Thermo King SLXi-100 - Maintenance Manual

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Revision A

January 2018

TTKK 6611555555--22--MMMM--EENN

Trailer Edition

SLXi-100 and SLXi-200

Single Temperature Units

Maintenance Manual

Main Page

Table of Contents4
Safety Precautions9
Danger, Warning, Caution, and Notice9
Battery Installation and Cable Routing9
Battery Removal10
Refrigerant Hazards10
Refrigerant Oil Hazards11
Electrical Hazards11
High Voltage11
Low Voltage12
Microprocessor Service Precautions13
Welding Precautions13
First Aid14
Specifications15
Engine15
Belt Tension16
Refrigeration System16
Electrical Control System17
Electrical Components17
Maintenance Inspection Schedule18
Unit Description21
Unit Overview21
Design Features21
CYCLE-SENTRY™ Start-Stop Controls22
Data Logging22
TK Bluebox23
Optiset23
Sequence of Operation23
Operating Modes24
Engine Compartment Components25
Unit Protection Devices26
Serial Number Locations26
Electrical Maintenance29
Alternator Diagnostic Procedures29
General Information29
Alternator Identification29
Base Controller Fuse F430
Test Equipment for Checking Voltage and Current30
Alternator Load Test31
General Diagnostic and Warranty Evaluation Procedure31
Field Current Test32
Battery33
Filler Cap Batteries33
Maintenance Free Batteries33
Battery Load Test33
Battery Cables33
Base Controller34
Base Controller Fuse Size & Function34
Fuse F1035
Fuse F1535
LED Functions36
Smart FET Outputs36
SMART REEFER 3 (SR-3) Microprocessor Controller36
Fuse Link36
Air Heater37
Wire Harness Routing37
Low Voltage Disconnect Switch (LVD)37
General Information37
How It Works38
LVD Maintenance38
Diagnosing the Low Voltage Disconnect (LVD)40
Engine Maintenance41
Emi 300041
Engine Lubrication System41
Engine Oil Change41
Oil Filter Change41
Low Oil Pressure41
Engine Cooling System42
Extended Life Coolant (ELC)43
Antifreeze Maintenance Procedure44
Bleeding Air from the Cooling System44
Engine Thermostat45
Coolant Level Switch45
Engine Fuel System47
Operation47
Fuel Line Routing47
Maintenance47
Fuel Return Line Replacement49
Bleeding the Fuel System50
Draining Water from Fuel Tank51
Fuel Filter/Water Separator51
Engine Speed Adjustments52
Injection Pump Timing53
Injection Pump Removal59
Injection Pump Reinstallation61
Fuel Solenoid Replacement61
Engine Valve Clearance Adjustment62
Crankcase Breather64
EMI 3000 Air Cleaner65
Belts65
Fan Drive Belt67
Engine/Cross Shaft Belt72
Water Pump Belt77
Refrigeration Maintenance78
Refrigerant Charge78
Testing the Refrigerant Charge with an Empty Trailer78
Testing the Refrigerant Charge with a Loaded Trailer78
Testing for an Overcharge79
Moisture Indicating Sight Glass80
Refrigerant Leaks81
Checking Compressor Oil81
High Pressure Cutout Switch (HPCO)82
Three-Way Valve Condenser Pressure Bypass Check Valve83
Refrigeration Service Operations85
Refrigeration System Components85
Compressor89
Removal89
Installation89
Compressor Coupling Removal (Standard Units)90
Compressor Coupling Installation (Standard Units)90
Compressors with Pressurized Seal Cavity92
Hex Drive Compressor Seal Replacement93
Condenser Coil97
Removal97
Installation98
Discharge Vibrasorber98
Removal98
In-Line Condenser Check Valve99
Condenser Check Valve Replacement99
Removal99
Installation99
Bypass Check Valve100
Removal100
Installation100
Receiver Tank100
Expansion Valve Assembly100
Installation101
Heat Exchanger101
Removal101
Installation102
Evaporator Coil Assembly102
Removal102
Accumulator103
Removal103
Installation103
Three-Way Valve Repair103
Removal/Disassembly104
End Cap Checks106
Assembly/Installation108
Three-Way Valve Condenser Pressure Bypass Check Valve Repair109
Removal109
Installation110
Pilot Solenoid111
Removal111
Installation111
Suction Vibrasorber111
High Pressure Cutout Switch112
Removal112
Installation112
High Pressure Relief Valve112
Mechanical Throttling Valve (Non-ETV Units)112
Disassembly/Repair112
Assembly114
Installation115
Compressors with Internal Oil Filter115
Internal Oil Filter Replacement115
Checking Compressor Oil Pressure117
Structural Maintenance118
Unit and Engine Mounting Bolts118
Unit Inspection118
Condenser, Evaporator, and Radiator Coils119
Micro-Channel Coil Cleaning Recommendations119
Defrost Drains121
Unit Installation121
Defrost Damper121
Testing Defrost Damper122
Troubleshooting Defrost Damper123
Replacing Damper Gear Motor123
Condenser and Evaporator Fan Location124
Condenser Inlet Orifice Alignment124
Evaporator Fan Blower Alignment125
Fan Shaft Assembly126
Removal126
Disassembly126
Reassembly127
Installation129
Lower Condenser Blower Assembly130
Removal130
Disassembly130
Reassembly131
Installation131
Cross Shaft Assembly131
Removal131
Disassembly131
Reassembly132
Installation132
Idler Assemblies133
Disassembly133
Reassembly133
Mechanical Diagnosis134
Refrigeration Diagnosis137
Refrigeration Diagrams139
Cool Cycle139
Heat/Defrost Cycle141
Diagram Index143

Thermo King SLXi-100 - Maintenance Manual

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