Thermo King MD-MT - Engine Smoke Emission Diagnosis

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Mechanical Diagnosis

140

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

• Incorrect timing

• Poor compression

• Faulty injectors

• Type of fuel used

• Cold engine

• Excessive load

• Clogged air intake system

• Faulty nozzles

• Poor compression

• Restricted exhaust

• Faulty injection pump

• Poor compression

• Defective valve seals

Main Page

Table of Contents5
List of Figures11
Safety Precautions13
General Practices13
Auto Start/Stop13
Refrigerant13
First Aid13
Refrigeration Oil14
First Aid14
Electrical Hazards14
Microprocessor Service14
Welding of Units or Truck Bodies15
High Voltage15
Low Voltage16
Specifications17
Engine-TK 3.7418
R-404A Refrigeration System19
Engine Clutch-Hilliard19
Air Switch19
Belt Tension20
Electrical Control System20
Electrical Components21
Thermostat21
Electric Standby21
Maintenance Inspection Schedule23
Unit Description25
General Description25
Figure 1: Typical Compartment Configurations25
X214 Compressor26
Spectrum Remote Evaporator26
Microprocessor Controller TG-V26
Figure 2: Spectrum Remote Evaporator26
Unit Operation27
Reading Mode of Operation Charts28
Mode of Operation Charts29
Zone 1 Cool and Zone 2 Cool33
Figure 3: Zone 1 Cool and Zone 2 Cool33
Zone 1 Cool and Zone 2 Heat34
Figure 4: Zone 1 Cool and Zone 2 Heat34
Operating Modes35
Engine, Continuous Run-Two Compartment Operation35
Figure 5: Zone 1 Evaporator Engine, Continuous Run, Two Compartment Control Algorithm35
Figure 6: Zone 2 Evaporator Engine, Continuous Run, Two Compartment Control Algorithm35
Engine, Continuous Run-Single Compartment Operation36
Figure 7: Zone 1 Evaporator Engine, Continuous Run, Single Compartment Control Algorithm36
Figure 8: Zone 2 Evaporator (Engine Set on Continuous Run) Single Compartment Control Algorithm36
CYCLE-SENTRY Operation37
Figure 9: Zone 1 Evaporator CYCLE-SENTRY Control Algorithm37
Figure 10: Zone 2 Evaporator CYCLE-SENTRY Control Algorithm37
Electric Operation38
Defrost Operation38
Figure 11: Electronic Control Algorithm38
Serial Number Locations39
Design Features40
Unit Photographs41
Figure 12: Roadside View41
Figure 13: Curbside View41
Figure 14: Top View42
Figure 15: Engine Side Door Open43
Figure 16: TG-V Multi-Temp Control Box44
Figure 17: TG-V In-Cab Controller for Multi-Temp Compartment Units45
Figure 18: X214 Compressor46
Figure 19: X214 Compressor47
Operating Instructions49
Unit Controls49
TG-V Multi-Temp Control Box49
TG-V In-Cab Controller for Multi-Compartment Units50
Electric Standby Power Receptacle51
Figure 20: Electric Standby Power Receptacle51
Other Controls52
Unit Indicators52
Unit Protection Devices52
Unit Operation53
Pretrip Inspection53
Starting the Unit-Auto Start Diesel Operation54
Manually Starting Units on Diesel Operation54
Starting the Unit-CYCLE-SENTRY Units on Diesel Operation54
Operating Instructions (Continued)54
Starting the Unit-Electric Operation56
Starting Zone 2 Evaporator57
After Start Inspection57
Loading Procedure57
Post Load Procedure57
Post Trip Checks58
Electrical Maintenance59
Alternator (Prestolite)59
Figure 21: Prestolite Terminal Locations59
Battery60
Charging System60
Unit Wiring60
Glow Plugs61
Engine Reset Switch61
High Water Temperature Switch (HWT)61
Low Oil Pressure Switch (LOP)62
Circuit Breakers62
Main Circuit Breaker62
Control Circuit Breaker62
Evaporator Circuit Breaker62
Fan Circuit Breakers62
7X-CH Circuit Fuse62
Figure 22: Control Box Components62
Unloading Timer (EUT)63
Testing the Unloading Timer63
Control Circuit Fuse63
Defrost System64
Zone 1 Evaporator Defrost Cycle Diesel Operation64
Zone 1 Evaporator Defrost Cycle Electric Operation64
Zone 1 Evaporator Defrost Cycle Checkout Procedure65
Zone 2 Evaporator Defrost Cycle Diesel Operation66
Zone 2 Evaporator Defrost Cycle Electric Operation67
Zone 2 Evaporator Defrost Cycle Checkout Procedure67
Figure 23: Defrost Relay Locations68
Defrost System Components69
Figure 24: Defrost Termination Switch69
Figure 25: Air Switch Testing and Adjustment71
Fan Speed Control72
Circuit Boards72
CYCLE-SENTRY Option72
Option Board Jumpers72
Figure 26: Option Board72
Multi-Temp Relay Board73
Figure 27: Multi-Temp Relay Board73
AC Components74
Contactors74
Overload Relay74
In-Cab TG-V Controller74
Figure 28: Multi-Temperature In-Cab TG-V Controller74
Figure 29: Connect Tester to Controller75
Figure 30: Connector on Back of Multi-Temperature In-Cab TG-V76
Door Sentry II77
Figure 31: Door Sentry-II Relay Identification77
Engine Maintenance79
Emi 200079
Engine Lubrication System79
Engine Low Oil Pressure Switch79
Engine Oil Change79
Oil Filter Change80
Crankcase Breather80
Engine Air Cleaner80
Emi 200080
Figure 32: Oil Filter Parts80
Figure 33: EMI 2000 Dry Type Air Cleaner80
Oil Bath Type81
Dry Type (Optional)81
Figure 34: Oil Bath Air Cleaner81
Figure 35: Dry Air Cleaner (Optional)81
Figure 36: Air Restriction Indicator81
Engine Cooling System82
Figure 37: Engine Cooling System Components82
ELC (Extended Life Coolant)83
Figure 38: ELC Nameplate-Located on Expansion Tank83
Antifreeze Maintenance Procedures84
Engine Maintenance (Continued)84
Figure 39: Accumulator Tank Drain84
Figure 40: Water Pump Assembly and Thermostat85
Engine Fuel System86
Figure 41: Fuel and Oil System Components87
Bleeding the Fuel System88
Water in the Fuel System88
Fuel Filter Replacement88
Electric Fuel Pump89
Figure 42: Electric Fuel Pump89
Integral Fuel Solenoid90
Figure 43: Integral Fuel Solenoid Components90
Electrical Changes91
Figure 44: Fuel Solenoid Timer91
Figure 45: Wiring Diagram of Fuel Solenoid Timer Starting 4Th Quarter 9791
Troubleshooting the Integral Fuel Solenoid System92
Figure 46: Fuel Solenoid Pin Identification92
Figure 47: Relay Socket Terminal Identification93
Fuel Stop Solenoid Replacement94
Figure 48: Fuel Stop Solenoid Components94
Engine Speed Adjustments95
Low Speed Adjustment95
High Speed Adjustment95
Injection Pump95
Injection Pump Adjustments95
Timing the Injection Pump to the Engine95
Timing Individual Cylinder Injection97
Figure 49: Timing Marks97
Fuel Limit Screw98
Engine Valve Clearance Adjustment98
Figure 50: Individual Cylinder Timing and Firing Order98
Figure 51: CARB California Air Resources Board Tag98
Engine Mounts for MD-MT Units99
Belts100
Engine/Compressor/Jackshaft /Belt Tension/Adjustments100
Figure 52: Engine-Compressor Belt Adjustment100
Figure 53: Belt Layout101
Compressor/Alternator Fan Belts102
Figure 54: Alternator Mounting and Belt Tension Screws102
Refrigeration Maintenance103
Figure 55: Evacuation Station104
Figure 56: Vacuum Gauge105
Refrigerant Charge106
Testing the Refrigerant Charge with an Empty Truck106
Testing the Refrigerant Charge with a Loaded Truck106
Testing for an Overcharge of Refrigerant106
Adjusting the Refrigerant Level107
Moisture Indicating Sight Glasses107
Figure 57: Moisture Indicating Sight Glasses107
Refrigerant Leaks108
Checking Compressor Oil108
Figure 58: X214 Compressor108
Compound Pressure Gauge109
High Pressure Cutout (HPCO)109
Figure 59: High Pressure Cutout Manifold109
Compressor Pump down and Checkout110
Evacuating and Charging Procedures110
Set-Up Electrical Controls110
Set-Up and Test Evacuation Equipment110
Figure 60: Set-Up and Test Evacuation Equipment111
Unit Evacuation112
Figure 61: Unit Evacuation113
Unit Charging114
Figure 62: Unit Charging115
Remove Evacuation Hoses116
Figure 63: Remove Evacuation Hoses116
Refrigeration Service Operations117
Commissioning Unit117
Low Side Pump down117
Compressor118
Removal118
Installation118
Compressor Pulley Removal and Installation (X214 Compressors)118
Figure 64: Anti-Seize Lubricant Application-X214 Compressors118
Condenser/Radiator Coil119
Removal119
Installation119
Drier119
High Pressure Cutout Switch and Receiver Tank Pressure Cutout Switch119
Refrigeration Service Operations (Continued)119
High Pressure Relief Valve120
Removal120
Installation120
Suction Pressure Regulator Valve120
Accumulator120
Receiver Tank121
Removal121
Installation121
Condenser Inlet Check Valve Repair121
Figure 65: Condenser Inlet Check Valve121
Condenser Inlet Check Valve Replacement122
Removal122
Installation122
Suction Line Check Valve and Purge Check Valve Repair (SLCV, RSLCV and PCV)122
Figure 66: Check Valve122
Suction Line Check Valve and Purge Check Valve Replacement (SLCV, RSLCV, and PCV)123
Removal123
Installation123
In-Line Check Valves123
Figure 67: Cross Section of In-Line Check Valve123
Receiver Tank Pressure Solenoid Valve (RTPS)124
Removal124
Installation124
Purge Valve (PV)124
Unit Identification125
Availability125
Leak Detection125
Compressor Oil125
Compressors Shipped with R-404A125
Figure 68: R-404A Decal125
Equipment Recommendations for Use with R-404A126
Figure 69: X214 Compressor Oil Filter and Stabilizer Bracket-Starting April 1997127
Hilliard Clutch Maintenance129
Large Truck Unit Centrifugal Clutch Change (P/N 107-291)129
Figure 70: Front View and Cross Section129
Figure 71: Clutch Assembly130
Clutch Maintenance131
Tools Required131
Grease131
Disassembly Procedure131
Figure 72: Housing Removal131
Figure 73: Bearing Removal131
Figure 74: Bushing Removal131
Assembly Procedure: Using New Bearings and Seal132
Figure 75: Bushing Insertion132
Figure 76: Clutch133
Structural Maintenance135
Unit and Engine Mounting Bolts135
Lift Points135
Fan Location135
Unit Inspection135
Figure 77: Check Bolts for Tightness135
Figure 78: Lift Points Front View135
Figure 79: Lift Points Side View135
Figure 80: Fan Blade Position in Orifice135
Mechanical Diagnosis137
CYCLE-SENTRY Diagnosis141
Electric Standby Diagnosis143
Refrigeration Diagnosis145
Remote Evaporator Specifications149
Refrigeration System149
Electrical149
Remote Evaporator Maintenance Inspection Schedule151
Remote Evaporator Unit Description153
Figure 81: Spectrum Evaporator153
Figure 82: Spectrum Evaporator-Front View154
Figure 83: Spectrum Evaporator-Back View154
Unit Operation155
Defrost155
Operating Modes155
Unit Features155
Unit Protection Devices155
Serial Number Location155
Figure 84: Serial Number Location155
Remote Evaporator Refrigeration Service Operations157
Expansion Valve Assembly157
Removal157
Installation157
Evaporator Coil157
Solenoid Valves158
Removal158
Installation158
Liquid Return Check Valve158
Figure 85: Cross Section of In-Line Check Valve158
Remote Evaporator Structural Maintenance159
Unit Inspection159
Defrost Drains159
Evaporator Coil159
Remote Evaporator System Diagnosis161
Index163
Wiring and Schematic Diagrams Index165

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Thermo King MD-MT - Engine Smoke Emission Diagnosis

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