Thermo King SLXi-300 User manual

Revision A
January 2018 TTKK 6611555522--22--MMMM--EENN
Trailer Edition
SLXi-300 and SLXi-400
Single Temperature Units
Maintenance Manual

©2018 Ingersoll and TK 61552-2-MM-EN
Introduction
This manual is published for informational purposes only. Thermo King®makes no representations warranties express
or implied, with respect to the information recommendations and descriptions contained herein. Information provided
should not be regarded as all-inclusive or covering all contingencies. If further information is required, Thermo King
Corporation Service Department should be consulted.
TThheerrmmoo KKiinngg’’ss wwaarrrraannttyy sshhaallll nnoott aappppllyy ttoo aannyy eeqquuiippmmeenntt wwhhiicchh hhaass bbeeeenn ““ssoo iinnssttaalllleedd,, mmaaiinnttaaiinneedd,, rreeppaaiirreedd
oorr aalltteerreedd aass,, iinn tthhee mmaannuuffaaccttuurreerr’’ss jjuuddggmmeenntt,, ttoo aaffffeecctt iittss iinntteeggrriittyy..””
MMaannuuffaaccttuurreerr sshhaallll hhaavvee nnoo lliiaabbiilliittyy ttoo aannyy ppeerrssoonn oorr eennttiittyy ffoorr aannyy ppeerrssoonnaall iinnjjuurryy,, pprrooppeerrttyy ddaammaaggee oorr aannyy
ootthheerr ddiirreecctt,, iinnddiirreecctt,, ssppeecciiaall,, oorr ccoonnsseeqquueennttiiaall ddaammaaggeess wwhhaattssooeevveerr,, aarriissiinngg oouutt ooff tthhee uussee ooff tthhiiss mmaannuuaall oorr
aannyy iinnffoorrmmaattiioonn,, rreeccoommmmeennddaattiioonnss oorr ddeessccrriippttiioonnss ccoonnttaaiinneedd hheerreeiinn.. TThhee pprroocceedduurreess ddeessccrriibbeedd hheerreeiinn sshhoouulldd
oonnllyy bbee uunnddeerrttaakkeenn bbyy ssuuiittaabbllyy qquuaalliiffiieedd ppeerrssoonnnneell.. FFaaiilluurree ttoo iimmpplleemmeenntt tthheessee pprroocceedduurreess ccoorrrreeccttllyy mmaayy ccaauussee
ddaammaaggee ttoo tthhee TThheerrmmoo KKiinngg uunniitt oorr ootthheerr pprrooppeerrttyy oorr ppeerrssoonnaall iinnjjuurryy..
Revision History
Revision A (12/17) Original release
General Information
The maintenance information in this manual covers unit models:
System SLXi-300 30 (903582) System SLXi-400 30 (903584)
System SLXi-300 50 (903581) System SLXi-400 50 (903583)
System SLXi-300 Whisper Pro (903589)
For further information, refer to:
SLXi Operator’s Manual TK 61452
SLXi-300 Parts Manual TK 61480
SLXi-300 Whisper Pro Parts Manual TK 61547
SLXi-400 Parts Manual TK 61481
SR-3 Trailer Single Temperature SL-400e, SLX/SLXe/SLXi Series Diagnostic Manual TK 56487
SLXi Single and Multi-Temperature Installation Manual TK 61451
SLXi Dealer Installation and Commissioning Manual TK 61450
TK482 and TK486 Engine Overhaul Manual TK 50136
X214, X418, X426 and X430 Compressor Overhaul Manual TK 6875
Diagnosing Thermo King Truck and Trailer Refrigeration Systems TK 60201
Tool Catalog TK 5955
Evacuation Station Operation and Field Application TK 40612
The information in this manual is provided to assist owners, operators and service people in the proper upkeep and maintenance of Thermo
King units.

TK 61552-2-MM-EN 3
Recover Refri erant
NNoottee In the USA, EPA Section 608 Certification is required to work on refrigeration systems. In the EU, local F-gas
Regulations must be observed when working on refrigeration systems.
At Thermo King®, we recognize the need to preserve the environment and limit the potential harm to the ozone layer
that can result from allowing refrigerant to escape into the atmosphere.
We strictly adhere to a policy that promotes the recovery and limits the loss of refrigerant into the atmosphere.
When working on transport temperature control systems, a recovery process that prevents or minimizes refrigerant
loss to the atmosphere is required by law. In addition, service personnel must be aware of the appropriate European
Union, National, Federal, State, and/or Local regulations governing the use of refrigerants and certification of
technicians. For additional information on regulations and technician programs, contact your local THE MO KING
dealer.
SSeerrvviiccee TToooollss - Use the proper service tools. Gauge manifold sets should include appropriate shutoff valves or
disconnects near the end of each service line.
eeccoovveerryy EEqquuiippmmeenntt - ecovery equipment must be used. Proper recovering, storing and recycling of refrigerants is
an important part of all service work.
SSeerrvviiccee PPrroocceedduurreess - ecommended procedures must be used to minimize refrigerant loss.
CCoommppoonneennttss mmaayy bbee iissoollaatteedd by closing service valves and performing system pump-downs.
CCoommppoonneennttss uunnaabbllee ttoo bbee iissoollaatteedd for service must be repaired only after refrigerant is properly recovered.
Customer Satisfaction Survey
Let your voice be heard!
Your feedback will help improve our manuals. The survey is accessible through any internet-connected device with a
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Scan the Quick esponse (Q ) code or click or type the web address http://irco.az1.qualtrics.com/SE/?SID=SV_
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IInnttrroodduuccttiioonn

4TK 61552-2-MM-EN
Safety Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Danger, Warning, Caution, and Notice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
General Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Battery Installation and Cable outing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Battery emoval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
efrigerant Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
efrigerant Oil Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Electrical Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
High Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
LowVoltage ............................................................................... 15
Microprocessor Service Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Welding Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
FirstAid....................................................................................... 17
Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Engine........................................................................................ 18
BeltTension................................................................................... 19
efrigeration System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Electrical Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Electrical Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Maintenance Inspection Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Unit Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
UnitOverview................................................................................. 24
Design Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Electronic Throttling Valve (ETV) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
CYCLE-SENT Y™Start-Stop Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
DataLogging .............................................................................. 26
TKBlueBox................................................................................ 27
OptiSet™.................................................................................. 28
Sequence of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Operating Modes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Engine Compartment Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Unit Protection Devices. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Serial Number Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Electrical Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Alternator Diagnostic Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Alternator Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Base Controller Fuse F4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Table of Contents

TK 61552-2-MM-EN 5
Test Equipment for Checking Voltage and Current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Alternator Load Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
General Diagnostic and Warranty Evaluation Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Field Current Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Battery........................................................................................ 38
Filler Cap Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Maintenance Free Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Battery Load Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Battery Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Base Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Base Controller Fuse Size & Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
FuseF10................................................................................... 40
FuseF15................................................................................... 40
LED Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Smart FET Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
SMA T EEFE 3 (S -3) Microprocessor Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
FuseLink...................................................................................... 42
AirHeater..................................................................................... 42
UnitWiring.................................................................................... 42
Wire Harness outing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Low Voltage Disconnect Switch (LVD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
HowitWorks .............................................................................. 43
LVD Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Diagnosing the Low Voltage Disconnect (LVD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Engine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
EMI3000...................................................................................... 47
Engine Lubrication System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Engine Oil Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Oil Filter Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Low Oil Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Engine Cooling System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Extended Life Coolant (ELC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Antifreeze Maintenance Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Bleeding Air from the Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Engine Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Coolant Level Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Engine Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Operation ................................................................................. 53
Fuel Line outing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Fuel eturn Line eplacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Bleeding the Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
TTaabbllee ooff CCoonntteennttss

6TK 61552-2-MM-EN
Draining Water from Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Fuel Filter/Water Separator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Fuel Filter/Water Separator eplacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Engine Speed Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Injection Pump Timing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Injection Pump emoval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Injection Pump einstallation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Fuel Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Engine Valve Clearance Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Crankcase Breather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
EMI 3000 Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Belts.......................................................................................... 74
Fan Drive Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Engine/Cross Shaft Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Water Pump Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
efrigeration Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
efrigerant Charge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Testing The efrigerant Charge With An Empty Trailer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Testing the efrigerant Charge with a Loaded Trailer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Testing for an Overcharge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Moisture Indicating Sight Glass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
efrigerant Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Checking Compressor Oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
High Pressure Cutout Switch (HPCO) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Three-Way Valve Condenser Pressure Bypass Check Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Electronic Throttling Valve (ETV) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Pressure Transducers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Hot Gas Bypass Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
efrigeration Service Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
efrigeration System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Compressor................................................................................... 99
emoval................................................................................... 99
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Compressor Coupling emoval (Standard Units) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Compressor Coupling Installation (Standard Units) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Compressors with Pressurized Seal Cavity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Hex Drive Compressor Seal eplacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Condenser Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
emoval..................................................................................107
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Discharge Vibrasorber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
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emoval..................................................................................108
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
In-Line Condenser Check Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Condenser Check Valve eplacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
emoval..................................................................................109
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Bypass Check Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
emoval..................................................................................110
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
eceiver Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
emoval..................................................................................110
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Filter-Drier (Dehydrator) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
emoval..................................................................................110
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Expansion Valve Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
emoval..................................................................................111
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Heat Exchanger. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
emoval..................................................................................112
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Evaporator Coil Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
emoval..................................................................................112
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
emoval..................................................................................113
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Three-Way Valve epair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
emoval/Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
End Cap Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
Assembly/Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
Three-Way Valve Condenser Pressure Bypass Check Valve epair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
emoval..................................................................................119
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
Pilot Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
emoval..................................................................................121
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Suction Vibrasorber. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
emoval..................................................................................121
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
High Pressure Cutout Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
emoval..................................................................................122
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
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High Pressure elief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
emoval..................................................................................122
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Discharge Pressure Transducer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
emoval..................................................................................122
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Suction Pressure Transducer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
emoval..................................................................................123
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
Electronic Throttling Valve (ETV) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
emoval..................................................................................123
Installation of Service Kit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
Installation of Complete ETV Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
Hot Gas Bypass Solenoid Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
emoval..................................................................................127
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
Compressors with Internal Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
Internal Oil Filter eplacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
Checking Compressor Oil Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
Structural Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
Unit and Engine Mounting Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
Unit Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
Condenser, Evaporator, and adiator Coils. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
Micro-Channel Coil Cleaning ecommendations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
Defrost Drains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
Unit Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
Defrost Damper. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
Testing Defrost Damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
Troubleshooting Defrost Damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
eplacing Damper Gear Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
Condenser and Evaporator Fan Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
Condenser Inlet Orifice Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
Evaporator Fan Blower Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
Fan Shaft Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
emoval..................................................................................138
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
eassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
Lower Condenser Blower Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
emoval..................................................................................142
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
eassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
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Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
Cross Shaft Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
emoval..................................................................................143
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
eassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
Idler Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
eassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
Mechanical Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
efrigeration Diagnosis. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
efrigeration Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
CoolCycle....................................................................................151
Heat/Defrost Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
Diagram Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
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Safety Precautions
Dan er, Warnin , Caution, and Notice
Thermo King®recommends that all service be performed by a Thermo King dealer and to be
aware of several general safety practices.
Safety advisories appear throughout this manual as required. Your personal safety and the
proper operation of this unit depend upon the strict observance of these precautions.
Indicates an imminently hazardous situation which, if not avoided, will result in death or
serious injury.
Indicates a potentially hazardous situation which, if not avoided, could result in death or
serious injury.
Indicates a potentially hazardous situation which, if not avoided, could result in minor or
moderate injury and unsafe practices.
Indicates a situation that could result in equipment or property-damage only accidents.
General Practices
DDAANNGGEE
HHaazzaarrdd ooff EExxpplloossiioonn!!
NNeevveerr aappppllyy hheeaatt ttoo aa sseeaalleedd rreeffrriiggeerraattiioonn ssyysstteemm oorr ccoonnttaaiinneerr.. HHeeaatt iinnccrreeaasseess iinntteerrnnaall
pprreessssuurree,, wwhhiicchh mmiigghhtt ccaauussee aann eexxpplloossiioonn rreessuullttiinngg iinn ddeeaatthh oorr sseerriioouuss iinnjjuurryy..
DDAANNGGEE
HHaazzaarrddoouuss GGaasseess!!
eeffrriiggeerraanntt iinn tthhee pprreesseennccee ooff aann ooppeenn ffllaammee,, ssppaarrkk,, oorr eelleeccttrriiccaall sshhoorrtt pprroodduucceess ttooxxiicc
ggaasseess tthhaatt aarree sseevveerree rreessppiirraattoorryy iirrrriittaannttss wwhhiicchh ccaann ccaauussee sseerriioouuss iinnjjuurryy oorr ppoossssiibbllee
ddeeaatthh..
DDAANNGGEE
iisskk ooff IInnjjuurryy!!
KKeeeepp yyoouurr hhaannddss,, ccllootthhiinngg,, aanndd ttoooollss cclleeaarr ooff ffaannss aanndd//oorr bbeellttss wwhheenn wwoorrkkiinngg oonn aa uunniitt
tthhaatt iiss rruunnnniinngg oorr wwhheenn ooppeenniinngg oorr cclloossiinngg ccoommpprreessssoorr sseerrvviiccee vvaallvveess.. LLoooossee ccllootthhiinngg
mmiigghhtt eennttaannggllee mmoovviinngg ppuulllleeyyss oorr bbeellttss,, ccaauussiinngg sseerriioouuss iinnjjuurryy oorr ppoossssiibbllee ddeeaatthh..
DDAANNGGEE
eeffrriiggeerraanntt VVaappoorr HHaazzaarrdd!!
DDoo nnoott iinnhhaallee rreeffrriiggeerraanntt.. UUssee ccaauuttiioonn wwhheenn wwoorrkkiinngg wwiitthh rreeffrriiggeerraanntt oorr aa rreeffrriiggeerraattiioonn
ssyysstteemm iinn aannyy ccoonnffiinneedd aarreeaa wwiitthh aa lliimmiitteedd aaiirr ssuuppppllyy.. eeffrriiggeerraanntt ddiissppllaacceess aaiirr aanndd ccaann
ccaauussee ooxxyyggeenn ddeepplleettiioonn,, rreessuullttiinngg iinn ssuuffffooccaattiioonn aanndd ppoossssiibbllee ddeeaatthh..
DDAANNGGEE
CCoonnffiinneedd SSppaaccee HHaazzaarrddss!!
AAvvooiidd eennggiinnee ooppeerraattiioonn iinn ccoonnffiinneedd ssppaacceess aanndd aarreeaass oorr cciirrccuummssttaanncceess wwhheerree ffuummeess ffrroomm
tthhee eennggiinnee ccoouulldd bbeeccoommee ttrraappppeedd aanndd ccaauussee sseerriioouuss iinnjjuurryy oorr ddeeaatthh..

TK 61552-2-MM-EN 11
WWAA NNIINNGG
HHaazzaarrdd ooff EExxpplloossiioonn!!
NNeevveerr cclloossee tthhee ccoommpprreessssoorr ddiisscchhaarrggee sseerrvviiccee vvaallvvee wwhheenn tthhee uunniitt iiss ooppeerraattiinngg.. NNeevveerr
ooppeerraattee tthhee uunniitt wwiitthh tthhee ddiisscchhaarrggee vvaallvvee cclloosseedd ((ffrroonntt sseeaatteedd)).. TThhiiss ccoonnddiittiioonn iinnccrreeaasseess
iinntteerrnnaall pprreessssuurree,, wwhhiicchh ccaann ccaauussee aann eexxpplloossiioonn..
WWAA NNIINNGG
PPrrooppeerr EEqquuiippmmeenntt CCoonnddiittiioonn!!
GGaauuggee mmaanniiffoolldd hhoosseess mmuusstt bbee iinn ggoooodd ccoonnddiittiioonn bbeeffoorree uussiinngg tthheemm.. NNeevveerr lleett tthheemm
ccoommee iinn ccoonnttaacctt wwiitthh mmoovviinngg bbeellttss,, ffaannss,, ppuulllleeyyss oorr hhoott ssuurrffaacceess.. DDeeffeeccttiivvee ggaauuggee
eeqquuiippmmeenntt ccaann ddaammaaggee ccoommppoonneennttss oorr ccaauussee sseerriioouuss iinnjjuurryy..
WWAA NNIINNGG
PPeerrssoonnaall PPrrootteeccttiivvee EEqquuiippmmeenntt ((PPPPEE)) eeqquuiirreedd!!
AAllwwaayyss wweeaarr ggoogggglleess oorr ssaaffeettyy ggllaasssseess wwhheenn wwoorrkkiinngg oonn aa uunniitt.. eeffrriiggeerraanntt lliiqquuiidd,, ooiill,,
aanndd bbaatttteerryy aacciidd ccaann ppeerrmmaanneennttllyy ddaammaaggee yyoouurr eeyyeess.. SSeeee ““FFiirrsstt AAiidd””..
WWAA NNIINNGG
EEqquuiippmmeenntt DDaammaaggee aanndd iisskk ooff IInnjjuurryy!!
NNeevveerr ddrriillll hhoolleess iinnttoo tthhee uunniitt uunnlleessss iinnssttrruucctteedd bbyy TThheerrmmoo KKiinngg.. HHoolleess ddrriilllleedd iinnttoo hhiigghh
vvoollttaaggee ccaabblleess ccoouulldd ccaauussee aann eelleeccttrriiccaall ffiirree,, sseevveerree ppeerrssoonnaall iinnjjuurryy,, oorr eevveenn ddeeaatthh..
WWAA NNIINNGG
iisskk ooff IInnjjuurryy!!
WWhheenn uussiinngg llaaddddeerrss ttoo iinnssttaallll oorr sseerrvviiccee rreeffrriiggeerraattiioonn ssyysstteemmss,, aallwwaayyss oobbsseerrvvee tthhee llaaddddeerr
mmaannuuffaaccttuurreerr’’ss ssaaffeettyy llaabbeellss aanndd wwaarrnniinnggss.. AA wwoorrkk ppllaattffoorrmm oorr ssccaaffffoollddiinngg iiss tthhee
rreeccoommmmeennddeedd mmeetthhoodd ffoorr iinnssttaallllaattiioonnss aanndd sseerrvviicciinngg..
CCAAUUTTIIOONN
SShhaarrpp EEddggeess!!
EExxppoosseedd ccooiill ffiinnss ccaann ccaauussee llaacceerraattiioonnss.. SSeerrvviiccee wwoorrkk oonn tthhee eevvaappoorraattoorr oorr ccoonnddeennsseerr
ccooiillss iiss bbeesstt lleefftt ttoo aa cceerrttiiffiieedd TThheerrmmoo KKiinngg tteecchhnniicciiaann..
NNOOTTIICCEE
EEqquuiippmmeenntt DDaammaaggee!!
AAllll mmoouunnttiinngg bboollttss mmuusstt bbee ttiigghhtt aanndd aarree tthhee ccoorrrreecctt lleennggtthh ffoorr tthheeiirr aapppplliiccaattiioonnss..
IImmpprrooppeerr ttoorrqquuee aanndd iinnccoorrrreecctt bboolltt lleennggtthhss ccaann ddaammaaggee eeqquuiippmmeenntt..
Battery Installation and Cable Routin
WWAA NNIINNGG
HHaazzaarrdd ooff EExxpplloossiioonn!!
AAnn iimmpprrooppeerrllyy iinnssttaalllleedd bbaatttteerryy ccoouulldd rreessuulltt iinn aa ffiirree,, eexxpplloossiioonn,, oorr iinnjjuurryy.. AA TThheerrmmoo KKiinngg
aapppprroovveedd bbaatttteerryy mmuusstt bbee iinnssttaalllleedd aanndd pprrooppeerrllyy sseeccuurreedd ttoo tthhee bbaatttteerryy ttrraayy..
SSaaffeettyy PPrreeccaauuttiioonnss

12 TK 61552-2-MM-EN
WWAA NNIINNGG
HHaazzaarrdd ooff EExxpplloossiioonn!!
IImmpprrooppeerrllyy iinnssttaalllleedd bbaatttteerryy ccaabblleess ccoouulldd rreessuulltt iinn aa ffiirree,, eexxpplloossiioonn,, oorr iinnjjuurryy.. BBaatttteerryy
ccaabblleess mmuusstt bbee iinnssttaalllleedd,, rroouutteedd,, aanndd sseeccuurreedd pprrooppeerrllyy ttoo pprreevveenntt tthheemm ffrroomm rruubbbbiinngg,,
cchhaaffffiinngg,, oorr mmaakkiinngg ccoonnttaacctt wwiitthh hhoott,, sshhaarrpp,, oorr rroottaattiinngg ccoommppoonneennttss..
WWAA NNIINNGG
FFiirree HHaazzaarrdd!!
DDoo nnoott aattttaacchh ffuueell lliinneess ttoo bbaatttteerryy ccaabblleess oorr eelleeccttrriiccaall hhaarrnneesssseess.. TThhiiss hhaass tthhee ppootteennttiiaall ttoo
ccaauussee aa ffiirree aanndd ccoouulldd ccaauussee sseerriioouuss iinnjjuurryy oorr ddeeaatthh..
WWAA NNIINNGG
PPeerrssoonnaall PPrrootteeccttiivvee EEqquuiippmmeenntt ((PPPPEE)) eeqquuiirreedd!!
AA bbaatttteerryy ccaann bbee ddaannggeerroouuss.. AA bbaatttteerryy ccoonnttaaiinnss aa ffllaammmmaabbllee ggaass tthhaatt ccaann iiggnniittee oorr
eexxppllooddee.. AA bbaatttteerryy ssttoorreess eennoouugghh eelleeccttrriicciittyy ttoo bbuurrnn yyoouu iiff iitt ddiisscchhaarrggeess qquuiicckkllyy.. AA bbaatttteerryy
ccoonnttaaiinnss bbaatttteerryy aacciidd tthhaatt ccaann bbuurrnn yyoouu.. AAllwwaayyss wweeaarr ggoogggglleess oorr ssaaffeettyy ggllaasssseess aanndd
ppeerrssoonnaall pprrootteeccttiivvee eeqquuiippmmeenntt wwhheenn wwoorrkkiinngg wwiitthh aa bbaatttteerryy.. IIff yyoouu ggeett bbaatttteerryy aacciidd oonn
yyoouu,, iimmmmeeddiiaatteellyy fflluusshh iitt wwiitthh wwaatteerr aanndd ggeett mmeeddiiccaall aatttteennttiioonn..
WWAA NNIINNGG
HHaazzaarrdd ooff EExxpplloossiioonn!!
AAllwwaayyss ccoovveerr bbaatttteerryy tteerrmmiinnaallss ttoo pprreevveenntt tthheemm ffrroomm mmaakkiinngg ccoonnttaacctt wwiitthh mmeettaall
ccoommppoonneennttss dduurriinngg bbaatttteerryy iinnssttaallllaattiioonn.. BBaatttteerryy tteerrmmiinnaallss ggrroouunnddiinngg aaggaaiinnsstt mmeettaall ccoouulldd
ccaauussee tthhee bbaatttteerryy ttoo eexxppllooddee..
CCAAUUTTIIOONN
HHaazzaarrddoouuss SSeerrvviiccee PPrroocceedduurreess!!
SSeett aallll uunniitt eelleeccttrriiccaall ccoonnttrroollss ttoo tthhee OOFFFF ppoossiittiioonn bbeeffoorree ccoonnnneeccttiinngg bbaatttteerryy ccaabblleess ttoo tthhee
bbaatttteerryy ttoo pprreevveenntt uunniitt ffrroomm ssttaarrttiinngg uunneexxppeecctteeddllyy aanndd ccaauussiinngg ppeerrssoonnaall iinnjjuurryy..
NNOOTTIICCEE
EEqquuiippmmeenntt DDaammaaggee!!
DDoo nnoott ccoonnnneecctt ootthheerr mmaannuuffaaccttuurreerr’’ss eeqquuiippmmeenntt ttoo tthhee uunniitt uunnlleessss aapppprroovveedd bbyy TThheerrmmoo
KKiinngg.. FFaaiilluurree ttoo ddoo ssoo ccaann rreessuulltt iinn sseevveerree ddaammaaggee ttoo eeqquuiippmmeenntt aanndd vvooiidd tthhee wwaarrrraannttyy..
Battery Removal
WWAA NNIINNGG
HHaazzaarrdd ooff EExxpplloossiioonn!!
DDiissccoonnnneecctt tthhee nneeggaattiivvee bbaatttteerryy tteerrmmiinnaall ((--)) ffiirrsstt wwhheenn rreemmoovviinngg aa bbaatttteerryy.. CCoonnnneecctt tthhee
ppoossiittiivvee tteerrmmiinnaall ((++)) ffiirrsstt wwhheenn iinnssttaalllliinngg aa bbaatttteerryy..
This order is important because the frame is grounded to the negative battery terminal. If the
negative terminal is still connected, a complete circuit exists from the positive terminal of the
battery to the frame. Metal objects contacting the positive side and the frame simultaneously will
cause sparks or arcing. If there are sufficient hydrogen gases emitted from the battery, an
explosion might occur, causing equipment damage, serious injury, even death.
SSaaffeettyy PPrreeccaauuttiioonnss

TK 61552-2-MM-EN 13
Refri erant Hazards
DDAANNGGEE
HHaazzaarrddoouuss PPrreessssuurreess!!
AAllwwaayyss ssttoorree rreeffrriiggeerraanntt iinn pprrooppeerr ccoonnttaaiinneerrss,, oouutt ooff ddiirreecctt ssuunnlliigghhtt aanndd aawwaayy ffrroomm
iinntteennssee hheeaatt.. HHeeaatt iinnccrreeaasseess pprreessssuurree iinnssiiddee ssttoorraaggee ccoonnttaaiinneerrss,, wwhhiicchh ccaann ccaauussee tthheemm ttoo
bbuurrsstt aanndd ccoouulldd rreessuulltt iinn sseevveerree ppeerrssoonnaall iinnjjuurryy..
DDAANNGGEE
CCoommbbuussttiibbllee HHaazzaarrdd!!
DDoo nnoott uussee ooxxyyggeenn ((OO22 )) oorr ccoommpprreesssseedd aaiirr ffoorr lleeaakk tteessttiinngg.. OOxxyyggeenn mmiixxeedd wwiitthh
rreeffrriiggeerraanntt iiss ccoommbbuussttiibbllee..
WWAA NNIINNGG
HHaazzaarrddoouuss GGaasseess!!
DDoo nnoott uussee aa HHaalliiddee ttoorrcchh.. WWhheenn aa ffllaammee ccoommeess iinn ccoonnttaacctt wwiitthh rreeffrriiggeerraanntt,, ttooxxiicc ggaasseess
aarree pprroodduucceedd.. TThheessee ggaasseess ccaann ccaauussee ssuuffffooccaattiioonn,, eevveenn ddeeaatthh..
WWAA NNIINNGG
PPeerrssoonnaall PPrrootteeccttiivvee EEqquuiippmmeenntt ((PPPPEE)) eeqquuiirreedd!!
eeffrriiggeerraanntt iinn aa lliiqquuiidd ssttaattee eevvaappoorraatteess rraappiiddllyy wwhheenn eexxppoosseedd ttoo tthhee aattmmoosspphheerree,, ffrreeeezziinngg
aannyytthhiinngg iitt ccoonnttaaccttss.. WWeeaarr bbuuttyyll lliinneedd gglloovveess aanndd ootthheerr ccllootthhiinngg aanndd eeyyee wweeaarr wwhheenn
hhaannddlliinngg rreeffrriiggeerraanntt ttoo hheellpp pprreevveenntt ffrroossttbbiittee..
NNOOTTIICCEE
EEqquuiippmmeenntt DDaammaaggee!!
WWhheenn bbeeiinngg ttrraannssffeerrrreedd,, rreeffrriiggeerraanntt mmuusstt bbee iinn lliiqquuiidd ssttaattee ttoo aavvooiidd ppoossssiibbllee eeqquuiippmmeenntt
ddaammaaggee..
Refri erant Oil Hazards
WWAA NNIINNGG
PPeerrssoonnaall PPrrootteeccttiivvee EEqquuiippmmeenntt ((PPPPEE)) eeqquuiirreedd!!
PPrrootteecctt yyoouurr eeyyeess ffrroomm ccoonnttaacctt wwiitthh rreeffrriiggeerraanntt ooiill.. TThhee ooiill ccaann ccaauussee sseerriioouuss eeyyee iinnjjuurriieess..
PPrrootteecctt sskkiinn aanndd ccllootthhiinngg ffrroomm pprroolloonnggeedd oorr rreeppeeaatteedd ccoonnttaacctt wwiitthh rreeffrriiggeerraanntt ooiill.. TToo
pprreevveenntt iirrrriittaattiioonn,, wwaasshh yyoouurr hhaannddss aanndd ccllootthhiinngg tthhoorroouugghhllyy aafftteerr hhaannddlliinngg tthhee ooiill..
uubbbbeerr gglloovveess aarree rreeccoommmmeennddeedd..
NNOOTTIICCEE
EEqquuiippmmeenntt DDaammaaggee!!
UUssee tthhee ccoorrrreecctt ooiill iinn TThheerrmmoo KKiinngg ssyysstteemmss ttoo aavvooiidd ddaammaaggiinngg eeqquuiippmmeenntt aanndd nnuulllliiffyyiinngg
iittss wwaarrrraannttyy..
NNOOTTIICCEE
EEqquuiippmmeenntt DDaammaaggee!!
DDoo nnoott mmiixx rreeffrriiggeerraanntt ooiillss.. MMiixxiinngg iinnccoommppaattiibbllee ooiillss wwiillll ddaammaaggee tthhee ssyysstteemm..
SSaaffeettyy PPrreeccaauuttiioonnss

14 TK 61552-2-MM-EN
NNOOTTIICCEE
EEqquuiippmmeenntt DDaammaaggee!!
UUssee ddeeddiiccaatteedd rreeffrriiggeerraattiioonn eeqquuiippmmeenntt ttoo pprreevveenntt ccoonnttaammiinnaattiinngg rreeffrriiggeerraattiioonn ssyysstteemmss
wwiitthh tthhee wwrroonngg ttyyppee ooff ooiill oorr rreeffrriiggeerraanntt..
NNOOTTIICCEE
SSyysstteemm CCoonnttaammiinnaattiioonn!!
DDoo nnoott eexxppoossee tthhee rreeffrriiggeerraanntt ooiill ttoo tthhee aaiirr aannyy lloonnggeerr tthhaann nneecceessssaarryy.. SSttoorree rreeffrriiggeerraanntt
ooiill iinn aann aapppprroovveedd sseeaalleedd ccoonnttaaiinneerr ttoo aavvooiidd mmooiissttuurree ccoonnttaammiinnaattiioonn.. TThhee ooiill wwiillll aabbssoorrbb
mmooiissttuurree,, wwhhiicchh rreessuullttss iinn mmuucchh lloonnggeerr eevvaaccuuaattiioonn ttiimmeess aanndd ppoossssiibbllee ssyysstteemm
ccoonnttaammiinnaattiioonn..
NNOOTTIICCEE
MMaatteerriiaall DDaammaaggee!!
WWiippee uupp ssppiillllss iimmmmeeddiiaatteellyy.. eeffrriiggeerraanntt ooiill ccaann ddaammaaggee ppaaiinnttss aanndd rruubbbbeerr mmaatteerriiaallss..
Electrical Hazards
Hi h Volta e
IImmppoorrttaanntt Do not move the vehicle if the power cable or the electric standby icon is illuminated.
DDAANNGGEE
HHaazzaarrddoouuss VVoollttaaggee!!
LLeetthhaall aammoouunnttss ooff vvoollttaaggee aarree pprreesseenntt iinn ssoommee eelleeccttrriiccaall cciirrccuuiittss.. UUssee eexxttrreemmee ccaarree wwhheenn
wwoorrkkiinngg oonn aann ooppeerraattiinngg rreeffrriiggeerraattiioonn uunniitt..
DDAANNGGEE
HHaazzaarrddoouuss VVoollttaaggee!!
DDaannggeerroouuss tthhrreeee pphhaassee AACC eelleeccttrriicc ppoowweerr iiss pprreesseenntt wwhheenneevveerr tthhee uunniitt iiss ooppeerraattiinngg iinn
eeiitthheerr DDiieesseell MMooddee oorr EElleeccttrriicc MMooddee aanndd wwhheenneevveerr tthhee uunniitt iiss ccoonnnneecctteedd ttoo aa ssoouurrccee ooff
eexxtteerrnnaall ssttaannddbbyy ppoowweerr.. VVoollttaaggeess ooff tthhiiss mmaaggnniittuuddee ccaann bbee lleetthhaall.. EExxeerrcciissee eexxttrreemmee
ccaauuttiioonn wwhheenn wwoorrkkiinngg oonn tthhee uunniitt..
WWAA NNIINNGG
HHaazzaarrddoouuss VVoollttaaggee!!
UUnniittss ffeeaattuurriinngg ooppttiioonnaall EElleeccttrriicc SSttaannddbbyy uuttiilliizzee 446600,, 440000,, oorr 223300 vvoolltt 33 pphhaassee AACC eelleeccttrriiccaall
ppoowweerr aannyy ttiimmee tthhee uunniitt iiss ooppeerraattiinngg iinn EElleeccttrriicc MMooddee.. TThhiiss vvoollttaaggee ppootteennttiiaall iiss aallssoo
pprreesseenntt aannyy ttiimmee tthhee uunniitt iiss ccoonnnneecctteedd ttoo aa ssoouurrccee ooff eexxtteerrnnaall ssttaannddbbyy ppoowweerr.. EExxttrreemmee
ccaarree mmuusstt bbee uusseedd wwhheenn wwoorrkkiinngg oonn tthhee uunniitt,, aass tthheessee vvoollttaaggeess aarree ccaappaabbllee ooff ccaauussiinngg
sseerriioouuss iinnjjuurryy oorr ddeeaatthh..
WWAA NNIINNGG
HHaazzaarrddoouuss VVoollttaaggee!!
TTrreeaatt aallll wwiirreess aanndd ccoonnnneeccttiioonnss aass iiff tthheeyy wweerree hhiigghh vvoollttaaggee uunnttiill aa mmeetteerr aanndd wwiirriinngg
ddiiaaggrraamm iinnddiiccaattee ootthheerrwwiissee.. OOnnllyy uussee ttoooollss wwiitthh iinnssuullaatteedd hhaannddlleess.. NNeevveerr hhoolldd
uunniinnssuullaatteedd mmeettaall ttoooollss nneeaarr eexxppoosseedd,, eenneerrggiizzeedd ccoonndduuccttoorrss..
WWAA NNIINNGG
HHaazzaarrddoouuss VVoollttaaggee!!
NNeevveerr wwoorrkk aalloonnee oonn hhiigghh vvoollttaaggee cciirrccuuiittss iinn tthhee rreeffrriiggeerraattiioonn uunniitt.. AAnnootthheerr ppeerrssoonn sshhoouulldd
bbee nneeaarrbbyy ttoo sshhuutt ooffff tthhee uunniitt aanndd pprroovviiddee aaiidd iinn tthhee eevveenntt ooff aann aacccciiddeenntt..
SSaaffeettyy PPrreeccaauuttiioonnss

TK 61552-2-MM-EN 15
WWAA NNIINNGG
PPeerrssoonnaall PPrrootteeccttiivvee EEqquuiippmmeenntt ((PPPPEE)) eeqquuiirreedd!!
SSaaffeettyy ggllaasssseess,, rruubbbbeerr--iinnssuullaatteedd gglloovveess,, aanndd ccaabbllee ccuutttteerrss sshhoouulldd bbee nneeaarr yyoouurr wwoorrkk aarreeaa
iinn tthhee eevveenntt ooff aann eelleeccttrriiccaall aacccciiddeenntt..
WWAA NNIINNGG
iisskk ooff IInnjjuurryy!!
DDoo nnoott mmaakkee rraappiidd mmoovveess wwhheenn wwoorrkkiinngg oonn hhiigghh vvoollttaaggee cciirrccuuiittss iinn rreeffrriiggeerraattiioonn uunniittss.. DDoo
nnoott ggrraabb ffoorr ffaalllliinngg ttoooollss bbeeccaauussee yyoouu mmiigghhtt aacccciiddeennttaallllyy ttoouucchh aa hhiigghh vvoollttaaggee ssoouurrccee..
WWAA NNIINNGG
HHaazzaarrddoouuss VVoollttaaggee ww//CCaappaacciittoorrss!!
BBee ccaarreeffuull wwhheenn wwoorrkkiinngg wwiitthh eelleeccttrriiccaall cciirrccuuiittss tthhaatt ccoonnttaaiinn ccaappaacciittoorrss.. SSoommee ccaappaacciittoorrss
hhoolldd aa ssiiggnniiffiiccaanntt eelleeccttrriiccaall cchhaarrggee tthhaatt mmiigghhtt ccaauussee bbuurrnnss oorr sshhoocckkss iiff aacccciiddeennttaallllyy
ddiisscchhaarrggeedd.. CCaappaacciittoorrss mmuusstt bbee ddiisscchhaarrggeedd bbeeffoorree wwoorrkkiinngg oonn eelleeccttrriiccaall cciirrccuuiittss..
Low Volta e
IImmppoorrttaanntt Some components are connected directly to un-switched battery power. All
connections and circuits labeled with a “2” prefix are connected directly to battery
power. Always disconnect the battery before servicing the unit.
WWAA NNIINNGG
LLiivvee EElleeccttrriiccaall CCoommppoonneennttss!!
CCoonnttrrooll cciirrccuuiittss uusseedd iinn rreeffrriiggeerraattiioonn uunniittss aarree llooww vvoollttaaggee ((1122 ttoo 2244 vvoollttss ddcc)).. HHoowweevveerr,,
tthhee llaarrggee aammoouunntt ooff aammppeerraaggee aavvaaiillaabbllee ccaann ccaauussee sseevveerree bbuurrnnss iiff aacccciiddeennttaallllyy sshhoorrtteedd ttoo
ggrroouunndd wwiitthh mmeettaall oobbjjeeccttss,, ssuucchh aass ttoooollss.. DDoo nnoott wweeaarr jjeewweellrryy,, wwaattcchheess,, oorr rriinnggss bbeeccaauussee
tthheeyy iinnccrreeaassee tthhee rriisskk ooff sshhoorrttiinngg oouutt eelleeccttrriiccaall cciirrccuuiittss aanndd ddaammaaggiinngg eeqquuiippmmeenntt oorr
ccaauussiinngg sseevveerree bbuurrnnss..
Microprocessor Service Precautions
Take precautions to prevent electrostatic discharge when servicing the microprocessor and its
related components. Even tiny amounts of current can severely damage or destroy electronic
components.
Observe the following precautions when servicing a microprocessor control system to avoid
damaging electronic components. efer to the appropriate microprocessor diagnosis manual for
more information.
• If the microprocessor has a power switch, turn it OFF before connecting or disconnecting the
battery.
• Disconnect power to the unit.
• Avoid wearing clothing that generates static electricity (wool, nylon, polyester, etc.).
• Wear a wrist strap (P/N 204-622 or equivalent) with the lead end connected to the
microprocessor’s ground terminal. These straps are available from most electronic
equipment distributors. DO NOT wear these straps with power applied to the unit.
• Avoid unnecessary contact with the electronic components.
• Store and ship electronic components in antistatic bags and protective packaging.
• Leave electronic components in their antistatic packing materials until you’re ready to use
them.
• After servicing any electronic components, check the wiring for possible errors before
restoring power to the unit.
• Never use a battery and a light bulb to test circuits on any microprocessor-based equipment.
SSaaffeettyy PPrreeccaauuttiioonnss

16 TK 61552-2-MM-EN
Weldin Precautions
Take precautions before electrically welding any portion of the unit or the vehicle to which it is
attached. Verify that welding currents are not allowed to flow through the unit’s electronic
circuits.
Observe the following precautions when welding to avoid damaging electronic components.
• If the microprocessor has a power switch, turn it OFF before connecting or disconnecting the
battery.
• Disconnect power to the unit.
• Disconnect all wire harnesses from the microprocessor. Disconnect the ECU and the battery
charger if so equipped.
• If there are any electrical circuit breakers in the control box, switch them OFF.
• Close the control box.
• Components that could be damaged by welding sparks should be removed from the unit.
• Use normal welding procedures, but keep the ground return electrode as close to the area
being welded as practical. This will reduce the likelihood of stray welding currents passing
through any electronic circuits.
SSaaffeettyy PPrreeccaauuttiioonnss

TK 61552-2-MM-EN 17
First Aid
EEFF IIGGEE AANNTT
•EEyyeess:: For contact with liquid, immediately flush eyes with large amounts of water and get
prompt medical attention.
•SSkkiinn:: Flush area with large amounts of warm water. Do not apply heat. emove
contaminated clothing and shoes. Wrap burns with dry, sterile, bulky dressing to protect from
infection. Get prompt medical attention. Wash contaminated clothing before reuse.
•IInnhhaallaattiioonn:: Move victim to fresh air and use Cardio Pulmonary esuscitation (CP ) or mouth-
to-mouth resuscitation to restore breathing, if necessary. Stay with victim until emergency
personnel arrive.
•FFrroosstt BBiittee:: In the event of frost bite , the objectives of First Aid are to protect the frozen area
from further injury, warm the affected area rapidly, and to maintain respiration.
EEFF IIGGEE AANNTT OOIILL
•EEyyeess:: Immediately flush with large amounts of water for at least 15 minutes. Get prompt
medical attention.
•SSkkiinn:: emove contaminated clothing. Wash thoroughly with soap and water. Get medical
attention if irritation persists.
•IInnhhaallaattiioonn:: Move victim to fresh air and use Cardio Pulmonary esuscitation (CP ) or mouth-
to-mouth resuscitation to restore breathing, if necessary. Stay with victim until emergency
personnel arrive.
•IInnggeessttiioonn:: Do not induce vomiting. Immediately contact local poison control center or
physician.
EENNGGIINNEE CCOOOOLLAANNTT
•EEyyeess:: Immediately flush with large amounts of water for at least 15 minutes. Get prompt
medical attention.
•SSkkiinn:: emove contaminated clothing. Wash thoroughly with soap and water. Get medical
attention if irritation persists.
•IInnggeessttiioonn:: Do not induce vomiting. Immediately contact local poison control center or
physician.
BBAATTTTEE YY AACCIIDD
•EEyyeess:: Immediately flush with large amounts of water for at least 15 minutes. Get prompt
medical attention. Wash skin with soap and water.
EELLEECCTT IICCAALL SSHHOOCCKK
Take IMMEDIATE action after a person has received an electrical shock. Get quick medical
assistance, if possible.
The source of the shock must be quickly stopped, by either shutting off the power or removing
the victim. If the power cannot be shut off, the wire should be cut with an non-conductive tool,
such as a wood-handle axe or thickly insulated cable cutters. escuers should wear insulated
gloves and safety glasses, and avoid looking at wires being cut. The ensuing flash can cause
burns and blindness.
If the victim must be removed from a live circuit, pull the victim away with a non-conductive
material. Use wood, rope, a belt or coat to pull or push the victim away from the current. DO NOT
TOUCH the victim. You will receive a shock from current flowing through the victim’s body. After
separating the victim from power source, immediately check for signs of a pulse and respiration.
If no pulse is present, start Cardio Pulmonary esuscitation (CP ). If a pulse is present,
respiration might be restored by using mouth-to-mouth resuscitation. Call for emergency
medical assistance.
AASSPPHHYYXXIIAATTIIOONN
Move victim to fresh air and use Cardio Pulmonary esuscitation (CP ) or mouth-to-mouth
resuscitation to restore breathing, if necessary. Stay with victim until emergency personnel
arrive.
SSaaffeettyy PPrreeccaauuttiioonnss

18 TK 61552-2-MM-EN
Specifications
En ine
Table 1.
Model TK486V
Fuel Type Diesel fuel must conform to EN590
Oil Capacity 12.3 liters/litres crankcase and oil filter
Fill to full mark on dipstick
Oil Type Petroleum Multi-grade Oil
Synthetic Multi-grade Oil
API Type CI-4, ACEA Class E3
API Type CI-4, ACEA Class E3 (after first 500 hours)
Oil Viscosity -30°C to +0°C: SAE 5W-30
-25°C to +30°C: SAE 10W-30
-25°C to +40°C: SAE 10W-40
-15°C to +40°C (or -10°C to +50°C): SAE 15W-40
Engine RPM
NNOOTTIICCEE
EEqquuiippmmeenntt DDaammaaggee!!
DDoo NNOOTT ooppeerraattee tthhee eennggiinnee
iinn AANNYY uunniitt mmoorree tthhaann 110000
PPMM oovveerr tthhee hhiigghh ssppeeeedd
sseettttiinngg sshhoowwnn ttoo aavvooiidd
bblloowweerr oovveerrssppeeeedd aanndd//oorr
ddaammaaggee..
SLXi-300 and Whisper
SLXi-300 Whisper Pro
SLXi-400
1450 +/- 25 RPM High Speed, 1200 +/- 25 RPM Low Speed
2000 +/- 25 RPM High Speed, 1250 +/- 25 RPM Low Speed
(PIEK speed)
2000 +/- 25 RPM High Speed, 1200 +/- 25 RPM Low Speed
Engine Oil Pressure 2.1 to 5.5 bar (30 to 80 psi)
Intake Valve Clearance 0.15 to 0.25 mm
Exhaust Valve Clearance 0.15 to 0.25 mm
Valve Setting Temperature 21°C
Timing Injection Pump 12° +/– 1° BTDC (timed on No. 1 cylinder, flywheel side)
Low Oil Pressure Switch (Normally
Closed)
0.55 to 0.83 bar (8 to 12 psi)
High Coolant Temperature Switch Sensor - 101.7 to 107.2 C or higher (Shutdown)
Engine Coolant Thermostat 71°C
Engine Coolant Type
NNOOTTIICCEE
SSyysstteemm CCoonnttaammiinnaattiioonn!!
DDoo nnoott aadddd ““GG EEEENN”” oorr ““BBLLUUEE--GG EEEENN”” ccoonnvveennttiioonnaall
ccoooollaanntt ttoo ccoooolliinngg ssyysstteemmss uussiinngg ““ EEDD”” EExxtteennddeedd LLiiffee
CCoooollaanntt,, eexxcceepptt iinn aann eemmeerrggeennccyy.. IIff ccoonnvveennttiioonnaall ccoooollaanntt iiss
aaddddeedd ttoo EExxtteennddeedd LLiiffee CCoooollaanntt,, tthhee ccoooollaanntt mmuusstt bbee
cchhaannggeedd aafftteerr 22 yyeeaarrss iinnsstteeaadd ooff 55 yyeeaarrss..
ELC (Extended Life Coolant), which is “RED”
Use a 50/50 concentration of any of the following
equivalents:
Texaco ELC (7997, 7998, 16445, 16447)
Havoline Dex-Cool®(7994, 7995)
Havoline XLC for Europe (30379, 33013)
Shell Dexcool®(94040)
Shell Rotella (94041)
Saturn/General Motors Dex-Cool®
Caterpillar ELC
Detroit Diesel POWERCOOL®Plus
Coolant System Capacity 7.1 liters/litres with overflow tank
6.6 liters/litres with overflow tank (with Microchannel Coil)
Radiator Cap Pressure 0.48 bar (7 psi)

TK 61552-2-MM-EN 19
Table 1. (continued)
Drive Model 30 Direct to compressor; belts to fans, alternator, and water
pump
Model 50 Centrifugal clutch to compressor; belts to electric standby
motor, fans, and water pump
Belt Tension
Table 2.
Use of Frequency Gauge P/N 204-1903 to measure
frequency (Hz) is recommended.
Model 30/50 New Belt Field Reset
Electric Motor/Compressor Drive
Belt
Units fitted with original SLX clutch (up until build
date 13 August 2013)
73-76 67-72
Units fitted with SLX clutch retrofit (P/N 78-1884) Use service tool P/N 204-2436 to set belt tension.
Distance of 139.0 mm as set by service tool equates
to 78-81 Hz for a new belt, and 69-73 Hz for a field
reset belt.
Units fitted with SLXe/SLXi clutch (P/N 77-3189) Use service tool P/N 204-2436 to set belt tension.
Distance of 139.0 mm as set by service tool equates
to 95 Hz for a new belt.
Fan Drive Belt SLX/SLXe/SLXi 106-118 95-106
Water Pump Belt Tension Number on TK Gauge 204–427 Field Reset: 35-40
Refri eration System
Table 3.
Compressor Thermo King X430P®
Refrigerant Charge - Type SLXi-300, SLXi-300 Whisper Pro
SLXi-400
CCAAUUTTIIOONN
HHaazzaarrddoouuss!!
FFlluuoorriinnaatteedd eeffrriiggeerraanntt ggaasseess sshhoouulldd nnoott bbee
vveennttiillaatteedd ttoo tthhee aattmmoosspphheerree..
5.00 kg - R404A/R452A*
5.70 kg - R404A/R452A*
Compressor Oil Charge X430LSC5 4.10 liters/litres**
6.62 liters/litres (deep sump)**
Compressor Oil Type Polyol Ester type P/N 203-413
High Pressure Cutout Opens: 32.41 +/- 0.48 bar (470 +/-7
psi)
Closes: Automatic reset @ 25.86 +/-
2.62 bar (375 +/- 38 psi)
High Pressure Relief
Valve
Opens: 34.48 +/- 3.45 bar (500 +/- 50
psi)
Reset: 27.58 bar (400 psi)
Heat/Defrost Method Engine Operation
Electric Operation
Hot gas
Hot gas and electric heater strips (Model
50)
SSppeecciiffiiccaattiioonnss

20 TK 61552-2-MM-EN
Table 3. (continued)
Electronic Defrost
Termination Switch
Coil must be below 7°C for defrost
initiation
Coil must be above 14°C for defrost
termination
* From January 2015. Refer to the refrigerant decal on the unit to confirm refrigerant type.
** When the compressor or compressor oil filter is removed from the unit, oil level should be noted or the oil removed from the compressor
should be measured so that the same amount of oil can be added before placing the replacement compressor in the unit.
Notes:
1. From January 2015 are available with R-404A or R-452A Refrigerants. Both of which comply with F-Gas legislation revision 2014
(Regulation (EC) No 517/2014).
2. Verify the refrigerant type (label on outside of unit), and do not to cross-contaminate.
Electrical Control System
Table 4.
Voltage 12.5 Vdc (nominal)
Battery Wet Cell: 12 volt, AHr Rating - 92AHrs, 760 Cold Cranking Amps at -18°C
EON: 12 volt, AHr Rating - 64AHrs, 880 Cold Cranking Amps at -18°C
Battery Charging (Alternator) 37 ampere brush type (optional: 65 ampere brush type)
Voltage Regulator Setting
(Alternator)
13.8 to 14.2 volts @ 25°C
Electrical Components
Table 5.
Note: Disconnect components from the unit circuit to check resistance.
Component Current Draw (Amperes) at
12.5 Vdc
Resistance (Ohms)
Starter Motor 350 to 475 (cranking)
Air Heater 89 0.14
Fuel Solenoid Pull-in Coil
Hold-in Coil
35 to 45
0.5 or 1.0
0.2 to 0.3
24 to 29
Throttle Solenoid 2.0 4.3
Pilot Solenoid 0.7 17.0
Damper Motor 2.1 6.0
Damper Gear Motor 2.5 to 3.1 4.0 to 5.0
Modulation Valve (if used) 1.7 7.6
Hot Gas Bypass Valve (if used) 1.1 11.1
SSppeecciiffiiccaattiioonnss