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Table of Contents

7

Refrigeration Service Operations   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Low Side Pump Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Compressor   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

Compressor Coupling Removal  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Compressor Coupling Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

Condenser Coil  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Discharge Vibrasorber   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
In-Line Check Valves   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Receiver Tank  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Filter Drier  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Expansion Valve Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Heat Exchanger   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Evaporator Coil  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Accumulator   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Suction Vibrasorber   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
High Pressure Cutout Switch and High Pressure Switch  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Discharge Pressure Sensor   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
High Pressure Relief Valve  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Throttling Valve  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

Removal  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Disassembly  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Reassembly  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Installation   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

Liquid Line Solenoid Valves (LLS and LLS2)  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Hot Gas Solenoid Valves (HGS and HGS2)  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Suction Line Solenoid Valves (SLS and SLS2)   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Check Valve Repair (SLCV, SLCV2, SLCV3, LRCV, and PVC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Check Valve Replacement (SLCV, SLCV2, SLCV3, LRCV, and PVC)   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Condenser Inlet Solenoid Valve (CIS)   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

Installation   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

Condenser Inlet Check Valve (CICV) Repair   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Condenser Inlet Check Valve (CICV) Replacement  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Receiver Tank Pressure Solenoid Valve (RTPS)  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Purge Valve (PV)   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Compressor Oil Filter   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Checking Compressor Oil Pressure  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Priming New Compressor Installations  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

Structural Maintenance   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Unit and Engine Mounting Bolts  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Unit Inspection   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Condenser, Evaporator, and Radiator Coils  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Defrost Drains  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Unit Installation  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
DE Defrost Dampers  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Condenser and Evaporator Fan Location  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100

Condenser Fan Blower Alignment  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Evaporator Fan Blower Alignment  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100

DE Evaporator Fan Blower Removal and Installation  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Fan Shaft Assembly   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102

Fan Shaft Assembly Overhaul  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102

Idler Assembly   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104

Idler Assembly Overhaul   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104

Summary of Contents for Spectrum DE 30-2

Page 1: ...Spectrum DE TK 51298 2 MM Rev 3 11 04 Copyright 2001 Thermo King Corp Minneapolis MN U S A Printed in U S A...

Page 2: ...not be held liable in contract or in tort including negligence for any special indirect or consequential damages including injury or damage caused to vehicles contents or persons by reason of the ins...

Page 3: ...formation on regulations and technician certification programs contact your local Thermo King dealer R 404A WARNING Use only Polyol Ester based refrigeration compressor oil in R 404A See Thermo King P...

Page 4: ...4...

Page 5: ...tional 21 Sequence of Operation 22 Defrost 22 System Operation 22 Refrigeration System Diagrams 23 Zone 1 Cool Zone 2 Cool and Zone 3 Cool 24 Zone 1 Cool Zone 2 Cool and Zone 3 Heat 26 Design Features...

Page 6: ...el Filter Water Separator Replacement 56 Engine Speed Adjustments 57 Injection Pump Timing 58 Injection Pump Removal 59 Injection Pump Reinstallation 60 Fuel Solenoid System 61 Engine Valve Clearance...

Page 7: ...S2 91 Check Valve Repair SLCV SLCV2 SLCV3 LRCV and PVC 92 Check Valve Replacement SLCV SLCV2 SLCV3 LRCV and PVC 92 Condenser Inlet Solenoid Valve CIS 93 Installation 93 Condenser Inlet Check Valve CIC...

Page 8: ...Location 120 Remote Evaporator Electrical Maintenance 121 Smart Reefer Multi Temp P IV Microprocessor Controlled Components 121 Unit Wiring 121 Remote Evaporator Refrigeration Service Operations 123...

Page 9: ...56 Figure 24 Injection Pump 56 Figure 25 Filling Fuel Filter Water Separator 57 Figure 26 Engine Speed Adjustments 57 Figure 27 Component Location 58 Figure 28 Top Dead Center One and Four 58 Figure...

Page 10: ...ling Valve Reassembly 90 Figure 63 Check Valve with Cap Nut 92 Figure 64 Compressor Oil Filter 94 Figure 65 Unit and Engine Mounting Bolts 97 Figure 66 Rear View of DE Damper Assembly 98 Figure 67 Com...

Page 11: ...ds to displace air and can cause oxygen depletion resulting in suffocation 11 EPA Section 608 Certification is needed to work on refrigeration systems Refrigerant Although fluorocarbon refrigerants ar...

Page 12: ...Safety Precautions 12...

Page 13: ...06 to 0 010 in 0 15 to 0 25 mm Exhaust Valve Clearance 0 006 to 0 010 in 0 15 to 0 25 mm Valve Setting Temperature 70 F 21 C Fuel Injection Timing 10 BTDC timed on No 1 cylinder Low Oil Pressure Switc...

Page 14: ...mpressor should be measured so that the same amount of oil can be added before placing the replacement compressor in the unit Electrical Control System Voltage 12 5 Vdc Battery One group C31 12 volt b...

Page 15: ...he direct drive starter and approximately 80 amps on the gear reduction starter Smart Reefer Multi Temp P IV Microprocessor Temperature Controller Temperature Controller Electronic Smart Reefer Multi...

Page 16: ...Specifications 16...

Page 17: ...r prefilter Check and adjust engine speeds high and low speed Check condition of drive coupling bushings per Service Bulletin T T 171 Check condition of engine mounts Replace standard silver fuel filt...

Page 18: ...r ducts and bulkheads Inspect tapered roller bearing fanshaft and idlers for leakage and bearing wear noise Clean entire unit including condenser and evaporator coils and defrost drains Check all unit...

Page 19: ...ird compartment Zone 3 Brief descriptions of the following components and features are given below Host Unit Zone 1 and Zone 2 Spectrum Remote Evaporator Zone 3 Thermo King TK 486 Engine Thermo King X...

Page 20: ...ter Units built before mid February 2003 are equipped with compressors that have a 4 quart sump Units built after mid February 2003 are equipped with compressors that have a 7 quart sump See Compresso...

Page 21: ...time Preheat indicator buzzer DAS Optional The DAS Data Acquisition System is an independent data logger that logs information from dedicated external DAS sensors and inputs The DAS features up to si...

Page 22: ...oil temperature does not rise above 58 F 14 C within the Defrost Duration DDUR time limit the microprocessor will terminate defrost and display the Alarm Icon The Defrost Duration can be set for eithe...

Page 23: ...arge pressure exceeds 375 psi 2586 kPa High speed is enabled if required when the discharge pressure drops below 300 psi 2068 kPa Refrigeration System Diagrams The following pages show examples of the...

Page 24: ...Zone 3 expansion valve into the Zone 3 evaporator There the liquid refrigerant cools the Zone 3 evaporator as it evaporates into low pressure vapor The refrigerant returns to the compressor through t...

Page 25: ...Unit Description 25 1 Zone 1 Control Box Side Evaporator 2 Zone 2 Compressor Side Evaporator 3 Zone 1 Remote Evaporator Figure 4 Zone 1 Cool Zone 2 Cool and Zone 3 Cool 1 2 3 AGA211...

Page 26: ...ant returns to the compressor through the SLS2 the suction line the SLCV2 and the accumulator Host Unit and Zone 1 Evaporator 1 Liquid Line Solenoid LLS Open 2 Liquid Return Check Valve LRCV Closed 3...

Page 27: ...Unit Description 27 1 Zone 1 Control Box Side Evaporator 2 Zone 2 Compressor Side Evaporator 3 Zone 1 Remote Evaporator Figure 5 Zone 1 Heat Zone 2 Cool and Zone 3 Cool AGA212 1 2 3...

Page 28: ...nic Air Cleaner 3000 Hour Fuel Filter Water Separator 3000 Hour Dual Lube Oil Filter 5 Year 12 000 Hour Service Interval Extended Life Coolant ELC Smart Reefer Multi Temp P IV Microprocessor Controlle...

Page 29: ...ening the Secondary Door Latch Later model units are equipped with a secondary door latch These units also have a secondary door latch nameplate located below the front doors After opening the door la...

Page 30: ...e Stamped on an nameplate on the valve cover Compressor Stamped on the end above the oil pump Figure 11 Laminated Serial Number Plate Located Where Shown Above 1 Serial Number Location Figure 8 Compre...

Page 31: ...Unit Description 31 1 Access Panels 2 Defrost Dampers Figure 12 Back View of Unit 1 2 AGA215...

Page 32: ...2 Suction Service Valve 10 Receiver Tank Sight Glass 3 Throttling Valve 11 Hand Primer Pump 4 Throttle Solenoid 12 Dipstick 5 Fuel Solenoid 13 Oil Filter 6 Air Restriction Indicator 14 Starter 7 Fuel...

Page 33: ...Unit Description 33 1 Microprocessor Control Panel 2 Display 3 Keypad 4 Switch Panel 3 Temp Unit Shown 5 Computer Port Optional 6 Printer Port Optional Figure 14 Control Panel 2 3 4 1 AJA919 5 6...

Page 34: ...Unit Description 34 1 DAS Module Optional 2 Fan Relays FR33 and FR32 3 Fuel Solenoid Pull In Relay 4 Relay Board 5 Microprocessor Figure 15 Typical Components Inside Control Box 1 2 3 4 5...

Page 35: ...sition the display will be off and the display backlight will be off The switch should always be placed in the Off position before servicing the unit When the switch is in the On position the display...

Page 36: ...rm condition exists The Zone Icons indicate which zone is currently displayed Cool Icon Appears when the indicated zone is operating in cool mode Heat Icon Appears when the indicated zone is operating...

Page 37: ...s or two years whichever occurs first if air clean indicator has not reached 25 in Remote Status Light Optional The remote status light indicates the operating status of the unit The green T indicates...

Page 38: ...ply must be adequate to guarantee engine operation to the next check point Engine Oil The engine oil level should be at the FULL mark with the dipstick turned threaded into oil pan Never overfill Cool...

Page 39: ...ibly recorded other Shutdown Alarms Go to step 5 5 View the Alarms with the CODE key refer to the appropriate Microprocessor Diagnosis Manual for detailed information about alarms a Correct the alarm...

Page 40: ...e ammeter reading by pressing the AMPS key The ammeter should indicate normal battery charging current It may be fairly high right after starting the unit but should taper off as the battery is rechar...

Page 41: ...nt Some loads require that the bulkheads be removed In that case run the Zone 1 and Zone 2 evaporators to control the temperature Make sure the setpoints for Zone 1 and Zone 2 are exactly the same Pos...

Page 42: ...Operating Instructions 42...

Page 43: ...an equivalent CAUTION Full fielding alternators with the integral regulator is accomplished by installing a jumper from terminal F2 to ground Attempting to full field the alternator by applying batte...

Page 44: ...r higher If not check the excitation circuit EXC or equivalent in the alternator harness and in the main wire harness 8 If battery voltage is present on the sense and excitation circuits connect the a...

Page 45: ...t indicates an open circuit or excessive resistance in the field circuit Replace the voltage regulator and brush assembly inspect the slip rings and repeat the test If the brushes are not the problem...

Page 46: ...components in the host unit A 25 amp fuse Fuse F12 Zone 3 Fan Motors protects the FMR3 circuit which supplies power to the Zone 3 evaporator fan motors and relays A 15 amp fuse Fuse F13 Zone 3 Soleno...

Page 47: ...ck the resistance of the air intake heater with an ohmmeter between the M6 terminal on the front of the heater and the screw on the back of the heater or the heater case The resistance should be 0 1 t...

Page 48: ...Electrical Maintenance 48...

Page 49: ...ld be changed according to the Maintenance Inspection Schedule Drain the oil only when the engine is hot to ensure that all the oil drains out When changing oil keep unit and trailer level so all the...

Page 50: ...nown Good Oil Pressure Gauge Check Oil Pressure Oil Pressure OK Oil Pressure Low Remove Oil Pump Access the oil pump by removing the crankshaft pulley the sound shield and the timing gear cover Check...

Page 51: ...corrosion acid that can attack accumulator tanks water tubes radiators and core plugs 4 Provides lubrication for the water pump seal ELC Extended Life Coolant ELC has been phased into all trailer uni...

Page 52: ...s become worn out and must be replaced by changing the antifreeze Change ELC red engine coolant every five years or 12 000 hours whichever occurs first Do not mix green or blue green engine coolant wi...

Page 53: ...to make a 50 50 mixture Do not add antifreeze and then add water to the unit This procedure may not give a true 50 50 mixture because the exact cooling system capacity may not always be known 8 Refill...

Page 54: ...cover The injection pump raises the pressure of the fuel and meters the correct amount of fuel to the nozzle at the correct time The increased fuel pressure will lift the spring loaded nozzle to admit...

Page 55: ...ir 5 Injection line replacement 6 Injection pump and governor adjustments 7 Injection pump timing 8 Nozzle spray pattern testing and adjustment 9 Minor rebuilding of nozzles 3 2 1 4 5 6 7 8 1 Check Va...

Page 56: ...r nozzles Damage to the fuel system will subsequently cause more expensive damage to the engine A large accumulation of water in the bottom of the fuel tank will stop a diesel engine Water should be d...

Page 57: ...hut the unit off 3 Remove the ball joint from the eye bolt in the high speed solenoid 4 Remove the boot from the high speed solenoid 5 Pull the plunger out of the solenoid enough to loosen the jam nut...

Page 58: ...mark on the flywheel lines up with the index mark in the timing mark access hole b Check the rocker arms on the number one cylinder to see if they are loose c If the rocker arms are loose the engine i...

Page 59: ...to recheck the timing 15 If the timing is off by more than 1 degree 0 1 in 2 5 mm loosen the mounting nuts on the studs that fasten the injection pump to the engine and rotate the injection pump to ch...

Page 60: ...ear Caution should be made to align the screw over the center of the injection pump shaft 6 Remove the screw and adapter leaving the tool plate in place This holds the gear in proper tooth alignment u...

Page 61: ...onnected to the 8D circuit The fuel solenoid relay coil is also connected to the 8D circuit and it is grounded through the fuel solenoid timer The fuel solenoid pull in coil is connected to the 2A cir...

Page 62: ...the following illustrations to identify the pins in the wire connectors a If battery voltage is not present on the 8D circuit check the 8D circuit and the related circuits and components for a fault...

Page 63: ...but should not click when the pull in coil is de energized c De energize the hold in coil by removing the jumper from the red wire 8D pin A and the positive battery terminal The fuel solenoid should...

Page 64: ...the fuel solenoid by energizing the run relay RUNR with the Relay Board Test mode NOTE The fuel solenoid must be energized when it is being installed If it is not the plunger and the linkage may not l...

Page 65: ...in good condition and is positioned squarely on the top of the valve stem Replace the valve stem cap if it shows significant wear 5 Adjust the valves if necessary by loosening the locknut and turning...

Page 66: ...ld This prevents condensation from collecting in the breather hose The condensation can plug the breather hose if it collects and freezes in the hose Air Cleaner Before the first quarter of 2001 a hea...

Page 67: ...uch strain on the belt fibers and bearings Using belt tension gauge P N 204 427 is the best method of checking belts for tightness Install the belt gauge in the center of the longest belt span Press t...

Page 68: ...belts are adjusted at the same time in one procedure NOTE If a fan belt is loose or damaged replace the belt see Fan Belt Replacement on page 69 1 Loosen the idler assembly pivot bolts and the idler...

Page 69: ...he idler adjusting arm OUT The upper fan belt should slip off the idler pulley as the idler pulley hub clears the curbside idler mounting bracket 4 Loosen the two condenser fan hub to the shaft clampi...

Page 70: ...e Maintenance 70 8 Pull the idler adjusting arm forward and install the lower fan belt 1 Blower Wheel 2 Inlet Ring 3 Alignment Mark 4 Edge of Inlet Ring Figure 47 Condenser Blower Alignment 4 3 2 1 AE...

Page 71: ...nditions the ball should be floating in the receiver tank sight glass If refrigerant is not visible in the receiver tank sight glass the unit is low on refrigerant Testing the Refrigerant Charge with...

Page 72: ...he liquid flow so the suction pressure increases approximately 20 psig 138 kPa g Maintain a discharge pressure of at least 325 to 400 psig 2241 to 2758 kPa while adding refrigerant h Close the hand va...

Page 73: ...he top of its gasket surface Compressor Oil Level The recommended compressor oil level is the same for both compressors The sight glass should be 1 4 to 1 2 full See Checking Compressor Oil on page 74...

Page 74: ...mum suction pressure and a 185 psig 1275 kPa minimum discharge pressure for 15 minutes or more After the unit has maintained the above conditions for 15 minutes observe the oil level The oil should be...

Page 75: ...rge pressure drops below 200 psig 1379 kPa Use the following procedure to test the HPSW 1 Install a gauge manifold on the compressor 2 Disconnect the HPSW from the 7K1 and HP wires in the main wire ha...

Page 76: ...CT key If OFF and PRNT appear on the display press the SELECT key again The letters REV should appear in the lower display and the revision number should appear in the upper display 8 With the revisio...

Page 77: ...remains below 2000 microns for 5 minutes restart the pump open the Evacuation Station valve nearest the pump and back seat the suction service valve while the evacuation pump is still operating Repla...

Page 78: ...sure that all zones run in Cool mode Allow the unit to start 9 Cover the condenser as required to maintain discharge pressure from 325 to 400 psig 2241 to 2758 kPa and add the remaining charge by weig...

Page 79: ...the condenser to flow into the accumulator undoing the low side pump down b Place the unit in the Evacuation mode Refer to the Service Test mode in the appropriate Microprocessor Diagnosis Manual The...

Page 80: ...stall the mounting bolts 4 Install the service valves using new gaskets soaked in compressor oil Connect the HPCO wires the HPSW wires and install the compressor oil filter 5 Pressurize the compressor...

Page 81: ...with 20 ft lb 27 N m torque This insures that the key cannot hold the tapers apart when the final bolt torque is applied Use the following procedure to install a compressor coupling on the compressor...

Page 82: ...d in farther it may cause the coupling to move off center on the shaft 9 Re install the bolt and heavy flat washer and snug the bolt down by hand Torque the bolt to 90 ft lb 122 N m 10 Spray a corrosi...

Page 83: ...the compressor oil level In Line Check Valves This unit uses some in line check valves An in line check valve is not repairable and must be replaced if it fails A heat sink must be used on the in line...

Page 84: ...he mounting screws and nuts 3 Install and tighten the inlet ORS nut Hold the drier with a back up wrench on the hex behind the ORS fitting 4 Release a small amount of refrigerant to purge the air thro...

Page 85: ...of the bulkhead Seal the openings through the bulkhead with putty when the refrigerant lines have cooled off 4 Solder the suction inlet line connection 5 Solder the liquid line connections 6 Pressuri...

Page 86: ...s 2 Solder the inlet and outlet suction lines to the accumulator 3 Pressurize the low side and test for refrigerant leaks If no leaks are found evacuate the low side 4 Open the refrigeration valves an...

Page 87: ...e discharge pressure sensor Installation 1 Apply refrigerant Loctite to the threads on the discharge pressure sensor 2 Screw the discharge pressure sensor into the adapter on the end of the tube Use a...

Page 88: ...2 Flatwasher 11 Piston 3 Plate bellows end 12 Spring piston 4 Gasket end plate 13 Nut adjusting 5 Washer adjusting 14 Pin cotter 6 Spring bellows 15 Housing piston 7 Bellows Shaft assy 16 O ring valv...

Page 89: ...lows is normally replaced 9 Clean the parts that will be reused Reassembly 1 Install the bellows with the O ring in the housing 2 Center the spring on the bellows shoulder 3 Oil the gasket install it...

Page 90: ...isassembled before soldering Removal 1 Pump down the low side and equalize pressure to slightly positive 2 Remove the evaporator access panels 3 Remove the coil and disassemble the valve 4 Unsolder th...

Page 91: ...erant charge and compressor oil Suction Line Solenoid Valves SLS and SLS2 NOTE Valves that have nylon seats must be disassembled before soldering Removal 1 Pump down the low side and equalize the pres...

Page 92: ...run the unit Check the refrigerant charge and compressor oil Check Valve Replacement SLCV SLCV2 SLCV3 LRCV and PVC Removal 1 Pump down the low side and equalize the pressure to slightly positive 2 Rem...

Page 93: ...o 45 ft lb 61 N m 3 Pressurize the refrigeration system and test for leaks 4 If no leaks are found evacuate the system 5 Recharge the unit with proper refrigerant and check the compressor oil Condense...

Page 94: ...surize the refrigeration system and test for leaks 5 If no leaks are found evacuate the system 6 Recharge the unit with the proper refrigerant Compressor Oil Filter This unit is equipped with a compre...

Page 95: ...a gauge manifold to the fitting on the side of the throttling valve This fitting allows you to monitor the suction pressure in the compressor below the throttling valve 3 Start the unit and note the...

Page 96: ...first 30 seconds allow the starter to cool for a few minutes and the crank the engine again for 30 seconds If 10 psi 96 kPa of net oil pressure still does not develop first check the compressor oil le...

Page 97: ...ed maintenance inspections Remove any debris e g leaves or plastic wrap that reduces the air flow Clean dirty coils with compressed air or a pressure washer Be careful not to bend the fins when cleani...

Page 98: ...ize the solenoid apply 12 volts to the 29A or 29 2 circuit and check Distance A the distance from the upper mounting hole to the end of the solenoid rod when the solenoid is energized Control Box Side...

Page 99: ...ts and moving the solenoid Tighten the solenoid mounting bolts when both damper blades contact the damper housing 4 Adjust the damper blade stops so they contact the edges of the damper blade This kee...

Page 100: ...lower hub bolts to 18 ft lb 24 N m Evaporator Fan Blower Alignment 1 Loosen the inlet rings on the sides of the blower housing 2 Center the blower wheel in the blower housing with equal overlap on bot...

Page 101: ...ower components aligned 3 Remove the other two 5 16 18 x 3 0 in bolts form the blower ring 4 Remove the blower ring the curbside blower and the spacer 5 Remove the seal housing and the seal with the i...

Page 102: ...assembly that contains tapered roller bearings in a sealed oil reservoir This assembly does not require any maintenance There is a level plug and a fill plug but they are not normally used except afte...

Page 103: ...hims to obtain correct end play 7 After correct end play is obtained add oil for the bearings 8 Lock the assembly in a vise with the vent facing up Pour the oil P N 203 278 through the top plug until...

Page 104: ...rive bearing down Turn the shaft upside down and use the pipe to drive the other bearing down 2 Install a new oil seal on the curbside end of the assembly after replacing the bearing race and splash g...

Page 105: ...tructural Maintenance 105 AEA722 1 Oil Seal 6 Shaft 2 Cap and Shims 7 Housing 3 O ring 8 Breather Vent 4 Roller Bearing 9 Oil Plug Screw Use Oil P N 203 278 5 Splash Guard Tube Figure 74 Idler Assembl...

Page 106: ...Structural Maintenance 106...

Page 107: ...Replace nozzles Incorrect timing Adjust timing Air cleaner clogged Replace air filter Exhaust plugged Clean exhaust Defective HPCO Replace HPCO Engine stops after starting Air in injection pump Bleed...

Page 108: ...r Wash radiator Coolant level is low Add coolant Cooling system heavily scaled Cleaning cooling system Cylinder head gasket leaks Replace cylinder head gasket Use correct gasket Faulty thermostat Chec...

Page 109: ...ning Excessive Fuel to Air Ratio Oil Consumption Air or water in fuel Type of fuel used Poor compression Incorrect timing Cold engine Defective valve seals Poor compression Excessive load Faulty injec...

Page 110: ...Mechanical Diagnosis 110...

Page 111: ...mbient Air in refrigerant system Condenser fan blades bent or broken Air short cycling around evaporator coil Air through evaporator restricted Evaporator needs defrosting Compressor discharge valves...

Page 112: ...osed Zone 2 or 3 hot gas solenoid HGS2 or 3 Leaky Zone 2 or 3 liquid line solenoid LLS2 or 3 Closed Zone 2 or 3 liquid line solenoid LLS2 or 3 Leaky Zone 2 or 3 liquid return check valve LRCV2 or 3 Le...

Page 113: ...er CB1 Zone 3 Fan Motors 30 amp auto reset Fuse F12 Zone 3 Fan Motors 25 amp Fuse F13 Zone 3 Solenoids 15 amp Fan Motors each Power Rating 0 13 hp 100 Watts rpm 2390 Full Load Amps 7 amps per motor Re...

Page 114: ...Remote Evaporator Specifications 114...

Page 115: ...These Items Electrical Inspect wire harness for damaged wires or connections Inspect replace DC fan motors Structural Visually inspect unit for fluid leaks Visually inspect unit for damaged loose or...

Page 116: ...Remote Evaporator Maintenance Inspection Schedule 116...

Page 117: ...Return Air Sensor Graded 9 Terminal Board Bracket 2 Hot Gas Solenoid 6 Variable Blower 12 V 10 Terminal Board 3 Liquid Solenoid 7 Blower Housing 11 Terminal Board Markstrip 4 Suction Line Solenoid 8 B...

Page 118: ...Remote Evaporator Unit Description 118 Figure 76 Spectrum S 3 Evaporator Front View Figure 77 Spectrum S 3 Evaporator Back View AJA984 AJA985...

Page 119: ...V microprocessor energizes the remote liquid line solenoid valve Refrigerant flows through the evaporator coil to provide cooling When the compartment temperature is near setpoint the Smart Reefer Mul...

Page 120: ...s Circuit Breaker in Host Unit located inside the control box Fuses in Host Unit located on the relay board Serial Number Location Unit Nameplate on the right end of the unit frame Figure 78 Serial Nu...

Page 121: ...to the appropriate Microprocessor Diagnosis Manual for information about maintenance of the microprocessor controlled components Unit Wiring Inspect the unit wiring and wire harnesses during scheduled...

Page 122: ...Remote Evaporator Electrical Maintenance 122...

Page 123: ...ion valves and place the unit in operation 8 Test the unit to see that the expansion valve is properly installed Evaporator Coil Removal 1 Pump down the low side and equalize the pressure to slightly...

Page 124: ...nels 6 Open the refrigeration valves and run the unit Check the refrigerant charge and compressor oil Add as required For the hot gas valve recharge the unit with proper refrigerant Liquid Return Chec...

Page 125: ...erant charge and compressor oil Heat Exchanger Removal 1 Pump down the low side and equalize the pressure to slightly positive 2 Remove the access panels 3 Remove the mounting hardware used to mount h...

Page 126: ...Remote Evaporator Refrigeration Service Operations 126...

Page 127: ...repair or replacement of parts Defrost Drains Clean the defrost drains during scheduled maintenance inspections to make sure the lines remain open Evaporator Coil Clean the evaporator coil during sche...

Page 128: ...Remote Evaporator Structural Maintenance 128...

Page 129: ...dirty evaporator coil Defrost or clean evaporator coil Expansion valve open too much Replace or adjust valve Poor fitting trailer door Repair or replace doors Liquid line solenoid partially closed or...

Page 130: ...Remote Evaporator System Diagnosis 130...

Page 131: ...System 21 defrost 22 remote evaporator 119 defrost damper adjustment 98 defrost drains 97 defrost drains remote evaporator 127 diagnosis mechanical 107 refrigeration 111 remote evaporator system 129...

Page 132: ...rol box 21 remote evaporator coil cleaning 127 replacement 123 remote evaporators 20 remote expansion valve replacement 123 remote heat exchanger replacement 125 remote liquid return check valve repai...

Page 133: ...133 Wiring and Schematic Diagrams Index Drawing No Drawing Title Page 5D56216 Schematic Diagram 135 136 5D56217 Wiring Diagram 137 140...

Page 134: ...Wiring and Schematic Diagrams Index 134...

Page 135: ...135 Schematic Diagram Page 1 of 2...

Page 136: ...136 Schematic Diagram Page 2 of 2...

Page 137: ...137 Wiring Diagram Page 1 of 4...

Page 138: ...138 Wiring Diagram Page 2 of 4...

Page 139: ...139 Wiring Diagram Page 3 of 4...

Page 140: ...140 Wiring Diagram Page 4 of 4...

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