400
SLX SPECTRUM
SLX Whisper
SLX Ferry
SLXe-100
SLXe-200
SLXe-300
SLXe-400
SLXe SPECTRUM
SLXe Whisper
SLXe-300 Whisper Pro
SLXe SPECTRUM Whisper
Pro
SLXi-100
SLXi-200
SLXi-300
SLXi-400
SLXi Spectrum
SLXi-300 Whisper Pro
SLXi SPECTRUM Whisper
Pro
TK 50045 (Rev. 16, 01-2018)
Ingersoll Rand Company Ltd. • Monivea Road • Mervue, Galway • Ireland

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the SL-100 and is the answer not in the manual?

Questions and answers

Related Manuals for Thermo King SL-100

Summary of Contents for Thermo King SL-100

  • Page 1 Maintenance Manual Trailer Units SL-100 SL-200 SL-300 SL-400 SL-TCI SL-100e SL-200e SL-400e SPECTRUM SL SLX-100 SLX-200 SLX-300 SLX-400 SLX SPECTRUM SLX Whisper SLX Ferry SLXe-100 SLXe-200 SLXe-300 SLXe-400 SLXe SPECTRUM SLXe Whisper SLXe-300 Whisper Pro SLXe SPECTRUM Whisper SLXi-100 SLXi-200...
  • Page 2 Recover Refrigerant At Thermo King we recognise 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. We strictly adhere to a policy that promotes the recovery and limits the loss of refrigerant into the atmosphere.

  • Page 3: Table Of Contents

    Table Of Contents Introduction ............1-1 About This Manual .
  • Page 4 Controller) ............. . 5-13 Thermo King SR basic operational sequence Diesel Mode ......5-16 Operation .
  • Page 5 Unit Operation (Single or Multi-Temp SR-2/SR-3) ........6-10 Manual Pretrip Inspection (Before Starting Unit) .
  • Page 6 Alternator (Thermo King) ........
  • Page 7 TK 482, TK 486, TK 486V Engines ..........Engine Air Cleaner .
  • Page 8 Refrigerant Overcharge Check ..........10-6 Moisture Indicating Sight Glass (where fitted) .
  • Page 9 Condenser Inlet Solenoid Valve (CIS) or Hot Gas Solenoid Valve (HGS, HGS2, HGS3, RHGS, HGBP or CHGS) ........... . 11-23 Suction Line Check Valve (SLCV, SLCV2, SLCV3, RSLCV or CSLCV), Purge Check Valve (PCV) or Liquid Return Check Valve (LRCV, LRCV2, LRCV3, RLRCV or CLRCV) .
  • Page 10 Zone 1* on Cool, Zone 2** on Cool and Zone 3*** on Cool ......16-4 Zone 1* on Cool, Zone 2** on Cool and Zone 3*** on Heat ......16-5 SLX, SLXe, SLXI Spectrum .

  • Page 11: Introduction

    The information in this manual is provided to assist owners, SL-100e 30 (049172) operators and service people in the proper upkeep and SL-100e 50 (049173) maintenance of Thermo King units. Each unit family includes SL-200e 30 (049174) many specific models. When maintenance information differs SL-200e 50 (049175)

  • Page 12: Other Reference Manuals

    Controller Operation and Diagnosis Manual TK 41168 OTHER REFERENCE MANUALS Thermoguard µP-IV Multi-Temp Microprocessor For detailed descriptions of Thermo King engines, Controller Operations and Diagnosis Manual TK 50033 compressors or temperature control systems, refer to the TK 482 and TK 486 Engine Overhaul Manual...

  • Page 13: Safety Precautions

    2 Safety Precautions GENERAL PRACTICES 1. ALWAYS WEAR GOGGLES OR SAFETY GLASSES. Refrigerant liquid and battery acid can permanently damage the eyes (see First Aid). 2. Never close the compressor discharge service valve with the unit operating. Never operate the unit with the compressor discharge valve closed.

  • Page 14: Sl-400E, Slx, Slxe And Slxi With Smart Reefer 2/3 (Sr-2/Sr-3) Controller

    REFRIGERANT Note: 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. Fluorinated Green House gases should not be ventilated to atmosphere.

  • Page 15: Electrical

    ELECTRICAL Microprocessor Service Precautions must be taken to prevent electrostatic discharge when servicing the microprocessor controller and related components. Potential differences considerably lower than those which produce a small spark from a finger to a door knob can severely damage or destroy solid-state integrated circuit components. The following procedures must be rigidly adhered to when servicing units to avoid microprocessor damage or destruction.

  • Page 16: Precautions

    UNIT DECALS Serial number decals, refrigerant type decals and warning decals appear on all Thermo King equipment. These decals provide information that may be needed to service or repair the unit. Service technicians should especially read and follow the instructions on all warning decals.
  • Page 17 Warning Decals Safety Precautions...
  • Page 18 Warning Decals Information Decals Safety Precautions...

  • Page 19: Specifications

    3 Specifications Engine ............. . Drive System .

  • Page 20: Engine

    ENGINE Diesel Engine Model: SL-100 and SL-200 TK 482 SL-100e, SL-200e, SL-300, SL-400, SL-400e, SL TCI and SPECTRUM SL TK 486 and TK 486V (starting in August 2006) All SLX, SLXe and SLXi models TK 486 V Fuel Type: All models...
  • Page 21 ENGINE (CONTINUED) Timing Injection Pump: TK 482, TK 486 and TK 486V +/- 1 BTDC (timed on No. 1 cylinder, fly wheel side) Low Oil Pressure Switch (Normally Closed): TK 482, TK 486 and TK 486V 0.55 to 0.83 bar (8 to 12 psi) High Coolant Temperature Switch*: TK 482, TK 486 and TK 486V Sensor*...

  • Page 22: Drive System

    DRIVE SYSTEM NOTE: Use belt tension gauge TK P/N 204-427 whenever possible to check belt tension. However, on some unit models, and on some belts, it is difficult to use the gauge. Adjust these belts to allow 12 mm of deflection at the centre of the longest span. New belts should be tensioned cold and tensioned cold again after 10 hours of unit operation.

  • Page 23: Refrigeration System

    NOTE: Please take note of your refrigerant type (label on outside of unit), and make sure not to cross-contaminate. Refrigerant R-404A 3922 R-452A 2140 R-404A/R-452A Compressor Model: SL-100, SL-100e, SL-200 and SL-200e X426 SL-300, SL-400, SL-400e, SL TCI and X430 SPECTRUM SL SLX/SLXe-100 X426LSC5 SLX/SLXe-200, SLX/SLXe-300, SLX/ X430LSC5...

  • Page 24: Heat And Defrost System

    R-404A/R-452A High Pressure Cutout: SL, SLe, SLX, SLXe, SLXi and Opens: 32.41 +/- 0.48 bar, 470 +/-7 psi SPECTRUM Closes: Automatic reset @ 25.86 +/- 2.62 bar, 375 +/- 38 psi High Pressure Control Switch (Receiver Tank): SL TCI and SLe SPECTRUM models Opens: 20.68 +/- 1.72 bar, 300 +/- 25 psi Closes: 13.79 +/- 0.69 bar, 200 +/- 20 psi High Pressure Relief Valve: All models...

  • Page 25: Controller

    CONTROLLER Type: SL-100, SL-100e, SL-200, SL-200e, and SMX-II Thermoguard VI controller (TG-VI) Thermoguard μP-IV multi-temp controller (μP-IV SL TCI and SPECTRUM SL Multi-Temp) Thermoguard μP-V controller (μP-V) SL-300 Thermoguard μP-VI controller (μP-VI) SL-400 and SL-400e or Smart Reefer 2 (SR-2) on SL-400e...

  • Page 26: Electrical Control System

    ELECTRICAL CONTROL SYSTEM Voltage: All models 12.5 Vdc (nominal) Battery Wet Cell 12 Vdc, AHr Rating - 92AHrs, 760 Cold Cranking Amps at -18 C 12.8 Vdc Nominal, AHr Rating - 65AHrs, 880 Cold Cranking Amps at -18 C TG-VI, µP-IV, µP-V, µP-VI and SR-2 Controllers: 2 Circuit: SL, SLe models 40 ampere fuse...

  • Page 27: Electrical Components

    ELECTRICAL COMPONENTS Disconnect components from unit circuit to check resistance. Current Draw (Amperes) Resistance at 12.5 Vdc (Ohms) Starter Motor: TK 482, TK 486, se 2.2 and di 2.2* 250 to 375 (cranking) 80 (bench test) TK 486V 350 to 475 (cranking) Air Heater: TK 482, TK 486 and TK 0.14...
  • Page 28 EVAPORATOR FAN MOTORS Number 2 or 3 Voltage 12 Vdc Full Load Amps 7 amperes SPECTRUM Remote Evaporator Fan Motor (S-2 after Jan 2012) Number Voltage 12 Vdc Full Load Amps 6 amperes Specifications 3-10...

  • Page 29: Electric Standby

    Resistance (cold and disconnected) 122 ohms *Electric heater strips are standard on SLXi, SLXe, SLX, SL-400 and SL-400e models, and not available on SL-100, SL-100e, SL-200 and SL-200e models. **Models with a TG-VI, µP-IV, µP-V or µP-VI controller use the evaporator coil sensor to provide evaporator high temperature protection.
  • Page 30 Electrical 1.3 amps Remote Liquid Line Solenoid: Current Draw Units built from October 2015: the remote evaporator states Note: "PTC” (remote Liquid line solenoid pulsing) - current draw remains the same. Resistance 9.6 ohms Remote Hot Gas Solenoid: Current Draw 1.5 amps Resistance 8.3 ohms...

  • Page 31: Maintenance Inspection Schedule

    4 Maintenance Inspection Schedule SL and SLe ............Remote Evaporators: ECT, ELT, EW, SPECTRUM and TLE.

  • Page 32: All Sl And Sle And Spectrum Models Host Unit

    UNIT MODELS: ALL SL AND SLe AND SPECTRUM MODELS HOST UNIT 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 33 UNIT MODELS: ALL SL AND SLe AND SPECTRUM MODELS HOST UNIT 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 34 Miscellaneous Check accuracy of return and discharge sensors as per local    regulations Check operation of all unit attached accessories Thermo King and    non Thermo King. Check service records and ensure all service and warranty ...

  • Page 35: Remote Evaporators: Ect, Elt, Ew, Spectrum And Tle

    Remote Evaporators: ECT, ELT, EW, SPECTRUM and TLE 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 36: All Slx, Slxe Range And Spectrum Models Host Unit

    UNIT MODELS: ALL SLX, SLXe RANGE AND SPECTRUM MODELS HOST UNIT 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 37 UNIT MODELS: ALL SLX, SLXe RANGE AND SPECTRUM MODELS HOST UNIT 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 38 Miscellaneous Check accuracy of return and discharge sensors as per local    regulations Check operation of all unit attached accessories Thermo King and    non Thermo King. Check service records and ensure all service and warranty ...

  • Page 39: Slx, Slxe Spectrum

    UNIT MODELS: SLX, SLXe SPECTRUM 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. If parts not considered in suitable condition, they should be replaced.

  • Page 40: All Slxi-100, Slxi-200, Slxi-300, Slxi-400, Slxi Spectrum Range

    UNIT MODELS: ALL SLXi-100, SLXi-200, SLXi-300, SLXi-400, SLXi SPECTRUM RANGE N N o o t t e e : : Please refer to your SLXi Operator Manual TK 61452-2-OP for Operator Weekly Checks Maintenance Inspection Schedule 4-10...
  • Page 41 UNIT MODELS: ALL SLXi-100, SLXi-200, SLXi-300, SLXi-400, SLXi SPECTRUM RANGE Maintenance Inspection Schedule 4-11...
  • Page 42 UNIT MODELS: ALL SLXi-100, SLXi-200, SLXi-300, SLXi-400, SLXi SPECTRUM RANGE C C A A U U T T I I O O N N 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 ! ! E E n n s s u u r r e e l l i i q q u u i i d d l l i i n n e e i i s s e e m m p p t t y y b b e e f f o o r r e e o o p p e e n n i i n n g g c c o o n n n n e e c c t t i i o o n n s s .
  • Page 43 UNIT MODELS: ALL SLXi-100, SLXi-200, SLXi-300, SLXi-400, SLXi SPECTRUM RANGE N N o o t t e e : : *If using ELC Coolant, drain and refill every 12,000 hours or 60 months (whichever comes first). Do not mix antifreeze types. N N o o t t e e : : **EON battery is maintenance free and does not require topping up of electrolyte.
  • Page 44 UNIT MODELS: ALL SLX, SLXe, SLXi AND SPECTRUM MODELS Preventative Maintenance Schedule Weekly • Check fuel supply. • Check & adjust engine oil level.  • Perform Automatic Pre-Trip • Listen for unusual noises, vibrations, etc. • Visually inspect unit for fluid leaks (coolant, oil, refrigerant) •...

  • Page 45: Unit Description

    Sequence of Operation ............SL-100, SL-100e, SL-200 and SL-200e (TG-VI Controller) ......

  • Page 46: Single Temperature Systems

    Engines • SL-100 and SL-200 and models feature a TK 482, four-cylinder, diesel engine rated at 21.3 kW at 1900 rpm. • SL-100e, SL-200e, SL-300, SL-400, SL-400e, SL TCI, SPECTRUM models feature a TK 486, four-cylinder, diesel engine rated at 25.3 kW at 2200 rpm.

  • Page 47: Service Test Mode (Standard On Tg-Vi, Μp-Iv, Μp-V, Μp-Vi, Sr-2 And Sr-3 Controllers)

    The µP-IV, µP-V or µP-VI controller is a programmable microprocessor that controls all unit functions to maintain the cargo at the proper temperature. The controller integrates the following functions: thermostat, digital thermometer, defrost timer, CYCLE-SENTRY system, hourmeters, oil pressure gauge, coolant temperature gauge, ammeter, voltmeter, tachometer, mode indicator, refrigeration system controller and diagnostic system.

  • Page 48: Data Logging Option (Μp-Iv, Μp-V, Μp-Vi, Sr-2 And Sr-3 Controllers)

    This trip data can be retrieved (but not erased) from the controller memory using an IBM compatible laptop or desktop microcomputer and Thermo King Wintrac or Service Tool software. Detailed graph or table trip reports can then be created and printed.

  • Page 49: Economy Mode Control Option

    The start/stop nature of CYCLE-SENTRY does not satisfy the temperature control or airflow requirements for perishable or temperature sensitive products. Thermo King therefore does NOT recommend the use of CYCLE-SENTRY control for these products.

  • Page 50: Optiset™ Option

    OptiSet™ Option µP-VI, SR-2 and SR-3 control systems include the OptiSet feature as standard. OptiSet allows each customer to program a set of unit operating details for a specific setpoint or setpoint temperature range. When the unit setpoint falls within a programmed setpoint range, all unit operation is automatically determined by the OptiSet settings for that setpoint range.
  • Page 51 Electric Operation Continuous Mode • Cool • Null 3, 4 • Heat • Defrost Fuelsaver I, Modulation and CYCLE-SENTRY are locked out on electric standby operation. The drive motor and compressor do NOT operate during the Null mode. Heat is delayed for 8 minutes on units with Fuelsaver II (or TG-V controller). Exceptions: Initial unit start-up. Null if setpoint is below -9.5 C.
  • Page 52 When a Defrost cycle is initiated, the defrost relay energises the damper motor, pilot solenoid and heater contactor (during electric standby operation on Model 50 units with optional electric heaters). If the unit is in Null mode on CYCLE-SENTRY or Electric Standby operation, pressing the manual defrost key will initiate a manual defrost.
  • Page 53 Electric Operation (Model 50 Only) During electric operation, the operating characteristics of the system are basically the same with the following exceptions: • If the host unit (front) and remote controllers are both calling for Low Speed Heat, the host unit will shift to Null, the electric motor will stop and the unit will not operate.

  • Page 54: 100, Sl-100E, Sl-200 And Sl-200E (Tg-Vi Controller)

    SL-100, SL-100e, SL-200 and SL-200e (TG-VI Controller) Note, Please refer to the relevant refrigeration system diagram in Chapter 18 of this manual. Operating Characteristics of TG-VI Controller • TG-VI software uses a complex algorithm to determine the unit operating mode. Therefore you can NOT predict the unit mode of operation by comparing the setpoint to the return air temperature.

  • Page 55: Μp-Iv Or Μp-V Controller)

    If unit is equipped with modulation. If setpoint is below -9 C, modulation valve operation is locked out. Unit mode is Null when battery charge level is satisfied. Null mode if setpoint is below -9 C. Electric heaters are not available on SL-100, SL-100e, SL-200 and SL-200e. 1, 2 Cycle-Sentry Mode with or without Modulation •...
  • Page 56 Engine Operation Continuous Mode without Modulation • High Speed Cool • Low Speed Cool • Low Speed Heat • High Speed Heat • Defrost High Speed Heat is locked out if controller setpoint is below Fresh/Frozen temperature setting. Continuous Mode with Modulation •...

  • Page 57: 400, Sle-400, Slx/Slxe/Slxi And Slx/Slxe/Slxi Spectrum

    1, 2 CYCLE-SENTRY Mode with or without Modulation • Cool • Null • Hot Gas Heat • Full Heat (hot gas and electric heaters) • Defrost (hot gas and electric heaters) Modulation valve operation is locked out during CYCLE-SENTRY operation. Software versions 300 and above: If battery condition requires unit start-up during Null mode, unit starts and operates in Hot Gas Heat or Cool.
  • Page 58 Engine Operation Continuous Mode for µP-VI (with ETV) • High Speed Cool • Low Speed Cool • Low Speed Modulated Cool • Low Speed Modulated Heat • Low Speed Heat • High Speed Heat • Defrost ETV operation and High Speed Heat are locked out if controller setpoint is below Fresh/Frozen temperature setting. Continuous Mode with SR-2/SR-3 (without ETV) •...
  • Page 59 Electric Operation Continuous Mode (includes Modulation) • Cool • Modulated Cool • Null 1, 3 • Modulated Heat • Hot Gas Heat • Full Heat (hot gas and electric heaters) • Defrost (hot gas and electric heaters) ETV operation is locked out if controller setpoint is below Fresh/Frozen temperature setting. Null mode ONLY when the setpoint is BELOW the Fresh/Frozen temperature setting.

  • Page 60: Thermo King Sr Basic Operational Sequence Diesel Mode

    The below description of operation is a guide to understand the basic operational sequence of the automatic start sequence and Cycle Sentry operation. Note: Because Thermo King Microprocessors are programmable some functionality may change as a result of this programming, therefore this is a guide to units that are set at factory default settings.
  • Page 61 Thermo King SR basic operational sequence Diesel Mode Note: The Unit will remain running in Cycle Sentry until the following occurs: 1. Box temperature is satified 2. Engine temperature is warm 3. Unit is not in defrost 4. Battery is recharged...

  • Page 62: Thermo King Sr Basic Operational Sequence Electric Standby Mode

    The below description of operation is a guide to understand the basic operational sequence of the automatic start sequence and Cycle Sentry operation. Note: Because Thermo King Microprocessors are programmable some functionality may change as a result of this programming, therefore this is a guide to units that are set at factory default settings.
  • Page 63 Thermo King SR basic operational sequence Electric Standby Mode Note: The unit will remain running in Cycle Sentry until the following occurs: 1. Box temperature is satisfied 2. Unit is not in defrost 3. The battery is recharged Unit Description...

  • Page 64: Multi-Temp Sr-2/Sr-3 Controller)

    SL TCI, SPECTRUM SL (Multi-Temp µP-IV Controller) and SLX/SLXe/SLXi SPECTRUM (with Multi-temp SR-2/SR-3 Controller). Note, Please refer to the relevant refrigeration system diagram in Chapter 19 of this manual. Operating Characteristics of Multi-Temp µP-IV Software • Software uses a complex algorithm to determine the unit operating mode. Therefore you can NOT predict the unit mode of operation by comparing the setpoint to the return air temperature.
  • Page 65 Modulation (SLX Spectrum ETV, SLXe Spectrum, SLXi Spectrum) The modulation temperature range is factory set at -9 C to 27 C. The lower limit (-9 C) is adjustable through the keypad to -4C. The upper limit (27 C) can be field adjusted from 27 C down to -9 C. Ito -4 C or -9 C depending on setting. If the upper limit is set to -4 C or -9 C, the modulation mode is completely disabled.
  • Page 66 Zone 1 on COOL, Zone 2 on COOL and Zone 3 on HEAT NOTE: The following example shows a DE-3, TCI-3 or SPECTRUM-3 Multi-Temp system for a 3 compartment trailer. The operation of a DE-2, TCI-2 or SPECTRUM-2 system for a 2 compartment trailer is similar. See refrigeration system diagram on the previous page.
  • Page 67 75C1/FO20 SR-3 Trailer MT Guarded Access Menu 2. Then you have to select the zone to run PTC from the Mode menu: a. In MAIN Menu go to MODE, b. Press SELECT and NEXT to display PRECISION TEMPERATURE CONTROL ZONE OFF, c.
  • Page 68 When PTC is activated, the pulsing of the LLS is fully monitored by the controller from complex algorithms, to deliver improved temperature management and better fuel consumption. To perform pulsing of the LLS in a zone, there must be at least one other zone where LLS is open (energised). This ensures that there is always a path for refrigerant flow, to prevent low suction pressure.
  • Page 69 Expansion Module Base Controller/Interface Board Assembly High Voltage Tray HMI Control Panel Typical Components Inside Control Box Unit Description 5-25...

  • Page 70: Engine Compartment Components

    Engine Compartment Components The following maintenance items can be checked visually. WARNING: The unit can start at any time without warning. Press the Off key on the HMI control panel and place the microprocessor On/Off switch in the Off position before inspecting any part of the unit.

  • Page 71: Remote Evaporator Unit Description

    Remote Evaporator Unit Description Coil Temperature Sensor (Ungraded) 6. Variable Blower (12 V) Terminal Board Markstrip Hot Gas Solenoid Blower Housing 12. Drain Heater (Resistance Wire) Liquid Solenoid Blower Cover 13. Return Air Sensor (Graded) Suction Line Solenoid Terminal Board Bracket 14.

  • Page 72: Unit Operation

    The SR-2/SR-3 multi-temperature refrigeration system provides heavy duty temperature control for multiple compartment trailers. The system provides direct expansion cooling in all trailer compartments. Non-contaminating refrigerant tap-ins in the host unit evaporator provide convenient refrigerant piping connections for the remote evaporator(s). The host unit mounts on the front of the trailer with the evaporator protruding into the trailer.

  • Page 73: Protection Devices

    PROTECTION DEVICES TG-VI, µP-IV, µP-V, µP-VI and SR-2/SR-3 Control Systems • Engine High Coolant Temperature Sensor • Engine Low Oil Pressure Sensor (Except µP-VI) • Engine Low Oil Level Switch • Evaporator High Temperature Sensor • Refrigerant High Pressure Cutout Switch •...
  • Page 74 Unit Description 5-30...

  • Page 75: Operating Instructions

    6 Operating Instructions Unit Controls ............Unit Control Panel .

  • Page 76: Unit Controls

    UNIT CONTROLS Unit Control Panel UNIT ON/OFF Switch. This switch energises the electrical system of the unit including TG-IV, TG-V and TG-VI controllers. This switch must be OFF before changing a TG-VI controller or software chip ; or before the battery is connected or disconnected. •...
  • Page 77 THERMOGUARD μP IV + TEMPERATURE CYCLE COOL SENTRY HEAT ALARM DEFROST MODULATION HIGH SPEED HIGH SPEED SETPOINT WATER TEMP HOURS OIL PRESS AMPS SETPOINT SELECT ENTER CODE CLEAR ALARM Typical Multi-Temp MT µP-IV, µP-V or µP-VI Controller LCD Display: Display symbols (icons) that appear vary slightly between controller models.
  • Page 78 The manual defrost function is built into the controller. Scroll to the dEF screen in the menu display. Then press the ENTER key to initiate Defrost. The display will briefly show LOAD or Lod and enter Defrost. WARNING: With the CYCLE-SENTRY icon ON in controller display and the unit On/Off switch in the ON position, the unit may start at any time without prior warning.
  • Page 79 • CYCLE-SENTRY (Auto Start-Stop): All unit starting functions including glow plug (or air heater) preheat, fuel and throttle solenoid control, and cranking are performed automatically. NOTE: Units equipped with a µP-VI controller include the CYCLE-SENTRY mode as standard in the software menu display. Scroll to the CYCLS screen in the menu display.

  • Page 80: Smart Reefer 2/3 Multi-Temp (Sr-2/Sr-3 Mt) Control System

    SMART REEFER 2/3 Multi-Temp (SR-2/SR-3 MT) Control System The microprocessor control system components are located inside the control box, which is located inside the lower roadside service door. The microprocessor is connected to an HMI (Human Machine Interface) Control Panel, which is used to operate the unit. (The CargoWatch and Printer ports are used to retrieve data from the data logging system.) Control Box with Service Door Open (SLX/SLXe/SLXi Spectrum)

  • Page 81: Hmi Control Panel

    HMI Control Panel CAUTION: The unit can start at any time without warning. Press the O key on the HMI control panel and place the microprocessor On/Off switch in the Off position before inspecting or servicing any part of the unit. Use the HMI control panel to operate the unit.

  • Page 82: Display

    Display The display presents information to the operator. This information can include setpoint and temperature for each zone, unit or zone operating information, gauge readings, temperatures and other information as selected by the operator. The default display is called the Standard Display. See 6-13 for more information about Standard Displays. The Standard Display of box temperature and setpoint for 3 zones is shown in Figure below.

  • Page 83: Control Panel Keys (Single Or Multi-Temp Sr-2/Sr-3)

    On Key Press this key to turn the host unit and Zone 1 on. First the display will briefly show the Thermo King Logo, and then the statement “Configuring System - Please Wait”. When the power-up sequence is complete, the display shows the Standard Display of box temperature and setpoint.

  • Page 84: Unit Operation (Single Or Multi-Temp Sr-2/Sr-3)

    UNIT OPERATION (SINGLE OR MULTI-TEMP SR-2/SR-3) Manual Pretrip Inspection (Before Starting Unit) The following Manual Pretrip Inspection should be completed before starting the unit and loading the trailer. While the pretrip inspection is not a substitute for regularly scheduled maintenance inspections, it is an important part of the preventive maintenance program designed to head off operating problems and breakdowns before they happen.

  • Page 85: Turning Unit On (Single Or Multi-Temp Sr-2/Sr-3)

    Press On Key On Key Display 2. The display briefly shows a Thermo King Logo as the display initializes. NOTE: With extremely cold ambient temperatures it may take up to 15 seconds for the first display to appear. DIESEL ENGINE STARTING...

  • Page 86: Turning Unit Off (Single Or Multi-Temp Sr-2/Sr-3)

    3. The “Configuring System” Screen briefly appears while communications are established and the unit prepares for operation. 4. The Standard Display showing box temperatures and setpoints briefly appears. 5. The “Diesel Engine Starting” Screen briefly appears as the engine preheats and starts. On Model 50 units the electric standby run screen will appear instead if the unit is connected to standby power.

  • Page 87: Standard Display

    Standard Display The Standard Display is the default display that appears if no other display function is selected. Two Zone Standard Display A Two Zone Standard Display is shown below. It shows the return air temperature and setpoint for two zones. The top of the display shows that the unit is operating in Continuous mode.

  • Page 88: Operating The Unit In Single Zone Control Mode

    Single Zone Standard Display Operating The Unit In Single Zone Control Mode There are two methods of operating the unit in Single Zone Control. Method 1: The unit may be operated with each Zone individually set to the same setpoint temperature. For example, each Zone could be individually set to 35 C.

  • Page 89: Standard Display Variations

    Standard Display Variations The Standard Display has variations. A display showing any of the following variations is still considered a Standard Display. The top of the display will show that the unit is operating in either CYCLE-SENTRY or Continuous Mode. The temperature can be displayed in degrees Fahrenheit (F) or degrees Celsius (C).

  • Page 90: Temperature Watch Display

    NOTE: Zone specific alarm codes use the standard Thermo King alarm code numbers. If an alarm is specific to a zone then both the alarm code number and affected zone number are displayed. NOTE: If the large alarm icon only appears, then the active alarm(s) are unit level alarm(s). If a zone alarm icon and the large alarm icon are displayed there is a zone level alarm or a combination of zone level and unit level alarms present.
  • Page 91 DEFROST TIMER. A solid-state defrost timer automatically places the unit on Defrost every 2, 4, 8 or 12 hours, depending on the interval selected. On TG-VI, MT µP-IV, µP-V, µP-VI , SR-2 and SR-3 controllers, the defrost timer function is built into the controller menu display.

  • Page 92: Unit Instruments

    DATA INTERFACE. A serial port on the front of the MT µP-IV, µP-V, , SR-2 , SR-3 and µP-VI controllers can be connected to a computer with Thermo King Wintrac software to download data. OIL PRESSURE GAUGE. The oil pressure gauge indicates engine oil pressure. Engine oil pressure should rise immediately on starting.
  • Page 93 COMBO DISPLAY (Option SLX/SLXe/SLXi).Allows viewing of unit status and alarms directly from the driver’s cab, including operating mode, box temperature and fuel level. Operating Instructions 6-19...

  • Page 94: Unit Protection Devices

    UNIT PROTECTION DEVICES Units equipped with a TG-VI, MT µP-IV, µP-V, µP-VI, SR-2 or SR-3 controller use the microprocessor to protect the engine. FUSES (TG-VI, MT µP-IV, µP-V, µP-VI , SR-2 and SR-3 control systems). A number of fuses located on the relay board protect unit circuits and components.
  • Page 95 COOLANT. The engine coolant must be above the ADD mark and have antifreeze protection to -34 C. Check and add coolant in the expansion tank. WARNING: Do not remove the expansion tank cap while coolant is hot. CAUTION: Do not add “GREEN” or “BLUE-GREEN” conventional coolant to cooling systems using “RED” Extended Life Coolant, except in an emergency.

  • Page 96: Selection Of Operating Modes On Cycle-Sentry Equipped Units

    Selection of Operating Modes on CYCLE-SENTRY Equipped Units The Thermo King CYCLE-SENTRY Start-Stop system is designed to save temperature and control fuel costs. The savings vary with the commodity, ambient temperatures and trailer insulation. CYCLE-SENTRY is designed for use only with products which do not require tight temperature control or continuous airflow, such as all deep frozen products and non-perishable non-frozen products.

  • Page 97: Starting Units On Continuous Run, Diesel Operation

    After the unit starts on CYCLE-SENTRY operation, the control system monitors the voltage across the field of the alternator and will keep the unit operating until the battery is recharged sufficiently. The unit operates in whichever mode the controller requires to properly maintain the load temperature.

  • Page 98: Starting Model 50 Units On Electric Standby Power

    Starting Model 50 Units on Electric Standby Power TG-VI, MT µP-IV, µP-V, µP-VI , SR-2 and SR-3 NOTE: A unit that has been OFF for a long time should be put through a Full Pre-trip Test before releasing the unit for service. 1.

  • Page 99: Loading Procedure

    TG-VI, MT µP-IV, µP-V, µP-VI , SR-2 and SR-3 Controllers: Perform a Full Pre-trip Test or Unit Self Check to check the trailer, unit and unit control circuits. The test must be performed with the unit in Diesel mode and no alarms present. A Full Pre-trip Test may take up to 30 minutes. The unit will operate unattended. Clear and correct all alarms conditions before beginning.

  • Page 100: Post Load Procedure

    Post Load Procedure 1. Make sure all the doors are closed and locked. 2. Make sure the setpoint is at the desired setting. 3. Start the unit. 4. A half hour after loading, defrost the unit by manually initiating a defrost cycle. If the evaporator coil temperature is below 7 C (6 C on units with a TG-V controller;...

  • Page 101: Controller Operation

    7 Controller Operation Thermoguard Multi-temp MT µP-IV and µP-V Controllers ..... Entering Setpoint Temperature ..........Selecting CYCLE-SENTRY or Continuous Run Mode (Multi-Temp MT µP-IV and µP-V ONLY) .

  • Page 102: Thermoguard Multi-Temp Mt Μp-Iv And Μp-V Controllers

    THERMOGUARD MULTI-TEMP MT ΜP-IV AND ΜP-V CONTROLLERS The MT µP-IV, Multi-Temp MT µP-IV and µP-V controllers are programmable microprocessors that control all unit functions to maintain the cargo at the proper temperature. The controller continuously monitors unit operational information including: Return air, discharge air, coil and ambient temperature sensors;...

  • Page 103: Entering Setpoint Temperature

    Entering Setpoint Temperature The setpoint temperature of the unit can be easily changed. To adjust the setpoint, begin from the Standard Display: 1. Multi-Temp MT µP-IV: Press the SELECT key to scroll to the Standard Display of the zone you want to enter a new setpoint. •...

  • Page 104: Viewing Information (Display) Screens

    WATER TEMP HOURS OIL PRESS AMPS SETPOINT SELECT ENTER CODE CLEAR ALARM MT µP-IV, Multi-Temp MT µP-IV and µP-V Keypad HOURS Key OIL PRESSURE Key WATER TEMPERATURE Key AMPS Key TK Key SELECT Key UP Key DOWN Key ENTER Key 10.

  • Page 105: Checking The Software Version

    Prompt Display RET.A Return Air Temperature, Zone 1 DIS.A Discharge Air Temperature, Zone 1 TPDF Temperature Differential, Zone 1 COIL Coil Temperature, Zone 1 RET.A Return Air Temperature, Zone 2 TPDF* Temperature Differential, Zone 2 COIL Coil Temperature, Zone 2 RET.A Return Air Temperature, Zone 3 COIL...

  • Page 106: Unit Pre-Trip Test

    Multi-Temp MT µP-IV NOTE: If an alarm is specific to a zone, the appropriate Zone icon also appears in the display. 2. Write down each alarm code that appears. Then correct the cause of each alarm. NOTE: Turn the Unit On/Off switch OFF to stop unit before inspecting or servicing the unit. Turn the unit Microprocessor On/Off switch to OFF to service the microprocessor module or disconnect the unit battery.

  • Page 107: Thermoguard Tg-Vi Controller

    THERMOGUARD TG-VI CONTROLLER The Thermoguard TG-VI controller is a one-piece, programmable microprocessor. The microprocessor uses external relays to control unit functions to maintain the cargo at the proper temperature. The TG-VI continuously monitors unit operational information including: Return air, discharge air and coil temperature sensors; unit hourmeters; oil pressure gauge; water temperature gauge;...

  • Page 108: Entering Setpoint Temperature

    Entering Setpoint Temperature The setpoint temperature of the unit can be easily changed. To adjust the setpoint: 1. Turn the unit On/Off switch ON. The Standard Display will appear. 2. Press the UP or DOWN arrow key until the desired setpoint temperature shows in the lower display. 3.

  • Page 109: Initiating Manual Defrost

    Initiating Manual Defrost 1. With the Standard Display on the controller, press and release the SELECT key until dEF appears in the upper display. 2. With dEF in the upper display, press the ENTER key to enter Defrost. NOTE: The coil temperature must be below 7°C and the unit must be operating to initiate a defrost cycle. •...

  • Page 110: Unit Self-Check Test

    Prompt Display Alarm codes if present. If no codes exist this screen will not appear. Defrost mode. CYCLS Continuous Run or Cycle-Sentry mode screen: Yes = Cycle-Sentry, No = Continuous Run. dIS* Discharge air sensor temperature. Total hours the unit has been ON (On key ON). Total hours the diesel engine has operated.

  • Page 111: Multi-Temp Remote Control Panel

    • Low Speed Cooling Check: Second cooling test ensures that unit can cycle between Heat and Cool modes. • Full Modulation Capacity Check (Modulation Option Only): Checks ability of modulation valve to fully close. • No Modulation Capacity Check (Modulation Option Only): Checks ability of modulation valve to fully open. Unit Self-Check Report When the Unit Self-Check is complete, the controller displays the results: •...

  • Page 112: Displaying Operating Data

    Displaying Operating Data Unit operational information appears on liquid crystal display (LCD). During normal operation, the Standard Display appears on the screen. The Standard Display is the return air temperature (upper display) and setpoint temperature (lower display). Check the symbols (icons) that appear on the display. These symbols identify the operating information that currently appears. The ZONE icons at the bottom of the display identify the zone information that appears in the display.

  • Page 113: Thermoguard Μp-Vi Controller

    3. When the correct setpoint shows in the lower display, press the ENTER key to load the new setpoint in the microprocessor memory. • “Lod” will appear in the lower display for a few seconds. • The new setpoint will then appear. Check the setpoint shown in the display against the zone shown in the display to be certain that the setpoint was changed for the correct zone.

  • Page 114: Entering Setpoint Temperature

    Unit operational information appears on liquid crystal display (LCD). During normal operation, the Standard Display appears on the screen. Return air temperature (upper display) and setpoint temperature (lower display) is the factory set Standard Display (this may be changed). Check the symbols (icons) that appear on the display. These symbols identify the operating information that currently appears.

  • Page 115: Selecting Economy Mode - Revision 4000 And 4010 Software Only

    PRETRIP MODE HOURS HOURS GAUGES SETPOINT SELECT ENTER CODE CLEAR ALARM µP-VI Keypad MODE Key HOURS Key GAUGES Key PRETRIP Key TK Key SELECT Key UP Key DOWN Key ENTER Key 10. ALARM Key 11. ALARM CLEAR Key Selecting Economy Mode - Revision 4000 and 4010 Software Only NOTE: Economy Mode is controlled using OptiSet and this display does not appear in Revision 4020, 4021, and later software.
  • Page 116 View HOURS Display Screens: 1. With the unit operating, press the HOURS key to display information screens. If no alarms exist, the first screen to appear will be the TLHR screen. 2. Repeatedly press the HOURS key to display additional information screens. Prompt Display TLHR...

  • Page 117: Checking The Software Version

    View TK LOGO Display Screens: 1. With the unit operating, press the Thermo King LOGO key for 3 seconds to display information screens. If no alarms exist, the first screen to appear will be the PrE TRIP screen. 2. Repeatedly press the LOGO key to display additional information screens.

  • Page 118: Displaying And Clearing Alarm Codes

    Displaying and Clearing Alarm Codes When the controller senses an alarm condition, an alarm symbol appears on the display. A two or three digit alarm code is used to identify the type of alarm. There are three types of alarms: •...

  • Page 119: Entering A Start Of Trip In The Data Logger

    Unit Pretrip Report When the Unit Pre-trip is complete, the controller displays the results: • PASS: Unit passed the test. • CHEC: Alarm conditions (check or stored alarms) were detected during the test. A dash (-) is displayed in front of these alarms on the controller display to indicated that they were detected during a Unit Self-Check test.

  • Page 120: Sr-2/Sr-3 Controller

    SR-2/SR-3 CONTROLLER The SR-2/SR-3 controller is a programmable microprocessor that controls all unit functions to maintain the cargo at the proper temperature. The SR-2/SR-3 integrates the following functions: changing setpoint and operating mode, viewing gauge/sensor and hourmeter readings, initiating Defrost cycles, viewing and clearing alarms. WARNING: This unit is capable of automatic operation and could start at any time.

  • Page 121: Changing The Setpoint

    Mode Key Press this key to switch back and forth between the CYCLE-SENTRY mode and the Continuous Run mode. The four “soft” keys under the display are multi-purpose keys. Their function changes depending on the operation being performed. If a soft key is active, it’s function will be shown in the display directly above the key. Changing the Setpoint To change the setpoint complete the following steps.

  • Page 122: Viewing Sensor Readings

    Viewing Sensor Readings Use the following steps to view miscellaneous sensor readings. 1. Press the Sensor soft key from the Standard Display. 2. Press the Back or Next soft keys to scroll through the following sensor screens: Control Return Air Temperature, Display Return Air Temperature, Control Discharge Air Temperature, Display Discharge Air Temperature, Temperature Differential, Evaporator Coil Temperature, Ambient Air Temperature, Spare 1 Temperature, optional Datalogger Temperature Sensors 1-6 and Board Temperature Sensor.
  • Page 123 Mode Menu. Operating modes between CYCLE-SENTRY mode and Continuous Run mode as follows: 1. Press the Menu soft key on the Standard Display. 2. Press the Next and Back soft keys as required to show the the Mode Menu. 3. Press Select soft key to enter the Mode Menu. 4.
  • Page 124 Electric Standby/Diesel Mode. Select Electric Standby/Diesel Mode as follows: 1. Press the Menu soft key on the Standard Display. 2. Press the Next soft key as required to display the Electric Standby/Diesel Mode Screen. 3. Press the Select soft key to select the mode shown on the display. Adjust Brightness.

  • Page 125: Alarm Codes For Μp-Iv, Multi-Temp Μp-Iv, Μp-V, Μp-Vi, Tg-Vi , Sr-2 And Sr-3 Controllers

    ALARM CODES FOR ΜP-IV, MULTI-TEMP ΜP-IV, ΜP-V, ΜP-VI, TG-VI , SR-2 AND SR-3 CONTROLLERS NOTE: The alarms recorded by a controller depend on the controller type, software version, unit model and optional equipment. See the Alarm code chart on your unit or the appropriate Controller Operation and Diagnosis Manual for more specific information.
  • Page 126 Purge Valve Circuit Check Radio Expansion Board Configuration Condenser Inlet Solenoid Circuit Check Auto Fresh Air Exchange Circuit Door Open Time-Out High Discharge Pressure Suction Line Solenoid Circuit Unit Configuration Check Remote Fans Electric Heat Circuit Multiple Alarms - Cannot Run High Pressure Cutout Switch High Pressure Cut In Switch (Not Currently Used) Auto Switch from Diesel to Electric...

  • Page 127: Telematic Status Alerts For Tk Bluebox

    TELEMATIC STATUS ALERTS FOR TK BLUEBOX NOTE: Please refer to TK Bluebox Diagnostic’s Manual for more information. NOTE: If you suspect an issue with your TK Bluebox, you can check using your SR-3 maintenance menu. Please refer to your SR-3 diagnostic’s manual for more information. SIM not inserted Data delayed to TracKing Check SIM PIN...
  • Page 128 Controller Operation 7-28...

  • Page 129: Electrical Maintenance

    Alternator Installation ............8-12 Alternator (Thermo King, P/N 41-6780, 41-6781, 41-6782) ..... 8-13 Alternator Removal .

  • Page 130: Alternator (Australian Bosch)

    Attempting to full-field the alternator by applying battery voltage to terminal F2 will cause voltage regulator failure. Complete the following checkout procedure before replacing the voltage regulator or the alternator. • When testing alternators use accurate equipment such as a Thermo King (FLUKE 23) digital multimeter and a Thermo King amp clamp or an equivalent. •...
  • Page 131 Check Points for Bosch Alternator Test Check 2A Amperage Here Check B+ Voltage Here Check Excitation Circuit Voltage Here Place Full Fielding Jumper Here • The battery must be well charged, the battery cable connections must be clean and tight, and the 2A and excitation circuits must be connected properly.
  • Page 132 8. Attach a clamp-on ammeter to the 2A wire connected to the B+ terminal on the alternator. 9. Connect a voltmeter between the B+ terminal and a chassis ground. 10. Start the unit and operate it in high speed. 11. Connect a jumper wire between the F2 terminal and a chassis ground. This will full field the alternator. CAUTION: DO NOT full field the alternator for more than seven seconds while checking the meter readings, or the electrical system may be damaged.

  • Page 133: Field Current Test

    NOTE: An alternator can easily exceed its rated output. An alternator MUST at least reach its rated output when full fielded. An alternator that has a defective rectifier diode may reach 75% of its rated output with a full field. 13.

  • Page 134: Alternator Removal

    Alternator Removal 1. Disconnect the battery power from the unit. 2. Remove the wires from the alternator terminals. Note the location of each wire so they will be installed correctly. 3. Remove the mounting bolts and remove the alternator. Alternator Disassembly 1.
  • Page 135 Removing Rotor Rear Housing Stator Rotor Removing Diode Plate/Stator Diode plate secured by 3 screws 6. Remove the diode plate-stator assembly. a. Remove the three screws that secure the diode plate to the rear housing. b. Applying finger pressure on the B+ terminal at the rear of the alternator, slide the stator-diode plate assembly toward the front of the alternator and remove.

  • Page 136: Inspecting And Diagnosing Components

    Stator Lead Connection Diode Plate Stator Three (3) Leads Inspecting and Diagnosing Components Brushes 1. Inspect the brush assembly. The original brush set may be reused if the brushes are 4.8 mm or longer and if the brushes are not oil soaked, cracked, or show evidence of grooves on the sides of the brushes caused by vibration. 2.
  • Page 137 Rear Housing Inspection O-ring Bearing Bore Rotor 1. Place 15 volts dc across the slip rings on the rotor. CAUTION: Turn off the dc power source before installing or removing test leads on slip rings to prevent arcing and damage to the slip ring surface.

  • Page 138: Alternator Assembly

    Rotor Bearings (2) Slip Rings Pole Fingers (Rotor Body) Strator The stator assembly consists of three individual windings terminated in the delta-type connections. Using an ohmmeter or test lamp, check for winding continuity between leads A, B, and C. There should be no continuity from any lead to point D (laminations).
  • Page 139 2. Install the diode plate-stator assembly into the rear housing. a. Install the insulating washer on the B+ terminal of the diode plate. b. Install the insulating spacer on the B+ terminal of the diode plate. c. Align the B+ terminal of the diode plate with the hole on the rear housing labelled B+, and slide the diode plate-rotor assembly into the rear housing.

  • Page 140: Alternator Installation

    4. Install the front housing. a. Align the marks of the rear housing and the front housing. (Marks refer to the marks made during disassembly.) Slide the front housing over the rotor shaft and onto the bearing. b. Install the four through bolts and tighten. c.

  • Page 141: Alternator (Thermo King)

    ALTERNATOR (THERMO KING) Thermo King Alternators are painted Black and are identified by a label on the side of the Alternator that lists the Amp Rating, the Service Part number and the drawing number. Amp Rating Interchangeable with Bosch Alternators The Thermo King Series Alternators are interchangeable with the current Bosch Alternators.
  • Page 142 Note:The Current through the L Terminal must be limited through a 300ohm resistor in the EXC or 7-circuit. (Like the bosch Alternator). The Alternator will be damaged if +12V is connected directly to the L Terminal. The Nominal Voltage regulator setting for Thermo King Alternators is 14.15 +/- 0.20 @ 25’C) Electrical Maintenance...

  • Page 143: Alternator Removal

    The following illustrations show schematic Diagrams for the alternators: Schematic Diagram for 37 and 65 Amp Alternator Schematic Diagram for 120 Amp Alternator Alternator Removal 1. Disconnect the battery power from the unit. 2. Remove the wires from the alternator terminals. 3.

  • Page 144: Unit Wiring

    Inspect and clean the battery terminals and check the electrolyte level during scheduled maintenance inspections. The minimum specific gravity should be 1.235. Add distilled water as necessary to maintain the proper water level. CAUTION: When Connecting the Battery - connect the positive Battery cable first and then the negative. CAUTION: When Disconnecting the Battery - disconnect the negative battery cable first and then the positive.

  • Page 145: Fuses

    FUSES Fuses (Units with TG-VI, MT µP-IV, µP-V, µP-VI, SR-2 or SR-3) A number fuses protect various circuits and components. The fuses are located on the relay board. • A 40 amp fuse protects the main power circuit. • 25 amp fuses protect the remote evaporator fan circuits on SL, TCI and SL Spectrum models; and On/Off switch circuit on SL-400 and SL-400e models.

  • Page 146: Relay Board

    RELAY BOARD Typical Relay Board – µP-VI Controller K1: Fuel Solenoid Pull-in Relay K2: High Speed Relay K3: Damper Relay K4: Preheat Relay K5: Starter Relay K7: Run Relay Typical Relay Board – Multi-Temp MT µP-IV K2: High Speed Relay K3: Damper Relay Zone 1 K4: Preheat Relay K5: Starter Relay...

  • Page 147: Tg-Vi, Mt Μp-Iv, Μp-V, Μp-Vi, Sr-2 Or Sr-3 Controller

    Typical Relay Board – SR-2/SR-3 K1: Run Relay K2: Preheat Relay K3: High Speed Relay K4: Damper Relay K5: D/E K6: Fuel Solenoid Pull In K7: Start Relay K8: Electric Clutch Relay K9: On/Off Relay TG-VI, MT µP-IV, µP-V, µP-VI, SR-2 or SR-3 Controller The microprocessor uses relays to operate unit valves and solenoids.

  • Page 148: Air Heater

    AIR HEATER The air heater heats the intake air to help the engine start in cold weather. The air heater is energised when the Preheat-Start switch is held in the PREHEAT or START position, or when the microprocessor initiates a unit start-up (CYCLE-SENTRY switch in the CYCLE position).

  • Page 149: Low Oil Level Switch

    LOW OIL LEVEL SWITCH The low oil level switch (LOL) or oil level switch (OLS) will close and cause the reset switch to open if the engine oil level drops below the actuation level. The low oil level switch is located in the oil pan on the front side of the engine near the oil filter. TG-VI, MT µP-IV, µP-V, µP-VI , SR-2 and SR-3 NOTE: This switch alerts the microprocessor that engine oil level is low.

  • Page 150: High Water Temperature Switch

    HIGH WATER TEMPERATURE SWITCH MT µP-IV NOTE: On units with an Emergency Bypass switch, the high water temperature switch operates ONLY when emergency operation is selected to bypass microprocessor control. The high water temperature switch will close and open the reset switch if the coolant temperature is greater than 104 C. Use a continuity tester to check the switch.

  • Page 151: Evaporator Heaters

    EVAPORATOR HEATERS (If So Equipped) Test the resistance of each evaporator heater by disconnecting it from the circuit. Check resistance with an ohmmeter. SL, SLE, SLX, SLXe, SLXi The resistance of each heater should be 115 to 140 ohms. AC COMPONENTS (MODEL 50 UNITS) NOTE: The unit uses high voltage alternating current (ac) during electric operation.

  • Page 152: Phase Correction Option

    PHASE CORRECTION OPTION Phase correction is a system that automatically adjusts the phase sequence of the power supply to correspond with the wiring of the electric motor. The main components of the system are the phase sensing module (PSM), two relays, and the two motor contactors (MC1 and MC2).
  • Page 153 Typical High Voltage Tray — SLX, SLXe, SLXi with SR-2/SR-3 Controller Overload Relay Heaters Contactor * Phase Selector Drive Motor Contactors Electrical Maintenance 8-25...

  • Page 154: Defrost System

    DEFROST SYSTEM Initiate a unit defrost cycle during Unit Preload Operation and during scheduled maintenance inspections to test defrost system components. To check the defrost cycle: 1. Set the thermostat to -2 C. 2. Operate the unit on cooling to drop the evaporator coil temperature below 3 C (TG-IV), 6 C (TG-V) or 7 C (TG-VI, MT µP-IV, µP-V, µP-VI, SR-2 or SR-3).

  • Page 155: Defrost Components

    Defrost Components Evaporator Coil Sensor (Units with TG-VI, MT µP-IV, µP-V, µP-VI, SR-2or SR-3) The evaporator coil sensor is mounted in the evaporator and senses the evaporator col temperature to control defrost. If the evaporator coil temperature is below 7 C, a Defrost cycle may be initiated by the microprocessor, air switch, or manual defrost. Internal Defrost Timer (Units with TG-VI, MT µP-IV, µP-V, µP-VI, SR-2or SR-3) The standard factory settings are 6 hours for in-range defrost intervals and 4 hours for pull down intervals.
  • Page 156 Electrical Maintenance 8-28...

  • Page 157: Engine Maintenance

    9 Engine Maintenance Engine Lubrication System ..........Engine Oil Change .

  • Page 158: Engine Lubrication System

    ENGINE LUBRICATION SYSTEM Oil pressure is affected by oil temperature, viscosity and engine speed. Subnormal oil pressures usually may be traced to a lack of oil, a defective oil pressure control valve, loose connection in the lubrication system or worn bearings. The use of improper viscosity oil will also produce low oil pressure shutdowns.

  • Page 159: Engine Air Cleaner

    Air Heater Air Restriction Indicator Intake Manifold Restrictor in Breather Hose Crankcase Breather Crankcase Breather System – TK 486V Engine Breather Hose Insulation Breather Cover O-Ring Baffle Breather Baffle Plate Intake Manifold Restrictor Location ENGINE AIR CLEANER Dry Type A dry element air cleaner filters all of the air entering the engine. Excessive restriction of the air intake system affects horsepower, fuel consumption and engine life.
  • Page 160 Typical Dry Air Cleaner System – SL, SLX, SLXe, SLXi and Spectrum Models (TK 482 or TK 486 Engine) Dry Air Cleaner with Air Cleaner Hose Dry Air Cleaner with Reasonator Tube (LDB Option) Air Restriction Tube Engine Maintenance...

  • Page 161: Cyclonic Air Cleaner

    The Cyclonic air cleaner is a dry element air cleaner. Replace the Cyclonic air filter element at 3000 hours or 2 years, whichever occurs first. It cannot be interchanged with air filters used on previous Thermo King trailer units, however it can be retrofit on previous units by using the Cyclonic Air Cleaner Conversion Kit.

  • Page 162: Engine Cooling System

    ENGINE COOLING SYSTEM The engine uses a closed, circulating type, pressurised cooling system. Correct engine temperatures are controlled and maintained by a radiator, fan and thermostat. The coolant is circulated through the system by a belt-driven centrifugal pump. The pump draws the coolant from the side of the radiator, circulates it through the cylinder block and head, then back to the radiator.
  • Page 163 SL, SLX, SLXe, SLXi Spectrum MODEL NOTE: The expansion tank vent tube vents air from the expansion tank to the top of the radiator inlet tube while the cooling system is being filled. If the vent tube becomes bent, coolant can be trapped in a low spot in the tube.
  • Page 164 Engine Cooling System - SLX, SLXe, SLXi Expansion Tank Cap Expansion Tank Coolant Level Sensor Radiator Engine Coolant INLET Engine Coolant OUTLET Vent Tube Engine Thermostat Housing Engine Maintenance...

  • Page 165: Elc (Extended Life Coolant)

    ELC (Extended Life Coolant) ELC has been phased into all trailer units equipped with TK 486, TK 482 and TK 486V. A nameplate on the coolant expansion tank identifies units with ELC. NOTE: The new engine coolant, Texaco Extended Life Coolant, is RED in colour instead of the current GREEN or BLUE-GREEN coloured coolants.

  • Page 166: Checking The Antifreeze

    ELC cannot be used in older units. The water pump seal bellows and O-rings used on older units are not compatible with ELC. To upgrade new production engines for ELC use, all water pump seal bellows were changed from NBR to HNBR elastomer, and the O-rings upgraded from NBR to EPDM elastomer.

  • Page 167: Engine Thermostat

    3. Tighten plug on water pump (TK 482 or TK 486 engine). 4. Pour coolant into the system until it appears to be full. 5. Make sure that the amount of coolant that goes back into the system is approximately equal to the amount of coolant that was drained from the system.

  • Page 168: Engine Fuel System

    ENGINE FUEL SYSTEM The components of a typical fuel system include: 1. Fuel tank 2. Prefilter or fuel strainer 3. Fuel filter (or Primary and Secondary Fuel Filters) 4. Water separator 5. Hand fuel pump 6. Transfer pump (or electric fuel pump) 7.

  • Page 169: Tk 482, Tk 486 And Tk 486V

    TK 482, TK 486 and TK 486V TK 482 and TK 486, direct injection diesel engines use an in-line injection pump. TK 486V injection diesel engines use an mono-plunger and distributor injection pump. The mono-plunger and distributor injection pump uses a higher injection pressure than the in-line injection pump.

  • Page 170: Maintenance

    Maintenance The fuel system is relatively trouble-free and if correctly maintained will usually not require major service repairs between engine overhauls. Contamination is the most common cause of fuel system problems. Therefore, to ensure best operating results, the fuel must be clean and fuel tanks must be free of contaminants.

  • Page 171: Water In The Fuel System

    TK 486 - Injection Pump Bleed Screw Priming Pump TK 486V - Injection Pump Bleed Screw Priming Pump Water in the Fuel System Water in the fuel system can damage the injection pump, nozzles and prechambers. This damage will subsequently cause more expensive damage to the engine.

  • Page 172: Single Element Fuel Filter/Water Separator Replacement

    Single Element Fuel Filter/Water Separator Replacement TK 486 and 486V – Engine Fuel System Relief Valve (Keeps air from entering fuel system when engine is not running.) Filter Head Bleed Screw Mono-Plunger and Distributor Injection Pump Fuel Transfer Pump Priming Pump Fuel Filter/Water Separator A single element fuel filter/water separator is used on all engines.

  • Page 173: Tk 482, Tk 486 And Tk 486V Engines

    TK 482, TK 486 and TK 486V Engines NOTE: Use the Service Test mode to operate units with a TG-VI, MT µP-IV, µP-V, µP-VI, SR-2 or SR-3 controller. See the appropriate Controller Operation and Diagnosis manual for instructions. High Speed 1.

  • Page 174: Diagnosing The Integral Fuel Solenoid System

    NOTE: Models SL-400, SL-400e, SLX, SLXe and SLXi units do not have a fuel solenoid timer printed circuit board. The µP-VI controller and standard relay board control the pull-in coil in the fuel solenoid. NOTE: On units with a TK482, TK 486 or TK 486V engine, the unit may be restarted immediately. Diagnosing the Integral Fuel Solenoid System NOTE: The fuel solenoid pull-in coil may require 35 to 45 amperes to pull the solenoid plunger in.
  • Page 175 3. Adjust the following unit switches if they are provided on your unit: • Place the Diesel-Electric switch in the DIESEL position. • Place the Cycle-Sentry switch in the CONTINUOUS RUN position. • Place On-Off switch(es) in the ON position. 4.
  • Page 176 7. Test the pull-in coil by momentarily placing a jumper between the 8DP circuit pin in the connector on the fuel solenoid and terminal 2 at the fuse link. The fuel solenoid should make a definite click when the pull-in coil is energised and should click again when the pull-in coil is de-energised.
  • Page 177 Integral Fuel Solenoid Components Integral Fuel Solenoid O-ring Fuel Injection Pump Groove Engine Maintenance 9-21...

  • Page 178: Fuel Solenoid Replacement

    12. Check the voltage on the 2A or 2B circuit at terminal 30 in the fuel solenoid relay socket. a. If battery voltage is not present on the 2A or 2B circuit, check circuit 2A or 2B for an open or a short. b.
  • Page 179 9. Rotate the engine forward, clockwise from the front, to the injection timing mark. NOTE: The injection timing mark is a line scribed in the flywheel approximately 35 mm from the TC mark. The injection timing mark has no identification markings. 10.

  • Page 180: Tk 482, Tk 486 And Tk 486V Engines

    TK 482, TK 486 and TK 486V Engines NOTE: The procedure outlined will assume the pump is being removed and replaced on the engine. If the pump has not been removed, only the last portion of the procedure is used for timing. Injection Pump Removal 1.
  • Page 181 3. Remove the idler shaft and idler gear. 4. Install the injection pump gear, lock washer and mounting nut. Make sure the key is aligned properly. Torque the mounting nut to 60 to 68 Nm. 5. Turn the injection pump gear to the position shown in the “Align Timing Marks” illustration. 6.
  • Page 182 Injection Pump Timing (except TK 486V Engine) This timing procedure requires fuel pressure at the injection pump inlet. This can be accomplished by pumping the priming pump by hand, or by using an electric fuel pump to supply fuel to the fuel pump inlet. 1.
  • Page 183 4. Remove the rocker arm cover. 5. Place the engine at top dead center of the compression stroke for the number one cylinder. e. Rotate the engine in the normal direction of rotation (clockwise viewed from the water pump end) until the 1-4 timing mark on the flywheel lines up with the index mark in the timing mark access hole.
  • Page 184 Index Marks Location – TK 486V Engines Index Marks 2. Clean the area with brake cleaner or something similar. Place an injection angle sticker on the gear case so the center line on the sticker is aligned with the index mark on the injection pump. An injection angle sticker is provided with the new injection pump.

  • Page 185: Tk 482, Tk 486 And Tk 486V Engines

    TK 482, TK 486 and TK 486V Engines 1. Remove the rocker arm cover. 2. Remove the round cover (plug) from the timing mark access hole on the front of the bell housing. CAUTION: Loosen all of the injection lines at the injection nozzles to prevent the possibility of the engine firing while it is being rotated.
  • Page 186 10. Place the engine at top dead center of the compression stroke for the number four cylinder. a. Rotate the engine again in the normal direction of rotation until the 1-4 timing mark on the flywheel lines up with the index mark in the access hole.

  • Page 187: Belt Tension Adjustment And Belt Replacement

    BELT TENSION ADJUSTMENT AND BELT REPLACEMENT NOTE: Belt tension specifications are measured using Thermo King belt gauge tool, (P/N: See tool catalogue) Belts should be regularly inspected during unit pre-trip for wear, scuffing or cracking and correct tension. Correct belt tension is critical for correct unit operation. Belts that are too loose will slip, squeal or whip causing excessive vibration levels and poor unit performance.

  • Page 188: Sl Belt Adjustments

    SL Belt Adjustments WARNING: DO NOT attempt to adjust belts with the unit operating. Alternator Belt Replacement and Adjustment The alternator belt tension should read 30 on the belt tension gauge. When replacing or adjusting the fan belts, adjust the alternator belt tension last.
  • Page 189 Upper and Lower Fan Belt Replacement and Adjustment NOTE: Do not remove or install the belts without loosening the components correctly. Belts that are installed by prying them over the pulleys are likely to fail. NOTE: The alternator belt must be removed to remove the upper belt. 1.
  • Page 190 8. Place the upper belt in the blower pulley, the idler, and the jackshaft pulley. Check the upper belt alignment in the idler. Belt center must align with the idler groove center. Align by adjusting the idler pulley between the support brackets. 9.
  • Page 191 Compressor Drive Belt Replacement and Adjustment (Model 50) Removal: 1. Loosen the six (three on each end) mounting bolts on the electric motor. 2. Insert a pry bar into the access hole in the unit frame and pry the electric motor upward to remove the tension from the compressor drive belts.

  • Page 192: Sle, Slx, Slxe, Slxi And Spectrum Belt Adjustments

    Water Pump Belt Replacement and Adjustment The water pump belt tension should read 35 on the belt gauge. Thermo King Belt Gauge Tool (P/N see tool catalogue) NOTE: On model 30 units, the lower fan belt must be removed to remove the water pump belt. (SLe and Spectrum SL units only) 1.

  • Page 193: Blower Belts - Upper And Lower Poly-V Groove Belt Replacement On Sl Units And Upper Belt Only On Slx, Slxe, Slxi

    Blower Belts - Upper and Lower Poly-V Groove Belt Replacement on SL Units and Upper Belt Only on SLX, SLXe, SLXi WARNING: The belt tension device is spring loaded. It is strongly recommended to use tension pawl lock and hold tool - to avoid accidental entrapment of hands, fingers and clothing.
  • Page 194 Belt Arrangement – SLe and Spectrum SL 50 Models Water Pump Belt 10. Alternator Pulley Lower Polygroove Belt (Blower) 11. Jackshaft Pulley (Upper Belt) Idler 12. Jackshaft Teinioner Assembly 13. Electric Motor Jackshaft Pulley (Lower Polygroove Belt) 14. Electric Motor Pulley (Lower Polygroove Belt) Alternator 15.

  • Page 195: Slx, Slxe, Slxi Belt Replacement

    SLX, SLXe, SLXi Belt Replacement Belt Arrangement – SLX, SLXe, SLXi Blower Belt 11. Blower - Upper Alternator Pulley 12. Condenser Spinning 37 Amp Alternator 13. Motor Pulley Belt Tensioner 14. Motor 15HP Grooved Idler 15. SLX Clutch Tensioner Smooth Idler 16.

  • Page 196: Slx, Slxe Upper Belt Replacement

    SLX, SLXe Upper Belt Replacement NOTE: For SLX and SLXe units with tensioner service p/n: 78-1904 installed, refer to the below procedure for upper belt replacement. 1. Place the tensioner tool socket over the head of the tensioner (4) pivot bolt. Screw the tool fixing bolt into the tensioner base. Make sure that the tensioner tool is secured tightly in position.
  • Page 197 Tensioner Tool – SL, SLX, SLXe and Spectrum Units Tensioner Tool Tensioner Pivot Bolt Tool Fixing Bolt Tensioner Tool Nut Tensioner Base Pawl Release Mechanism Tensioner Assembly Tensioner Tool Socket NOTE: Can be used on tensioner service p/n: 78-1904. Tensioner tool cannot be used on tensioner assembly service p/n: 77-3192 (implemented in October 2016). For SLXi units, please use a size 17mm spanner wrench.

  • Page 198: Slxe (From October 2016) And Slxi Upper Belt Replacement

    SLXe (from October 2016) and SLXi Upper Belt Replacement NOTE: For SLX, SLXe and SLXi units with tensioner assembly service p/n: 77-3192 installed, refer to the below procedure for upper belt replacement. 1. Place a 17 mm socket T-bar/spanner over the head of the tensioner bolt in a horizontal starting position. Gently apply downward force until the force of the tensioner spring has been taken up by the spanner.
  • Page 199 9. Set the tensioner as per the recommended tension for a new belt using a belt frequency meter (new belt: 106-118 Hz). If the tension is within the recommended guidelines, then the mark on the arm should align close to the lower mark on the housing as shown below.
  • Page 200 NOTE 2 To adjust the sliding idler: • Perform steps 1 - 3 again to loosen the belt tension, • Loosen the sliding idler bolt and adjust sliding idler position as required (see note 1), • Tighten sliding idler bolt, •...

  • Page 201: Compressor Drive Belt Replacement And Adjustment (Model 50)

    SL Compressor Drive Belt Replacement and Adjustment (Model 50) Please refer to Specifications Section “Drive System” on page 3-4 for TK belt tension gauge tension settings for the compressor drive belt. Removal 1. Remove the two (one on each end) lower electric motor mounting bolts. 2.
  • Page 202 SL Compressor Drive Belt Adjustment 1. Loosen the six (three on each end) electric motor mounting bolts until the lockwashers disengage. 2. Loosen the lock nut on the adjusting bolt. 3. Turn the adjusting bolt as necessary to obtain the correct belt tension. 4.

  • Page 203: Lower (Engine To Electric Motor Or Cross Shaft) Belt (Slx Only)

    4. Fit belt over Poly-V pulley Grooves 5. Tighten the adjusting screw to tension the automatic tension arm spring. 6. Check and adjust the tension with Thermo King belt frequency measuring tool, P\N 204-1903 to tension number 85-90 on the tool 7.

  • Page 204: Slx Retrofit Clutch Tensioner

    SLX retrofit Clutch Tensioner 1. Remove the existing belt guard and Tensioner 2. Grind or cut off the tab from the side of the bolt-on frame post. NOTE: For ease of setting the belt tension, it is recommended 1. Ensure that the distance between the motor pulley and the motor bracket is 42mm, or the distance between the motor pulley and the eccentric plate is 14.8 mm.
  • Page 205 4. The dimension of the dampener spring (bolt head to bolt head) should be set to 139 mm to ensure the correct tension on the belt. NOTE: Corresponding tension to a dimension of 139 mm is 78-81 Hz with a new belt. This frquency should reduce to a tension of 69 - 73 Hz after 15 to 20 minutes running time.

  • Page 206: Clutch Drive Tensioning Schematic Slxe And Slxi

    SLXe and SLXi Clutch drive tensioning Schematic Note: Engine Belt Tension for these units is set by position not by frequency method. Set Engine Belt Tension by setting Centre to centre dimension between tensioning element screws & checking using checking gauge - 139.0mm tensioning gauge tool (P/N: 2042436) Description of SLXe and SLXi tensioning system Warning: Only use the screws provided with the tensioning system.
  • Page 207 SLXe/SLXi system belt and tensioning system 1. System Belt 6. Bracket Support 2. Tensioning System 7. Arm 3. Eccentric plate 8. Idler grooved 4. Square hole For 1/2’’ standard Socket Wrench 9. Idler Flat 5. Tensioner Element 10. Pivot screw : M14 l 100 mm Torque: 110 Ft.LB ± 4 Ft-lb (150Nm±5Nm) Engine Maintenance 9-51...
  • Page 208 Assembly of the SLXe/SLXi tensioning system 1. Remove the screw retainer of the pivot screw (S1). Place the tensioning system on the frame. Hand tighten the screws (S1), (S2), (S3) with appropriate tool. Tighten only the pivot screw (S1) until the required torque is reached. Warning: DO NOT tighten the plate screws (S2) and (S3) to keep the plate movable during the adjustment of the tensioning system, just make sure the plate screws are in contact with the plate.

  • Page 209: Clutch Maintenance

    4.Adjust the position of the tensioning system: by using the square hole of the plate, rotate the arm slowly down and compress the tensioner element until you can fit the gauge tool on the 2 screw heads of the tensioner. Warning: The gauge tool must not be locked on the screw heads but must move freely on and off the head screws.
  • Page 210 Clutch Assembly – SL, SLe Bearing Spring Friction Shoe 6-Pin Coupling: • (see Parts Catalogue for P/N) 8-Pin Coupling: • (see Parts Catalogue for P/N) Engine Maintenance 9-54...

  • Page 211: Sl And Sle Models

    6. Inspect the friction shoes and springs. a. Replace the friction shoes if the linings are worn to a thickness of less than 1.6 to 2.4 mm. b. Replace the springs if they are worn or broken. 7. Install the bearings with seal side out and the shield side in. Fill the cavity between the bearings 1/3 full with Mobil #28 or equivalent grease.
  • Page 212 6. Support the compressor and unbolt the compressor from the bell housing studs. 7. Remove the compressor from the bell housing and turn the compressor to provide better access to the clutch. NOTE: Unbolt the discharge and suction service valves from the compressor to allow more movement of the compressor for better access to the clutch.

  • Page 213: 10 Refrigeration Maintenance

    10 Refrigeration Maintenance Service Tools ............10-2 Leak Detection .

  • Page 214: Service Tools

    HFC refrigerants. Residual non-HFC refrigerants or non-ester based oils will contaminate and damage HFC systems. See Thermo King Truck and Trailer Diagnosing manual TK 60201-8-OD for additional information Leak Detection Leaks can be detected with the use of soap bubbles or a Halogen leak detector such as the GE H10G (P/N 204-712) or GE H10N (portable model, P/N 204-756) or a Halogen leak detector with a minimal sensitivity of 5g/year (P/N 204-1888 or equivalent).

  • Page 215: Refrigeration Maintenance Procedures

    Refrigeration Maintenance Procedures The following procedures can be found in the Thermo King Truck and Trailer Diagnosing Manual TK 60201-8-OD 1. Installing Gauge Mainfold 2. Compressor Pump Down and Checkout 3. Low Side Pump Down Additional Information Low Side Pump Down for TCI and SPECTRUM Models 1.

  • Page 216: Compressor Oil Acid Test

    NOTE: Repeat the pump down procedure if the pressures equalise above 1.40 bar, 20 psi. If suitably low pressures cannot be achieved after the third pump down, the refrigerant must be recovered to perform service on the low side. If the reading on the gauge manifold’s high pressure gauge increases after the high and low side pressures have been equalised, the condenser inlet check valve is leaking.

  • Page 217: Refrigerant Charge

    REFRIGERANT CHARGE NOTE: Use the Service Test mode to operate units with a TG-VI, µP-IV, µP-V, µP-VI, SR-2 or SR-3 controller. See the appropriate Controller Operation and Diagnosis manual for instructions. NOTE: For additional information regarding category A, B & C for SLX/SLXe/SLXi, see SLX/ SLXe/SLXi charging procedure later in this chapter.

  • Page 218: Refrigerant Overcharge Check

    The ball in the sight glass should be floating. If there is no indication of refrigerant in the sight glass, the unit is low on refrigerant. For category B SLX, open doors to view the sight glass and close again NOTE: If the ball floats, there is sufficient refrigerant in the unit for that load at that particular compartment temperature.

  • Page 219: Moisture Indicating Sight Glass (Where Fitted)

    To add refrigerant: 1. Connect and purge/evacuate a gauge manifold set to a refrigerant bottle and the suction service valve. 2. Set the refrigerant bottle for liquid charging. Note: For Category B unit, close all doors on unit and ensure all unit panels and skins are securely attached. 3.

  • Page 220: Slx, Slxe, Slxi Spectrum Charging Procedures

    11 below. Unit configuration categories. As a result of continuous improvement and design changes, Thermo King SLX SPECTRUM units may be categorized as A, B or C depending on the date of manufacture.

  • Page 221: Slx, Slxe, Slxi Spectrum Charging Procedure

    Category A Category B Category C Condenser Finned-tube Micro-channel Micro-channel Throttle valve Mechanical Mechanical Electronic Receiver Charge (approximate) 7.5kg Host + 6kg Host + 0.75kg 6kg Host + 0.75kg 0.75kg (per S-2) or (per S-2) or (per S-2) or 1.0kg (per S-3) for 1.0kg (per S-3) for 1.0kg (per S-3) for each evaporator,...

  • Page 222: Refrigerant Leaks

    An overcharge of refrigerant will cause compressor damage. Therefore, Thermo King recommends that all major repairs to the refrigeration system include the removal and reclamation (cleaning) of the refrigerant, followed by a thorough evacuation using the proper tools and procedures. A major repair is any repair that requires soldering, replacement of a major system component or leaves open a portion of the system to the atmosphere for more than 30 minutes.
  • Page 223 Vacuum Gauge 100 Microns 500 Microns 1000 Microns 2500 Microns 5000 Microns 20,000 Microns Atmospheric Pressure Refrigeration Maintenance 10-11...
  • Page 224 Constant Pressure Rise After Evacuation Indicates System Leak Close the vacuum valve and watch the movement of vacuum gauge needle. If needle continues to rise, this is an indication that a leak exists in the unit or connecting line. The leak must then be located and eliminated.

  • Page 225: Set-Up And Test Evacuation Equipment

    The primary objective of evacuation is to bring the system’s pressure to a low micron level to ensure the removal of moisture and non-condensables. There are some other principles that must be observed. These are: • Evacuate from 3-points to access both sides of check valves and solenoids. Energise solenoids during evacuation to prevent trapping of refrigerant or non-condensables.
  • Page 226 Unit Evacuation Vacuum Gauge Scale Isolation Valve Open Refrigerant Vacuum Valve Back Seated Valves Gauge Manifold NOTE: Evacuation hose to the evacuation pump should be larger than the other three hoses to the unit. This will speed up evacuation time. Refrigeration Maintenance 10-14...

  • Page 227: Unit Evacuation

    8. Evacuate the hoses to 100 microns, or the lowest achievable level below 500 microns. 9. When a vacuum of 100 microns has been reached, close the vacuum valve and stop the vacuum pump. 10. Wait 5 minutes and then check the vacuum gauge. The pressure should not exceed 1500 microns. 11.

  • Page 228: Unit Charging

    Unit Evacuation 1. Leave hand valve closed for first 5 minutes of evacuation 2. Valves to be in cracked open position Unit Charging NOTE: The electrical system must be energised throughout this procedure. NOTE: Please take note of your refrigerant type (label on outside of unit), and make sure not to cross-contaminate. NOTE: Before charging the system, make sure that the refrigerant lines from the gauge manifold to the refrigerant supply bottle have been evacuated or purged.
  • Page 229 5. If additional refrigerant must be added, close the gauge manifold hand valve. Then turn the unit (and remote evaporator) On/Off switch(es) OFF. a. Leave the valve set for liquid charging. b. Back seat the receiver outlet valveto the suction service valve. c.

  • Page 230: Remove Evacuation Hoses

    Remove Evacuation Hoses Refer to Thermo King Truck and Trailer Diagnosing Manual for correct procedure HIGH PRESSURE CUTOUT discharge manifold. If the discharge pressure exceeds the pressure The high pressure cutout (HPCO) is located on the compressor switch setting, the switch opens the 8D circuit, de-energizing the fuel solenoid to stop the unit. See Specifications chapter switch settings.

  • Page 231: Modulation Valve

    3. Install a service gauge manifold set on compressor. 4. Front seat the receiver tank outlet valve. 5. Operate the unit on cooling and pump down the low side to -0.68 bar, 20 in. Hg vacuum. 6. Stop the unit. The condenser and suction pressures should remain stable, indicating no leaks. 7.

  • Page 232: Electronic Throttling Valve (Etv)

    ELECTRONIC THROTTLING VALVE (ETV) The electronic throttling valve (ETV) is a variable position valve operated by a stepper motor. The ETV is located in the suction line between the heat exchanger and the accumulator. The ETV controls the flow of refrigerant returning to the compressor. Therefore, it replaces the modulation valve and compressor throttling valve.

  • Page 233: Spectrum Multi-Temperature Refrigeration Components

    SPECTRUM MULTI-TEMPERATURE REFRIGERATION COMPONENTS Host Unit Components These three valves are located in the condenser section of the host unit. Condenser Inlet Solenoid (CIS) This valve controls the flow of refrigerant to the condenser. This solenoid is typically energized (closed) when any compartment is operating in heat or defrost mode.
  • Page 234 Refrigeration Maintenance 10-22...

  • Page 235: Refrigeration Service Operations

    11 Refrigeration Service Operations Refrigeration System Components ........11-2 Low Side Pump Down .

  • Page 236: Refrigeration System Components

    REFRIGERATION SYSTEM COMPONENTS NOTE: It is generally good practice to replace the filter drier whenever the high side is opened or when the low side is opened for more than 30 minutes. Replace the external mounted compressor oil filter whenever the filter drier is replaced. This is not required for units with P compressor with internal oil filter.

  • Page 237: High Pressure Cutout Switch Or High Pressure Cycle (Control) Switch

    Installation 1. Replace clutch from compressor crankshaft on Model 50 units, or on drive coupling on model 30 units. 2. Lift compressor into the unit and install the mounting bolts. NOTE: The 8-pin compressor drive hub will only slide onto the coupling pins in one of two positions that are 180 degrees apart.

  • Page 238: Condenser Coil

    Condenser Coil Removal 1. Recover the refrigerant charge. 2. Drain engine coolant from the expansion tank. • SL and SLe: Unbolt and remove coolant expansion tank from condenser coil frame. Unsolder tank breather tube. • SLX (with copper tube and fin): Drain all coolant. Remove coolant hoses from radiator portion of the coil. 3.
  • Page 239 Installation 1. Prepare the suction hose and tube fittings for soldering by cleaning thoroughly. 2. Solder the vibrasorber to the suction service valve. CAUTION: Use a heat sink or wrap vibrasorber with wet rags to prevent damaging the vibrasorber. 3. Solder the suction hose connection to the accumulator. 4.

  • Page 240: Receiver Tank

    Typical Condenser Inlet Check Valve Gasket Spring Seat Receiver Tank Removal 1. Recover the refrigerant charge. 2. Unsolder liquid inlet line from the receiver tank. 3. Disconnect the filter drier line from receiver tank. 4. SL and SLe: Disconnect bypass check valve line from receiver tank. Remove the bypass check valve from the receiver tank. 5.

  • Page 241: High Pressure Relief Valve

    High Pressure Relief Valve Removal 1. Recover the refrigerant charge. 2. Unscrew and remove the high pressure relief valve. Installation 1. Apply compressor oil to the O-ring on the high pressure relief valve. 2. Apply a refrigerant locktite to the threads of the high pressure relief valve. 3.

  • Page 242: Evaporator Coil

    Installation 1. Install and bolt the expansion valve assembly in the unit. 2. Solder (95-5 Solder) the inlet liquid line and the distributor to the expansion valve. 3. Solder (95-5 Solder) the equaliser line to the expansion valve. 4. Clean the suction line to a bright polished condition. Install the feeler bulb clamps and the feeler bulb on the side of the suction line in its former position.

  • Page 243: Heat Exchanger

    Heat Exchanger Removal 1. Pump down the low side and equalise the pressure to 0 psig, (0 bar g). 2. Remove the evaporator access panels. 3. Remove the mounting bolts that hold the heat exchanger on the bulkhead. TLE and SPECTRUM REMOTE EVAPORATOR NOTE: Unsolder the inlet and outlet connections. Then go to step 8a. 4.

  • Page 244: Pilot Solenoid

    3. Tighten the accumulator tank mounting bolts. 4. Replace Drier 5. Pressurise the low side and test for refrigerant leaks. If no leaks are found, evacuate the low side. 6. Open the receiver tank outlet valve. Place the unit in operation. Check refrigerant charge and compressor oil level and add as required.

  • Page 245: Throttling Valve (Non-Etv Units)

    Installation 1. Clean the tubes for soldering. 2. Remove the coil from the new valve. Correctly position the valve hot gas line. 3. Solder the connections. CAUTION: Use a heat sink or wrap valve with wet rags to prevent damaging the valve. 4.
  • Page 246 Throttling Valve Piston End Cap Inspect Cap Inspect Spring Shims 5. Break the gasket free and remove the end cap. 6. Note the number of shims next to the cap. These can be reused. 7. Remove bellows (discard). 8. Inspect all the parts. (Replace if excess wear is found.) a.
  • Page 247 Throttling Valve Screw and Washer O-ring, Valve to Compressor Bellows End Plate 10. Piston Housing Gasket End Plate Gasket 11. Piston Adjusting Washers (Shims) 12. Piston Spring Bellows Spring 13. Cotter Pin Bellows and Shaft 14. Adjusting Nut O-ring 15. Piston Housing Housing 16.

  • Page 248: Three-Way Valve Condenser Pressure Bypass Check Valve Repair

    Installation 1. Install the throttling valve using new O-ring soaked in compressor oil (same type of oil that is used in the system). Bolt the throttling valve to the compressor. 2. Connect the suction hose from the throttling valve to the accumulator tank. Install pilot solenoid line. 3.

  • Page 249: Three-Way Valve Repair

    Three-Way Valve Repair NOTE: The three-way valve can be repaired in the unit if leakage or damage to the Teflon seals should occur. There is usually enough movement in the copper tubing to separate the three sections of the valve without unsoldering any tubes. Removal 1.
  • Page 250 Assembly/Installation Three-Way Valve Assembly Screw Top Cap Check Valve Cap Check Valve Assembly Spring Piston (Valves built before 11/97) Clip Teflon Seal (Valves built before 11/97) O-ring (Valves built before 11/97) 10. Gasket 11. Seat 12. Gasket 13. Stem Assembly 14.

  • Page 251: External Compressor Oil Filter - X214, X426 Or X430 Compressor

    After cleaning and inspecting all parts, reassemble the valve. 1. Install the screen into the bottom cap. 2. Install new stem into the center section. 3. Install new gaskets on both sides of the valve body. Dip gaskets in compressor oil before installing. 4.

  • Page 252: Electronic Throttling Valve (Etv)

    Installation 1. Apply a thin layer of refrigerant oil to new O-rings and install in the inlet and outlet nuts. 2. Install the new oil filter and tighten the mounting bracket screws and nuts (inlet end of filter is labelled “IN”). 3.
  • Page 253 4. Unscrew the nut/four screws that attaches the stepper motor and piston assembly to the valve body. ARA2500 5. If the complete ETV assembly is being replaced, remove the ETV mounting hardware (if used) and unsolder and remove the valve body. It may be necessary to unsolder other tubes near the valve body to obtain enough clearance to remove the valve body.
  • Page 254 2. Lubricate the O-rings with refrigeration oil. Place one on the stepper motor and piston assembly and place the other in the valve body. ARA2502 Install O-Ring on Stepper Motor and Piston Assembly ARA2503 Install O-Ring Valve Body 3. Place stepper motor and piston assembly into the valve body and make sure the arrowhead marks on them are aligned as shown below (picture applicable for ETV standard from October 2016 only).
  • Page 255 Installation of Complete ETV Assembly 1. Clean the tubes for soldering. 2. Place the new complete ETV assembly (and any tubes that were removed) in the same position from which the old one was removed. The ETV assembly must be installed as shown below relative to the direction of refrigerant flow from the accumulator to the compressor.

  • Page 256: Multi-Temperature System Components

    MULTI-TEMPERATURE SYSTEM COMPONENTS NOTE: The following components are unique to multi-temperature systems, including: • TCI and SPECTRUM Host Units • TLE and SPECTRUM Remote Evaporators Discharge Pressure Sensor Removal 1. Recover the refrigerant charge. 2. Disconnect the wire connector. 3. Remove the mounting clamp from the sensor. 4.

  • Page 257: Condenser Inlet Solenoid Valve (Cis) Or Hot Gas Solenoid Valve (Hgs, Hgs2, Hgs3, Rhgs, Hgbp Or Chgs)

    Condenser Inlet Solenoid Valve (CIS) or Hot Gas Solenoid Valve (HGS, HGS2, HGS3, RHGS, HGBP or CHGS) NOTE: Valves that have nylon seats must be disassembled before soldering. Removal 1. Recover the refrigerant charge. 2. Remove the coil and disassemble the valve. 3.

  • Page 258: Receiver Tank Pressure Solenoid Valve (Rtps)

    Receiver Tank Pressure Solenoid Valve (RTPS) Removal 1. Recover the refrigerant charge. 2. Remove the coil from the valve. 3. Unsolder the hot gas lines from the valve. Remove the valve from the unit. CAUTION: Use a heat sink or wrap the valve with wet rags to prevent damage. Installation 1.

  • Page 259: 12 Structural Maintenance

    12 Structural Maintenance Unit and Engine Mounting Bolts ......... 12-2 Unit Inspection .

  • Page 260: Unit And Engine Mounting Bolts

    UNIT AND ENGINE MOUNTING BOLTS Periodically check and tighten all unit and engine mounting bolts. Torque the unit mounting bolts to 81.3 N•m. Torque the engine mounting bolts to 203 N•m. Typical Engine Mounting Bolt Location 1. Check and tighten four (4) engine mounting bolts. Typical Unit Mounting Bolt Location All Models: Check and tighten six (6) unit mounting bolts.

  • Page 261: Unit Inspection

    UNIT INSPECTION Inspect the unit during unit pre-trip and scheduled maintenance inspections. Look for loose or broken wires or hardware, compressor oil leaks, or other physical damage that might affect unit performance and require repair or replacement of parts. DEFROST DRAINS Clean the defrost drains during scheduled maintenance inspections to be sure the lines remain open.
  • Page 262 Coil Before Cleaning => Coil after Wiping Right Hand Side with Cloth Source Angle for Cleaning with Air or Water Structural Maintenance 12-4...

  • Page 263: Unit Installation

    UNIT INSTALLATION All nuts that hold the unit to the trailer are accessible using an impact wrench with a 25 cm extension, ball-type swivel and a deep-well socket. NOTE: The nuts for mounting the unit should be elastic stop nuts (Nylock type) Unit Installation –...

  • Page 264: Sl And Sle Top Center Nut

    SL and SLe Top Center Nut To reach the top center nut when installing unit: 1. Open the control box side condenser grille door. 2. Remove the coil blower access panel. This is the diagonal panel just above the blower inlet area. 3.

  • Page 265: Access To Mounting Holes Slx, Slxe, Slxi

    SL and SLe Optional Top Center Mounting Bolt Installation Side View Unit Condenser Coil Trailer Ceiling Unit Foam Evaporator Bolt Pocket Trailer Installed Top Center Mounting Bolt Access to Mounting Holes SLX, SLXe, SLXi 1. Access the top center and top left mounting holes is normally possible without removing the Unit Top Cover. 2.

  • Page 266: Defrost Damper

    DEFROST DAMPER Check the damper during scheduled maintenance inspections for shaft wear, end play and the ability to stop the airflow. The damper should close and seal so the airflow is stopped on the top and bottom edges with the solenoid plunger bottomed out. If the damper does not seal properly, adjust the damper assembly.
  • Page 267 When a switch is in the active position, the blue wire (pole 2) is connected to the red wire (throw) and the yellow wire (pole 1) is open. The two micro switches are connected in parallel to the defrost damper circuit. Energizing the 29 circuit closes the damper. Energizing the 29A circuit (29B on TCI models) opens the damper.
  • Page 268 Damper Closing Logic Defrost can be initiated manually or automatically when the evaporator coil temperature is below 3 C (TG-IV), 6 C (TG-V) or 7 C (TG-VI, µP-IV, µP-V or µP-VI). When defrost is initiated, the damper relay (K3 or D3) is energised. The 29 circuit is then energised by the 2AA (or 2A or 8VF) circuit through the damper fuse (F3) and the normally open contacts in the damper relay.
  • Page 269 At this point the outer cam is in contact with the outer micro switch and the outer micro switch is in the active position. The 29 circuit is connected to the damper motor through the outer micro switch. The outer cam leads the inner cam by 20 degrees, therefore the inner cam is not in contact with the inner micro switch and the inner micro switch is in the normal position.
  • Page 270 Outer Micro Switch Circuit Still Closing Damper – SL Damper Motor Inner Micro Switch Outer Micro Switch Damper Relay NOTE: 29A circuit is 29B on TCI models. Micro Switch Circuits When Damper Is Closed – SL Damper Motor Inner Micro Switch Outer Micro Switch Damper Relay NOTE: 29A circuit is 29B on TCI models.
  • Page 271 Outer Micro Switch Circuit Still Opening Damper – Damper Motor Inner Micro Switch Outer Micro Switch Damper Relay NOTE: 29A circuit is 29B on TCI models. Micro Switch Circuits When Damper Is Open – SL Damper Motor Inner Micro Switch Outer Micro Switch Damper Relay NOTE: 29A circuit is 29B on TCI models.
  • Page 272 At this point the outer cam is not in contact with the outer micro switch and the outer micro switch is in the normal position. The 29A (or 29B) circuit is connected to the damper motor through the outer micro switch. The outer cam leads the inner cam by 20 degrees, therefore the inner cam is in contact with the inner micro switch and the inner micro switch is in the active position.
  • Page 273 Install Damper Link – SL Damper Link Damper Motor Bracket When it stops, the flat should be on the left side of the output shaft and approximately parallel with the vertical sides of the gear case. In this position the damper would be open. The output shaft must be in this position (damper open) when the damper motor is being installed in the unit.
  • Page 274 3. Attach the damper link to the output shaft (see “Install Damper Link” illustration). NOTE: The damper link MUST be installed correctly. If the damper link is not installed correctly, the damper will not operate properly. The damper will move between half open and half closed and it will be impossible to adjust the damper properly. 4.
  • Page 275 4. Attach the damper door bracket to the damper door. Snug the mounting screws enough to hold the damper door bracket in place, but do not completely tighten the mounting screws. 5. Position the damper door bracket so the mounting screws are in the middle of the slots in the damper door. 6.
  • Page 276 Damper System Adjustment WARNING: This damper system can cause serious injuries. Make sure to keep your hands away from the damper door and the moving parts of the damper system while the damper motor is energised. It is necessary to change the position of the damper by energizing the damper motor during the adjustment procedure.
  • Page 277 Symptom – Damper motor does not turn when defrost is initiated (see “Defrost Cycle Checkout Procedure” in Electrical Maintenance chapter for additional information): • Make sure that the evaporator coil temperature is below 3 C (TG-IV), 6 C (TG-V) or 7 C (TG-VI, µP-IV, µP-V, µP-VI or SR-2).
  • Page 278 Damper Motor Heater The damper motor is equipped with a damper motor heater. The heater improves the operation of the damper motor at low temperatures. The damper motor heater consists of a length of resistance wire wrapped around the damper motor and a thermostat switch that is mounted on the damper motor.
  • Page 279 Testing the Damper Motor Heater • Units with TG-V: Disconnect the thermostat switch wire from the 7K wire in the evaporator wire harness. • Units with TG-VI, µP-IV, µP-V, µP-VI or SR-2: Disconnect the damper motor connector from the evaporator harness. •...

  • Page 280: Damper Door Motor With Current Sensing Blade Position Control

    Damper Door Motor with Current Sensing Blade Position Control (SLXi, SLXe, SLX, SLe and Late Model SL Units) SLXi/SLXe/SLX/SLe and late model SL units (SLe/SL units produced from August 2000) and some SL-400 units produced from April 2000 feature a defrost damper gear motor with a current sensing system to control damper blade position. The motor and gearbox are located at the damper door;...
  • Page 281 Closing the Damper Door When a Defrost cycle is initiated 12 volts is supplied to the A terminal of the gear motor controller via the 29 wire. The gear motor controller then supplies chassis ground to the gear motor via the Y terminal to energize the motor. The gear motor controller ignores the amount of current drawn for the first few seconds of operation to accommodate the current spikes that may result if the damper is frozen in position.
  • Page 282 Gear Motor Adjustment Procedure The gear motor adjustment is only required if the assembly is removed or replaced, once correctly set it will not require further adjustment. Install the Gear Motor and linkage in the position indicated in the attached drawings, note the linkage assembly orientation layout and the limit stop bolts.
  • Page 283 KEEP VERTICAL Figure 2 Spacer Washers Damper Bracket Ball Joint Link CLOSED POSITION Figure 3 Structural Maintenance 12-25...
  • Page 284 OPEN POSITION Figure 4 Note:Please refer to previous paragraphs on Damper Door Logic and Operation - this is the same principle on the SLXe/SLX. Defrost Damper Closed – SLXi, SLXe/SLX 1. Evaporator Grille 2. Damper Door 3. Evaporator Blower 4. Evaporator Blower Housing 5.

  • Page 285: Fan Shaft Assembly

    Defrost Damper Open – SLXi/SLXe/SLX 1. Evaporator Grille 2. Damper Door 3. Evaporator Blower 4. Evaporator Blower Housing 5. Blower Hub 6. Scroll Panel FAN SHAFT ASSEMBLY SL and SLe The SL and SLe are equipped with a one-piece fan shaft that is supported by separate compressor side and control box side bearing assemblies.
  • Page 286 3. Remove mounting hardware for the compressor side condenser orifice (item 1) and remove the compressor side condenser orifice. 4. Loosen the two evaporator blower mounting screws (item 16). 5. Remove mounting hardware for the control box side evaporator orifice (item 8). 6.
  • Page 287 Fan Shaft Assembly – SL and SLe Compressor Side Condenser Orifice 12. Fan shaft Pulley Control Box Side Condenser Orifice 13. Evaporator Shaft Seal Collar Compressor Side Condenser Blower 14. End Shaft Screws (2) Control Box Side Condenser Blower 15. Condenser Blower Mounting Screws (4) Fan Shaft 16.
  • Page 288 Assembly The fan shaft is symmetrical and either end can be put into the unit first. However, the fan shaft must be installed from the control box side of the unit. 1. Install the compressor side bearing assembly (item 6) and fasten it securely. The compressor side bearing is self-aligning and does not need to be adjusted.
  • Page 289 3. Slide the fan shaft (item 5) into the control box side condenser blower area. Place the control box side condenser orifice (item 2) around the fan shaft. Then slide the control box side condenser blower (item 4) over the compressor side end of the fan shaft.
  • Page 290 5. Place the control box side evaporator orifice (item 8) around the fan shaft. The draw on the control box side evaporator orifice should face the evaporator blower (toward the compressor side of the unit). The compressor side evaporator orifice will be fastened to the outside of the evaporator blower housing (item 19).
  • Page 291 Position Seal Plate – SL and SLe Fan shaft Uniform Clearance Around Fan shaft Seal Plate (This Face Up) 12. Slide the compressor side condenser blower (item 3) onto the compressor side end of the fan shaft and make sure to align the Woodruff key.
  • Page 292 Position Control Box Side Condenser Blower – SL and Bulkhead Seal Gauge Pin Control Box Side Condenser Blower (item 4) 16. Slide the fan shaft pulley (item 12) onto the control box side end of the fan shaft and make sure to align the Woodruff key. 17.
  • Page 293 Evaporator Shaft Seal Collar Position – SL and SLe Seal Plate (item 10) Evaporator Shaft Seal Collar (item 13) Fan shaft (item 5) 20. Position the seal plate (item 10) that is next to the evaporator blower so the hole in the seal plate is centered on the fan shaft. Tighten the seal plate mounting hardware to hold the seal plate in this position.

  • Page 294: Sl And Sle

    26. Place the forked prongs of the evaporator shaft seal gauge (item 21) between the evaporator seal plate (item 10) and the evaporator shaft seal collar (item 13). 27. Push the evaporator shaft seal collar up against the evaporator shaft seal gauge and tighten the 1/4-20 set screw on the shaft seal collar.
  • Page 295 34. Torque the two evaporator blower mounting screws (item 16) to 17.5 N•m. 35. Center each evaporator orifice in the evaporator blower and tighten the evaporator orifice mounting hardware to hold the evaporator orifice in this position. 36. Check the radial clearance of the evaporator blower by passing a 2.3 mm wire completely around the circumferences of the evaporator orifices and the evaporator blower.
  • Page 296 37. Fasten the compressor side condenser orifice (item 1) loosely in place. Center the condenser orifice in the condenser blower and tighten the condenser orifice mounting hardware to hold the condenser orifice in this position. Check the radial clearance of the blower by passing a 2.3 mm wire completely around the circumference of the condenser orifice and the condenser blower.
  • Page 297 Reassembly 1. Coat the outer edge of the oil seal with gasket sealant and press the seal into the bearing housing. 2. Install the inner wave spring washer. 3. Install the O-ring on the outer bearing race and place the roller bearing assembly and the inner race in the housing. Be careful not to damage the O-ring.
  • Page 298 Control Box Side Bearing Disassembly. 1. Remove the control box side bearing assembly from the unit. 2. Remove the oil plug and drain the oil. 3. Position the bearing assembly in a vise with protective jaws or use two pieces of wood to protect the bearing housing. 4.

  • Page 299: Slxi, Slxe, Slx Fan Shaft Assembly

    SLXi, SLXe, SLX Fan Shaft Assembly These models have a fanshaft with 2 main components - the Fanshaft and the Fanshaft housing.The fanshaft Assembly is supported in the housing by compressor and control box side Bearing Assemblies. Disassembly 1. Remove snap Ring (compressor side) 2.

  • Page 300: Lower Blower Assembly Slxi, Slxe, Slx

    Lower Blower Assembly SLXi, SLXe, SLX In these units, the two Condenser Blowers are in different positions to the SL. (Upper and Lower Blowers, instead of left and right of the Evaporator Blower) The Upper Blower is similar to the SL Blower. Here is the Lower Blower assembly. Note: See Chapter 9, (9-31) Belt Arrangement SLXi, SLXe, SLX for more details.

  • Page 301: Jackshaft/ Cross Shaft Assembly

    JACKSHAFT/ CROSS SHAFT ASSEMBLY The SL are equipped with a one-piece jackshaft assembly that contains tapered roller bearings in a sealed oil reservoir. Check the jackshaft during the pre-trip inspection for oil leakage. If there is any sign of leakage, remove the jackshaft assembly and repair it. NOTE: The jackshaft assembly requires a special oil, (see Parts Catalogue for P/N) Removal...
  • Page 302 Reassembly 1. Coat the outer edges of the oil seal with gasket sealant. 2. Using a suitable tool, slightly smaller than the outside diameter of bearing races, install the bearing races in the bearing housings. 3. Using a soft or wooden hammer, install the seals in the bearing housing and bearing housing cap. Fill the space between the seal lips with oil.

  • Page 303: Sle And Spectrum

    SLe and SPECTRUM SLe and SPECTRUM units are equipped with a jackshaft that contains special sealed bearings. The jackshaft bearings should be checked when the belts are replaced. Spin the jackshaft with the belts removed and listen. Unusually loud bearing noise indicates the jackshaft bearings should be replaced.
  • Page 304 Disassembly 1. Remove the pulleys and keys from the jackshaft. 2. Remove the snap rings. 3. Remove the jackshaft from the housing by tapping on either end of the jackshaft with a soft hammer. 4. Remove the bearing from the jackshaft by supporting the bearing and tapping on the end of the jackshaft. 5.
  • Page 305 Reassembly CAUTION: To prevent damage to the bearings, use bearing drivers (or other suitable tools) on the bearing races when installing the bearings. NOTE: Place a thin layer of grease (Mobil 28 or its equivalent) on the inner and outer bearing races before assembly. 1.
  • Page 306 Jackshaft Assembly – SLe Snap Ring Lower Mounting Bolt Tab Bearing Jackshaft Housing Wave Washer Small End of Jackshaft Large End of Jackshaft Structural Maintenance 12-48...

  • Page 307: Slxi, Slxe, Slx Cross Shaft Assembly

    SLXi, SLXe, SLX Cross Shaft Assembly Cross Shaft (Jackshaft) Assembly – SLXi, SLXe, SLX 1. Cross Shaft Housing 4. Shaft 2. Wave Washer 5. Snap Ring 3. Bearing 6. Key CrossShaft Assembly – SLXi, SLXe, SLX 1. Cross Shaft Housing 2.

  • Page 308: Remote Evaporator Unit

    REMOTE EVAPORATOR UNIT Unit Inspection Inspect the unit during the unit pre-trip inspection and scheduled maintenance inspections. Look for loose or broken wires or hardware, compressor oil leaks, or other physical damage that might affect unit performance and require repair or replacement of parts.

  • Page 309: 13 Mechanical Diagnosis

    13 Mechanical Diagnosis TK 482, TK 486 and TK 486V Engines ........13-2...

  • Page 310: Tk 482, Tk 486 And Tk 486V Engines

    TK 482, TK 486 and TK 486V Engines NOTE: This diagnosis guide applies to units equipped with TK 482, TK 486 and TK 486V engines. For major repair of TK 482, TK 486 and TK 486V engines, refer to Overhaul Manual TK 50136. NOTE: For diagnosis of units, see the appropriate Controller Operation and Diagnosis manual.
  • Page 311 CONDITION POSSIBLE CAUSE REMEDY TG-VI, μP-IV, μP-V or μP-VI: Batteries discharged Replace or lights come recharge battery Unit switch ON and LCD ON but Defective Preheat/Start switch Replace switch engine will not crank Defective starter solenoid Replace solenoid Corroded battery connections Clean and tighten Defective starter Repair starter...
  • Page 312 CONDITION POSSIBLE CAUSE REMEDY Engine stops after starting Air in injection pump Bleed fuel system Fuel filter obstructed Replace filter element High head pressure Eliminate cause of high head pressure Vent of fuel tank obstructed Unclog vent Clogged fuel tank or fuel lines Clean fuel tank and fuel lines Engine does not develop full power Air cleaner or intake system Clean air intake system;...
  • Page 313 CONDITION POSSIBLE CAUSE REMEDY Engine speed too high Misadjusted throttle solenoid Adjust throttle solenoid Control rod sticks Repair injection pump Engine fails to stop when unit is Fuel solenoid valve defective Replace Injection pump defective Replace pump Engine knocks heavily Air in system Bleed fuel system Injection pump not timed...
  • Page 314 CONDITION POSSIBLE CAUSE REMEDY Oil pressure too low or drops Insufficient oil in pan Add oil suddenly. Minimum oil pressure Oil relief valve sticking Disassemble and clean oil pressure regulator valve for a hot engine is 1.03 bar, 15 psi Defective oil pressure gauge Check oil line to oil pressure gauge to see if it is blocked.
  • Page 315 CONDITION POSSIBLE CAUSE REMEDY White Smoke (fuel is not burning) Cold engine Allow engine to warm up Low compression Check and eliminate possible causes. Repair as necessary Timing incorrect Readjust timing Air or water in fuel Bleed system. Replace filters, clean fuel system, drain and clean tank and check supply tank for water.
  • Page 316 Mechanical Diagnosis 13-8...

  • Page 317: Refrigeration System Diagnosis

    14 Refrigeration System Diagnosis All Models Except TCI and SPECTRUM ........14-2 TCI and SPECTRUM Models .

  • Page 318: All Models Except Tci And Spectrum

    ALL MODELS EXCEPT TCI AND SPECTRUM POSSIBLE CAUSE • • • • Overcharge of refrigerant • • • • • • Shortage of refrigerant • • • • • No refrigerant • • Air through condenser too hot (ambient) • •...
  • Page 319 ALL MODELS EXCEPT TCI AND SPECTRUM (Continued) POSSIBLE CAUSE • • • • Liquid refrigerant entering compressor • • • Restricted line on the low side • • • • Restricted line on the high side • • • • Restricted dehydrator •...

  • Page 320: Tci And Spectrum Models

    TCI AND SPECTRUM MODELS POSSIBLE CAUSE • • • Faulty Condenser Inlet Solenoid (CIS) • • • • • • Faulty hot gas solenoid (HGS) • • • Leaky check valve • • • • Faulty check valve • Leaky receiver tank pressure solenoid (RTPS) •...

  • Page 321: Remote Evaporator System Diagnosis

    REMOTE EVAPORATOR SYSTEM DIAGNOSIS NOTE: This diagnosis guide applies to all TCI and SPECTRUM host unit models and TLE and SPECTRUM remote evaporators. CONDITION POSSIBLE CAUSE REMEDY Load temperature too high Refrigerant shortage Repair leak and recharge Controller defective Replace thermostat Controller set too high Adjust thermostat setting Expansion valve plugged...
  • Page 322 Refrigeration System Diagnosis 14-6...

  • Page 323: Single Temperature Refrigeration System Diagrams

    15 Single Temperature Refrigeration System Diagrams SL/SLe 100, 200 and SLX, SLXe, SLXi 100, 200 without modulation ... . 15-2 Cooling Cycle ............. . 15-2 Heat and Defrost Cycles .

  • Page 324: Sl/Sle 100, 200 And Slx, Slxe, Slxi 100, 200 Without Modulation

    SL/SLe 100, 200 AND SLX, SLXe, SLXi 100, 200 WITHOUT MODULATION Cooling Cycle Compressor Discharge Service Valve Discharge Line Discharge Vibrasorber Three-way Valve Three-way Valve Bypass Check Valve Condenser Coil Condenser Check Valve High Pressure Relief Valve 10. Receiver Tank 11.

  • Page 325: Heat And Defrost Cycles

    Heat and Defrost Cycles Compressor Discharge Service Valve Discharge Line Discharge Vibrasorber Three-way Valve Three-way Valve Bypass Check Valve Condenser Coil Condenser Check Valve High Pressure Relief Valve 10. Receiver Tank 11. Sight Glass 12. Receiver Outlet Valve 13. Liquid Line 14.

  • Page 326: Sle 200 And 300

    SL, SLe 200 AND 300 Cooling Cycle with Modulation Compressor Discharge Service Valve Discharge Line Discharge Vibrasorber Three-way Valve Three-way Valve Bypass Check Valve Condenser Coil Condenser Check Valve High Pressure Relief Valve 10. Receiver Tank 11. Sight Glass 12. Receiver Outlet Valve 13.

  • Page 327: Heat And Defrost Cycles With Modulation

    Heat and Defrost Cycles with Modulation Compressor Discharge Service Valve Discharge Line Discharge Vibrasorber Three-way Valve Three-way Valve Bypass Check Valve Condenser Coil Condenser Check Valve High Pressure Relief Valve 10. Receiver Tank 11. Sight Glass 12. Receiver Outlet Valve 13.

  • Page 328: Sl-400 And Sl-400E

    SL-400 and SL-400e Cooling Cycle with Modulation Compressor Discharge Service Valve Discharge Line Discharge Vibrasorber Three-way Valve Three-way Valve Bypass Check Valve Condenser Coil Condenser Check Valve High Pressure Relief Valve 10. Receiver Tank 11. Sight Glass 12. Receiver Outlet Valve 13.

  • Page 329: Heat And Defrost Cycles With Modulation

    Heat and Defrost Cycles with Modulation Compressor Discharge Service Valve Discharge Line Discharge Vibrasorber Three-way Valve Three-way Valve Bypass Check Valve Condenser Coil Condenser Check Valve High Pressure Relief Valve 10. Receiver Tank 11. Sight Glass 12. Receiver Outlet Valve 13.

  • Page 330: Slx 200 Ppp, 300, 400, Slxe 300, 400 And Slxi 300, 400

    SLX 200 PPP, 300, 400, SLXe 300, 400 AND SLXi 300, 400 Cooling Cycle with Modulation Compressor Discharge Service Valve Discharge Line Discharge Vibrasorber Three-way Valve Three-way Valve Bypass Check Valve Condenser Coil Condenser Check Valve High Pressure Relief Valve 10.

  • Page 331: Heat And Defrost Cycles With Modulation

    Heat and Defrost Cycles with Modulation Compressor Discharge Service Valve Discharge Line Discharge Vibrasorber Three-way Valve Three-way Valve Bypass Check Valve Condenser Coil Condenser Check Valve High Pressure Relief Valve 10. Receiver Tank 11. Sight Glass 12. Receiver Outlet Valve 13.
  • Page 332 Single Temperature Refrigeration System Diagrams 15-10...

  • Page 333: Multi-Temperature Refrigeration System Diagrams

    16 Multi-Temperature Refrigeration System Diagrams SL TCI, or SPECTRUM ..........16-2 Zone 1* on Cool and Zone 2** on Cool .

  • Page 334: Sl Tci, Or Spectrum

    SL TCI, OR SPECTRUM Zone 1* on Cool and Zone 2** on Cool Z-1 Zone 1 Evaporator* (Host Unit): COOL Liquid Line Solenoid (LLS) – Open Liquid Return Check Valve (LRCV) – Closed Suction Line Check Valve (SLCV) – Open Suction Line Solenoid (SLS) –...

  • Page 335: Zone 1* On Cool And Zone 2** On Heat

    Zone 1* on Cool and Zone 2** on Heat Z-1 Zone 1 Evaporator* (Host Unit): COOL Liquid Line Solenoid (LLS) – Open Liquid Return Check Valve (LRCV) – Closed Suction Line Check Valve (SLCV) – Open Suction Line Solenoid (SLS) – Open Hot Gas Solenoid (HGS) –...

  • Page 336: Zone 1* On Cool, Zone 2** On Cool And Zone 3*** On Cool

    Zone 1* on Cool, Zone 2** on Cool and Zone 3*** on Cool Z-1 Zone 1 Evaporator* (Host Unit): COOL Liquid Line Solenoid (LLS) – Open Liquid Return Check Valve (LRCV) – Closed Suction Line Check Valve (SLCV) – Open Suction Line Solenoid (SLS) –...

  • Page 337: Zone 1* On Cool, Zone 2** On Cool And Zone 3*** On Heat

    Zone 1* on Cool, Zone 2** on Cool and Zone 3*** on Heat Z-1 Zone 1 Evaporator* (Host Unit): COOL Liquid Line Solenoid (LLS) – Open Liquid Return Check Valve (LRCV) – Closed Suction Line Check Valve (SLCV) – Open Suction Line Solenoid (SLS) –...

  • Page 338: Slx, Slxe, Slxi Spectrum

    SLX, SLXe, SLXi SPECTRUM Zone 1* on Cool, Zone 2** on Heat Note: SLX Spectrum ETV and SLXe/SLXi Spectrum modes are the same as the SLX Spectrum with the exception of host only operation, then Modulation control is activated for host zone. Note: Early generation of SLX Spectrum units (until 04-2012) are fitted with MTV (not ETV).
  • Page 339 Multi-Temperature Refrigeration System Diagrams 16-7...
  • Page 340 Multi-Temperature Refrigeration System Diagrams 16-8...

  • Page 341: Wiring Diagrams And Wiring Schematics

    17 Wiring Diagrams and Wiring Schematics The wiring diagrams and schematics indexed here can be found in the Thermo King Europe master wiring diagram book. Wiring diagrams and schematics can also be found in the appropriate Controller Operation and Diagnosis manual for units with a μP-VI, SR-2 or SR-3 controller.
  • Page 342 Wiring Diagrams and Wiring Schematics 17-2...

This manual is also suitable for:

Sl-200Sl-300Sl-400Sl-tciSl-100eSl-200e ... Show all

Table of Contents

Save PDF