Thermo King V250 Manual
  1. Manuals
  2. Brands
  3. Thermo King Manuals
  4. Refrigerator
  5. V250
  6. Manual

Thermo King V250 Manual

R-134a refrigerant
Hide thumbs
Table of Contents

Advertisement

Quick Links

V250
TK 40839-1-MM (Rev. 2, 1/99)
©
Copyright
1994 Thermo King Corp., Minneapolis, MN, U.S.A.
Printed in U.S.A.

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the V250 and is the answer not in the manual?

Questions and answers

Ron
May 8, 2025

Where are the charging ports on a v 250

User image 681cf4bec4483
0

Related Manuals for Thermo King V250

Summary of Contents for Thermo King V250

  • Page 1 V250 TK 40839-1-MM (Rev. 2, 1/99) © Copyright 1994 Thermo King Corp., Minneapolis, MN, U.S.A. Printed in U.S.A.
  • Page 2 If further information is required, Thermo King Corporation should be consulted. Sale of product shown in this manual is subject to Thermo King’s terms and conditions including, but not limited to, the Thermo King Limited Express Warranty. Such terms and conditions are available upon request.
  • Page 3 Keep Polyol Ester compressor oil in tightly sealed containers. If Polyol Ester oil becomes contaminated with moisture or standard oils, dispose of properly—DO NOT USE! WARNING: When servicing Thermo King R-404A and R-134a units, use only those service tools certified for and dedicated to R-404A or R-134a refrigerant and Polyol Ester compressor oils.

  • Page 4: Table Of Contents

    Troubleshooting the V250 Defrost System with P.C. Board P/N 41-776 ......41...
  • Page 5 M10 (V250/V-090) Cab Control Box Test Procedure ........
  • Page 6 V250 Installation Checklist ........

  • Page 7: Safety Precautions

    Safety Precautions GENERAL PRACTICES REFRIGERANT ALWAYS WEAR GOGGLES SAFETY Although fluorocarbon refrigerants are classified as safe GLASSES. Refrigerant liquid, refrigeration oil, and refrigerants, certain precautions must be observed when battery acid can permanently damage the eyes (see First handling them or servicing a unit in which they are used. Aid under Refrigeration Oil).

  • Page 8: Safety

    Safety Precautions (Rev 1/99) ELECTRICAL HAZARDS First Aid IMMEDIATE action must be initiated after a person has High Voltage received an electrical shock. Obtain immediate medical assistance if available. When servicing or repairing a refrigeration unit, the possi- bility of serious or even fatal injury from electrical shock The source of shock must be immediately removed by exists.

  • Page 9: Specifications

    Specifications General Compressor Belt driven, multi cylinder, wobble plate type driven by the truck engine (Model 10) and by the truck engine or electric motor. (Model 20) Engine Compressor Oil Charge 6 oz (177 ml) in compressor Total system: 12 oz (355 ml) Electric Standby Compressor Oil Charge 6 oz 177 ml) in each compressor Total system: 24 oz (710 ml)
  • Page 10 Specifications (Rev 1/99) R-404A REFRIGERATION SYSTEM Refrigerant Charge and Type 5 lb (2.3 kg) R-404A Defrost Termination Switch: Opens 52 F (11.1 C) Closes 42 F (5.6 C) Liquid Line Injection Switch: Opens 200 ± 5 F (93 ± 3 C) Closes 230 ±...
  • Page 11 Specifications (Rev 1/99) Electrical Standby Compressor Motors Full Load Overload Full Load Voltage Phase Frequency Horsepower Kilowatts Current Relay Setting (amps) (amps) 115 Vac 60 Hz 1750 15.0 16.0 230 Vac 60 Hz 1755 220 Vac 50 Hz 1460 10.0 11.0 230 Vac* 60 Hz...

  • Page 13: Maintenance Inspection Schedule

    Maintenance Inspection Schedule First Week Inspection and Maintenance AFTER FIRST WEEK OF OPERATION: • Check the belt tension • Tighten the unit mounting bolts • Check the refrigerant level Bi-monthly Annually Inspect/Service These Items ELECTRICAL • • Check defrost initiation and termination. •...

  • Page 15: Unit Description

    Unit Description The Thermo King V250 is a truck refrigeration system that The electric standby compressor is connected in parallel is designed for low and medium temperature applications with the engine-driven compressor. The engine compressor on medium-sized trucks. There are two basic models: is driven by a belt from the engine.

  • Page 16: Oil Separator

    Unit Description (Rev 1/99) Oil Separator Electric Standby Operation During electric standby operation, the thermostat controls An oil separator is a standard feature. It separates compres- the operation of the unit by energizing and de-energizing the sor oil from refrigerant vapor and returns the oil to the com- power relay, the electric relays, and the heat contactor.

  • Page 17: Unit Features

    Unit Description (Rev 1/99) Heat (Optional) The thermostat shifts the unit to heat at temperatures more than 3 F (1.7 C) below the thermostat setpoint. The thermo- stat keeps the unit running in heat until the temperature rises to 2.4 F (1.3 C) above the thermostat setpoint. During engine operation, the water pump and the evaporator fans operate while the unit is in heat.

  • Page 18: Protection Features

    Unit Description (Rev 1/99) • Manual Defrost Key • Heat, Truck Engine and Electric Standby Heater Strips (Model 20) • Suction Pressure Regulator • Paint, Special Color • Oil Separator • 24 V dc Converter • Six Cylinder Compressor • R-404A Dealer Installed •...
  • Page 19 Unit Description (Rev 1/99) AGA339 Vertical Mounted Condenser (Early Model) AGA673 Vertical Mounted Condenser (Later Model)
  • Page 20 Unit Description (Rev 1/99) AEA825 High Voltage Box Oil Separator Compressor Liquid Injection Solenoid Hot Gas Solenoid (Behind Fan Blade) Drier Hourmeters Location (Optional) Condenser Coil Low Voltage Box Check Valve Assembly Condenser Fan Motor (Model 20 only) Receiver Tank 24 Volt Converter Condenser Components—Front/Top View (Starting 1997)
  • Page 21 Unit Description (Rev 1/99) Expansion Valve Fan Motor Thermostat Sensor Suction Pressure Regulator Funnel Evaporator...
  • Page 22 Unit Description (Rev 1/99) Thermostat Sensor Expansion Valve Heat Exchanger Evaporator Coil Suction Pressure Regulator Thin-Line Evaporator...
  • Page 23 Unit Description (Rev 1/99) AEA667 Relays PC Board Low Voltage Box—Pre-1996...
  • Page 24 Unit Description (Rev 1/99) AEA660 Transformer Transformer Fuse Motor Start Capacitors Overload Relay Motor Start Relay Motor Contactor DC Power Filter Capacitor 9. Heat Contactor (Optional) Motor Run Capacitor High Voltage Box—Pre-1997...
  • Page 25 Unit Description (Rev 1/99) AEA826 Transformer Transformer Fuse Motor Start Capacitors Overload Relay DC Power Filter Capacitor 8. Motor Contactor Motor Run Capacitor Heat Contactor (Optional) Motor Start Relay High Voltage Box—Starting 1997...
  • Page 26 Unit Description (Rev 1/99) AGA340 D.C. Power Filter Capacitor Transformer Motor Starting Capacitor Motor Contactor Motor Start Relay Fuse and Fuseholder Motor Run Capacitor Motor Protector High Voltage Box - Typical for Single Phase P97...
  • Page 27 Unit Description (Rev 1/99) AGA345 D.C. Power Filter Capacitor Motor Contactor Transformer Fuse and Fuse Holder Overload Relay High Voltage Box - Typical for 3 Phase P97...
  • Page 28 Unit Description (Rev 1/99) AEA661 Power Cord Indicator Thermostat Dial Running Indicator Setpoint Key Defrost Indicator 10. AC Overload Indicator Heat Indicator Digital Display Cool Indicator 12. Manual Defrost Key Celsius Indicator 13. On-Off Key Fahrenheit Indicator 14. On Indicator Cab Control Box—M10 Pre-1997...
  • Page 29 Unit Description (Rev 1/99) NOTE: The M13 and M10 cab boxes are identified by the position of the defrost indicator light. On the M13 cab box the defrost indicator light is positioned on the defrost key. On the M10 cab box the defrost indicator light is positioned left of the digital display.

  • Page 31: Operating Instructions

    Operating Instructions UNIT CONTROLS 12. AC OVERLOAD INDICATOR. When this light is on, it indicates that the overload relay has opened. This Cab Control Box indicator must be reset by pressing the On-Off Key after allowing time for the overload relay to cool. ON-OFF KEY.

  • Page 32: Unit Protection Devices

    Operating Instructions (Rev 1/99) HEATER CONTACTOR (Optional). The heater con- F2 This 15 amp fuse protects the circuit to the evapo- tactor is used to control the operation of the optional rator fan motor. electric evaporator heaters. F3 This 10 amp fuse protects the circuit to the power relay and the heat relay.

  • Page 33: Unit Operation

    Operating Instructions (Rev 1/99) below 5 to 11 in. Hg of vacuum (-17 to -37 kPa), the inspection is not a substitute for regularly scheduled mainte- switch opens the circuit to the power relay, which stops nance inspections, it is an important part of the preventive the unit.

  • Page 34: Adjusting The Thermostat

    Operating Instructions (Rev 1/99) Adjust the thermostat to the proper setting. PRECOOLING. With the thermostat set at the correct temperature, allow the unit to run for one-half to one NOTE: The power cord indicator will come on if the hour (longer if possible) before loading the truck. Pre- unit is connected to an electric standby power supply.

  • Page 35: Post Loading Procedure

    Operating Instructions (Rev 1/99) One-half hour after loading, defrost the unit by momen- tarily pressing the Manual Defrost switch. If the coil temperature has dropped below 42 F (5.6 C), the unit will defrost. The defrost cycle should stop automati- cally.

  • Page 37: Electrical Maintenance

    Electrical Maintenance UNIT WIRING Place dip switch 3 in the proper position. ON for Celsius Periodically inspect the unit wiring and the wire harnesses OFF for Fahrenheit for loose, chafed or broken wires to protect against unit mal- functions due to open or short circuits. Replace the cover.

  • Page 38: Setpoint Differential Adjustment

    Electrical Maintenance (Rev 1/99) NOTE: Do not run a R-134a unit to -26 F (-32 C). R-404A Turn the adjusting potentiometer to the 12 o’clock posi- units may be operated at -24 F (-32 C). tion. Replace the cover and place the cab control box back in Setpoint Differential Adjustment its bracket.

  • Page 39: Testing The Cab Control Box

    Electrical Maintenance (Rev 1/99) Testing the Cab Control Box Initial Digital Display Test Turn the unit ON. Note what appears on the digital dis- The cab control box contains the thermometer and the ther- play. This is the temperature display. mostat.
  • Page 40 Electrical Maintenance (Rev 1/99) Steps 4 and 5 refer to Wiring Diagram 5D44456 and Sche- proper output voltages (X3-X4) and make sure that the matic Diagram 5D44455. electric standby power supply is turned ON. Steps 6 and 7 refer to Wiring Diagram 5D46190 and Sche- Check the voltage between the 2R3 circuit (pin 3) and matic Diagram 5D46179.

  • Page 41: Thermostat Switch Sequence Test

    Electrical Maintenance (Rev 1/99) Faulty Cab Control Box Continue to slowly turn the thermostat dial up to raise the thermostat setpoint about 2 F (1 C) every 5 Before replacing the cab control box make sure that another seconds. When the thermostat setpoint is approxi- problem, such as a loose wire connection or a bad ground, is mately 3.6 F (2 C) above the thermometer reading, the not causing the cab control box to malfunction.

  • Page 42: Defrost System

    Electrical Maintenance (Rev 1/99) Electric Standby Operation Test If the indicator lights come on and go off properly, but the unit does not shift operating modes properly, make sure that Start the unit on standby operation and set the thermo- the electric relays, the heat contactor, the associated wiring stat at least 6.3 F (3.5 C) below the thermometer read- and the wire connections are not defective before assuming...

  • Page 43: Electric Standby Operation (Model 20)

    Electrical Maintenance (Rev 1/99) NOTE: It takes more time to complete a defrost cycle in (5.6 C), completing the defrost circuit to ground (CH) and low ambient temperatures (below 35 F [2 C]) than it does preparing the electrical system for the defrost cycle. in high ambient temperatures (above 70 F [21 C]).

  • Page 44: V250 Defrost System And P.c. Board Identification And Testing

    Connect a test light between the screw terminal on the switch and the positive battery terminal. The V250 defrost system energizes a hot gas defrost sole- noid valve (HGV) to route hot gas through the evaporator NOTE: Attempting to test the electronic defrost ter- coil.

  • Page 45: P.c. Board Identification

    12A circuit is connected to the 12 circuit through the timer Currently, three different P.C. boards have been used on the for the maximum defrost time limit. If the 12 circuit is V250. grounded through a closed defrost termination switch, the defrost relay will energize and pull in.
  • Page 46 Electrical Maintenance (Rev 1/99) AGA406 Defrost Relay Jumper W2 Defrost Initiation Timer Defrost LED PL7 Potentiometer R17 Jumper W1 Defrost Termination Timer Service Part Number P.C. Board P/N 41-776 (First Version)
  • Page 47 Electrical Maintenance (Rev 1/99) AGA407 Defrost Relay Jumper W2 Defrost Initiation Timer Defrost LED PL7 Potentiometer R17 Jumper W1 Defrost Termination Timer Service Part Number Defrost Fuse F5 P.C. Board P/N 41-1619 (Second Version)
  • Page 48 Electrical Maintenance (Rev 1/99) AGA408 Defrost Relay Jumper W2 Defrost Initiation Timer Defrost LED PL7 Potentiometer R17 Jumper W1 Defrost Termination Timer Standard (Parked) Jumper Position Defrost Fuse F5 Service Part Number P.C. Board P/N 41-1812 (Third Version)

  • Page 49: Troubleshooting The V250 Defrost System With P.c. Board P/N 41-776

    Electrical Maintenance (Rev 1/99) Troubleshooting the V250 Defrost System nected and the 11 circuit energized, check the fol- lowing: with P.C. Board P/N 41-776 Remove the defrost relay from its socket. Unit will not defrost when the manual defrost Check for voltage on the 11 circuit at the 85 switch is pressed.
  • Page 50 Electrical Maintenance (Rev 1/99) If no voltage is present, check the wire harness circuits X1 (J5-4) and X4 (J5-1), and the rest of the from the cab control box to the P.C. board. If electric standby power supply. the wire harness is not defective, check the cab Check for voltage between pin 8 (11 circuit -gray control box (step c.).
  • Page 51 Electrical Maintenance (Rev 1/99) If voltage is present on the 26 circuit but the unit will If the resistance is in this range, the hot gas valve is not stay (latch) in defrost, diode D20 or its circuit is probably defective and should be replaced. probably defective.

  • Page 52: Troubleshooting The V250 Defrost System With P.c. Boards P/N 41-1619 And P/N 41-1812

    Electrical Maintenance (Rev 1/99) Troubleshooting the V250 Defrost System B. Check the P.C. Board. with P.C. Boards P/N 41-1619 and P/N 41- Check defrost fuse F5 (1 amp). 1812 If fuse F5 is burnt out, replace it and perform step A.2.
  • Page 53 Electrical Maintenance (Rev 1/99) If no voltage is present on the 11 circuit at the 85 Only for units equipped with electric standby) pin of the defrost relay socket while pressing the Check for voltage (approximately 12 volts) manual defrost switch, check the following: Check between pin 2 (2R1 circuit - red wire) and pin 9 for voltage between P1-11 (11 circuit - gray wire) (CH circuit - black wire) at the connector in the...
  • Page 54 Electrical Maintenance (Rev 1/99) Unit will defrost only when the manual defrost If the 26 circuit from the P.C. board to the hot gas valve switch is pressed and held in. is intact, check the CH circuit from the hot gas valve to the P.C.

  • Page 55: P.c. Board P/N 41-776 Test Procedure

    Electrical Maintenance (Rev 1/99) Defrost will not initiate automatically. 11. Turn the variable resistance until the cab box shows “05” degrees. Use the following procedure to check the defrost initiation timer. This procedure assumes the rest of the defrost system 12.

  • Page 56: Board P/N 41-1812 And P/N 41-1619

    Electrical Maintenance (Rev 1/99) 26. Turn variable resistance until the cab box shows “00” Plug in the six relays as specified on the board. degrees. Replace any fuses that are missing or blown. 27. LEDs PL3 and 6 should light. With the power supply turned on and the cab box 28.

  • Page 57: M10 (V250/V-090) Cab Control Box Test Procedure

    16. Close switch S2 to pin 4 and switch S4 to pin 7. M10 (V250/V-090) Cab Control Box Test 17. Press the defrost key on the cab box. PL3 connected to Procedure pin 8 and the defrost LED on the cab box should come Connect +12 Vdc Power to pin 3 and negative ground on but only while this key is being held.
  • Page 58 Electrical Maintenance (Rev 1/99) AGA409 M10 Cab Control Box Test Circuit...

  • Page 59: Condenser Fan Pressure Switch (Cfps)

    Electrical Maintenance (Rev 1/99) CONDENSER FAN PRESSURE SWITCH AC COMPONENTS (Model 20) (CFPS) CAUTION: The unit uses high voltage alternating current (ac) during electric operation. Lethal volt- The CFPS is located in the discharge line. Electrically it is age potentials can exist on connections in the high voltage located between F1 and the condenser fan motor.

  • Page 60: 12 Volt System

    Electrical Maintenance (Rev 1/99) When the unit is inoperative, follow a systematic checking sequence. This will save time and eliminate guesswork. Check the power cable receptacle for power. If power is present, check for power at the unit terminal board. Check for control circuit power at the circuit breaker.

  • Page 61: Refrigeration Maintenance

    Refrigeration Maintenance NOTE: The following procedures involve servicing the refrigeration system. Some of these service procedures are regu- lated by Federal, and in some cases, by State and Local laws. All regulated refrigeration service procedures must be performed by an EPA certified technician, using approved equip- ment and complying with all Federal, State and Local laws.
  • Page 62 Refrigeration Maintenance (Rev 1/99) Close the low side valve on the gauge manifold, leave 13. With these conditions established, open the low side the high side valve on the gauge manifold open, and valve on the gauge manifold and open the valve on the open the valve on the refrigerant drum to deliver liquid.

  • Page 63: Checking The Refrigerant Charge

    Refrigeration Maintenance (Rev 1/99) 18. Stop the unit, shut OFF the truck engine and remove the gauge manifold set. 19. The above conditions MUST be established each time the refrigerant level is checked or if refrigerant needs to be added for any reason. NOTE: To prevent oil migration from one compressor to another, and for proper oil return when a compressor is operating, operate a compressor for a minimum of 15 min-...

  • Page 64: Checking Compressor Oil Charge

    Refrigeration Maintenance (Rev 1/99) Testing the Refrigerant Charge with a Loaded Box Operate at a low speed (600 to 800 rpm) for 2 hours, or until the compressor oil level reaches a minimum Install a gauge manifold. allowable level, whichever occurs first. Drain the col- Run the unit in cool on engine operation.

  • Page 65: Low Pressure Cutout Switch (Lpco)

    Refrigeration Maintenance (Rev 1/99) Failure of the high pressure cutout system to stop com- pressor operation should be investigated first by check- ing the control circuit operation and second by replacing the HPCO. LOW PRESSURE CUTOUT SWITCH (LPCO) The low pressure cutout switch is located on the suction line in the evaporator.

  • Page 66: Cleanup Procedure For Small Truck Units

    Refrigeration Maintenance (Rev 1/99) CLEANUP PROCEDURE FOR SMALL Tools Required: TRUCK UNITS • Motor-driven TK 214 “Flushing Compressor” • Suction Line Filter (P/N 204-498 with Filter P/N 66- 2988) • Pipes (In Place of Oil Separator, Check Valve, Oil Sep- arator and Standby Compressor) Clean-up Procedure Make sure all hose routing is correct.
  • Page 67 Refrigeration Maintenance (Rev 1/99) will drain out of the suction line filter. (Add compressor oil as required.) Refrigerant oil in the flushing com- pressor will absorb acids from the system. 15. Test compressor oil for acid contamination. 16. Continue flushing until compressor oil is clean. Putting the Unit Back Into Operation Replace check valve (or check valve seats).

  • Page 69: Refrigeration Service Operations

    Refrigeration Service Operations NOTE: It is generally good practice to replace the filter drier whenever the high side is opened or when the low side is opened for an extended period of time. COMPRESSOR Loosen the drive belt adjuster and remove the compres- sor drive belt.

  • Page 70: Condenser Coil

    Refrigeration Service Operations (Rev 1/99) Installation Keep the compressor ports and the suction and dis- charge lines for the compressor covered to prevent con- Clean the tubes for soldering. tamination of system components. Place the coil in the unit and install the mounting hard- Remove the compressor mounting screws.

  • Page 71: Receiver Tank

    Refrigeration Service Operations (Rev 1/99) RECEIVER TANK Removal Remove the refrigerant charge. Removal Remove the coil and disassemble the valve. Remove the refrigerant charge. Unsolder the hot gas lines from the valve, and remove Disconnect the refrigerant lines from the receiver tank. the valve from the unit.

  • Page 72: Oil Separator

    Hold the oil separator with a backup wrench on the hex in unit. behind the ORS fitting. Tee-Fitting for V250 Suction Line Access Pressurize the refrigerant system and check for leaks. LIQUID INJECTION METERING ORIFICE If no leaks are found, evacuate the system.

  • Page 73: Testing The Liquid Injection Solenoid Valve And Metering Orifice

    Refrigeration Service Operations (Rev 1/99) NOTE: This orifice may become plugged with dirt Set the thermostat on the lowest setting. unless the refrigeration hose and solenoid valve are Start the truck and run the unit on the engine-driven kept clean. compressor until the suction pressure stabilizes.
  • Page 74 Refrigeration Service Operations (Rev 1/99) Cap Nut Piston Seat Sealing Washer Washer Spring Screw Piston Valve Body Check Valve Assembly NOTE: Illustration only, no service parts available.
  • Page 75 Refrigeration Service Operations (Rev 1/99) With the unit off, install a gauge manifold set on each and low sides were equalized. If the high side pressure compressor. is increasing or has increased noticeably, the discharge check valve is leaking internally. Stop the unit. Observe the gauge manifold readings of the electric standby compressor.

  • Page 76: Evaporator Coil

    Refrigeration Service Operations (Rev 1/99) Check Valve Replacement Remove the defrost termination switch wire. Unsolder the suction line from the evaporator coil. Removal Remove the mounting bolts and slide the coil from the Remove the refrigerant charge. unit. Disconnect the refrigeration line connections. Installation Remove the mounting hardware and remove the check valve.

  • Page 77: Expansion Valve Assembly

    Refrigeration Service Operations (Rev 1/99) 11. Open the refrigeration valves and place the unit in oper- Disconnect the equalizer line from the expansion valve. ation. Check the refrigerant charge and the compressor Disconnect the liquid line and the distributor from the oil and add as required.

  • Page 78: Low Pressure Cutout Switch

    Refrigeration Service Operations (Rev 1/99) Pressurize the low side and test for leaks. If no leaks Open the refrigeration valves, and place the unit in are found, evacuate the low side. operation. Check refrigerant charge and add refrigerant as required. LOW PRESSURE CUTOUT SWITCH REPLACING REFRIGERANT HOSES Removal...
  • Page 79 Refrigeration Service Operations (Rev 1/99) Place the socket on the hose and turn it counterclock- Screw the nipple into the socket. wise until the hose bottoms out. Then back it out 1/4 of a turn. AGA383 AGA341 Flare Fittings Install Socket The flare fittings on the liquid injection line should first be Lubricate the nipple threads and the inside of the hose tightened finger tight, then they should be turned 3/4 of a...

  • Page 81: V-250 R-404A Conversion Instructions

    V-250 R-404A Conversion Instructions This option should be only used with units containing a low voltage board. (2C20447G01). Service parts # 41-1812 with cycle clutch on high/low pressure cutout operation. Install new expansion valve. Install new high pressure cutout switch. Apply R-404A decals over the R-134a decals.

  • Page 83: Structural Maintenance

    Structural Maintenance UNIT INSPECTION Inspect the unit during the pre-trip inspection and during scheduled maintenance inspections for loose or broken wires or hardware, compressor oil leaks, or other physical damage which might affect the unit performance and require the repair or replacement of parts. EVAPORATOR COIL Clean the evaporator coil during scheduled maintenance inspection by blowing compressed air down through the...

  • Page 85: Compressor And Clutch Maintenance

    CLUTCH REMOVAL NOTE: Make sure the proper tools are available before performing maintenance procedures. Refer to the tool list- ing at the end of this chapter for tools required. Contact your local Thermo King dealer for further information. Remove Drive Plate...
  • Page 86 Compressor and Clutch Maintenance (Rev 1/99) Remove the snap ring using external snap ring pliers NOTE: To avoid damaging the pulley groove, the (TK 204-808). pulley claws should be hooked into (NOT UNDER) the pulley groove. Remove the cover. Snap Ring Cover Remove Pulley Remove Snap Ring and Cover...

  • Page 87: Clutch Installation

    Compressor and Clutch Maintenance (Rev 1/99) NOTE: DO NOT hold the coil by the lead wire. Coil Inspect the coil for a loose connector or cracked insula- tion. If the insulation is cracked, replace the coil. Repair or replace the wire or the connector if either is loose or damaged.
  • Page 88 Compressor and Clutch Maintenance (Rev 1/99) Install the cover and the snap ring using external ring pliers. NOTE: When installing the snap ring, the chamferred inner edge of the snap ring should face upward. Felt Install Coil Install the pulley assembly using the compressor holder (TK No.

  • Page 89: Shaft Seal Cover And Shaft Seal: Removal And Installation

    Compressor and Clutch Maintenance (Rev 1/99) After tightening the bolt, ensure that the pulley rotates NOTE: Specified clearance: 0.01 to 0.02 in. (0.3 to smoothly. 0.6 mm). Check Clearance Shims Electrical Connection Install Shims and Drive Plate Connect the lead wire to the electrical circuit. Ensure that the clutch clearance is as specified.
  • Page 90 Compressor and Clutch Maintenance (Rev 1/99) the hook on the shaft seal cover, then slowly pull the shaft seal cover out of the cylinder head. NOTE: The shaft seal cover SHOULD NOT be reused. Always use a new shaft seal cover when reas- sembling a compressor.
  • Page 91 Compressor and Clutch Maintenance (Rev 1/99) Shaft Seal Installation Place the shaft seal on the seal guide and slide the seal into the cylinder head. Before installing a shaft seal inspect it carefully (see Inspec- tion). Clean the section of the front cylinder head that holds shaft seal.

  • Page 92: Special Tools

    Compressor and Clutch Maintenance (Rev 1/99) Special Tools Place the seal guide (from the shaft seal kit P/N 204-805) on the end of the shaft. Place the shaft seal cover on the seal guide and slide the shaft seal cover into the cylinder head. 8932a Clutch Remover P/N 204-806 Install Shaft Seal Cover...
  • Page 93 Compressor and Clutch Maintenance (Rev 1/99) 8932c 8932e Clutch Installation Kit P/N 204-890 Shaft Seal Kit P/N 204-805 8932d Snap Ring Pliers P/N 204-808...

  • Page 94: System Compressor And Oil

    The correct oil to use in the V250 using R-134a and R- 404A is Polyol Ester (POE) oil (TK No. 203-413). Any extra or replacement oil should be placed into the sys- tem at the receiver tank port.

  • Page 95: Checking The Oil Level

    Compressor and Clutch Maintenance (Rev 1/99) Checking the Oil Level Oil contamination. Dirt in the oil. Drain the Oil Color changed to a varnish color. Presence of foreign substances, metal shavings, etc. in the oil. NOTE: Always replace oil with new fresh oil taken from a sealed container only.

  • Page 96: Clutch Test

    Compressor and Clutch Maintenance (Rev 1/99) Clutch Test BELT TENSIONS If the field coil lead wire is broken, replace the field Engine/Compressor Belt and Pulleys coil. Correct pulley alignment and proper belt tension are very Check the amperage and voltage. The amperage range important factors in compressor installation.

  • Page 97: Electric Motor/Compressor Belt

    0.5 in. (13 mm) at the center of the span with no motor movement. A belt that is too tight causes severe overload on the compressor and motor bearings. Use only approved Thermo King Service Parts replacement belts. They are specially designed for these units.

  • Page 99: Over-The-Road Mechanical Diagnosis

    Over-the-Road Mechanical Diagnosis If the desired box temperature cannot be obtained, any of a hand or hot towels to see if the valve opens. Evacuate the following may be indicated: the system in the same manner used during installation. Install a new drier. EXCESSIVE HEAT LOAD.

  • Page 100: Road Compressors

    Over-the-Road Mechanical Diagnosis (Rev 1/99) 15. COMPRESSOR LIFE. The following will shorten the • Insufficient oil charge life of a compressor: • Wrong oil or mixed oil • Operating a contaminated system • Lack of compressor lubrication on installation-startup • No oil trap •...

  • Page 101: Electric Standby Mechanical Diagnosis

    Electric Standby Mechanical Diagnosis CONDITION POSSIBLE CAUSE REMEDY Compressor does not run Improperly wired Check wiring against diagram Low line voltage Check line voltage—determine location of voltage drop Relay contacts not closing Check and replace relay if defective Open circuit in motor winding Check motor leads.
  • Page 102 Electric Standby Mechanical Diagnosis (Rev 1/99) CONDITION POSSIBLE CAUSE REMEDY Unit operates long or Shortage of refrigerant Repair leak and recharge continuously Discharge valve leaking Replace compressor Thermostat faulty Replace cab box Dirty condenser Clean condenser Air in system Purge Compressor inefficient Replace compressor Plugged expansion valve...
  • Page 103 Electric Standby Mechanical Diagnosis (Rev 1/99) CONDITION POSSIBLE CAUSE REMEDY Head pressure too low Refrigerant shortage Repair leak and recharge Compressor suction or discharge Replace compressor valve inefficient Noisy unit Insufficient compressor oil Add oil to proper level Mounting bolts loose Tighten Oil slugging or refrigerant flooding Adjust oil level or refrigerant charge.

  • Page 104: Electric Standby Service Checks

    Electric Standby Mechanical Diagnosis (Rev 1/99) ELECTRIC STANDBY SERVICE CHECKS 1. Motor does not run 1. Check for power at source 2. Check for power at plug 3. Check for power at compressor contactor 4. Check for power at overload terminals (contactor closed) 5.
  • Page 105 AGA666 Model 10 Cool...
  • Page 106 AGA667 Model 10 in Defrost...
  • Page 107 AGA668...
  • Page 108 AGA669 Model 20 in Defrost—Electric Standby Operation...
  • Page 109 AGA670 Model 20 in Cool—Vehicle Engine Operation...
  • Page 110 AGA671 Model 20 in Defrost—Vehicle Engine Operation...

  • Page 111: V250 Installation Checklist

    Suction pressure regulator set at 20 psi (138 kPa). Compressor belt tension is correct. During Installation Thermo King logo installed on condenser. Are hoses and harnesses routed to avoid sharp bends, Optional electric standby and electric heaters work abrasion, heat, brake lines, and sharp edges? properly.

  • Page 113: Wiring Diagrams And Schematic Index

    V250 Wiring Diagram 109-110 5D44455 V250 Schematic Diagram 111-112 5D44456 V250 Wiring Diagram 113-114 5D49374 115V 1PH 60Hz Wiring Diagram 5D49275 V250 Wiring Diagram 5D49360 V250 with P97 Power Pack Schematic Diagram 117-118 5D49368 230V 1PH 50/60 Hz Wiring Diagram...
  • Page 115 9 6FKHPDWLF 'LDJUDP²3DJH  RI ...
  • Page 116 9 6FKHPDWLF 'LDJUDP²3DJH  RI ...
  • Page 117 9 :LULQJ 'LDJUDP²3DJH  RI ...
  • Page 118 9 :LULQJ 'LDJUDP²3DJH  RI ...
  • Page 119 9 6FKHPDWLF 'LDJUDP²3DJH  RI ...
  • Page 120 9 6FKHPDWLF 'LDJUDP²3DJH  RI ...
  • Page 121 9 :LULQJ 'LDJUDP²3DJH  RI ...
  • Page 122 9 :LUH 'LDJUDP²3DJH  RI ...
  • Page 123 9 3+  +] :LULQJ 'LDJUDP...
  • Page 124 9 :LULQJ 'LDJUDP...
  • Page 125 9 ZLWK 3 3RZHU 3DFN 6FKHPDWLF 'LDJUDP²3DJH  RI ...
  • Page 126 9 ZLWK 3 3RZHU 3DFN 6FKHPDWLF 'LDJUDP²3DJH  RI ...
  • Page 127 9 3+ +] :LULQJ 'LDJUDP...

Table of Contents

Save PDF