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If further information is required, Thermo King Corporation should be consulted. Sale of product shown in this manual is subject to Thermo King’s terms and conditions including, but not limited to, the Thermo King Limited Express Warranty. Such terms and conditions are available upon request.
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Ester compressor oil in tightly sealed containers. If Polyol Ester oil becomes contaminated with moisture or standard oils, dispose of properly–DO NOT USE. When servicing Thermo King R-404A unit, use only those service tools certified for and dedicated to R-404A refrigerant and Polyol Ester compressor oils.
Safety Precautions General Practices Auto Start/Stop 1. Always wear goggles or safety glasses. CAUTION: The unit may start Refrigerant liquid, refrigeration oil, and automatically and at any time when the battery acid can permanently damage the eyes. unit On/Off switch is in the On position. 2.
Safety Precautions Refrigeration Oil The following procedures must be rigidly adhered to when servicing units to avoid microprocessor Observe the following precautions when working damage or destruction. with or around synthetic or polyol ester refrigerant 1. Disconnect all power to the unit. oil: 2.
Safety Precautions Welding of Units or Truck Bodies Precautions When electric welding is to be performed on any 1. Be certain the Unit On/Off switch is turned portion of the temperature control unit, truck or Off before connecting or disconnecting the truck chassis when the temperature control unit is standby power plug.
Safety Precautions If the victim must be removed from a live circuit, pull the victim off with a non-conductive material. Use the victim’s coat, a rope, wood, or loop your belt around the victim’s leg or arm and pull the victim off.
Specifications Engine—TK 3.74 Engine TK 3.74 Fuel Type No. 2 Diesel fuel under normal conditions No. 1 Diesel fuel is acceptable cold weather fuel Oil Capacity: Crankcase & Oil Filter 9 quarts (8.6 liters) w/Bypass Oil Filter 10 quarts (9.6 liters) Fill to full mark on dipstick Oil Type* API Type CF-4 or CG-4 or better multigrade oil...
** Thermo King synthetic oil is compatible with petroleum lubricants so there is no danger if accidental mixing occurs or if an emergency required addition of petroleum oil. Mixing is not recommended, however, since it will dilute the superior...
Specifications Electrical Components Current Draw (Amps) Resistance— at 12.5 Vdc (Ohms) Glow Plug 7 to 8.3 1.5 ± 0.15 Fuel Solenoid: Pull In 18 to 36 0.3 to 0.7 Hold In 0.49 to 0.6 22 to 26 High Speed Solenoid Condenser Inlet Solenoid (15 watt) 10.4 Receiver Tank Pressure Solenoid (15 watt)
Maintenance Inspection Schedule A closely followed maintenance program will The schedule covers units with conventional help to keep your Thermo King unit in top coolant and units with ELC. operating condition. The following general schedule is provided to assist in monitoring that maintenance.
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Maintenance Inspection Schedule 1,200 Annual/ Inspect/Service These Items trip Hours Hours 3,000 NOTE: The 1,200 hour maintenance interval may be extended to Hours 2,000 hours or 1 year (whichever occurs first) when equipped with EMI fuel filter and EMI bypass oil filter. Electrical •...
10.7 continuous horsepower condenser. (7.98 kW) at 2400 RPM. A centrifugal clutch The MD-MT operates under the control of a mounted on the engine and belt drive system TG-V microprocessor controller. The In-Cab transfer power to the compressor, water pump, Dual-Temp Controller provides safe, convenient condenser fan and alternator.
Unit Description The MD-MT will operate in one of the following A Spectrum remote evaporator is located in modes depending on the air temperature in the each compartment and can provide separate truck’s cargo compartment as sensed by the temperature controlled areas.
Unit Description Unit Operation • The flow of refrigerant through the system is controlled by the solenoid valves and the Several operating characteristics of the system check valves. during engine operation are: • The solenoid circuits are switched by the •...
Unit Description Reading Mode of Operation Charts The Mode of Operation Charts use the status of the 1K and 2K relays (or the R1K and R2K relays) to show the thermostat demand: D = De-energized (0 volts) E = Energized (12 volts) High Speed Cool—1K = D and 2K = E Low Speed Cool—1K = D and 2K = D Low Speed Heat—1K = E and 2K = D...
Unit Description Mode of Operation Charts Engine Operation* Two Compartment (with Door Sentry II) Thermostat Relays F Door R Door Solenoids Fans Fans Speed Zone 1 Zone 2 F-COOL CLOSED CLOSED HIGH R-COOL F-COOL CLOSED CLOSED R-COOL F-HEAT CLOSED CLOSED R-HEAT F-HEAT CLOSED CLOSED HIGH...
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Unit Description Engine Operation Single Compartment (with Door Sentry II) (One Large Compartment Using Both Evaporators)* Thermostat Relays F Door R Door Solenoids Fans Fans Speed Zone 1 Zone 2 F-COOL CLOSED CLOSED HIGH R-COOL F-COOL CLOSED CLOSED R-COOL F-HEAT CLOSED CLOSED R-HEAT F-HEAT...
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Unit Description Electric Operation* Two Compartment (with Door Sentry II) Thermostat Relays F Door R Door Elec. Solenoids Fans Fans Motor Zone 1 Zone 2 F-COOL CLOSED CLOSED D D D COOL COOL R-COOL F-COOL CLOSED CLOSED D D D COOL COOL R-COOL...
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Unit Description Electric Operation Single Compartment (with Door Sentry II) (One Large Compartment Using Both Evaporators)* Thermostat Relays F Door R Door Elec. Solenoids Fans Fans Motor Zone 1 Zone 2 F-COOL CLOSED CLOSED D D E COOL COOL R-COOL F-COOL CLOSED CLOSED D D E...
Unit Description Zone 1 Suction Line Check Valve (SLCV)— Zone 1 Cool and Zone 2 Cool Open High pressure refrigerant vapor leaves the Zone 1 Suction Line Solenoid (SLS)—Open compressor and flows through the open CIS to the condenser where the refrigerant condenses into Zone 1 Hot Gas Solenoid (HGS)—Closed high pressure liquid.
Unit Description Zone 1 Suction Line Solenoid (SLS)—Open Zone 1 Cool and Zone 2 Heat Zone 1 Hot Gas Solenoid (HGS)—Closed The CIS is closed so high pressure refrigerant vapor leaves the compressor and flows through Zone 2 Evaporator the Zone 2 hot gas line and the open RHGS into the Zone 2 evaporator.
Unit Description At setpoints above 15 F Operating Modes Zone 2 Evaporator: (-9.4 C), the Zone 2 evaporator operates in the High Speed Heat is normally locked out at following modes. setpoints below 15 F (-9.4 C). • Cool Engine, Continuous Run—Two •...
Unit Description At setpoints above 15 F Engine, Continuous Run—Single Zone 2 Evaporator: (-9.4 C), the Zone 2 evaporator operates in the Compartment Operation following modes. At setpoints above 15 F Zone 1 Evaporator: (-9.4 C), the Zone 1 evaporator operates in the •...
Unit Description CYCLE-SENTRY Operation Units that are equipped with the CYCLE-SENTRY option will shut down when both evaporators are in Null. The unit starts when either thermostat calls for high speed or when Defrost is initiated in either evaporator. Features of the CYCLE-SENTRY system are: •...
Electric Operation Defrost Operation During electric operation, the electric motor will As the MD-MT is operated to cool the cargo box, stop when both evaporators are in Null. The frost will gradually build up on the evaporator electric motor will not start until one of the coils.
Unit Description Three methods of Defrost initiation are available: Microprocessor Controller TG-V: Microprocessor Controller is programmed to automatically initiate a Defrost cycle every 4 hours during pulldown until return air temperature is in-range (between approximately 7 degrees above and 7 degrees below setpoint). The Air Switch automatically places Air Switch: the unit into Defrost when the frost accumulation...
Unit Description Design Features Unit Model Unit Model Unit Model Unit Model MD-MT 50 MD-MT 50 MD-MT 30 MD-MT 30 (920004) (920006) (920003) (920005) TK 3.74 Diesel Engine • • • • X214 Compressor with Solest 35 Compressor • •...
Unit Description AMA01 Engine Oil Dipstick Coolant Tank Compressor Oil Sight Glass Receiver Tank Sight Glass Electric Motor Reset (Model 50) Electric Motor (Model 50) Figure 14: Top View...
Unit Description 1. One Temp/Two Temp Switch 6. Preheat/Start Switch 2. Auto Start/Stop - Continuous Run Switch 7. Run Hourmeter (Optional on Model 50) 3. Stop Start Light (Optional) 8. Electric Operation Hourmeter (Optional on Model 50) 4. Engine Reset 9.
Unit Description AEA2127 Temperature Display (Zone 1) Temperature Display (Zone 2) Power Cord Indicator Light (Model 50) EFROST 10. Z EFROST NTER 12. W ELECT HISPER Figure 17: TG-V In-Cab Controller for Multi-Temp Compartment Units...
Unit Description aea04 NOTE: Apply Thread Sealant When Installing High Pressure Cutout Oil Seal (Location Not Shown) Crankshaft Discharge Port Cylinder Head Figure 18: X214 Compressor...
Operating Instructions Unit Controls • The Microprocessor Controller calls for heating or cooling. TG-V Multi-Temp Control Box • Manual Defrost initiated. WARNING: Do not operate the unit until • Engine block temperature drops below you are completely familiar with the 30F (-1 C).
Operating Instructions TG-V In-Cab Controller for Other situations which may cause the engine reset Multi-Compartment Units to open are: • Engine runs out of fuel. WARNING: Do not operate the TG-V until you are completely familiar with the • On/Off switch is left on accidentally without meaning of each display symbol, and the the engine being started.
Operating Instructions Used to select the various displays Key: During the normal operation, the standard display ELECT which can appear on the screen. is on the screen. Used to increase setpoint temperature Key: Return Air Temperature is factory standard when the setpoint symbol is on the screen. display setting (can be changed).
Operating Instructions Other Controls Unit Protection Devices A temperature Defrost Termination Switches: A thermal type manual reset Engine Reset Switch: sensitive switch is mounted on each evaporator switch protects the engine. The reset switch coil. It is used to control Defrost. The switch contains a heater coil that is attached to a sensor closes when the evaporator temperature drops to switch in the engine oil system, engine coolant...
Operating Instructions The engine low The engine oil level should be at the Engine Low Oil Pressure Cutout: Engine Oil: oil pressure cutout is a pressure sensitive switch FULL mark on the dipstick. Never overfill. located in the engine oiling system. This switch Check coolant level gauge for the correct Coolant: will trip the Engine Reset and stop the engine if...
CYCLE-SENTRY Equipped Units thermostat demand. The unit runs The Thermo King CYCLE-SENTRY system is continuously until it is turned off manually. designed to save refrigeration costs. The savings The start sequence, once initiated, is the vary with the commodity, ambient temperatures same for both systems.
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Operating Instructions Examples of Products Normally CYCLE-SENTRY Operation Acceptable for CYCLE-SENTRY Operation With the selector switch placed in the • Frozen foods (in adequately insulated trailers) CYCLE-SENTRY position, the CYCLE-SENTRY system shuts down the unit • Boxed or processed meats when the compartment temperature reaches the •...
Operating Instructions NOTE: A unit that is equipped with 7. At the end of the preheat period, the engine CYCLE-SENTRY should be manually started if will begin cranking. The glow plugs remain it has been turned off long enough for the engine energized during the cranking period.
Starting Zone 2 Evaporator 4. Products should be pre-cooled before loading. 1. Start the condensing unit Zone 2 will Thermo King units are designed to maintain automatically be on. loads at the temperature at which they were loaded. Transport refrigeration units are not 2.
Operating Instructions Post Trip Checks 1. Wash the unit. 2. Check for leaks. 3. Check for loose or missing hardware. 4. Check for physical damage to the unit.
Thermo King P/N NOTE: Units manufactured with 204-615 (FLUKE 23) digital multimeter and a CYCLE-SENTRY and alternators with integral Thermo King P/N 204-613 amp clamp or an regulators MUST use replacement alternators equivalent. with integral regulators.
Electrical Maintenance NOTE: All voltage readings should be taken b. If there is low or no output, the alternator between the negative battery terminal, or a good is probably faulty. However, the following chassis ground, and the terminals indicated, items are potential causes for not charging: unless stated otherwise.
Electrical Maintenance Glow Plugs Conditions that cause the reset switch to trip: • Engine coolant (water) temperature over Glow plugs heat the combustion chamber to aid in 220 F (104 C). quick starting. The glow plugs are energized when the Preheat/Start switch is held on the Preheat or •...
Electrical Maintenance Low Oil Pressure Switch (LOP) If the circuit breaker opens, check the unit for a grounded wire or a grounded condition in a relay The engine oil pressure should rise immediately or solenoid. after the engine is started. The LOP will trip the reset switch and stop the engine if the oil pressure Evaporator Circuit Breaker drops below 10 ±...
Electrical Maintenance Unloading Timer (EUT) 6. Place the On/Off switches in the On position and press the key. The unloading timer energizes the unloading relay 7. Check for battery voltage at the 7KB wire in (EUR) for approximately 20 seconds when the the main wire harness.
Electrical Maintenance Defrost System Zone 1 Evaporator Defrost Cycle Diesel Operation CAUTION: This unit is equipped with The Defrost cycle can be initiated with the ANUAL Auto Start. It will start automatically if the key, by the air switch, or by the defrost EFROST key is pressed while the On/Off timer in the TG-V Controller when the defrost...
Electrical Maintenance Zone 1 Evaporator Defrost Cycle Zone 1 Evaporator Does Not Defrost Checkout Procedure 1. Check the evaporator temperature: Make sure the evaporator temperature is CAUTION: This unit is equipped with actually below 42 F (6 C) if the unit will not Auto Start.
Electrical Maintenance Zone 1 Evaporator Sticks In Defrost 1. Check the evaporator temperature: Indefinitely Be sure the evaporator temperature is actually If the unit remains stuck in Defrost indefinitely, above 52 F (11 C) if the unit will not terminate check the defrost relay, the 11 circuit and the Defrost.
Electrical Maintenance Zone 2 Evaporator Does Not Defrost Initiating the Defrost cycle energizes the Zone 2 defrost relays, RD and RDR4. When RD is 1. Check the evaporator temperature: energized, it energizes the RHGS circuit, which energizes the RHGS and the 26 circuit. The 26 Make sure the evaporator temperature is circuit energizes the CIS (and the RTPS and PV actually below 42 F (6 C) if the unit will not...
Electrical Maintenance Zone 2 Defrost Relay (RD) Zone 1 Fan Relay (FR) Zone 2 Fan Relay (RFR) Zone 1 Defrost Relay (DR) Figure 23: Defrost Relay Locations Zone 2 Evaporator Will Not Terminate 1. Check the Zone 2 defrost relays: Defrost If the unit remains on Defrost indefinitely, If the defrost termination switch does not...
Electrical Maintenance Zone 2 Evaporator Continuously Fails to Defrost System Components Terminate Defrost In Less than 45 Minutes Defrost Termination Switches If the unit continually fails to complete the Defrost cycle in less than 45 minutes, and cycles Each electronic defrost termination switch uses between Cool and Defrost, check the evaporator solid state components to control the Defrost coil temperature, RHGS, CIS, PV, RTPS, RTPC,...
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Electrical Maintenance 2. Connect the negative lead of the switch to the 1. Remove plastic sensing tubing from both sides negative battery terminal. of the air switch. 3. Raise the temperature of the defrost 2. Disconnect one wire at the switch terminal. termination switch above 52 F (11 C).
Electrical Maintenance AGA271 Adjustment Screw Squeeze Bulb (P/N 204-494) Continuity Tester Pressure in Inches of Water (P/N 204-442) Figure 25: Air Switch Testing and Adjustment Measuring Evaporator Coil Pressure 4. Run the unit in High Speed Cool and measure Differential the evaporator coil pressure differential.
Diagnosis Manual for all operation and diagnosis is connected to the +12 Fan circuit, the Fan SC procedures. The MD-MT is not presently included circuit, and ground. The voltage on the Fan SC in that manual but the system is similar.
Electrical Maintenance Multi-Temp Relay Board The multi-temp relay board is located inside the control box. The thermostat relays and the associated control relays are located on the multi-temp relay board. The component locations are shown in the following illustration. AEA623 Zone 2 Heat/Cool Relay (R1K) 6.
Electrical Maintenance AC Components The In-Cab TG-V functions similarly to the standard unit mounted TG-V. However, the In-Cab TG-V Controller also has the following CAUTION: The unit uses high voltage additional features: alternating current (ac) during electric operation. Lethal voltage potentials can •...
Electrical Maintenance Field Test Procedure for 4. Press the key to display the setpoint(s) ELECT Multi-Temperature In-Cab TG-V and adjust the setpoint(s) to 80 F (27 C). Both Controllers setpoints must be adjusted to 80 F (27 C) to properly test the multi-temperature controller. Use tester P/N 204-831.
Electrical Maintenance Door Sentry II Opening Both Zone 1 and Zone 2 Doors Door Sentry II is a factory option that is designed Because power to operate the coils of relays XK1, to improve temperature control when the doors XK2 XK3 and XK4 is removed when the Zone 2 are opened during delivery.
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Electrical Maintenance Door Sentry-II Operation Modes Zone 1 Zone 2 Zone 1 Door Open Zone 2 Door Open Both Doors Open HS Cool Cool Unit goes to low speed, All power to Zone 2 unit Zone 1 unit ERC disabled. damper solenoid control circuits and Zone 1 unit runs normal.
NOTE: Units equipped with the EMI 2000 Maintenance consists of replacing the switch. package do require regular inspection in accordance with Thermo King’s maintenance Engine Oil Change recommendations. The engine oil should be changed according to the NOTE: The new EMI 2000 oil filters and new “Maintenance Inspection Schedule”.
25 in. (635 mm) of vacuum, or at 2,000 hours, or 1 year, whichever occurs first. It cannot be interchanged with air filter elements used on previous Thermo King truck units. Spin-on Oil Filter Pressure Valve Nut...
Engine Maintenance Oil Bath Type A heavy duty, oil bath air cleaner filters all of the air entering the engine. Excessive restriction of the air intake system reduces the flow of air to the engine affecting horsepower output, fuel consumption and engine life. The air cleaner removes abrasive material from the air entering the engine.
Engine Maintenance Engine Cooling System from the side of the radiator (large header), circulates it through the cylinder block and head, The engine employs a closed, circulating type, then back to the radiator. A thermostat mounted in pressurized cooling system. Correct engine the water outlet from the cylinder head to the temperatures are controlled and maintained by a radiator automatically maintains coolant...
To upgrade new production engines for ELC use, The following are the Extended Life Coolants all water pump seal bellows were changed from currently approved by Thermo King for use in NBR to HNBR elastomer, and the o-rings ELC units for five years or 12,000 hours: upgraded from NBR to EPDM elastomer.
Engine Maintenance Antifreeze Maintenance Procedures As with all equipment containing antifreeze, periodic inspection on a regular basis is required to verify the condition of the antifreeze. Inhibitors become worn out and must be replaced by changing the antifreeze. Change green or blue-green engine coolant every two years.
Engine Maintenance Bleeding Cooling System After filling the radiator, run the unit up to operating temperature to check for overheating and coolant level and allow the air to be purged for a few minutes. CAUTION: Do not remove the radiator cap while the engine is hot.
Engine Maintenance Engine Fuel System The fuel system used on the Thermo King TK 3.74 diesel is a high pressure system used in conjunction with a prechamber. The components of the fuel system are: • Fuel tank (may be the truck fuel tank) •...
Engine Maintenance Thermo King recommends that any major 3. Tighten the bleeder screw on the injection injection pump or nozzle repairs be done by a pump when clear flow of fuel appears. quality diesel injection service specialty shop. The NOTE: At initial start-up, open the bleeder...
Engine Maintenance Electric Fuel Pump If pump does not operate, check for: • Ground to the frame of the TK unit Operation • Clean and tighten electrical connections The electric fuel pump must be mounted next to • The pump voltage and polarity. It must be the the fuel tank.
Engine Maintenance Integral Fuel Solenoid When the fuel solenoid is energized, current is applied to the coil creating an electro-magnetic The fuel stop solenoid is located on the end of the field, which pulls the When in the “pulled-in” fuel injection pump. position, the plunger releases tension on the governor linkage.
Engine Maintenance The size of the capacitor has been changed to increase the pull-in time from 1 second to 2 seconds. This minimizes the chance that the pull-in coil would fail to open the fuel valve. The integral fuel solenoid contains two coils: the pull-in coil, and the hold-in coil.
Engine Maintenance Troubleshooting the Integral Fuel 5. Check the CH pin in the fuel solenoid wire Solenoid System connector for continuity to a good chassis ground. NOTE: The fuel solenoid pull-in coil will require 30 to 40 amps to turn on the fuel. The a.
Engine Maintenance b. Momentarily energize the pull-in coil by 12. Check the voltage on the 2B circuit at the 30 placing a jumper between the 8DP pin in terminal in the fuel solenoid relay socket. the fuel solenoid and the 2 terminal at the a.
Engine Maintenance Fuel Stop Solenoid Replacement NOTE: The fuel stop solenoid must be energized when it is being installed. If it is 1. Disconnect the 20 wire from the reset switch not, the plunger and the linkage may not line to prevent the reset switch from tripping.
Turn the screw out engine fully warmed up. to decrease the engine speed. The MD-MT has one solenoid to control the high 5. Set the engine speed at 1625 ± 25 RPM and speed function. The speed of the engine should be tighten the jam nut.
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Engine Maintenance 2. Remove the injection line from the number 1 CAUTION: The cylinders on the engine injector and the injection pump. Remove the are numbered from the flywheel end to the delivery valve holder, delivery valve and water pump end. The number 1 cylinder is spring.
Engine Maintenance 10. When the injection pump has been correctly 12. Reinstall the delivery valve and spring. timed to the engine, remove the pump and put Torque the delivery valve holder to 30 ft-lb a light coat of silicone gasket sealer on the (41 N•m).
CAUTION: Make sure the fuel rack is off procedures. California service technicians should to prevent the engine from starting. see your local Thermo King dealer for recent bulletins. a. Turn the engine so number 1 cylinder is on compression with piston to TDC. Both push rods should turn freely.
Engine Maintenance Engine Mounts for MD-MT Units The engine mounting system contains three vibration mounts and two snubber mounts. 0.020 Air Gap Between Lower Snubber and Vibration Mount (91-2276) Engine Bracket When Assembled (Snubbers Only) Snubber Mount (99-4820) Snubber Bracket (91-3201)
(or set) the belt tension. working on any part of the unit. a. The belt tension should be set at a reading of 70 ± 3 on the Thermo King Belt Tension Gauge. b. The belt should deflect 1/2 in. (13 mm) at the center of the longest (lower) span.
The engine/compressor belt tension should be set enough to allow the sprocket to rotate at a reading of 70 ± 3 on the Thermo King Belt freely. If not, the reading on the torque Tension Gauge.
50 ± 5 deflection of the compressor/alternator belts on the Thermo King Belt Tension Gauge. If the Thermo King Belt Tension Gauge is not used, the belt should deflect 1/2 in. (13 mm) at the center of the longest span.
(See evacuation should always be practiced. attached tool list and evacuation procedures.) See the diagram of the Thermo King Evacuation The primary objective of evacuation is to bring Station and note the location of the valves.
Refrigeration Maintenance AGA654 Two Stage Vacuum Pump Thermistor To 110 Vac Power Calibration Standard Vacuum or Micron Gauge Figure 55: Evacuation Station...
Refrigeration Maintenance Refrigerant Charge Testing the Refrigerant Charge with a Loaded Truck Testing the Refrigerant Charge with 1. Install a gauge manifold (optional). an Empty Truck 2. Run both evaporators on the Cool cycle. If the unit has an insufficient charge of refrigerant, 3.
Refrigeration Maintenance Moisture Indicating Sight 6. By the time the discharge pressure decreases approximately 50 psig (345 kPa), the ball in Glasses the receiver tank sight glass should begin to The receiver tank is equipped with a moisture move and the liquid level should decline. indicating sight glass.
Refrigeration Maintenance Refrigerant Leaks Checking Compressor Oil Use a reliable leak detector (e.g., electronic The compressor oil should be checked when there detector) to leak test the refrigeration system. is evidence of oil loss (oil leaks) or when Inspect for signs of oil leakage which is the first components in the refrigeration system have been sign of a leak in the refrigeration system.
Refrigeration Maintenance High Pressure Cutout (HPCO) To check compressor oil level with an ambient air Run the unit temperature below 50 F (10 C): The high pressure cutout is located on the through a complete Defrost cycle. After compressor cylinder head. If the discharge completing the Defrost cycle, run the unit on Cool pressure rises above 450 psig (3103 kPa) on for ten minutes.
Refrigeration Maintenance Evacuating and Charging 3. Raise the discharge pressure of the compressor by blocking the condenser coil air Procedures flow by covering the roadside condenser grille with a piece of cardboard. Set-up Electrical Controls NOTE: The discharge pressure should never 1.
Refrigeration Maintenance 5. Once a vacuum of 100 microns has been 7. If the pressure rises above 1500 microns in 5 reached, close the vacuum valve at the minutes, check all the hoses and connections vacuum pump and stop the pump. for leaks and repeat steps 3 through 6.
Refrigeration Maintenance Unit Evacuation 8. After the hour of additional evacuation time, open the suction service valve. The vacuum NOTE: The electrical system must be energized gauge reading will rise. Continue to evacuate throughout this procedure. the system back down to 500 microns. When 1.
Refrigeration Maintenance AEA2088 Vacuum Gauge Vacuum Valve Thermistor Leave Hand Valve Closed for First 5 Minutes of Evacuation Figure 61: Unit Evacuation...
Refrigeration Maintenance Unit Charging 5. Connect the HGSA wire and the RHGS wire to the relay board. Connect the condenser inlet NOTE: The electrical system must be energized solenoid wires (2 pin connector) to the main throughout this procedure. wire harness. Replace the front and rear fan 1.
Refrigeration Maintenance AEA2088 Refrigerant Scale Evacuate or Purge Closed Closed Open for Liquid; Back Seat for Vapor Back Seat for Liquid; Open for Vapor Figure 62: Unit Charging...
Refrigeration Maintenance Remove Evacuation Hoses 3. Back seat the suction service valve. 1. Run the Zone 1 and Zone 2 units in High 4. Remove the hoses from the receiver outlet and Speed Cool with the receiver outlet and discharge service valves. discharge service valves back seated.
Refrigeration Service Operations NOTE: It is generally good practice to replace 3. Prepare to perform service on the unit’s low the filter-drier whenever the high side is opened side by equalizing the high side and low side or when the low side is opened for an extended pressures.
Refrigeration Service Operations Compressor 5. Back seat the suction and discharge service valves. Removal 6. Operate the unit at least 30 minutes and then inspect the oil level in the compressor. Add or 1. Pump down the compressor and equalize the remove oil if necessary.
Refrigeration Service Operations Drier Whenever the two-piece pulley is removed from any type of unit service, anti-seize lubricant should be applied to the outside of the tapered Removal surface on the pulley bushing. Use one of the 1. Pump down the low side and equalize the following recommended anti-seize lubricants: pressure to slightly positive.
Refrigeration Service Operations Accumulator 4. If no leaks are found, open the refrigeration valves and place the unit in operation. Removal High Pressure Relief Valve 1. Pump down the low side and equalize the pressure to slightly positive. Removal 2. Drain the engine cooling system. 1.
Refrigeration Service Operations Receiver Tank Removal 1. Remove the refrigerant charge. 2. Unsolder the inlet tube from the receiver tank. 3. Unsolder the drier line from the receiver tank outlet tube. 4. Unbolt the mounting hardware and remove the receiver tank from the unit. Installation 1.
Refrigeration Service Operations Condenser Inlet Check Valve Installation Replacement 1. Inspect the inside of the check valve body for damage or foreign particles which might Removal adhere to the seat and damage the new seat. If the body is damaged, replace the check valve. 1.
Refrigeration Service Operations Suction Line Check Valve and Purge Check Valve Replacement (SLCV, RSLCV, and PCV) Removal 1. Pump down the low side and equalize the pressure to slightly positive. 2. Unsolder the lines and remove the check valve. 1. Spring 3.
Refrigeration Service Operations Receiver Tank Pressure Purge Valve (PV) Solenoid Valve (RTPS) NOTE: Valves that have nylon seats must be disassembled before soldering. Removal Removal 1. Pump down the low side and equalize the pressure in the high side to slightly positive. 1.
Compressor Oil The pressure temperature relationship of R-404A Thermo King Corporation has chosen to use a is similar to that of R-502. The capacities of this compressor oil called Polyol Ester (POE)—also new refrigerant is similar for box temperatures called ester based oil.
Dedicated Equipment Gauge manifolds and manifold hoses used with other Thermo King refrigerants maybe used but CAUTION: Equipment that has been used extreme care should be taken to prevent with other refrigerants MUST NOT be contamination of the R-404A systems with other used with R-404A refrigerants.
Hilliard Clutch Maintenance Large Truck Unit Centrifugal 107-204. Centrifugal clutch P/N 107-291 has three belt grooves and its engagement speed is Clutch Change (P/N 107-291) 600 ± 100 RPM. When this clutch is installed on a Beginning in the second quarter of 2000 most unit equipped with a two groove belt, the belt large truck units are equipped with centrifugal should be placed in the two grooves nearest to the...
Hilliard Clutch Maintenance Clutch Maintenance Using an inspection mirror, inspect the clutch every 1000 hours of operation or yearly, whichever occurs first. If clutch removal is necessary, clean the shoes and drum, regrease bearings or replace if they are worn. Inspect anchor bushings, shoe lining and springs for wear and replace if necessary.
Hilliard Clutch Maintenance 8. Remove inner race of roller bearing from the 2. Remove the inner race from the roller bearing, housing shaft. apply a small amount of Loctite #270 to race I.D. and press onto the housing shaft, seating NOTE: This race was Loctited and pressed against the step.
Hilliard Clutch Maintenance 14. Place the hub and shoe assembly into the housing and place flatwasher over the bearing. 15. Apply Loctite #680 to 3/8-16x1 screw and install through washer into housing shaft. The housing and hub will be drawn together to the proper relative position as the screw is tightened.
Structural Maintenance Unit and Engine Mounting Bolts Fan Location Periodically check and tighten all unit and engine When mounting the fan and hub assembly on the mounting bolts. Torque the unit mounting motor or jackshaft, position the assembly in the bolts to 60 ft-lb (81.3 N•m).
Mechanical Diagnosis Condition Possible Cause Remedy Unit switched On—indicator Batteries discharged Charge or replace batteries lights do not come on Reset switch tripped Check engine oil, coolant level, and CYCLE-SENTRY system (optional). Push in reset switch button Corroded battery connections Clean and tighten Circuit breaker tripping Check for short circuit in unit wiring...
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Mechanical Diagnosis Condition Possible Cause Remedy Engine stops after starting Air in injection pump Bleed fuel system Fuel filter obstructed Replace filter element High head pressure Eliminate cause of high head pressure Vent of fuel tank obstructed Unclog vent Reset switch trips Check engine oil, coolant level, and CYCLE-SENTRY system (optional).
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Mechanical Diagnosis Condition Possible Cause Remedy Engine runs hot Dirty radiator Clean radiator Coolant level is low Add coolant Cooling system heavily scaled Clean cooling system Cylinder head gasket leaks Replace cylinder head gasket. Use correct gasket Faulty thermostat Check or replace the thermostat Loose or worn water pump belt Replace belt Oil pressure too low or drops...
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Mechanical Diagnosis Engine Emits Excessive Smoke White Smoke Black Smoke Blue Smoke Fuel is not burning Excessive Fuel to Air Ratio Oil Consumption • Air or water in fuel • Type of fuel used • Poor compression • Incorrect timing •...
CYCLE-SENTRY Diagnosis Condition Possible Cause Test Procedure Run relay will not energize when Open 7A circuit from selector switch Test 7A circuit required to run relay Defective selector switch Test circuit from 7M or 7MA to 7A on switch in the CYCLE position Open 7M or 7MA circuits Test 7M and 7MA circuits Open diode from 77, R7C, 7C or 7X...
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CYCLE-SENTRY Diagnosis Condition Possible Cause Test Procedure Unit cranks only after preheat has Defective engine temperature Test engine temperature thermistor occurred for approximately 6 thermistor minutes Open BL1 or BL2 wires from option Check BL1 and BL2 wires board to engine temperature thermistor Defective CSM Test or replace CSM...
Electric Standby Diagnosis Condition Possible Cause Remedy Unit switch On— lights do not Battery discharged Charge or replace battery come on Dirty battery terminals Clean and retighten terminals Fuse F1 blown Replace fuse F1 Unit switch On— but electric No standby power Provide power to unit;...
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Electric Standby Diagnosis Condition Possible Cause Remedy Contact chatter Low battery voltage Check voltage condition. Check momentary voltage dip during starting—low voltage prevents magnet sealing Defective or incorrect coil Replace coil Poor contact in control circuit Check auxiliary switch contacts and overload relay contacts.
Refrigeration Diagnosis Possible Causes • • • • Overcharge of refrigerant • • • • • • Shortage of refrigerant • • • • • No refrigerant • Air through condenser too hot (ambient) • Air flow through condenser restricted •...
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Refrigeration Diagnosis Possible Causes • • Expansion valve open too much • • Expansion valve closed too much • • Expansion valve needle eroded or leaking • • • Expansion valve partially closed by ice, dirt or wax • • •...
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Refrigeration Diagnosis Possible Causes • • • • Leaky Zone 1 hot gas solenoid (HGS) • • Closed Zone 1 hot gas solenoid (HGS) • • • Leaky Zone 1 liquid line solenoid (LLS) • • • • • • Closed Zone 1 liquid line solenoid (LLS) •...
Remote Evaporator Specifications Refrigeration System Evaporator Coil Type Direct Expansion Refrigerant Type R404a Heat/Defrost Method Hot Gas Electrical Control System Voltage 12.5 Vdc Spectrum Evaporator Fan Motor: Horsepower 0.13 hp Fan Voltage 8 to 16 Vdc 1900 Full Load Amps 8.7 amps per motor Fuse F1-1, F1-2, F2-1, F2-2 30 amp...
Remote Evaporator Unit Description Unit Features The Spectrum multi-temperature refrigeration system provides heavy duty temperature control • Direct Expansion Evaporator Coil for multiple compartment trucks. The system provides direct expansion cooling in all cargo • 12 Vdc Fan Motor compartments. •...
Remote Evaporator Refrigeration Service Operations NOTE: It is generally good practice to replace 8. Test the unit to see that the expansion valve is the filter drier whenever the high side is opened properly installed. or when the low side is opened for an extended period of time.
Remote Evaporator Refrigeration Service Operations Solenoid Valves NOTE: Valves that have nylon seats must be disassembled before soldering. Removal 1. Pump down the low side and equalize the pressure to slightly positive. AEA648 2. Remove the access panels. 3. Remove the coil and disassemble the valve. Valve 4.
Remote Evaporator Structural Maintenance Unit Inspection Inspect the unit during the unit pretrip inspection and scheduled maintenance inspections for loose or broken wires or hardware, chaffed wires, compressor oil leaks, or other physical damage which might affect unit performance and require repair or replacement of parts.
Remote Evaporator System Diagnosis Condition Possible Cause Remedy Load temperature too high Refrigerant shortage Repair leak and recharge Setpoint too high Adjust setpoint Expansion valve plugged Clean or replace Partial obstruction in low side of Locate obstruction and repair refrigeration system Iced or dirty evaporator coil Defrost or clean evaporator coil Expansion valve open too much...
Index AC components 74 ELC (extended life coolant) 83 accumulator 120 electric fuel pump 89 after start inspection 57 electric operation 56 air switch, specifications 19 electric standby diagnosis 143 air switches 70 electric standby power receptacle 51 alarm codes 74 electric standby, specifications 21 alternator 59 electrical components, specifications 21...
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117 unit features 155 unit inspection 159 unit operation 155 maintenance inspection schedule 23 unit protection devices 155 MD-MT 30 25 MD-MT 50 25 mechanical diagnosis 137 safety precautions 13 mode of operation charts 29 auto start/stop 13...
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