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Thermo King
Temperature Controller
Spectrum DE 30-2
Thermo King Spectrum DE 30-2 User Manual
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St
ructural Ma
intenance
105
AEA722
1.
Oil Seal
6.
Shaft
2.
Cap an
d Shims
7.
Housi
ng
3.
O-ring
8.
Breat
her V
ent
4.
Roll
er Bear
ing
9.
Oil P
lug Scre
w (Use Oil P
/N 203-
278)
5.
Splash G
uard T
ube
Figu
re 74:
Idle
r Assembly
104
106
Table of Contents
Table of Contents
5
List of Figures
9
Safety Precautions
11
General Practices
11
Refrigerant
11
Refrigerant Oil
11
Specifications
13
Engine
13
Belt Tension
14
Refrigeration System
14
Electrical Control System
14
Electrical Components
15
Smart Reefer Multi-Temp Μp-IV Microprocessor Temperature Controller
15
Maintenance Inspection Schedule
17
Unit Description
19
General Description
19
Host Unit
19
Figure 1:Front View (Old Skins)
19
Figure 2:Front View (New Skins)
19
Spectrum Remote Evaporator
20
Thermo King TK 486 Engine
20
Thermo King X430L Compressor
20
Smart Reefer Multi-Temp Μp-IV Microprocessor
20
Figure 3:S-3 Spectrum Remote Evaporator
20
CYCLE-SENTRY Start-Stop Controls
21
DAS (Optional)
21
Remote Control Box (Optional)
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
Figure 4:Zone 1 Cool, Zone 2 Cool, and Zone 3 Cool
25
Zone 1 Cool, Zone 2 Cool, and Zone 3 Heat
26
Figure 5:Zone 1 Heat, Zone 2 Cool, and Zone 3 Cool
27
Design Features
28
Opening the Front Doors
29
Opening the Secondary Door Latch
29
Figure 6:Door Latch Location
29
Figure 7:Opening Secondary Door Latch
29
Serial Number Locations
30
Figure 8:Compressor Serial Number Location
30
Figure 9:Engine Serial Number Location
30
Figure 10:Unit Serial Number Location
30
Figure 11:Laminated Serial Number Plate (Located Where Shown Above)
30
Figure 12:Back View of Unit
31
Figure 13:Engine Compartment
32
Figure 14:Control Panel
33
Figure 15:Typical Components Inside Control Box
34
Operating Instructions
35
Control Panel
35
Zone 1 On/Off Switch
35
Figure 16:Control Panel
35
Zone 2 On/Off Switch
36
Zone 3 On/Off Switch
36
Display
36
Keypad
36
Computer Port
37
Printer Port
37
Unit Indicators
37
Unit Protection Devices
37
Unit Operation
38
Manual Pretrip Inspection (before Starting Unit)
38
Starting Unit with Electronic Full Pretrip Test
38
Selection of Operating Modes
39
Restarting Unit
40
After Start Inspection
40
Loading Procedure
40
Single Temperature Loading Procedure
41
Post Load Procedure
41
Post Trip Checks
41
Electrical Maintenance
43
Australian Bosch Alternator
43
Charging System Diagnostic Procedures
43
Figure 17:Check Points for Alternator Test
43
Field Current Test
45
Battery
46
Fuses
46
Figure 18:Control Box
46
Fuse Link
47
Air Heater
47
Smart Reefer Multi-Temp Μp-IV Microprocessor Controller
47
Unit Wiring
47
Figure 19:Air Heater
47
Engine Maintenance
49
Emi 3000
49
Engine Lubrication System
49
Engine Oil Change
49
Oil Filter Change
49
Low Oil Pressure
49
Engine Cooling System
51
ELC (Extended Life Coolant)
51
Figure 20:ELC Nameplate Located on Expansion Tank
51
Antifreeze Maintenance Procedure
52
Figure 21:Engine Cooling System
52
Bleeding Air from the Cooling System
53
Engine Thermostat
54
Engine Fuel System
54
Operation
54
Maintenance
54
Figure 22:Engine Fuel System
55
Bleeding the Fuel System
56
Draining Water from Fuel Tank
56
Fuel Filter/Water Separator
56
Fuel Filter/Water Separator Replacement
56
Figure 23:Fuel Tank
56
Figure 24:Injection Pump
56
Engine Speed Adjustments
57
Figure 25:Filling Fuel Filter/Water Separator
57
Figure 26:Engine Speed Adjustments
57
Injection Pump Timing
58
Figure 27:Component Location
58
Figure 28:Top Dead Center One and Four
58
Injection Pump Removal
59
Figure 29:Timing Mark Alignment
59
Figure 30:Correct Injection Timing Mark Alignment
59
Injection Pump Reinstallation
60
Figure 31:Injection Pump Gear Tool
60
Fuel Solenoid System
61
Figure 32:Fuel Solenoid Location
61
Figure 33:Fuel Solenoid Timer
61
Figure 34:Simplified Schematic Diagram of Fuel Solenoid System
62
Figure 35:Main Wire Harness Connector Pin Identification
62
Figure 36:Fuel Solenoid Connector Pin Identification
62
Figure 37:Relay Socket Terminal Identification
63
Engine Valve Clearance Adjustment
64
Figure 38:Fuel Solenoid Components
64
Figure 39:Top Dead Center One and Four
64
Figure 40:Adjusting the Valve Clearance
65
Crankcase Breather
66
Air Cleaner
66
EMI 3000 Air Cleaner
66
Figure 41:Crankcase Breather
66
Figure 42:EMI 3000 Air Cleaner Assembly
66
Figure 43:EMI 3000 Air Filter Element
66
Air Restriction Indicator
67
Belts
67
Figure 44:EMI 3000 Air Cleaner System
67
Figure 45:Air Restriction Indicator
67
Belt Adjustments
68
Figure 46:Model 30 Belt Arrangement
68
Fan Belt Replacement
69
Figure 47:Condenser Blower Alignment
70
Refrigeration Maintenance
71
Refrigerant Charge
71
Testing the Refrigerant Charge with an Empty Trailer
71
Testing the Refrigerant Charge with a Loaded Trailer
71
Testing for an Overcharge
71
Adjusting Refrigerant Level
72
Moisture Indicating Sight Glass
72
Refrigerant Leaks
72
Figure 48:Moisture Indicating Sight Glass
72
Compressor Sump Sizes
73
Figure 49:Compressor with 4-Quart Sump
73
Figure 50:Compressor with 7-Quart Sump
73
Checking Compressor Oil
74
High Pressure Cutout Switch (HPCO)
74
High Pressure Switch (HPSW) Test
75
Figure 51:High Pressure Cutout Manifold
75
Evacuating and Charging Smart Reefer Multi-Temp Systems
76
Set-Up Unit
76
Evacuating the System
76
Figure 52:Multi-Temp Evacuation and Charging (Two Zone Unit Shown Other Units Similar)
77
Charging the System
78
Refrigeration Service Operations
79
Low Side Pump down
79
Compressor
79
Compressor Coupling Removal
80
Compressor Coupling Installation
81
Figure 53:Compressor Coupling Removal Tool
81
Condenser Coil
82
Figure 54:Keyway Tool P/N 204-972
82
Figure 55:Compressor Coupling Installation
82
Discharge Vibrasorber
83
In-Line Check Valves
83
Figure 56:Cross Section of In-Line Check Valve
83
Receiver Tank
84
Filter Drier
84
Expansion Valve Assembly
84
Heat Exchanger
85
Evaporator Coil
85
Figure 57:Location of Expansion Valve Bulb
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
Figure 58:Throttling Valve Assembly
88
Disassembly
89
Reassembly
89
Figure 59:Inspect the Parts
89
Figure 60:Inspect for Wear
89
Figure 61:Inspect for Damage
89
Installation
90
Liquid Line Solenoid Valves (LLS and LLS2)
90
Figure 62:Throttling Valve Reassembly
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
Figure 63:Check Valve with Cap Nut
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
Figure 64: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
Figure 65:Unit and Engine Mounting Bolts
97
DE Defrost Dampers
98
Figure 66:Rear View of de Damper Assembly
98
Figure 67:Compressor Side Damper Solenoid
98
Figure 68:Control Box Side Damper Solenoid
98
Figure 69:Damper Adjustment (Control Box Side Shown Compressor Side Similar)
99
Condenser and Evaporator Fan Location
100
Condenser Fan Blower Alignment
100
Evaporator Fan Blower Alignment
100
Figure 70:Condenser Blower Alignment
100
Figure 71:Evaporator Fan Location
100
Evaporator Fan Blower Removal and Installation
101
Figure 72:DE Evaporator Blower Components
101
Fan Shaft Assembly
102
Fan Shaft Assembly Overhaul
102
Figure 73:Fan Shaft Assembly
103
Idler Assembly
104
Idler Assembly Overhaul
104
Figure 74:Idler Assembly
105
Mechanical Diagnosis
107
Refrigeration Diagnosis
111
Remote Evaporator Specifications
113
Refrigeration System
113
Electrical
113
Remote Evaporator Maintenance Inspection Schedule
115
Remote Evaporator Unit Description
117
Figure 75:Spectrum S-3 Evaporator Components
117
Figure 76:Spectrum S-3 Evaporator - Front View
118
Figure 77:Spectrum S-3 Evaporator - Back View
118
Unit Operation
119
Defrost
119
Operating Modes
119
Unit Features
119
Unit Protection Devices
120
Serial Number Location
120
Figure 78:Serial Number Location
120
Remote Evaporator Electrical Maintenance
121
Smart Reefer Multi-Temp Μp-IV Microprocessor Controlled Components
121
Unit Wiring
121
Remote Evaporator Refrigeration Service Operations
123
Expansion Valve Assembly
123
Evaporator Coil
123
Solenoid Valves
124
Liquid Return Check Valve Repair
124
Figure 79:Check Valve with Cap Nut
124
Liquid Return Valve Replacement
125
Heat Exchanger
125
Remote Evaporator Structural Maintenance
127
Unit Inspection
127
Defrost Drains
127
Evaporator Coil
127
Remote Evaporator System Diagnosis
129
Index
131
Wiring and Schematic Diagrams Index
133
4
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Thermo King Spectrum DE 30-2 Specifications
General
Brand
Thermo King
Model
Spectrum DE 30-2
Category
Temperature Controller
Language
English
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