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121

Remote Evaporator Maintenance Inspection

Schedule

Pretrip

Every

1,500

Hours

Every

3,000

Hours*

Annual/

4,500

Hours

Inspect/Service 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 broken parts.

•••Clean entire unit including evaporator coils and defrost drains.

• Check all unit mounting bolts, brackets, lines, hoses, etc.

Table of Contents5
List of Figures9
Safety Precautions11
General Practices11
Refrigerant11
Refrigerant Oil11
Electrical Hazards11
High Voltage11
Low Voltage12
Specifications13
Engine13
Belt Tension14
Refrigeration System14
Electrical Control System15
Electrical Components15
Smart Reefer Multi-Temp Μp-IV Microprocessor Temperature Controller16
Electric Standby (Model 50 Units Only)16
Maintenance Inspection Schedule17
Unit Description19
General Description19
Host Unit19
Spectrum Remote Evaporators19
Thermo King TK 486 Engine19
Figure 1:Front View19
Figure 2:S-3 Spectrum Remote Evaporator19
Thermo King X430L Compressor20
Smart Reefer Multi-Temp Μp-IV Microprocessor20
CYCLE-SENTRY Start-Stop Controls20
DAS (Optional)21
Remote Control Box (Optional)21
Sequence of Operation21
Defrost21
System Operation22
Refrigeration System Diagrams23
Zone 1 Cool, Zone 2 Cool, and Zone 3 Cool24
Figure 3:Zone 1 Cool, Zone 2 Cool, and Zone 3 Cool25
Zone 1 Cool, Zone 2 Cool, and Zone 3 Heat26
Figure 4:Zone 1 Cool, Zone 2 Cool, and Zone 3 Heat27
Design Features28
Serial Number Locations29
Figure 5:Compressor Serial Number Location29
Figure 6:Engine Serial Number Location29
Figure 7:Unit Serial Number Locations29
Figure 8:Laminated Serial Number Plate (Located Where Shown Above)29
Figure 9:Front View30
Figure 10:Back View31
Figure 11:Engine Compartment32
Figure 12:Control Panel33
Figure 13:Typical Components Inside Control Box34
Operating Instructions35
Control Panel35
Zone 1/Host On/Off Switch35
Figure 14:Control Panel35
Zone 2 On/Off Switch36
Zone 3 On/Off Switch36
Diesel/Electric Switch (Model 50 Only)36
Display36
Keypad36
Computer Port37
Printer Port37
Unit Indicators37
Unit Protection Devices37
Unit Operation38
Manual Pretrip Inspection (before Starting Unit)38
Starting Unit with Electronic Full Pretrip Test39
Selection of Operating Modes39
Restarting Unit-Diesel Operation40
Restarting Unit-Electric Operation40
After Start Inspection41
Operating Instructions (Continued)41
Loading Procedure41
Single Temperature Loading Procedures41
Figure 15:Single Temperature Load, Host on and Remote Off, Bulkhead Open/Removed41
Post Load Procedure42
Post Trip Checks42
Figure 16:Same Temperatures in each Compartment, Host and Remote Running, Bulkhead Closed42
Electrical Maintenance43
Australian Bosch Alternator - Model 3043
Amp Charging System Diagnostic Procedures43
Figure 17:Check Points for Alternator Test43
Field Current Test45
Prestolite Alternator - Model 5046
Amp Charging System Diagnostic Procedures46
Figure 18:Prestolite Terminal Locations46
Battery48
Fuses48
Figure 19:Control Box48
Fuse Link49
Air Heater49
Smart Reefer Multi-Temp Μp-IV Microprocessor Controller49
Unit Wiring49
AC Components (Model 50 Units Only)49
Electrical Contactors49
Evaporator Heaters49
Figure 20:Air Heater49
Auto Phase System50
Figure 21:Host Unit Air Flow50
Figure 22:High Voltage Tray51
Engine Maintenance53
Emi 300053
Engine Lubrication System53
Engine Oil Change53
Oil Filter Change53
Low Oil Pressure53
Engine Cooling System55
ELC (Extended Life Coolant)55
Figure 23:ELC Nameplate Located on Expansion Tank55
Antifreeze Maintenance Procedure56
Figure 24:Engine Cooling System56
Bleeding Air from the Cooling System57
Engine Thermostat58
Engine Fuel System58
Operation58
Maintenance58
Figure 25:Engine Fuel System59
Bleeding the Fuel System60
Draining Water from Fuel Tank60
Fuel Filter/Water Separator60
Fuel Filter/Water Separator Replacement60
Figure 26:Fuel Tank60
Figure 27:Injection Pump60
Engine Speed Adjustments61
Figure 28:Filling Fuel Filter/Water Separator61
Figure 29:Engine Speed Adjustments61
Injection Pump Timing62
Figure 30:Component Location62
Figure 31:Top Dead Center One and Four62
Injection Pump Removal63
Figure 32:Timing Mark Alignment63
Figure 33:Correct Injection Timing Mark Alignment63
Injection Pump Reinstallation64
Figure 34:Injection Pump Gear Tool64
Fuel Solenoid System65
Figure 35:Fuel Solenoid Location65
Figure 36:Fuel Solenoid Timer65
Figure 37:Simplified Schematic Diagram of Fuel Solenoid System66
Figure 38:Main Wire Harness Connector Pin Identification66
Figure 39:Fuel Solenoid Connector Pin Identification66
Figure 40:Relay Socket Terminal Identification67
Engine Valve Clearance Adjustment68
Figure 41:Fuel Solenoid Components68
Figure 42:Top Dead Center One and Four68
Figure 43:Adjusting the Valve Clearance69
Crankcase Breather70
Air Cleaner70
EMI 3000 Air Cleaner70
Figure 44:Crankcase Breather70
Figure 45:EMI 3000 Air Cleaner Assembly70
Figure 46:EMI 3000 Air Filter Element70
Air Restriction Indicator71
Belts71
Figure 47:EMI 3000 Air Cleaner System Model 30 Shown Model 50 Similar71
Figure 48:Air Restriction Indicator71
Model 30 Belt Adjustments72
Figure 49:Model 30 Belt Arrangement72
Model 30 Fan Belt Replacement73
Model 50 Belt Adjustments74
Figure 50:Condenser Blower Alignment74
Model 50 Compressor Belt Replacement75
Figure 51:Model 50 Belt Arrangement75
Model 50 Fan Belt Replacement76
Clutch (Model 50)76
Figure 52:Clutch78
Refrigeration Maintenance79
Refrigerant Charge79
Testing the Refrigerant Charge with an Empty Trailer79
Testing the Refrigerant Charge with a Loaded Trailer79
Testing for an Overcharge79
Adjusting Refrigerant Level80
Moisture Indicating Sight Glass80
Refrigerant Leaks80
Figure 53:Moisture Indicating Sight Glass80
Compressor Sump Sizes81
Figure 54:Compressor with 4-Quart Sump81
Figure 55:Compressor with 7-Quart Sump81
Checking Compressor Oil82
High Pressure Cutout Switch (HPCO)82
High Pressure Switch (HPSW) Test83
Figure 56:High Pressure Cutout Manifold83
Evacuating and Charging Smart Reefer Multi-Temp Systems84
Set-Up Unit84
Evacuating the System84
Figure 57:Multi-Temp Evacuation and Charging (Two Zone Unit Shown Other Units Similar)85
Charging the System86
Refrigeration Service Operations87
Low Side Pump down87
Compressor87
Compressor Coupling Removal88
Compressor Coupling Installation89
Figure 58:Compressor Coupling Removal Tool89
Condenser Coil90
Figure 59:Keyway Tool P/N 204-97290
Figure 60:Compressor Coupling Installation90
Discharge Vibrasorber91
In-Line Check Valves91
Figure 61:Cross Section of In-Line Check Valve91
Receiver Tank92
Filter Drier92
Expansion Valve Assembly92
Heat Exchanger93
Evaporator Coil93
Figure 62:Location of Expansion Valve Bulb93
Accumulator94
Suction Vibrasorber94
High Pressure Cutout Switch and High Pressure Switch94
Discharge Pressure Sensor95
High Pressure Relief Valve95
Throttling Valve95
Removal95
Figure 63:Throttling Valve Assembly96
Disassembly97
Reassembly97
Figure 64:Inspect the Parts97
Figure 65:Inspect for Wear97
Figure 66:Inspect for Damage97
Installation98
Liquid Line Solenoid Valve (LLS)98
Figure 67:Throttling Valve Reassembly98
Hot Gas Solenoid Valve (HGS)99
Suction Line Solenoid Valve (SLS)99
Check Valve Repair (SLCV, SLCV2, SLCV3, LRCV, and PVC)100
Figure 68:Suction Line Check Valve100
Figure 69:Check Valve with Cap Nut100
Check Valve Replacement (SLCV, SLCV2, SLCV3, LRCV, and PVC)101
Condenser Inlet Solenoid Valve (CIS)101
Installation101
Condenser Inlet Check Valve (CICV) Repair101
Condenser Inlet Check Valve (CICV) Replacement102
Receiver Tank Pressure Solenoid Valve (RTPS)102
Purge Valve (PV)102
Compressor Oil Filter103
Checking Compressor Oil Pressure103
Figure 70:Compressor Oil Filter103
Priming New Compressor Installations104
Structural Maintenance105
Unit and Engine Mounting Bolts105
Unit Inspection105
Condenser, Evaporator, and Radiator Coils105
Defrost Drains105
Unit Installation105
Figure 71:Unit and Engine Mounting Bolts105
Defrost Damper106
Figure 72:Defrost Damper Adjustment106
Condenser and Evaporator Fan Location107
Condenser Fan Blower107
Evaporator Fan Blower107
Figure 73:Condenser Blower Alignment107
Figure 74:Evaporator Fan Location107
Fan Shaft Assembly108
Fan Shaft Assembly Overhaul108
Figure 75:Fan Shaft Assembly108
Idler Assembly109
Idler Assembly Overhaul109
Figure 76:Idler Assembly110
Mechanical Diagnosis111
Electric Standby Diagnosis115
Refrigeration Diagnosis117
Remote Evaporator Specifications119
Refrigeration System119
Electrical119
Remote Evaporator Maintenance Inspection Schedule121
Remote Evaporator Unit Description123
Figure 77:Spectrum S-3 Evaporator Components123
Figure 78:Spectrum S-3 Evaporator - Front View124
Figure 79:Spectrum S-3 Evaporator - Back View124
Unit Operation125
Defrost125
Operating Modes125
Unit Features125
Unit Protection Devices126
Serial Number Location126
Figure 80:Serial Number Location126
Remote Evaporator Electrical Maintenance127
Smart Reefer Multi-Temp Μp-IV Microprocessor Controlled Components127
Unit Wiring127
Remote Evaporator Refrigeration Service Operations129
Expansion Valve Assembly129
Evaporator Coil129
Solenoid Valves130
Liquid Return Check Valve Repair130
Figure 81:Check Valve with Cap Nut130
Liquid Return Valve Replacement131
Heat Exchanger131
Remote Evaporator Structural Maintenance133
Unit Inspection133
Defrost Drains133
Evaporator Coil133
Remote Evaporator System Diagnosis135
Index137
Wiring Diagrams Index141

Brand	Thermo King
Model	Spectrum SB Series
Category	Refrigerator
Language	English

Thermo King Spectrum SB Series User Manual

Table of Contents

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Thermo King Spectrum SB Series Specifications

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