Thermo King MD-MT User Manual

MD-MT
w/TK 3.74
TK 51703-1-MM (Rev. 0, 08/02)
Copyright© 1999 Thermo King Corp., Minneapolis, MN, USA.
Printed in USA.

Thermo King MD-MT Specifications

General

Brand	Thermo King
Model	MD-MT
Category	Refrigerator
Language	English

Summary

Safety Precautions

General Practices

General safety guidelines for operating and maintaining the unit.

Refrigerant Handling and Safety

Precautions for handling refrigerants, including first aid for exposure.

Auto Start/Stop Warning

Caution regarding automatic unit starting when the On/Off switch is in the On position.

Refrigeration Oil Safety

Precautions for working with or around synthetic or polyol ester refrigerant oil.

Electrical Hazards and Microprocessor Service

Precautions to prevent electrostatic discharge when servicing electronic components.

Welding Safety and Procedures

Procedures to ensure welding currents do not flow through electronic circuits.

High Voltage Safety Precautions

Critical safety measures and first aid for working with high voltage electrical systems.

Low Voltage Safety Precautions

Precautions when working with low voltage control circuits and potential burn hazards.

Specifications

Engine—TK 3.74 Specifications

Detailed technical specifications for the TK 3.74 diesel engine, including oil, RPM, and pressure.

Engine Coolant Type and Capacity

Information on conventional and ELC coolants, system capacity, and radiator cap pressure.

R-404A Refrigeration System Specifications

Specifications for the R-404A system, including refrigerant charge, oil, and pressure settings.

Engine Clutch—Hilliard Specifications

Specifications for the Hilliard centrifugal clutch, including engagement speed and torque.

Air Switch Unit Setting

Specification for the air switch setting on Spectrum 2 or Spectrum 3 remote units.

Belt Tension Specifications

Tension settings for various belts using a TK gauge or deflection method.

Electrical Control System Specifications

Details on control system voltage, fuses, breakers, alternator, and unloading timer.

Electrical Components Current Draw and Resistance

Current draw and resistance values for electrical components like solenoids and motors.

Thermostat Specifications

Type, range, and heat lockout conditions for the thermostat.

Electric Standby Motor Specifications

Specifications for the electric standby motor, including horsepower, RPM, and power requirements.

Maintenance Inspection Schedule

Microprocessor and Engine Maintenance Tasks

Scheduled inspection and service items for the microprocessor and engine.

Electrical System Maintenance Tasks

Scheduled inspections for electrical components like sensors, switches, and contacts.

Refrigeration System Maintenance Tasks

Scheduled checks for refrigerant level, compressor oil, and system pressures.

Structural Maintenance Tasks

Inspections for fluid leaks, damage, and cleaning of unit components.

Unit Description

General Unit Description

Overview of the MD-MT system, its models, engine, and power transfer mechanism.

Microprocessor Controller TG-V Features

Description of the TG-V controller's functions, including defrost, fuel saver, and alarms.

X214 Compressor Details

Information on the X214 compressor used in the MD-MT unit.

Spectrum Remote Evaporator Description

Description and visual representation of the Spectrum remote evaporator unit.

Unit Operation Modes Explained

Explanation of continuous run, CYCLE-SENTRY, and electric standby operating modes.

Reading Mode of Operation Charts Guide

How to interpret mode charts using relay and solenoid abbreviations.

Zone 1 and Zone 2 Cooling Operation

Description of refrigerant flow and component states during dual-zone cooling.

Zone 1 Cooling and Zone 2 Heating Operation

Description of refrigerant flow and component states during mixed-mode operation.

Operating Modes Overview

Details on operating modes for two-compartment and single-compartment configurations.

Serial Number Locations

Identification of where serial number plates are located on the unit, engine, and compressor.

Design Features by Model

Comparison of design features across MD-MT 30 and 50 models with NAD and EEC options.

Unit Photographs and Views

Visual representations of the unit from different perspectives.

TG-V Multi-Temp Control Box Overview

Identification and function of controls on the TG-V multi-temp control box.

TG-V In-Cab Controller Overview

Description of the in-cab controller's keys, displays, and functions.

X214 Compressor Component Identification

Visual guide identifying key parts of the X214 compressor.

Remote Evaporator Unit Overview

Description of the Spectrum remote evaporator system and its components.

Remote Evaporator Unit Features

List of key features of the remote evaporator system.

Serial Number Location for Remote Evaporator

Location of the serial number nameplate on the remote evaporator unit.

Operating Instructions

TG-V Multi-Temp Control Box Controls

Detailed explanation of the functions for each control on the TG-V Multi-Temp Control Box.

TG-V In-Cab Controller Functions

Instructions for using the In-Cab Controller for unit operation, temperature setting, and defrost.

Key Controller Functions and Displays

Explanation of SELECT, UP, DOWN, DEFROST, ENTER, WHISPER MODE keys, and display icons.

Electric Standby Power Receptacle Operation

Operation of the On/Off switch, Diesel/Electric switch, and power receptacle.

Unit Indicators and Protection Devices

Information on defrost switches, air switches, unit indicators, and protection devices.

Pretrip Inspection Procedures

Essential checks before operation, including fuel, oil, coolant, battery, belts, and structure.

Unit Starting Procedures

Steps for starting the unit in Auto Start Diesel, Manual Diesel, and CYCLE-SENTRY modes.

CYCLE-SENTRY and Continuous Run Modes

Guidelines for selecting and operating CYCLE-SENTRY vs. Continuous Run modes.

Loading and Post-Load Procedures

Procedures for pre-cooling, loading, and post-trip checks to ensure proper operation.

Electrical Maintenance

Alternator (Prestolite) Testing and Maintenance

Procedures for testing the alternator, including voltage regulator checks.

Battery and Charging System Maintenance

Inspection and maintenance of battery terminals, electrolyte, and charging system.

Unit Wiring Inspection Procedures

Guidelines for inspecting unit wiring and harnesses for damage or faults.

Glow Plugs and Engine Reset Switch Maintenance

Maintenance and troubleshooting for glow plugs and the engine reset switch.

Low Oil Pressure Switch (LOP) Testing

Testing procedures for the engine low oil pressure switch to ensure proper function.

Circuit Breaker and Fuse Identification

Identification and troubleshooting for various circuit breakers and fuses in the control box.

Unloading Timer (EUT) Testing

Testing procedures for the unloading timer to ensure it functions correctly.

Defrost System Troubleshooting

Procedures for initiating, checking, and troubleshooting defrost cycles for both zones.

Door Sentry II System Operation and Relays

Explanation of the Door Sentry II system, its relays, and operational logic.

Engine Maintenance

EMI 2000 Extended Maintenance Package

Details on the EMI 2000 package, components, and benefits of extended service intervals.

Engine Lubrication System Description

Overview of the engine's pressure lubrication system and factors affecting oil pressure.

Engine Oil and Filter Change Procedures

Steps for changing engine oil and filters, including oil type and capacity recommendations.

Air Cleaner System Maintenance

Maintenance procedures for EMI 2000 dry type and oil bath air cleaners, including restriction indicators.

Engine Cooling System Description

Explanation of the engine's closed, circulating, pressurized cooling system.

ELC (Extended Life Coolant) Information

Details on approved ELC coolants, their compatibility, and maintenance.

Antifreeze Maintenance Procedures

Guidelines for checking antifreeze concentration and changing coolant.

Engine Fuel System Overview

Description of the high-pressure fuel system and the importance of fuel cleanliness.

Fuel System Bleeding and Filter Replacement

Procedures for bleeding air from the fuel system and replacing the fuel filter.

Electric Fuel Pump Operation and Maintenance

Information on the electric fuel pump's operation, mounting, and service limitations.

Integral Fuel Solenoid Operation

Explanation of how the integral fuel solenoid controls engine speed and fuel flow.

Engine Speed Adjustment Procedures

Steps for adjusting low and high engine speeds to meet performance specifications.

Injection Pump Timing Procedures

Detailed instructions for timing the injection pump relative to the engine and cylinders.

Engine Valve Clearance Adjustment Procedure

Steps for checking and adjusting engine valve clearance for optimal operation.

Engine Mounts for MD-MT Units

Identification of engine mounting vibration and snubber components.

Belt Tensioning and Adjustment Procedures

Procedures for tensioning and adjusting engine, compressor, and alternator belts.

Refrigeration Maintenance

Refrigeration System Evacuation Principles

Importance of evacuation, use of micron gauge, and 3-point access for moisture removal.

Refrigerant Charge Testing Procedures

Methods to test refrigerant charge in empty or loaded trucks and identify overcharging.

Adjusting Refrigerant Level

Procedures for adding or removing refrigerant to achieve correct levels in the sight glass.

Moisture Indicating Sight Glass Interpretation

How to interpret sight glass colors to assess system moisture content.

Refrigerant Leak Detection Methods

Techniques for detecting refrigerant leaks using detectors and soap bubbles.

Checking Compressor Oil Level

Procedures for checking compressor oil level in different ambient temperature conditions.

Compound Pressure Gauge Usage

How to use and recalibrate the compound pressure gauge for low-side monitoring.

High Pressure Cutout (HPCO) Testing

Location, function, and testing of the HPCO switch to prevent over-pressurization.

Compressor Pump Down and Checkout Procedures

Steps for pumping down the compressor and performing a checkout of system components.

Evacuating and Charging Procedures Setup

Steps for setting up electrical controls and evacuation equipment before charging.

Unit Evacuation Procedure

Detailed steps for evacuating the system to a low micron level.

Unit Charging Procedure

Procedures for charging the system with refrigerant using liquid and vapor methods.

Remove Evacuation Hoses Procedure

Steps to safely remove evacuation hoses and preparing the unit for operation.

Refrigeration Service Operations

Commissioning Unit Procedure

Procedure for bringing a unit into service after major component replacement or system flush.

Low Side Pump Down Procedure

Steps for pumping down the low side and checking system component seals.

Compressor Removal and Installation

Detailed procedures for removing and installing the X214 compressor, including pulley service.

Condenser/Radiator Coil Service Procedures

Steps for removing and installing the condenser/radiator coil.

Drier Removal and Installation

Procedures for removing and installing the refrigerant drier assembly.

High Pressure Cutout and Receiver Tank Pressure Cutout Switch Service

Procedures for removing and installing cutout switches.

High Pressure Relief Valve Service

Procedures for removing and installing the high pressure relief valve.

Suction Pressure Regulator Valve Service

Procedures for removing and installing the suction pressure regulator valve.

Accumulator Tank Service

Procedures for removing and installing the accumulator tank.

Receiver Tank Service Procedures

Procedures for removing and installing the receiver tank.

Condenser Inlet Check Valve Repair and Replacement

Procedures for repairing and replacing the condenser inlet check valve.

Suction Line and Purge Check Valve Service

Procedures for repairing and replacing suction line and purge check valves.

In-Line Check Valves Service

Information on in-line check valves, their replacement, and installation requirements.

Receiver Tank Pressure Solenoid Valve (RTPS) Service

Procedures for removing and installing the RTPS solenoid valve.

Purge Valve (PV) Service Procedures

Procedures for removing and installing the purge valve.

R-404A Refrigerant Information

Properties, identification, availability, and safety of R-404A refrigerant.

Equipment Recommendations for R-404A Use

Guidelines for dedicated equipment, vacuum pumps, gauge sets, and system clean-up with R-404A.

Oil Filter Maintenance for X214 Compressors

Maintenance recommendations for the bypass oil filter used with R-404A systems.

Hilliard Clutch Maintenance

Large Truck Unit Centrifugal Clutch Change (P/N 107-291)

Procedure for changing the centrifugal clutch on large truck units, superseding P/N 107-204.

Clutch Maintenance Procedures

Steps for inspecting, disassembling, cleaning, and assembling the clutch components.

Tools Required for Clutch Maintenance

List of specialized tools needed for performing clutch maintenance.

Structural Maintenance

Unit and Engine Mounting Bolt Torque Specifications

Torque values for tightening unit and engine mounting bolts.

Unit Lift Points Identification

Visual identification of the three required lift points for the unit.

Fan Blade Position in Orifice Guidelines

Instructions for positioning the fan assembly for optimal airflow performance.

Unit Inspection for Physical Damage

Inspection of wiring, hardware, leaks, and physical damage affecting unit performance.

Mechanical Diagnosis

Troubleshooting Unit Power and Cranking Issues

Diagnosing conditions where unit lights do not come on or the engine does not crank.

Engine Cranking and Starting Problems

Diagnosing issues when the engine cranks but fails to start, or starts and stops.

Engine Operation Problems

Diagnosing and resolving issues like engine stopping after starting, low power, or knocking.

Engine Running Condition Diagnosis

Troubleshooting engine overheating, low oil pressure, and high oil consumption.

Battery Charging System Diagnosis

Diagnosing problems related to the battery not recharging or overcharging.

Engine Smoke Emission Diagnosis

Identifying causes of excessive white, black, or blue smoke from the engine exhaust.

CYCLE-SENTRY Diagnosis

Relay and Control Module (CSM) Fault Diagnosis

Troubleshooting issues with run relays, preheat relays, and defective CSM units.

Starter Engagement and Crank Timing Diagnosis

Diagnosing starter issues like premature disengagement or incorrect crank timing.

Electric Standby Diagnosis

Unit Power and Electric Motor Operation Issues

Troubleshooting when the unit switch is on but the electric motor does not run or hums.

Contact Chatter and Freezing Issues

Diagnosing contact chatter, welding, or freezing in electric standby components.

Battery Charging System Issues in Electric Standby

Troubleshooting battery not recharging or overcharging during electric standby operation.

Refrigeration Diagnosis

Symptom-Based Refrigeration Diagnosis Guide

Cross-references operational symptoms with potential causes for refrigeration system failures.

Remote Evaporator Specifications

Remote Evaporator Refrigeration System Specifications

Details on the evaporator coil type and the refrigerant used in the system.

Remote Evaporator Electrical Specifications

Electrical ratings for the remote evaporator, including voltage, motor, and solenoid specifications.

Remote Evaporator Maintenance Inspection Schedule

Remote Evaporator Electrical Inspection Items

Scheduled inspection of wiring harnesses and fan motor brushes for the remote evaporator.

Remote Evaporator Structural Inspection Items

Scheduled visual inspection of remote evaporator for fluid leaks, damage, and component integrity.

Remote Evaporator Unit Description

Spectrum Evaporator Component Identification

Diagram and list identifying components of the Spectrum evaporator.

Remote Evaporator Operating Modes

Explanation of Cool, Null, Heat, and Defrost operating modes for remote evaporators.

Remote Evaporator Unit Features

List of key features of the remote evaporator system.

Remote Evaporator Unit Protection Devices

Information on fuses located on the condensing unit interface board for protection.

Remote Evaporator Serial Number Location

Location of the serial number nameplate on the remote evaporator unit frame.

Remote Evaporator Refrigeration Service Operations

Expansion Valve Assembly Service Procedures

Procedures for removing and installing the expansion valve assembly on remote evaporators.

Evaporator Coil Service Procedures

Procedures for removing and installing the evaporator coil, including cleaning and soldering.

Solenoid Valve Service Procedures

Procedures for removing and installing solenoid valves, emphasizing heat sink use.

Liquid Return Check Valve Service Procedures

Procedures for removing and installing the in-line liquid return check valve.

Remote Evaporator Structural Maintenance

Remote Evaporator Unit Inspection

Inspection of wiring, hardware, leaks, and physical damage affecting performance.

Defrost Drain Cleaning

Cleaning defrost drains to ensure proper line clearance.

Evaporator Coil Cleaning and Inspection

Procedures for cleaning the evaporator coil and inspecting for damage.

Remote Evaporator System Diagnosis

Troubleshooting High Load Temperature

Diagnosing causes for high load temperatures, such as refrigerant issues or expansion valve problems.

Troubleshooting Evaporator Fan Motor Not Running

Diagnosing reasons for the evaporator fan motor not operating, including electrical checks.