Related Manuals for Thermo King MD-200
Summary of Contents for Thermo King MD-200
- Page 1 MD-200 w/TK 3.74 TK 51912-1-MM (Rev. 0, 07/03) Copyright© 2000 Thermo King Corp., Minneapolis, MN, USA. Printed in USA.
- Page 2 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.
- Page 3 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.
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Page 5: Table Of Contents
Table of Contents List of Figures ................9 Safety Precautions . - Page 6 Start Up Mode ............... . 56 MD-200 Units Equipped with a Three-Phase Electric Motor and a Phase Converter That Operates on Single-Phase Power .
- Page 7 Table of Contents Refrigeration Maintenance ..............91 Evacuation .
- Page 8 Table of Contents Refrigeration Service Operations (continued) Three-way Valve Repair ..............109 Removal .
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Page 9: List Of Figures
Figure 5: Access Panel Open (Curbside)—MD-200 ........ - Page 10 List of Figures Figure 59: Condenser Pressure Bypass Check Valve ......... . . 108 Figure 60: Three-way Valve Assembly .
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Page 11: Safety Precautions
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. -
Page 12: Refrigeration Oil
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. -
Page 13: Welding Of Units Or Truck Bodies
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. -
Page 14: Low Voltage
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. -
Page 15: Specifications
Specifications ENGINE SPECIFICATIONS Engine TK 3.74 Fuel Type No. 2 Diesel fuel under normal conditions 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 API Synthetic type CF-4, CG-4 or better after first 500 hours... - Page 16 Specifications R-404A REFRIGERATION SYSTEM Compressor Model X214 Refrigerant Charge 6.5 lb. (2.95 kg) R-404A Compressor Oil Charge 102 oz. (3.0 liters)* Compressor Oil Type: R-404A (Solest 35) TK No. 203-413 (Ester base) required Suction Pressure Regulator Setting 20 psig (138 kPa) Heat/Defrost Method: Engine Operation Hot gas Electric Operation...
- Page 17 Specifications ELECTRICAL CONTROL SYSTEM Control System Voltage 12.5 Vdc Battery Charging System 12 V 23 amp brush type integral alternator Voltage Regulator Setting 14 V @ 70 F (21.1 C) Alternator/Regulator Capacitor 4.7 µfd 50 Vdc Alternator/Output Capacitor 0.5 µfd 100 Vdc NOTE: Disconnect components from unit circuit to check resistance.
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Page 19: Maintenance Inspection Schedule
Maintenance Inspection Schedule A closely followed maintenance program will help to keep your Thermo King unit in top operating condition. The following general schedule is provided to assist in monitoring that maintenance. 1,200 2,000 Annual/ Inspect/Service These Items trip Hours... - Page 20 Maintenance Inspection Schedule 1,200 2,000 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 •...
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Page 21: Unit Description
MD-200 30: Cooling and heating on engine operation. Thermo King X214 Compressor MD-200 50: Cooling and hot gas heating on The MD-200 unit features a Thermo King X214, engine operation and electric standby electric two-cylinder compressor with 13.92 in. -
Page 22: Unit Instruments
Pressing the SELECT key causes the display to • X214 Compressor show the other sensor readings. The alarm icon comes on whenever ALARM ICON: MD-200 Options: there is an alarm code stored in the microprocessor memory. • Automatic Phase Correction (Model 50) The receiver RECEIVER TANK SIGHT GLASS: •... -
Page 23: Unit Protection Devices
Unit Description Unit Protection Devices excess pressure. Tapping the valve lightly may help the valve reseat and SEAL PROPERLY. The A number of fuses are located on the FUSES: valve is non-repairable and requires no relay board. The sizes and functions are shown in adjustment. -
Page 24: Unit Operation
Unit Description The preheat Starting Unit (Full Unit Self Check) PREHEAT INDICATOR BUZZER: indicator buzzer is energized whenever the The procedure is used for a complete checkout of GLOW PLUGS are energized on units equipped the truck, unit, and unit control circuits. It should with CYCLE-SENTRY. -
Page 25: Selection Of Operating Modes On Cycle-Sentry Equipped Units
Selection of Operating Modes on Consult your grower or shipper if you have any CYCLE-SENTRY Equipped Units questions about the operating mode selection of The Thermo King CYCLE-SENTRY system is your type of load. designed to save refrigeration fuel costs. The Continuous Run Operation savings vary with the commodity, ambient temperatures and trailer insulation. -
Page 26: Restarting The Unit
Unit Description drops to 35 F (18 C on units without Preheat). If cooling or heating is required and the engine When the unit starts up because of low engine temperature is below approximately 120 F (96 C), block temperature, the unit will operate in but the engine fails to start automatically: whichever operating mode the unit thermostat is •... -
Page 27: Loading Procedure
DO NOT block the evaporator inlet or outlet. 4. Products should be pre-cooled before loading. Thermo King units are designed to maintain loads at the temperature at which they were loaded. Transport refrigeration units are not designed to pull hot loads down to temperature. -
Page 28: Unit Photographs
Unit Description Unit Photographs AMA412 Figure 1: Front Curbside view—MD-200 AMA401 Figure 2: Front Roadside View—MD-200... -
Page 29: Figure 3: X214 Compressor
Unit Description AMA397 Note: Apply Thread Sealant When Installing High Pressure Cutout Oil Seal (Location Not Shown) Crankshaft Cylinder Head Figure 3: X214 Compressor... -
Page 30: Figure 4: X214 Compressor
Unit Description AMA397 Cylinder Head Oil Pump Cover Crankshaft Pressure Regulator Assembly Oil Fill Plug Oil Pump Gauge Access Sight Glass 10. Suction Port Serial Number Suction Valve Adapter Oil Drain Plug 12. Discharge Port Figure 4: X214 Compressor... -
Page 31: Figure 5: Access Panel Open (Curbside)-Md-200
Unit Description AMA406 Cyclonic Engine Air Filter Oil Filter Fuel Filter Bypass Oil Filter Throttle Solenoid Figure 5: Access Panel Open (Curbside)—MD-200 AMA411 Evaporator Figure 6: Rear View (Curbside)—MD-200... -
Page 32: Figure 7: Side View (Roadside)
Unit Description AMA411 Power Switch Coil Sensor Location Microprocessor Switch Figure 7: Side View (Roadside) -
Page 33: Figure 8: Top View
Unit Description AMA409 Muffler Air Defrost Switch Evaporator 10. Drier Suction Pressure Regulator Electric Motor (Model 50) Compressor 12. Condenser Coil Alternator 13. Three-Way Valve Nameplate 14. Expansion Tank High Pressure Relief Valve 15. Fuel Filter Receiver Tank Figure 8: Top View... -
Page 34: Figure 9: Control Box
Unit Description AMA413 High Voltage Module (Caution) K13 Electric Motor Relay K8 Motor Reset Relay 12. Remote Control Cab Box Harness Connector K5 Throttle Relay 13. K14 Electric/Diesel Relay K1 Alternator Relay 14. Motor Contactor (under cover) K4 Fuel Solenoid Pull-In Coil Relay 15. -
Page 35: Figure 10: Power Receptacle Box-Md-200 50
Unit Description AMA410 Figure 10: Power Receptacle Box—MD-200 50... -
Page 36: Figure 11: Thermoguard Remote Control Panel
Unit Description AMA404 Keypad LED Display Figure 11: THERMOGUARD Remote Control Panel... -
Page 37: Μp-T System Description
µP-T System Description General Description the Interface Board and control circuits via CB1. To completely remove power from the control The µp-T microprocessor controllers are self system disconnect the unit battery. contained temperature control units designed for MD-II Smart Reefer truck units. Model 30 units are powered by a diesel engine and Model 50 units are powered by either a diesel engine or an external electric standby power... -
Page 38: Standard Model 50 Features
µP-T System Description CAUTION: Electric operation mode is not stored in the controller if the microprocessor power switch is turned . Turning the switch back again, even with the power cord connected, will not assure start up in Electric Standby. If the voltage is low or an electric phase is missing, the Electric icon will not be present in the display and the unit will... -
Page 39: Figure 15: High Voltage Tray With Electric Heat
µP-T System Description Figure 17: High Voltage Tray Figure 15: High Voltage Tray with Single Phase Power and Electric Heater with Electric Heat Figure 16: High Voltage Tray with Phase Correction and Electric Heat... - Page 40 µP-T System Description...
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Page 41: Remote Control Panel Features
Remote Control Panel Features The remote panel is connected to the the dashboard using the supplied plastic mounting microprocessor and is used to operate the unit. It strips. An optional body mount enclosure kit is may be located in the truck dashboard using the available to mount the remote control panel on the supplied DIN mounting ring, under the dashboard truck box. -
Page 42: Display Icons
Remote Control Panel Features DISPLAY ICONS READING A TYPICAL DISPLAY COOL ICON. Appears when the unit is cooling. HEAT ICON. Appears when the unit is heating. This icon appears during a remote control This display shows the following information: panel test but is not used on truck units. 1. -
Page 43: The Standard Display
Remote Control Panel Features THE STANDARD DISPLAY temperature of 35.8 F and a setpoint of 35 F. The Standard Display is the starting point used to The Standard Display appears when the unit is reach all other prompts and displays. To return to turned ON and no other functions have been this display from any other prompts or display, selected. -
Page 44: Selecting Cycle-Sentry Or Continuous Mode
Remote Control Panel Features SELECTING CYCLE-SENTRY or CONTINUOUS MODE 1. Press the ON key to turn the unit ON. 4. Press the Enter key to load the new operating mode selection into the microprocessor. 2. Press the Select key to display IMPORTANT: The Enter key must [CYCLS] and [YES] or [no]. -
Page 45: Initiating A Manual Defrost Cycle
Remote Control Panel Features INITIATING A MANUAL DEFROST CYCLE 1. The unit must be running in either CYCLE when the unit starts a defrost cycle. The SENTRY or CONTINUOUS mode and the defrost cycle will terminate automatically. If coil temperature must be below 45 F. Press the the unit is not running or the coil temperature Defrost key to start a manual defrost cycle. -
Page 46: Viewing Prompt And Display Screens
Remote Control Panel Features VIEWING PROMPT and DISPLAY SCREENS [oIL]Diesel engine oil pressure. OK or LO 1. Press the ON key to turn the unit ON. [Ent]Diesel engine coolant temperature. [rPn]Diesel engine RPM. 2. Press the Select key repeatedly to [bAt]Battery voltage of the unit battery. -
Page 47: Viewing And Clearing Alarm Codes
Remote Control Panel Features VIEWING and CLEARING ALARM CODES µp-T Alarms 1. Press the ON key to turn the unit ON. Alarms and Alarm Codes If an abnormal condition is sensed by the 2. If the Alarm icon is present, one or microprocessor, an alarm code is generated and more alarms have been detected. - Page 48 Remote Control Panel Features • Stored Alarm. Indicates that a condition exists that does not affect unit operation but that should be investigated. The Alarm icon will appear for 30 seconds when the unit On-Off switch is turned ON and then disappear.
- Page 49 Remote Control Panel Features µP-T ALARM CODES Stored Check Shutdown Code Description No Fault Evaporator Coil Sensor Return Air Sensor Discharge Air Sensor Engine Water Temperature Sensor Engine RPM Sensor High Evaporator Temperature High Discharge Pressure or Compressor Temperature Unit Controlling on Discharge Air Sensor Sensor Shut Down Engine Failed to Crank (CYCLE SENTRY) High Engine Water Temperature...
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Page 50: Μp-T Unit Self Check Test
Remote Control Panel Features µP-T Unit Self Check Test RPM Check The diesel engine RPM is checked in both high The Unit Self Check is a functional test of the and low speed. unit’s operating capability. Once the test is started by the operator, it is fully automatic and requires Cooling Check no operator attendance. -
Page 51: Electrical Maintenance
Electrical Maintenance Alternator (Prestolite) Charging CAUTION: Full-fielding alternators System Diagnostic Procedures with the integral regulator is NOTE: Units manufactured with accomplished by installing a jumper from CYCLE-SENTRY and alternators with integral terminal F2 to ground. Attempting to regulators MUST use replacement alternators full-field the alternator by applying battery with integral regulators. -
Page 52: Excessive Voltage Output
Setting: circuit. a truck, it is often connected to a truck battery. When both the Thermo King unit and the truck 5. Use the Service Test mode to place the unit in engine are running on the truck battery, the high speed cool before the engine starts. -
Page 53: Unit Wiring
Electrical Maintenance RPM Sensor Inspect/clean the battery terminals and check the electrolyte level during scheduled maintenance The RPM sensor is in the engine bell housing inspections. A dead or low battery can be the adjacent to, but not touching, the flywheel cause of an ammeter indicating discharge due to (backed off 1/2 turn). -
Page 54: Glow Plugs
Electrical Maintenance 3. Place the unit in Continuous Run. Run the unit Each glow plug should have a resistance of on low speed and high speed. Check the AC approximately 1.5 ohms or a current draw of voltage output across the sensor terminals. about 8 amps. -
Page 55: Figure 22: Testing Air Switch
Electrical Maintenance the air switch (correct reading is 0.70 ± 0.05 in. [17.8 ± 1.3 mm] H Release the pressure. Adjustment Screw Figure 23: Air Switch 6. Repeat test procedure several times to be sure the setting is correct. 7. Remove the test equipment. Install wire on switch terminal and air sensing tubes on air switch. -
Page 56: High Capacity Thermax
Electrical Maintenance High Capacity TherMax Heat/Condenser Evacuation Mode Heating System The unit will run in the Condenser Evacuation mode for two minutes before entering the Heat The high capacity heating system increases the mode. This is accomplished by opening capacity of the Heat mode by making more (energizing) the TherMax solenoid while the refrigerant available for use in the Heat mode. -
Page 57: Units Equipped With A Three-Phase Electric Motor And A Phase Converter That Operates On Single-Phase Power
NOTE: Refer to drawings 1E19109 and 1E04148 diagrams in the back of this manual. • a filter capacitor MD-200 units are equipped with a three-phase • two start capacitors (400 to 480 µF each) electric motor. Automatic Phase Conversion is •... -
Page 58: Figure 24: First And Second-Phase Connections
Electrical Maintenance Figure 24: First and Second-Phase Connections L1 and L2 supply power directly to the first and second windings in both sets of windings in the motor. A branch of T2 passes through the motor contactor to become T3. A branch of T3 passes through the motor start contactor and a start capacitor to become T3E, which is connected to the third winding in one set. -
Page 59: Figure 25: Motor Start Contactor Control Coil Circuit
Electrical Maintenance Figure 25: Motor Start Contactor Control Coil Circuit 7EA energizes the motor start contactor through the start relay when the current in T2-T2A exceeds 27 amps. Wire 7EA supplies control voltage from the unit to the current relay at terminal 4. When the current relay is energized, control voltage passes through the contacts to terminal 2 and wire 7EB to energize the motor start relay. -
Page 60: Run System
Electrical Maintenance Figure 26: Third Phase Connection During a Start L2 supplies power to the third windings in both sets of motor windings through the start As the motor approaches normal running speed, the current through T2-T2A drops. When this current drops below 22 amps, the current relay is de-energized. -
Page 61: Figure 27: Third Phase Connection During A Start
Electrical Maintenance Figure 27: Third Phase Connection During a Start L2 supplies power to the third windings in both sets of motor windings through the start second windings in both sets of windings in the motor. The primary winding of the run transformer is The current relay, motor start relay, motor start connected to L1A on one side and to L2A on the contactor, and a test point strip are located in the... -
Page 62: Troubleshooting The Phase Conversion System
Electrical Maintenance Troubleshooting the Phase Electric Motor Tests Conversion System Test 1. Run the motor with three-phase power. If the electric motor does not run properly, first Disconnect the T1, T2, T2A, T3E, and T3F wires check the line voltage, the motor contactor, and from the motor and connect three-phase power the motor overload relay. - Page 63 Electrical Maintenance If the motor starts correctly but the current remains at approximately 20 amps after 3 seconds, the start system is not being de-energized. Use the following procedure. 1. Locate the current relay in the main control panel. 2. Disconnect the 7EA and 7EB wires. 3.
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Page 64: Troubleshooting Chart
Electrical Maintenance Troubleshooting Chart NOTE: All amperage and voltage measurements should be taken with the unit turned ON and the motor running or attempting to start. Most of the voltage measurements can be taken inside the unit control box, from the components in the high voltage tray and from the test point strip. - Page 65 Electrical Maintenance Problem/Probable Cause Test/Solution Current Relay Check the voltage between T1 and T2 at terminal 1 of the current relay and between T1 and T2A at terminal 3 of the current relay. If there is voltage between T1 and T2, but not T1 and T2A, the control coil is open.
- Page 66 Electrical Maintenance Problem/Probable Cause Test/Solution Start Capacitors Voltage Test With line voltage present between T1 and T3C and T1 and T3D at the start capacitors, check the voltage between T1 and T3 and T1 and T3F. Both voltages should be within 10% of line voltage.
- Page 67 2.Check the connections between the electric motor leads and the Thermo King wiring in the connection box on the electric motor. Compare these connections to those indicated in the wiring diagrams and schematics. / Repair the wiring connections as necessary.
- Page 68 Electrical Maintenance CAUTION: If the electric motor is being • Leads 1 and 7 together—8 to 18 amps rewound, it must be rewound to the factory • Leads 3 and 9 together—10 to 14 amps specifications because this special application requires the phases to be split. •...
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Page 69: Engine Maintenance
2,000 hours, or 1 year, whichever occurs first. NOTE: Units equipped with the EMI 2000 package do require regular inspection in accordance with Thermo King’s maintenance recommendations. AJA1521 Figure 28: Engine Oil Pressure Switch Engine Oil Pressure Switch Engine oil pressure switch should rise immediately on starting. -
Page 70: Engine Oil Change
2,000 hours, or 1 year, whichever occurs first. It Specifications chapter of this manual for correct cannot be interchanged with air filter elements type of oil. used on previous Thermo King truck units. Oil Filter Change The oil filters should be changed along with the engine oil. -
Page 71: Engine Cooling System
Engine Maintenance Engine Cooling System All water-cooled engines are shipped from the factory with a mixture of 50% permanent type antifreeze concentrate and 50% water in the General Description engine cooling system. The engine employs a closed, circulating type, This provides the following: pressurized cooling system. -
Page 72: Elc (Extended Life 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. -
Page 73: Antifreeze Maintenance Procedure
Engine Maintenance Antifreeze Maintenance c. Open the drain cock to drain water and flushing solution. Procedure As with all equipment containing antifreeze, CAUTION: Avoid direct contact with hot periodic inspection on a regular basis is required coolant. to verify the condition of the antifreeze. Inhibitors become worn out and must be replaced by 3. -
Page 74: Engine Thermostat
Therefore, this equipment is not found in most repair shops. The fuel system used on the Thermo King diesel engine is a high pressure system used in The following procedures can be done under field conjunction with a prechamber. -
Page 75: Bleeding The Fuel System
Engine Maintenance • Pump timing. • Nozzle spray pattern testing and adjustment. • Minor rebuilding of nozzles. Bleeding the Fuel System The fuel system will have to have the air bled out if the engine runs out of fuel, if repairs are made to the fuel system, or air gets into the system for any other reason. -
Page 76: Figure 34: Fuel And Oil System Components
Engine Maintenance Figure 34: Fuel and Oil System Components... -
Page 77: Figure 35: Fuel And Oil System Components For Figure 122
Engine Maintenance Elbow—hose fitting (3/8) Lockwasher Kit—sleeve & eyelet (3/8) Flatwasher Nut (3/8) Washer (nylon) Hose (3/8 od x 35 ft lg) Switch—oil pressure Not Used Nut—switch Kit—sleeve & eyelet (1/4) Lockwasher Nut (1/4) Flatwasher Elbow Fitting—engine (3.0 in lg) Hose Pump—fuel (12V) 10. -
Page 78: Draining Water From Fuel Tank
Engine Maintenance Draining Water from Fuel Tank Reassembly Water run through the system may damage the Place the cover gasket on the bottom cover and injection pump or nozzles. Damage to the fuel install the filter and cover assembly. Replace the system will subsequently cause more expensive three screws. -
Page 79: Injection Pump
Engine Maintenance Timing the Injection Pump to the Engine 2. Remove the filter, cover and cover gasket. Wash the filter in cleaning solvent and blow There are two different types of timing procedures out the dirt and cleaning solvent with used on the engine. -
Page 80: Figure 37: Timing Marks
Engine Maintenance TDC Mark File V-Notch Here Injection Timing Mark Timing Mark Round Notch Figure 37: Timing Marks 1. Rotate the engine in the direction of rotation The timing mark on the starter mounting (clockwise as viewed from the water pump plate is a line stamped on the side of the plate end) until the number 1 cylinder (closest to facing the flywheel. -
Page 81: Figure 38: Individual Cylinder Timing And Firing Order
Engine Maintenance Timing Individual Cylinder Injection CAUTION: The 8S wire on the starter This procedure should be used when a poor motor should be disconnected. running engine has had all possible problems checked but continues to run badly. If the CAUTION: Loosen the injection lines on injection pump has been repaired or replaced, the the injection nozzles of the number 2 and... -
Page 82: Adjust Engine Valve Clearance
California service technicians should valves and seats. Excessive valve clearance see your local Thermo King dealer for recent will result in noisy valve operation and bulletins. abnormal wear of the valves and rocker arms. -
Page 83: Fuel Solenoid Diagnostic And Replacement
Engine Maintenance Fuel Solenoid Diagnostic and Replacement See the Interface Board diagnostic procedures in the Microprocessor Controller Diagnosis Manual. Throttle Lever Eye Bolt Fuel Solenoid Boot Low Speed Adjustment Screw Throttle Solenoid Ball Joint Clip Figure 40: Integral Fuel Solenoid Components BELT TENSIONS Correct belt tension is critical for proper unit operation. -
Page 84: Auto Start/Stop
Engine Maintenance AMA414 Engine Fan Pulley Engine Clutch Compressor Drive Motor (Model 50) Fan Pulley Compressor Idler Water Pump Alternator Figure 41: MD-II SR Belt Arrangement Auto Start/Stop WARNING: DO NOT jump belts on by cranking the engine; personal injury may CAUTION: The unit may start result. -
Page 85: Figure 42: Idler Assembly
Engine Maintenance Compressor/Electric Motor/Jackshaft Belt This tension allows 1/2 in. (13 mm) deflection in the center of the span. Slide the jackshaft or induction alternator away from the compressor to tighten this belt. Water Pump Belt Belts should be tensioned cold and retensioned Adjust tension by adding or removing shims cold after 10 hours of unit running. -
Page 86: Figure 43: New Idler Assembly
Adjust the compressor/evaporator a. The belt tension should be set at a reading fan/alternator belt to the proper tension after it of 70 to 80 on the Thermo King Belt is centered in the slot. Tension Gauge P/N 204-427. -
Page 87: Figure 44: Belt Layout
Jackshaft or Electric Motor Figure 44: Belt Layout The engine/compressor belt tension should be set at a reading of 70 to 80 on the Thermo King Belt Tension Gauge P/N 204-427. The compressor/jackshaft (electric motor) belt tension should be set at a reading of 64 to 70 on the Thermo King Belt Tension Gauge P/N 204-427. -
Page 88: Figure 45: Alternator Mounting And Belt Tension Screws
Engine Maintenance Belts should be tensioned cold and retensioned cold after 10 hours of running. Belt Adjustment Nut Pivot Bolt Bracket Mounting Bolt Alternator Mounting Bolt Belt Adjustment Screw Bracket Figure 45: Alternator Mounting and Belt Tension Screws... -
Page 89: Engine Speed Adjustments
Engine Maintenance Engine Speed Adjustments Low Speed Adjustment 1. Start the unit and let it run until the engine is warmed up. 2. Set the thermostat to make the engine run in low speed and check the engine speed. The engine speed should be 1625 ±... - Page 90 Engine Maintenance...
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Page 91: Refrigeration Maintenance
• Evacuate from 3-points to access both sides of See the diagram of the Thermo King Evacuation check valves and solenoids. Energize Station and note the location of the valves. solenoids during evacuation to prevent... -
Page 92: Figure 46: Evacuation Station
Refrigeration Maintenance AGA654 Two Stage Vacuum Pump Thermistor To 110 Vac Power Calibration Standard Vacuum or Micron Gauge Figure 46: Evacuation Station... -
Page 93: Figure 47: Vacuum Gauge
Refrigeration Maintenance 100 Microns 500 Microns 1000 Microns 2500 Microns 5000 Microns 20,000 Microns Atmospheric Pressure Calibration Adjustment Screw Example: Meter needle shown at calibration position when Calibration Standard specifies 0.15 mm Hg. Figure 47: Vacuum Gauge... -
Page 94: Set Up And Test Of Evacuation Equipment
Refrigeration Maintenance Set Up and Test of Evacuation • Isolate the pump from the system by closing Equipment the proper valve. Watch the movement of the vacuum gauge needle. If the needle continues NOTE: See the previous two pages for the to rise, this is an indication that a leak exists in following discussion. -
Page 95: Unit Evacuation
CAUTION: Do not attempt to evacuate a Refrigerant Leaks unit until you are certain that the unit is NOTE: Refer to Diagnosing Thermo King leak free. A unit with less than a full Refrigeration Systems (TK 5984-3-TM) for leak refrigerant charge should be thoroughly detection procedures. - Page 96 Refrigeration Maintenance 4. Back seat (close) the receiver outlet valve. Back seat the discharge service valve. Open the suction service valve. 5. Open the refrigerant supply valve for liquid. Open the gauge manifold hand valve. 6. Start and operate the unit with the thermostat set for cool.
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Page 97: Figure 50: Unit Charging
Refrigeration Maintenance Calibration Standard Vacuum or Micron Gauge Thermistor Two Stage Vacuum Pump To 110 Vac Power Figure 50: Unit Charging... -
Page 98: Refrigerant Charge
Refrigeration Maintenance Refrigerant Charge 4. As the head pressure is rising, check the receiver tank sight glass. The ball should be Testing the Refrigerant Charge with floating. If there is no indication of refrigerant an Empty Box in the receiver tank sight glass, the unit is low on refrigerant. -
Page 99: High Pressure Cutout (Hpco)
Refrigeration Maintenance 1. Connect the gauge manifold to the discharge service port with a heavy duty, black jacketed thick wall #HCA 144 hose with a 900 psig (6204 kPa) working pressure rating. Add Compressor Oil Here Oil Level Sight Glass Figure 51: X214 Compressor To check compressor oil level with an ambient air Run the unit... -
Page 100: Compressor Pump Down And Checkout
Refrigeration Maintenance Compressor Pump Down And Checkout 1. Install a gauge manifold set on the compressor. Open the service valves (crack the valves off of the back seated position) to access system pressure. NOTE: Purge air from the gauge set. 2. -
Page 101: Three-Way Valve Condenser Pressure Bypass Check Valve
Refrigeration Maintenance NOTE: Repeat the pump down procedure if 5. Operate the unit on cool, and pump down the the pressures equalize above 20 psig low side to 0 in. (0 kPa) of vacuum. (138 kPa). If acceptable low pressures 6. - Page 102 Refrigeration Maintenance 8. Gauges will remain in this position (approximately 30 to 50 psig [207 to 345 kPa]) if the three-way valve seals properly toward the condenser and the condenser pressure bypass check valve seals properly. 9. Back seat condenser pressure bypass check valve stem against snap ring.
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Page 103: Refrigeration Service Operations
Refrigeration Service Operations NOTE: It is generally good practice to replace 7. Lift the compressor out of the unit. Keep the the filter-drier whenever the high side is opened compressor ports covered to prevent dust, dirt, or when the low side is opened for an extended etc., from falling into the compressor. -
Page 104: Installation
Refrigeration Service Operations Dehydrator (Filter-Drier) 5. Unbolt and remove the condenser/radiator cap. Removal Installation 1. Pump down the refrigeration system and 1. Clean the tubes for soldering. equalize the pressure to slightly positive. 2. Place the coil in the unit and install the 2. -
Page 105: Expansion Valve Assembly
Refrigeration Service Operations 4. Solder the suction line and drain pan hot gas line connections to the evaporator coil. 5. Connect the distributor to the expansion valve assembly. 6. Connect the air switch hoses and install the high temperature cutout switch and electric heaters (Model 50). -
Page 106: Heat Exchanger
Refrigeration Service Operations 3. Solder liquid inlet and suction outlet line connections on the condenser side of the bulkhead. Seal openings through bulkhead with putty when refrigerant lines have cooled off. 4. Tighten the heat exchanger mounting hardware securely. 5. Solder suction line connection to the evaporator coil. -
Page 107: High Pressure Cutout Switch
Refrigeration Service Operations High Pressure Cutout Switch 2. Disconnect the lines to the solenoid and immediately cap to prevent moisture and air from entering the system. Removal NOTE: The lines from the three-way valve to the 1. Install gauge manifold set. pilot solenoid will leak refrigerant at a high 2. -
Page 108: Receiver Tank
Refrigeration Service Operations Receiver Tank Removal 1. Remove the refrigerant charge. 2. Unsolder the inlet tube from the receiver tank. 3. Unsolder the filter drier line from the receiver tank outlet tube. 4. Unbolt the mounting brackets and remove the Teflon Check Valve receiver tank from the unit. -
Page 109: Three-Way Valve Repair
Refrigeration Service Operations 7. Coat sealing area in cap with compressor oil a. Stem assembly (use same type of oil that is used in the b. All gaskets system), install and tighten the cap on the three-way valve. c. Teflon seal and o-ring 8. -
Page 110: Installation
Refrigeration Service Operations Installation NOTE: Three-way valve kit is used to repair three-way valves (see Tool Catalog). After cleaning and inspecting all parts, reassemble the valve. Clean solder off the condenser line and condenser head with sandpaper and tubing brush. 1. -
Page 111: Oil Filter Maintenance
Refrigeration Service Operations to 7 to 10 ft-lb (23 to 14 N•m). Whenever the bushing. Use one of the following recommended two-piece pulley is removed from any type of unit anti-seize lubricants: Fel-Pro C5-A, Loctite 767, service, anti-seize lubricant should be applied to Never-Seez NS-12, or Never-Seez NS-160. -
Page 112: Figure 62: Compressor Oil Filter
13. Compressor Inlet Tube 20. 9/16 O-ring Bracket Nut 14. Filter Assembly Figure 62: Compressor Oil Filter Compressors Shipped with R-134a X214 Thermo King compressors are charged with Polyol Ester oil (POE) (TK No. 203-413). All gauge fittings are 1/4 inch fittings. -
Page 113: Equipment Recommendations For Use With R-404A
R-404A systems because residual refrigerants may remain in used vacuum pumps. Pumps used with other Thermo King refrigerants may be used but extreme care should be taken to prevent contamination of R-404A systems with other refrigerants. - Page 114 Gauge manifold sets that show the correct pressure-temperature relationship should be used. Gauge manifolds and manifold hoses used with other Thermo King refrigerants maybe used but extreme care should be taken to prevent contamination of the R-404A systems with other refrigerants.
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Page 115: Hilliard Clutch Maintenance
Hilliard Clutch Maintenance Large Truck Unit Centrifugal Clutch Change The centrifugal clutch has three belt grooves and its engagement speed is 600 ± 100 RPM. Figure 63: Front View and Cross Section... -
Page 116: Figure 64: Hilliard Centrifugal Clutch
Hilliard Clutch Maintenance aea558 (3 belt grooves) Screw Grease Seal Washer Roller Bearing Inner Race Snap-Ring Pulley Housing Ball Bearing Elastic Stop Nuts (6) Large & Small Spacers Connector Link (6) Rolling Bearing Spring (6) Lockwasher (12) Shoe Assembly (3) Bushing (6) Screws (6) Figure 64: Hilliard Centrifugal Clutch... -
Page 117: Clutch Maintenance
Hilliard Clutch Maintenance Clutch Maintenance 3. Remove housing from hub by supporting hub (in a minimum of three places) in spoke area, Using an inspection mirror, inspect the clutch and pressing on the housing shaft. The inner every 1000 hours of operation or yearly, race of the roller bearing will remain on the whichever occurs first. -
Page 118: Assembly Procedure (Using New Bearings And Seal)
Hilliard Clutch Maintenance 7. Press bushings out of hub. Figure 67: Bushing Removal 8. Remove inner race of roller bearing from the housing shaft. Figure 68: Bushing Insertion NOTE: This race had Loctite applied and was pressed in place. A puller will be *DO NOT USE SOAP OR OIL TO required to remove it. -
Page 119: Figure 69: Clutch
Hilliard Clutch Maintenance 6. Apply Mobil (see Tool Catalog) grease to roller bearing and fill cavity between large and small spacers. A small amount of grease should also be applied to the seal lip and space between the seal and roller bearing. 7. - Page 120 Hilliard Clutch Maintenance...
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Page 121: Structural Maintenance
Structural Maintenance Unit And Engine Mounting CAUTION: Air pressure should not be Bolts high enough to damage coil fins. Periodically check and tighten all unit and engine mounting bolts. Torque the unit mounting Condenser Coil bolts to 60 ft-lb (81.3 N•m). Torque the engine mounting bolts to 50 ft-lb (68 N•m). -
Page 122: Jackshaft Assembly
Jackshaft Assembly NOTE: There are shims between the bearing retainer cap and the housing. These should be The MD-200 30 does not have electric standby saved for possible reuse during reassembly. capability, therefore, the electric motor is replaced 4. Remove the shaft and bearings. - Page 123 Structural Maintenance Reassembly 6. Use a punch and hammer to tap the oil sling retainer into the jackshaft housing until it is 1. Coat the edges of the oil seals with a gasket centered beneath the air vent opening and past sealant.
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Page 124: Fanshaft Assembly
Structural Maintenance 11. Pour 3.5 ozs (104 ml) of fanshaft oil P/N 2. After draining the oil from the housing, 203-278 into the jackshaft housing. remove the four retaining bolts from the bearing retainer cap. Fill Plug and Vent Oil Level Plug Figure 73: Jackshaft Assembly FanShaft Assembly The unit is equipped with a one-piece fanshaft... -
Page 125: Reassembly
Structural Maintenance 7. To replace the bearings, first remove the roll 2. When replacing the bearing race on the pin that is in the center of the shaft. evaporator end of the assembly, the splash guard will come out with the race. Reinstall the splash guard after replacing the bearing race. -
Page 126: Figure 82: Torquing Retainer Plate Bolts
6. Torque the bolts in a criss-cross pattern in NOTE: Use ONLY Thermo King special equal steps to 80 in-lbs (9.04 N•m). fanshaft grease (P/N 203-278) in this assembly. Lock the assembly in a vise with the vent facing up. -
Page 127: Mechanical Diagnosis
Mechanical Diagnosis Condition Possible Cause Remedy Unit switch On—nothing happens Dead battery Recharge or replace battery Remote switch Off (optional) Turn On Fuse open Replace Corroded battery connections Clean and tighten Main harness fuse blown Check for shorted main harness and replace fuse Unit switch On—indicator lights Battery low... - Page 128 Mechanical Diagnosis Condition Possible Cause Remedy Engine stops after starting Air in injection pump Bleed fuel system Fuel filter obstructed Replace filter element High water temperature coolant Add coolant. Check for leaks Low oil pressure Add oil. Check for leaks Vent of fuel tank obstructed Remove obstruction Electric fuel pump not operating...
- Page 129 Mechanical Diagnosis Condition Possible Cause Remedy Engine is sooting heavily, emits Wrong fuel Drain and refill with correct fuel thick black clouds of smoke Clogged air intake system Clean air cleaner (excessive fuel to air ratio) Restricted exhaust system Clean or replace Opening pressure of nozzle is Repair nozzle.
- Page 130 Mechanical Diagnosis Condition Possible Cause Remedy Clogged air cleaner Clean air cleaner Damaged valve seals Replace seals on valve stem Worn valve stem or valve guides Replace valves and valve guides Broken piston rings or cylinder bore Have engine repaired. Replace worn or scored broken piston rings Crankcase breather clogged...
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Page 131: Electric Standby (Optional) Diagnosis
Electric Standby (Optional) Diagnosis Condition Possible Cause Remedy Unit switch On—Microprocessor Battery discharged Charge or replace battery display does not come on Electric motor reset switch tripping Check for short circuit in unit wiring (high voltage) Fuse blown Replace fuse Dirty battery terminals Clean and retighten terminals Unit switch On—Microprocessor... - Page 132 Electric Standby (Optional) 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.
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Page 133: Refrigeration Diagnosis
Refrigeration Diagnosis Possible Causes • • • • Overcharge of refrigerant • • • • • • Shortage of refrigerant • • • • • No refrigerant • Air through condenser too hot (ambient) • Air flow through condenser restricted •... - Page 134 Refrigeration Diagnosis Possible Causes • • • Expansion valve feeler bulb making poor contact • • 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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Page 135: Index
Index alternator 51 lift points 121 antifreeze Liquid Injection Valve 104 maintenance procedures 73 Low Side Pump Down 100 low side pump down 103 battery 52 maintenance inspection schedule 19 Mechanical Diagnosis 127 Mounting Bolts 121 charging system 53 Clutch Maintenance 115 commissioning unit 103 compressor 103 oil change, engine 70... - Page 136 Index...
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Page 137: Wiring And Schematic Diagrams Index
Wiring and Schematic Diagrams Index Dwg No. Drawing Title Page 1E18921 Schematic Diagram 139-140 1E19109 Wiring Diagram 141-142... - Page 138 Wiring and Schematic Diagrams Index...
- Page 139 MD-200 Schematic Diagram—Page 1 of 2...
- Page 140 TMD-200 Schematic Diagram—Page 2 of 2...
- Page 141 MD-200 Wiring Diagram—Page 1 of 2...
- Page 142 MD-200 Wiring Diagram—Page 2 of 2...
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Istruzioni per sostituire regolatore di tensione thermo king MD200