Thermo King RD-MT Manuals

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

Thermo King RD-MT Manual (190 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 3.95
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
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: Front View
41
Figure 13: Top View
41
Figure 14: Engine Side Door Open
42
Figure 15: TG-V Multi-Temp Control Box
43
Figure 16: TG-V In-Cab Controller for Multi-Temp Compartment Units
44
Operating Instructions
45
Unit Controls
45
TG-V Multi-Temp Control Box
45
TG-V In-Cab Controller for Multi-Compartment Units
46
Electric Standby Power Receptacle
47
Figure 17: Electric Standby Power Receptacle
47
Other Controls
48
Unit Indicators
48
Unit Protection Devices
48
Unit Operation
49
Pretrip Inspection
49
Starting the Unit-Auto Start Diesel Operation
50
Manually Starting Units on Diesel Operation
50
Starting the Unit-CYCLE-SENTRY Units on Diesel Operation
50
Operating Instructions (Continued)
50
Starting the Unit-Electric Operation
52
Starting Zone 2 Evaporator
53
After Start Inspection
53
Loading Procedure
53
Post Load Procedure
53
Post Trip Checks
54
Electrical Maintenance
55
Alternator (Prestolite)
55
Figure 18: Prestolite Terminal Locations
55
Battery
56
Charging System
56
Unit Wiring
57
Glow Plugs
57
Engine Reset Switch
57
High Water Temperature Switch (HWT)
58
Low Oil Pressure Switch (LOP)
58
Circuit Breakers
58
Main Circuit Breaker
58
Control Circuit Breaker
58
Evaporator Circuit Breaker
58
Fan Circuit Breakers
58
7X-CH Circuit Fuse
58
Unloading Timer (EUT)
59
Testing the Unloading Timer
59
Figure 19: Control Box Components
59
Control Circuit Fuse
60
Defrost System
60
Zone 1 Evaporator Defrost Cycle Diesel Operation
61
Zone 1 Evaporator Defrost Cycle Electric Operation
61
Zone 1 Evaporator Defrost Cycle Checkout Procedure
61
Zone 2 Evaporator Defrost Cycle Diesel Operation
63
Zone 2 Evaporator Defrost Cycle Electric Operation
63
Zone 2 Evaporator Defrost Cycle Checkout Procedure
63
Figure 20: Defrost Relay Locations
64
Defrost System Components
66
Figure 21: Defrost Termination Switch
66
Figure 22: Air Switch Testing and Adjustment
67
Fan Speed Control
68
Circuit Boards
68
CYCLE-SENTRY Option
68
Option Board Jumpers
69
Figure 23: Option Board
69
Multi-Temp Relay Board
70
Figure 24: Multi-Temp Relay Board
70
AC Components
71
Contactors
71
Overload Relay
71
In-Cab TG-V Controller
71
Figure 25: Multi-Temperature In-Cab TG-V Controller
71
Figure 26: Connecting Tester to Controller
72
Figure 27: Connector on Back of Multi-Temperature In-Cab TG-V
73
Door Sentry II
74
Figure 28: Door Sentry-II Relay Identification
74
Engine Maintenance
77
Emi 2000
77
Engine Lubrication System
77
Engine Oil Change
78
Oil Filter Change
78
Crankcase Breather
78
Engine Air Cleaner
78
Emi 2000
78
Figure 29: Oil Filter Parts
78
Oil Bath Type
79
Dry Type (Optional)
79
Figure 30: EMI 2000 Dry Type Air Cleaner
79
Figure 31: Oil Bath Air Cleaner
79
Figure 32: Dry Air Cleaner (Optional)
80
Figure 33: Air Restriction Indicator
80
Engine Cooling System
81
Figure 34: Engine Cooling System Components
81
ELC (Extended Life Coolant)
82
Figure 35: ELC Nameplate-Located on Expansion Tank
82
Figure 36: Accumulator Tank Drain
83
Engine Fuel System
84
Figure 37: Thermostat
84
Figure 38: Fuel System
85
Bleeding the Fuel System
86
Water in the Fuel System
86
Engine Maintenance (Continued)
86
Fuel Filter Replacement
86
Electric Fuel Pump
87
Figure 39: Electric Fuel Pump
87
Fuel Solenoid System
88
Figure 40: Fuel Solenoid Timer
88
Figure 41: Fuel Solenoid Location
88
Fuel Solenoid Timer Operation
89
Figure 42: Simplified Schematic Diagram of Fuel Solenoid System
89
Troubleshooting the Fuel Solenoid System
90
Figure 43: Main Wire Harness Connector Pin
90
Figure 44: Fuel Solenoid Connector Pin
90
Figure 45: Relay Socket Terminal Identification
91
Fuel Solenoid Replacement
92
Engine Speed Adjustments
92
Low Speed Adjustment
92
High Speed Adjustment
92
Figure 46: Fuel Solenoid Components
92
Injection Pump
93
Injection Pump Removal
93
Figure 47: Engine Speed Adjustments
93
Injection Pump Installation
94
Timing the Injection Pump to the Engine
94
Figure 48: Timing Marks
95
Timing Individual Cylinder Injection
96
Fuel Limit Screw and Maximum Speed Stop Screw
96
Engine Valve Clearance Adjustment
96
Figure 49: Individual Cylinder Timing and Firing Order
96
Figure 50: Adjusting the Valve Clearance
97
Engine Mounts
98
Figure 51: Engine Mounting Components
98
Belts
99
Engine-Compressor Belt Adjustment
100
Figure 52: Engine-Compressor Belt Adjustment
100
Figure 53: Belt Arrangement
101
Compressor-Alternator Belt Adjustment
102
Compressor-Electric Motor Belt Adjustment
102
Water Pump Belt
102
Figure 54: Alternator Belt Adjustment
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
106
Adjusting the Refrigerant Level
107
Moisture Indicating Sight Glasses
107
Refrigerant Leaks
107
Figure 57: Moisture Indicating Sight Glasses
107
Checking Compressor Oil
108
Figure 58: X426 Compressor
108
High Pressure Cutout Switch (HPCO)
109
Figure 59: High Pressure Cutout Manifold
109
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 Hoses
116
Refrigeration Service Operations
117
Commissioning Unit
117
Low Side Pump down
117
Compressor
118
Removal
118
Installation
118
Condenser/Radiator Coil
118
Drier
118
Installation
119
High Pressure Cutout Switch and Receiver Tank Pressure Cutout Switch
119
Removal
119
High Pressure Relief Valve
119
Refrigeration Service Operations (Continued)
119
Accumulator
119
Installation
120
Receiver Tank
120
Removal
120
Condenser Inlet Check Valve Repair
120
Figure 64: Condenser Inlet Check Valve
120
Condenser Inlet Check Valve Replacement
121
Removal
121
Installation
121
Suction Line Check Valve and Purge Check Valve Repair
121
Suction Line Check Valve and Purge Check Valve Replacement
121
In-Line Check Valves
122
Removal
122
Installation
122
Receiver Tank Pressure Solenoid Valve (RTPS)
122
Figure 65: Cross Section of In-Line Check Valve
122
Purge Valve (PV)
123
Removal
123
Installation
123
Throttling Valve
123
Disassembly
123
Figure 66: Inspect Throttling Valve Components
123
Reassembly
124
Figure 67: Inspect Piston and Cap for Wear
124
Figure 68: Inspect Pilot Hole for Damage
124
Throttling Valve Installation
125
Figure 69: Throttling Valve Assembly
125
Compressor Oil Filter Change
126
Figure 70: Compressor Oil Filter
126
Hilliard Clutch Maintenance
127
Large Truck Unit Centrifugal Clutch Change (P/N 104-272)
127
Figure 71: Front View and Cross Section
127
Clutch Maintenance
129
Tools Required
129
Grease
129
Disassembly Procedure
129
Figure 72: Housing Removal
129
Figure 73: Bearing Removal
129
Figure 74: Bushing Removal
129
Assembly Procedure: Using New Bearings and Seal
130
Figure 75: Bushing Insertion
130
Figure 76: Clutch
131
Structural Maintenance
133
Unit Mounting Bolts
133
Condenser, Evaporator and Radiator Coils
133
Fan Location
133
Unit Inspection
133
Figure 77: Check Bolts for Tightness
133
Figure 78: Fan Blade Position in Orifice
133
Mechanical Diagnosis
135
CYCLE-SENTRY Diagnosis
139
Electric Standby Diagnosis
141
Refrigeration Diagnosis
143
Remote Evaporator Specifications
147
Refrigeration System
147
Electrical
147
Remote Evaporator Maintenance Inspection Schedule
149
Remote Evaporator Unit Description
151
Figure 79: Spectrum Evaporator
151
Figure 80: Spectrum Evaporator-Front View
152
Figure 81: Spectrum Evaporator-Back View
152
Unit Operation
153
Defrost
153
Operating Modes
153
Unit Features
153
Unit Protection Devices
153
Serial Number Location
153
Figure 82: Serial Number Location
153
Remote Evaporator Refrigeration Service Operations
155
Expansion Valve Assembly
155
Removal
155
Installation
155
Evaporator Coil
155
Solenoid Valves
156
Removal
156
Installation
156
Liquid Return Check Valve
156
Figure 83: Cross Section of In-Line Check Valve
156
Remote Evaporator Structural Maintenance
157
Unit Inspection
157
Defrost Drains
157
Evaporator Coil
157
Remote Evaporator System Diagnosis
159
Index
161
Wiring and Schematic Diagrams Index
163

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