Thermo King MD-MT Manuals

Manuals and User Guides for Thermo King MD-MT. We have 1 Thermo King MD-MT manual available for free PDF download: Operator's Manual

Thermo King MD-MT Operator's Manual (192 pages)

Brand: Thermo King | Category: Refrigerator | Size: 10 MB

Table of Contents
5
List of Figures
11
Safety Precautions
13
General Practices
13
Auto Start/Stop
13
Refrigerant
13
First Aid
13
Refrigeration Oil
14
First Aid
14
Electrical Hazards
14
Microprocessor Service
14
Welding of Units or Truck Bodies
15
High Voltage
15
Low Voltage
16
Specifications
17
Engine-TK 3.74
18
R-404A Refrigeration System
19
Engine Clutch-Hilliard
19
Air Switch
19
Belt Tension
20
Electrical Control System
20
Electrical Components
21
Thermostat
21
Electric Standby
21
Maintenance Inspection Schedule
23
Unit Description
25
General Description
25
Figure 1: Typical Compartment Configurations
25
X214 Compressor
26
Spectrum Remote Evaporator
26
Microprocessor Controller TG-V
26
Figure 2: Spectrum Remote Evaporator
26
Unit Operation
27
Reading Mode of Operation Charts
28
Mode of Operation Charts
29
Zone 1 Cool and Zone 2 Cool
33
Figure 3: Zone 1 Cool and Zone 2 Cool
33
Zone 1 Cool and Zone 2 Heat
34
Figure 4: Zone 1 Cool and Zone 2 Heat
34
Operating Modes
35
Engine, Continuous Run-Two Compartment Operation
35
Figure 5: Zone 1 Evaporator Engine, Continuous Run, Two Compartment Control Algorithm
35
Figure 6: Zone 2 Evaporator Engine, Continuous Run, Two Compartment Control Algorithm
35
Engine, Continuous Run-Single Compartment Operation
36
Figure 7: Zone 1 Evaporator Engine, Continuous Run, Single Compartment Control Algorithm
36
Figure 8: Zone 2 Evaporator (Engine Set on Continuous Run) Single Compartment Control Algorithm
36
CYCLE-SENTRY Operation
37
Figure 9: Zone 1 Evaporator CYCLE-SENTRY Control Algorithm
37
Figure 10: Zone 2 Evaporator CYCLE-SENTRY Control Algorithm
37
Electric Operation
38
Defrost Operation
38
Figure 11: Electronic Control Algorithm
38
Serial Number Locations
39
Design Features
40
Unit Photographs
41
Figure 12: Roadside View
41
Figure 13: Curbside View
41
Figure 14: Top View
42
Figure 15: Engine Side Door Open
43
Figure 16: TG-V Multi-Temp Control Box
44
Figure 17: TG-V In-Cab Controller for Multi-Temp Compartment Units
45
Figure 18: X214 Compressor
46
Figure 19: X214 Compressor
47
Operating Instructions
49
Unit Controls
49
TG-V Multi-Temp Control Box
49
TG-V In-Cab Controller for Multi-Compartment Units
50
Electric Standby Power Receptacle
51
Figure 20: Electric Standby Power Receptacle
51
Other Controls
52
Unit Indicators
52
Unit Protection Devices
52
Unit Operation
53
Pretrip Inspection
53
Starting the Unit-Auto Start Diesel Operation
54
Manually Starting Units on Diesel Operation
54
Starting the Unit-CYCLE-SENTRY Units on Diesel Operation
54
Operating Instructions (Continued)
54
Starting the Unit-Electric Operation
56
Starting Zone 2 Evaporator
57
After Start Inspection
57
Loading Procedure
57
Post Load Procedure
57
Post Trip Checks
58
Electrical Maintenance
59
Alternator (Prestolite)
59
Figure 21: Prestolite Terminal Locations
59
Battery
60
Charging System
60
Unit Wiring
60
Glow Plugs
61
Engine Reset Switch
61
High Water Temperature Switch (HWT)
61
Low Oil Pressure Switch (LOP)
62
Circuit Breakers
62
Main Circuit Breaker
62
Control Circuit Breaker
62
Evaporator Circuit Breaker
62
Fan Circuit Breakers
62
7X-CH Circuit Fuse
62
Figure 22: Control Box Components
62
Unloading Timer (EUT)
63
Testing the Unloading Timer
63
Control Circuit Fuse
63
Defrost System
64
Zone 1 Evaporator Defrost Cycle Diesel Operation
64
Zone 1 Evaporator Defrost Cycle Electric Operation
64
Zone 1 Evaporator Defrost Cycle Checkout Procedure
65
Zone 2 Evaporator Defrost Cycle Diesel Operation
66
Zone 2 Evaporator Defrost Cycle Electric Operation
67
Zone 2 Evaporator Defrost Cycle Checkout Procedure
67
Figure 23: Defrost Relay Locations
68
Defrost System Components
69
Figure 24: Defrost Termination Switch
69
Figure 25: Air Switch Testing and Adjustment
71
Fan Speed Control
72
Circuit Boards
72
CYCLE-SENTRY Option
72
Option Board Jumpers
72
Figure 26: Option Board
72
Multi-Temp Relay Board
73
Figure 27: Multi-Temp Relay Board
73
AC Components
74
Contactors
74
Overload Relay
74
In-Cab TG-V Controller
74
Figure 28: Multi-Temperature In-Cab TG-V Controller
74
Figure 29: Connect Tester to Controller
75
Figure 30: Connector on Back of Multi-Temperature In-Cab TG-V
76
Door Sentry II
77
Figure 31: Door Sentry-II Relay Identification
77
Engine Maintenance
79
Emi 2000
79
Engine Lubrication System
79
Engine Low Oil Pressure Switch
79
Engine Oil Change
79
Oil Filter Change
80
Crankcase Breather
80
Engine Air Cleaner
80
Emi 2000
80
Figure 32: Oil Filter Parts
80
Figure 33: EMI 2000 Dry Type Air Cleaner
80
Oil Bath Type
81
Dry Type (Optional)
81
Figure 34: Oil Bath Air Cleaner
81
Figure 35: Dry Air Cleaner (Optional)
81
Figure 36: Air Restriction Indicator
81
Engine Cooling System
82
Figure 37: Engine Cooling System Components
82
ELC (Extended Life Coolant)
83
Figure 38: ELC Nameplate-Located on Expansion Tank
83
Antifreeze Maintenance Procedures
84
Engine Maintenance (Continued)
84
Figure 39: Accumulator Tank Drain
84
Figure 40: Water Pump Assembly and Thermostat
85
Engine Fuel System
86
Figure 41: Fuel and Oil System Components
87
Bleeding the Fuel System
88
Water in the Fuel System
88
Fuel Filter Replacement
88
Electric Fuel Pump
89
Figure 42: Electric Fuel Pump
89
Integral Fuel Solenoid
90
Figure 43: Integral Fuel Solenoid Components
90
Electrical Changes
91
Figure 44: Fuel Solenoid Timer
91
Figure 45: Wiring Diagram of Fuel Solenoid Timer Starting 4Th Quarter 97
91
Troubleshooting the Integral Fuel Solenoid System
92
Figure 46: Fuel Solenoid Pin Identification
92
Figure 47: Relay Socket Terminal Identification
93
Fuel Stop Solenoid Replacement
94
Figure 48: Fuel Stop Solenoid Components
94
Engine Speed Adjustments
95
Low Speed Adjustment
95
High Speed Adjustment
95
Injection Pump
95
Injection Pump Adjustments
95
Timing the Injection Pump to the Engine
95
Timing Individual Cylinder Injection
97
Figure 49: Timing Marks
97
Fuel Limit Screw
98
Engine Valve Clearance Adjustment
98
Figure 50: Individual Cylinder Timing and Firing Order
98
Figure 51: CARB California Air Resources Board Tag
98
Engine Mounts for MD-MT Units
99
Belts
100
Engine/Compressor/Jackshaft /Belt Tension/Adjustments
100
Figure 52: Engine-Compressor Belt Adjustment
100
Figure 53: Belt Layout
101
Compressor/Alternator Fan Belts
102
Figure 54: Alternator Mounting and Belt Tension Screws
102
Refrigeration Maintenance
103
Figure 55: Evacuation Station
104
Figure 56: Vacuum Gauge
105
Refrigerant Charge
106
Testing the Refrigerant Charge with an Empty Truck
106
Testing the Refrigerant Charge with a Loaded Truck
106
Testing for an Overcharge of Refrigerant
106
Adjusting the Refrigerant Level
107
Moisture Indicating Sight Glasses
107
Figure 57: Moisture Indicating Sight Glasses
107
Refrigerant Leaks
108
Checking Compressor Oil
108
Figure 58: X214 Compressor
108
Compound Pressure Gauge
109
High Pressure Cutout (HPCO)
109
Figure 59: High Pressure Cutout Manifold
109
Compressor Pump down and Checkout
110
Evacuating and Charging Procedures
110
Set-Up Electrical Controls
110
Set-Up and Test Evacuation Equipment
110
Figure 60: Set-Up and Test Evacuation Equipment
111
Unit Evacuation
112
Figure 61: Unit Evacuation
113
Unit Charging
114
Figure 62: Unit Charging
115
Remove Evacuation Hoses
116
Figure 63: Remove Evacuation Hoses
116
Refrigeration Service Operations
117
Commissioning Unit
117
Low Side Pump down
117
Compressor
118
Removal
118
Installation
118
Compressor Pulley Removal and Installation (X214 Compressors)
118
Figure 64: Anti-Seize Lubricant Application-X214 Compressors
118
Condenser/Radiator Coil
119
Removal
119
Installation
119
Drier
119
High Pressure Cutout Switch and Receiver Tank Pressure Cutout Switch
119
Refrigeration Service Operations (Continued)
119
High Pressure Relief Valve
120
Removal
120
Installation
120
Suction Pressure Regulator Valve
120
Accumulator
120
Receiver Tank
121
Removal
121
Installation
121
Condenser Inlet Check Valve Repair
121
Figure 65: Condenser Inlet Check Valve
121
Condenser Inlet Check Valve Replacement
122
Removal
122
Installation
122
Suction Line Check Valve and Purge Check Valve Repair (SLCV, RSLCV and PCV)
122
Figure 66: Check Valve
122
Suction Line Check Valve and Purge Check Valve Replacement (SLCV, RSLCV, and PCV)
123
Removal
123
Installation
123
In-Line Check Valves
123
Figure 67: Cross Section of In-Line Check Valve
123
Receiver Tank Pressure Solenoid Valve (RTPS)
124
Removal
124
Installation
124
Purge Valve (PV)
124
Unit Identification
125
Availability
125
Leak Detection
125
Compressor Oil
125
Compressors Shipped with R-404A
125
Figure 68: R-404A Decal
125
Equipment Recommendations for Use with R-404A
126
Figure 69: X214 Compressor Oil Filter and Stabilizer Bracket-Starting April 1997
127
Hilliard Clutch Maintenance
129
Large Truck Unit Centrifugal Clutch Change (P/N 107-291)
129
Figure 70: Front View and Cross Section
129
Figure 71: Clutch Assembly
130
Clutch Maintenance
131
Tools Required
131
Grease
131
Disassembly Procedure
131
Figure 72: Housing Removal
131
Figure 73: Bearing Removal
131
Figure 74: Bushing Removal
131
Assembly Procedure: Using New Bearings and Seal
132
Figure 75: Bushing Insertion
132
Figure 76: Clutch
133
Structural Maintenance
135
Unit and Engine Mounting Bolts
135
Lift Points
135
Fan Location
135
Unit Inspection
135
Figure 77: Check Bolts for Tightness
135
Figure 78: Lift Points Front View
135
Figure 79: Lift Points Side View
135
Figure 80: Fan Blade Position in Orifice
135
Mechanical Diagnosis
137
CYCLE-SENTRY Diagnosis
141
Electric Standby Diagnosis
143
Refrigeration Diagnosis
145
Remote Evaporator Specifications
149
Refrigeration System
149
Electrical
149
Remote Evaporator Maintenance Inspection Schedule
151
Remote Evaporator Unit Description
153
Figure 81: Spectrum Evaporator
153
Figure 82: Spectrum Evaporator-Front View
154
Figure 83: Spectrum Evaporator-Back View
154
Unit Operation
155
Defrost
155
Operating Modes
155
Unit Features
155
Unit Protection Devices
155
Serial Number Location
155
Figure 84: Serial Number Location
155
Remote Evaporator Refrigeration Service Operations
157
Expansion Valve Assembly
157
Removal
157
Installation
157
Evaporator Coil
157
Solenoid Valves
158
Removal
158
Installation
158
Liquid Return Check Valve
158
Figure 85: Cross Section of In-Line Check Valve
158
Remote Evaporator Structural Maintenance
159
Unit Inspection
159
Defrost Drains
159
Evaporator Coil
159
Remote Evaporator System Diagnosis
161
Index
163
Wiring and Schematic Diagrams Index
165

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