Thermo King RD-MT - Engine Emits Excessive Smoke

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Mechanical Diagnosis

138

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 3.9518
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
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: Front View41
Figure 13: Top View41
Figure 14: Engine Side Door Open42
Figure 15: TG-V Multi-Temp Control Box43
Figure 16: TG-V In-Cab Controller for Multi-Temp Compartment Units44
Operating Instructions45
Unit Controls45
TG-V Multi-Temp Control Box45
TG-V In-Cab Controller for Multi-Compartment Units46
Electric Standby Power Receptacle47
Figure 17: Electric Standby Power Receptacle47
Other Controls48
Unit Indicators48
Unit Protection Devices48
Unit Operation49
Pretrip Inspection49
Starting the Unit-Auto Start Diesel Operation50
Manually Starting Units on Diesel Operation50
Starting the Unit-CYCLE-SENTRY Units on Diesel Operation50
Operating Instructions (Continued)50
Starting the Unit-Electric Operation52
Starting Zone 2 Evaporator53
After Start Inspection53
Loading Procedure53
Post Load Procedure53
Post Trip Checks54
Electrical Maintenance55
Alternator (Prestolite)55
Figure 18: Prestolite Terminal Locations55
Battery56
Charging System56
Unit Wiring57
Glow Plugs57
Engine Reset Switch57
High Water Temperature Switch (HWT)58
Low Oil Pressure Switch (LOP)58
Circuit Breakers58
Main Circuit Breaker58
Control Circuit Breaker58
Evaporator Circuit Breaker58
Fan Circuit Breakers58
7X-CH Circuit Fuse58
Unloading Timer (EUT)59
Testing the Unloading Timer59
Figure 19: Control Box Components59
Control Circuit Fuse60
Defrost System60
Zone 1 Evaporator Defrost Cycle Diesel Operation61
Zone 1 Evaporator Defrost Cycle Electric Operation61
Zone 1 Evaporator Defrost Cycle Checkout Procedure61
Zone 2 Evaporator Defrost Cycle Diesel Operation63
Zone 2 Evaporator Defrost Cycle Electric Operation63
Zone 2 Evaporator Defrost Cycle Checkout Procedure63
Figure 20: Defrost Relay Locations64
Defrost System Components66
Figure 21: Defrost Termination Switch66
Figure 22: Air Switch Testing and Adjustment67
Fan Speed Control68
Circuit Boards68
CYCLE-SENTRY Option68
Option Board Jumpers69
Figure 23: Option Board69
Multi-Temp Relay Board70
Figure 24: Multi-Temp Relay Board70
AC Components71
Contactors71
Overload Relay71
In-Cab TG-V Controller71
Figure 25: Multi-Temperature In-Cab TG-V Controller71
Figure 26: Connecting Tester to Controller72
Figure 27: Connector on Back of Multi-Temperature In-Cab TG-V73
Door Sentry II74
Figure 28: Door Sentry-II Relay Identification74
Engine Maintenance77
Emi 200077
Engine Lubrication System77
Engine Oil Change78
Oil Filter Change78
Crankcase Breather78
Engine Air Cleaner78
Emi 200078
Figure 29: Oil Filter Parts78
Oil Bath Type79
Dry Type (Optional)79
Figure 30: EMI 2000 Dry Type Air Cleaner79
Figure 31: Oil Bath Air Cleaner79
Figure 32: Dry Air Cleaner (Optional)80
Figure 33: Air Restriction Indicator80
Engine Cooling System81
Figure 34: Engine Cooling System Components81
ELC (Extended Life Coolant)82
Figure 35: ELC Nameplate-Located on Expansion Tank82
Figure 36: Accumulator Tank Drain83
Engine Fuel System84
Figure 37: Thermostat84
Figure 38: Fuel System85
Bleeding the Fuel System86
Water in the Fuel System86
Engine Maintenance (Continued)86
Fuel Filter Replacement86
Electric Fuel Pump87
Figure 39: Electric Fuel Pump87
Fuel Solenoid System88
Figure 40: Fuel Solenoid Timer88
Figure 41: Fuel Solenoid Location88
Fuel Solenoid Timer Operation89
Figure 42: Simplified Schematic Diagram of Fuel Solenoid System89
Troubleshooting the Fuel Solenoid System90
Figure 43: Main Wire Harness Connector Pin90
Figure 44: Fuel Solenoid Connector Pin90
Figure 45: Relay Socket Terminal Identification91
Fuel Solenoid Replacement92
Engine Speed Adjustments92
Low Speed Adjustment92
High Speed Adjustment92
Figure 46: Fuel Solenoid Components92
Injection Pump93
Injection Pump Removal93
Figure 47: Engine Speed Adjustments93
Injection Pump Installation94
Timing the Injection Pump to the Engine94
Figure 48: Timing Marks95
Timing Individual Cylinder Injection96
Fuel Limit Screw and Maximum Speed Stop Screw96
Engine Valve Clearance Adjustment96
Figure 49: Individual Cylinder Timing and Firing Order96
Figure 50: Adjusting the Valve Clearance97
Engine Mounts98
Figure 51: Engine Mounting Components98
Belts99
Engine-Compressor Belt Adjustment100
Figure 52: Engine-Compressor Belt Adjustment100
Figure 53: Belt Arrangement101
Compressor-Alternator Belt Adjustment102
Compressor-Electric Motor Belt Adjustment102
Water Pump Belt102
Figure 54: Alternator Belt Adjustment102
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 Overcharge106
Adjusting the Refrigerant Level107
Moisture Indicating Sight Glasses107
Refrigerant Leaks107
Figure 57: Moisture Indicating Sight Glasses107
Checking Compressor Oil108
Figure 58: X426 Compressor108
High Pressure Cutout Switch (HPCO)109
Figure 59: High Pressure Cutout Manifold109
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 Hoses116
Refrigeration Service Operations117
Commissioning Unit117
Low Side Pump down117
Compressor118
Removal118
Installation118
Condenser/Radiator Coil118
Drier118
Installation119
High Pressure Cutout Switch and Receiver Tank Pressure Cutout Switch119
Removal119
High Pressure Relief Valve119
Refrigeration Service Operations (Continued)119
Accumulator119
Installation120
Receiver Tank120
Removal120
Condenser Inlet Check Valve Repair120
Figure 64: Condenser Inlet Check Valve120
Condenser Inlet Check Valve Replacement121
Removal121
Installation121
Suction Line Check Valve and Purge Check Valve Repair121
Suction Line Check Valve and Purge Check Valve Replacement121
In-Line Check Valves122
Removal122
Installation122
Receiver Tank Pressure Solenoid Valve (RTPS)122
Figure 65: Cross Section of In-Line Check Valve122
Purge Valve (PV)123
Removal123
Installation123
Throttling Valve123
Disassembly123
Figure 66: Inspect Throttling Valve Components123
Reassembly124
Figure 67: Inspect Piston and Cap for Wear124
Figure 68: Inspect Pilot Hole for Damage124
Throttling Valve Installation125
Figure 69: Throttling Valve Assembly125
Compressor Oil Filter Change126
Figure 70: Compressor Oil Filter126
Hilliard Clutch Maintenance127
Large Truck Unit Centrifugal Clutch Change (P/N 104-272)127
Figure 71: Front View and Cross Section127
Clutch Maintenance129
Tools Required129
Grease129
Disassembly Procedure129
Figure 72: Housing Removal129
Figure 73: Bearing Removal129
Figure 74: Bushing Removal129
Assembly Procedure: Using New Bearings and Seal130
Figure 75: Bushing Insertion130
Figure 76: Clutch131
Structural Maintenance133
Unit Mounting Bolts133
Condenser, Evaporator and Radiator Coils133
Fan Location133
Unit Inspection133
Figure 77: Check Bolts for Tightness133
Figure 78: Fan Blade Position in Orifice133
Mechanical Diagnosis135
CYCLE-SENTRY Diagnosis139
Electric Standby Diagnosis141
Refrigeration Diagnosis143
Remote Evaporator Specifications147
Refrigeration System147
Electrical147
Remote Evaporator Maintenance Inspection Schedule149
Remote Evaporator Unit Description151
Figure 79: Spectrum Evaporator151
Figure 80: Spectrum Evaporator-Front View152
Figure 81: Spectrum Evaporator-Back View152
Unit Operation153
Defrost153
Operating Modes153
Unit Features153
Unit Protection Devices153
Serial Number Location153
Figure 82: Serial Number Location153
Remote Evaporator Refrigeration Service Operations155
Expansion Valve Assembly155
Removal155
Installation155
Evaporator Coil155
Solenoid Valves156
Removal156
Installation156
Liquid Return Check Valve156
Figure 83: Cross Section of In-Line Check Valve156
Remote Evaporator Structural Maintenance157
Unit Inspection157
Defrost Drains157
Evaporator Coil157
Remote Evaporator System Diagnosis159
Index161
Wiring and Schematic Diagrams Index163

Thermo King RD-MT - Engine Emits Excessive Smoke

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