Ingersoll-Rand Thermo King V-520 Series Maintenance Manual
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Ingersoll-Rand Thermo King V-520 Series Maintenance Manual

Ingersoll-Rand Thermo King V-520 Series Maintenance Manual

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Maintenance Manual
SB-210+
SB-210+
SB-210+
V-520 MAX
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Additional text information
Additional text information
TK 54343-1-MM (Rev 3, 03/15)
V-520
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TK 5XXXX-X-PL
TK 5XXXX-X-PL
TK 5XXXX-X-PL

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  • Page 1 Maintenance Manual SB-210+ SB-210+ SB-210+ V-520 V-520 MAX Additional text information Additional text information Additional text information to be placed here to be placed here to be placed here TK 54343-1-MM (Rev 3, 03/15) TK 5XXXX-X-PL TK 5XXXX-X-PL TK 5XXXX-X-PL...
  • Page 3 V-520 V-520 MAX TK 54343-1-MM (Rev 3, 03/15) Copyright© 2009 Thermo King Corp., Minneapolis, MN, USA. Printed in USA.
  • Page 4 The maintenance information in this manual covers unit models: V-520 10 (900829) V-520 MAX 30 (902053) V-520 20 (900830) V-520 MAX 50 (902054) V-520 30 (902041) V-520 SPECTRUM 10 (900834) V-520 50 (902049) V-520 SPECTRUM 20 (900835) V-520 MAX 10 (900831) V-520 SPECTRUM 50 (902235) V-520 MAX 20 (900833) For further information, refer to:...
  • Page 5 No warranties, express or implied, including warranties of fitness for a particular purpose or merchantability, or warranties arising from course of dealing or usage of trade, are made regarding the information, recommendations, and descriptions contained herein. Manufacturer is not responsible and will not be held liable in contract or in tort (including negligence) for any special, indirect or consequential damages, including injury or damage caused to vehicles, contents or persons, by reason of the installation of any Thermo King product or its mechanical failure.
  • Page 6 CHANGES, COMMENTS and SUGGESTIONS You are invited to comment on this manual so it can be updated and improved to better meet you needs. Any corrections, comments or suggestions are welcome. Please complete the following information: Manual Form Number _____________________________________________________ Section and Page # _______________________________________________________ Your Name ______________________________________________________________ Company Name __________________________________________________________...

  • Page 7: About This Manual

    About This Manual Purpose The purpose of this manual is to provide general maintenance information necessary to maintain the climate control unit at peak operating standards. This includes system and bill of material numbers, safety information, general unit information, maintenance procedures and related information (such as wiring and schematic diagrams), and some diagnostic and troubleshooting information.
  • Page 8 About This Manual Roadside/Curbside Terminology Roadside/Curbside terminology: These terms can be confusing because of differences between North America and Europe. Please note: Curbside: The side to the driver’s right when the driver is in his seat and facing forward. Roadside: The side to the driver’s left when the driver is in his seat and facing forward.

  • Page 9: Table Of Contents

    Table of Contents About This Manual ............... 5 Safety Precautions .
  • Page 10 Table of Contents Entering the Setpoint Temperature ............33 In Single-Temperature Units .
  • Page 11 Table of Contents Liquid Line Check Valve (Model 30 and 50 Only) ..........53 Liquid Line Check Valve Test .
  • Page 12 Table of Contents Electric Standby Mechanical Diagnosis ........... . . 81 Electric Standby Service Checks .

  • Page 13: Safety Precautions

    Safety Precautions General Practices Auto Start/Stop 1. Always wear goggles or safety glasses. CAUTION: The unit may start Refrigerant liquid, refrigeration oil, and automatically and at any time when the battery acid can permanently damage the eyes. unit On/Off switch is in the On position. 2.

  • Page 14: Refrigeration Oil

    Safety Precautions Refrigeration Oil The following procedures must be rigidly adhered to when servicing units to avoid microprocessor Observe the following precautions when working damage or destruction. with or around synthetic or polyol ester refrigerant 1. Disconnect all power to the unit. oil: 2.

  • Page 15: Welding Of Units Or Truck Bodies

    Safety Precautions Welding of Units or Truck Bodies Precautions When electric welding is to be performed on any 1. Be certain the Unit On/Off switch is turned portion of the temperature control unit, truck or Off before connecting or disconnecting the truck chassis when the temperature control unit is standby power plug.

  • Page 16: Low Voltage

    Safety Precautions If the victim must be removed from a live circuit, CAUTION: Do not connect other pull the victim off with a non-conductive material. manufacturer’s equipment or accessories Use the victim’s coat, a rope, wood, or loop your to the Thermo King unit. This could result belt around the victim’s leg or arm and pull the in severe damage to equipment and void victim off.

  • Page 17: Model Systems (System Designations)

    Model Systems (System Designations) Thermo King Model V-520 Truck Refrigeration Systems System System Designation Install Kit Refrigerant Schematic, Wiring Diagrams Number V-520 10 900829 800319 R-134a 2E54898, 2E54899 V-520 20 900830 800319 R-134a 1PH = 2E54900, 2E54901 3PH = 2E54902, 2E54903 V-520 30 902041 800319...

  • Page 18: Specifications

    Specifications Electrical System Fuses 12 Volt 24 Volt Fuse 1: Power Supply Circuit to PCB1 5 amps 5 amps Fuse 2: Condenser Fan Motor (CFM1) 15 amps 10 amps Fuse 3: Evaporator Fan Motor (EF1) 15 amps 10 amps Fuse 4: Evaporator Fan Motor (EF2) 15 amps 10 amps Fuse 5: Compressor Clutch 1 (CCL1), Liquid Injection Switch (LIS),...

  • Page 19: Refrigerant System

    Specifications Refrigerant System R-134A REFRIGERATION SYSTEM (V-520) Refrigerant Charge: V-520 - Model 10 7.93 lb (3.60 kg) R-134a V-520 - Model 20 7.93 lb (3.60 kg) R-134a V-520 - Model 30 8.00 lb (3.63 kg) R-134a V-520 - Model 50 8.00 lb (3.63 kg) R-134a Defrost Termination Switch: Opens...

  • Page 20: Compressors

    Specifications Compressors Main Compressor 10 cu. in. (163 cc), Engine Driven, Swash Plate, 6 Cylinder Electric Standby Compressor - Model 20 and 50 Only D211Y, Reciprocating, 3 Cylinder, System Oil Capacity: Model 10 12 oz (355 cc) Model 20 64 oz (1893 cc) Model 30 18 oz (532 cc) Model 50 70 oz (2070 cc) SPECTRUM Model 10 16 oz (473 cc)

  • Page 21: Solder Applications

    Specifications Solder Applications Refrigeration Component For general refrigeration tubing connections: Joint Clearances: 0.003 to 0.005 in. (0.076 to 0.127 mm) copper to copper or copper to brass Use: Solder Type 15% Silver TK No. 203-364 Use: Flux Type TK No. 203-365 For refrigeration tubing connections of dissimilar Joint Clearances: 0.003 to 0.005 in.

  • Page 22: General Description

    General Description Introduction The Thermo King V-520 and V-520 MAX truck refrigeration systems are two or three piece units. They are designed for medium-sized trucks and vans carrying fresh produce and frozen and deep frozen goods. The system condenser is mounted on the front of AMA1003 the truck box or container.

  • Page 23: Compressor

    General Description Compressor Refrigeration hoses or lines are used to connect the condenser, the evaporator, the main compressor and any other refrigeration components. Model 20 and 50 units have an electric compressor mounted in the condenser section for Figure 2: In-Cab Control Box electric standby operation.

  • Page 24: Oil Separator

    General Description The In-Cab Control Box keys are Lit Keypad: Oil Separator always lit except when the unit is disconnected An oil separator is a standard feature. The oil (no power) or when the unit is connected but has separator separates compressor oil from been manually switched off from the In-Cab refrigerant vapor and returns the oil to the Control Box (when there is no active alarm).

  • Page 25: Evaporator Drain Tube Heaters

    General Description Evaporator Drain Tube Heaters • Low Pressure Cutout Switch - The Low Pressure Cutout Switch is a pressure sensitive Evaporator heaters are used in R-404A units to switch located in the suction line. If the avoid drain tube blockage because of ice pressure falls below 5 to 11 in.
  • Page 26 General Description Connector 1 PCB1 Connector 1 PCB2 Connector 2 PCB1 Connector 2 PCB2 Figure 3: ECM Platform 2 with Covers Installed Fuse 1 (5 amps) Power Supply Circuit to PCB1 Fuse 6 (10 amps) Condenser Fan Motor (CFM1 and CFM2) Fuse 2 (15 amps) Condenser Fan Motor (CFM1) Fuse 7 (15 amps) Condenser Fan Motor (CFM2)

  • Page 27: Unit Operation

    General Description Unit Operation Operation Standard Model 10 and 20 units (without heat The vehicle engine must be running and the unit options) operate in Cool mode or Null mode, as must be turned on. On units with Electric Standby, required, to maintain the load compartment connect the external power cord and the unit temperature at the setpoint temperature.

  • Page 28: Null Mode - All Units

    General Description Heat Mode - Model 10 and 20 Units • When the discharge pressure is greater than Only 300 psig (2068 kPa), RY6 and RY10 close and RY9 opens. CF1 and CF2 become connected If the Heat option is present, the unit enters Heat in parallel, receive high voltage, and operate at mode when the temperature falls a pre-determined high speed.

  • Page 29: Purge Mode - Model 30 And 50 Units Only

    General Description Purge Mode - Model 30 and 50 Units NOTE: The unit will not go into the Purge mode Only when coming out of the Null mode because it reached setpoint. The unit will only go into the When the temperature falls a pre-determined Purge mode when first going into the Heat mode number of degrees below the setpoint because the unit is powering up or when going...

  • Page 30: Heat Mode - Model 30 And 50 Units Only

    General Description Heat Mode - Model 30 and 50 Units refrigerant vapor leaves the compressor and flows Only through the defrost line, defrost solenoid, and drain pan heater to the evaporator. There, the The unit enters Heat mode when the temperature refrigerant heats the evaporator and returns to the falls a pre-determined number of degrees below compressor through the accumulator, CPR, and...

  • Page 31: Defrost Mode

    General Description Defrost Mode Serial Number Locations Defrost can be initiated any time the evaporator Nameplate located on the back inside Condenser: wall of condenser frame. coil temperature is below 36 F (2.2 C), causing the defrost termination switch to close. Defrost is Nameplate located Engine Driven Compressor: initiated automatically by the defrost timer, or...

  • Page 32: Unit Components

    General Description Unit Components AMA511 Filter-Drier Oil Separator Transformer Cover Liquid Sight Glass Electric Standby Compressor Condenser Fans Liquid Injection Valve Condenser Coil AC Compressor Electric Box Receiver Tank Rectifier Heat Sink Defrost Valve Figure 8: Unit Components (Model 20) AMA1005 AMA1004 Electronic Control Module...
  • Page 33 General Description AMA51 AMA513 Evaporator Fans Temperature Sensor Expansion Valve Defrost Switch Figure 10: Evaporator AMA525 Hot Water Heat Defrost Coil High Temperature Limit Switch Electric Heat Element Air Temperature Sensor Figure 11: Evaporator with Hot Water and Electric Heat Options...

  • Page 34: Operating Instructions

    Operating Instructions Unit Controls In truck-driven units, temperature control is based on two values: The setting (Setpoint) of the WARNING: Never operate the unit unless you electronic thermostat and the evaporator return completely understand the controls; otherwise temperature. The difference between these two serious injury may occur.

  • Page 35: Starting The Unit

    Operating Instructions Single-Temperature Units Warns of the need to carry out Maintenance maintenance to the unit. Symbol 13. Defrost Indicates the unit is in Defrost Mode. Symbol 14. Electrical Indicates that the unit is in Electric Symbol Standby. Starting the Unit Figure 14: Single-Temperature Units The example in the drawing shows: 10.8 C Engine Operation...

  • Page 36: In Multi-Temperature Units

    Operating Instructions 2. Press the Up or Down arrow keys to select the 4. Remote Compartment: The present Setpoint desired Setpoint Temperature. Each time Temperature in the remote compartment and either of these buttons is pressed and released, the letters SP2 will appear on screen. the Setpoint Temperature will change 1 degree.

  • Page 37: Alarms

    Operating Instructions 2. To activate manual defrost, press the Enter Press and release the Select key to display the key and then the Up or Down key and the current alarm code on screen. If there is more than defrost condition will change to On. one active alarm, all the alarm codes on the unit can be viewed in sequence by pressing and releasing the Select key.

  • Page 38: Buzzers

    Operating Instructions Press and release the Select key to display the Alarm Description current alarm code on screen. If there is more than Main or Single Cargo Box Return Air one active alarm, all the alarm codes on the unit Temperature Reading Error (open circuit or can be viewed in sequence by pressing and short-circuit).

  • Page 39: After Start Inspection

    Operating Instructions After Start Inspection 4. Half an hour after loading the truck, initiate a defrost cycle with the In-Cab Control Box. If Adjust the thermostat setting to Thermostat: the coil temperature is below 36 F (2.2 C), the above and below the compartment temperature to unit will defrost.

  • Page 40: Maintenance Inspection Schedule

    Maintenance Inspection Schedule NOTE: Thermo King reserves the right to deny NOTE: See the appropriate chapter in this warranty coverage on claims due to lack of maintenance manual for instructions on how to maintenance or neglect. Claims in question must correctly perform required maintenance.

  • Page 41: Electrical Maintenance

    Electrical Maintenance Maintenance Inspection Schedule Semi- Procedures Weekly Monthly Annual Annually Check defrost initiation and termination. • • Check thermostat cycle sequence. • • Check operation of protection shutdown circuits. • • Check thermostat and thermometer calibration in 32 F •...

  • Page 42: Liquid Injection System

    Electrical Maintenance Condenser Fan Motors the Defrost Termination Timer has timed-out. If the timer is set at 0 (zero), this is a test position. NOTE: Non-repairable fan motor assemblies are Defrost mode stops in 15 seconds. used. If a motor malfunctions, it must be replaced.

  • Page 43: Evaporator Fan Motors

    Electrical Maintenance Evaporator Fan Motors Check the power cable receptacle for power. If power is there, check for power at the unit NOTE: Non-repairable fan motor assemblies are terminal plug. used. If a motor malfunctions, it must be If the contactor is pulled down and the overload replaced.
  • Page 44 Electrical Maintenance 6. Check the voltage on the 2RB1 wire at the 13. Check the continuity of the 69 wire from the battery disconnect relay. If voltage is not compressor contactor to the thermal motor present, check the continuity of the 2RB1 wire protector.

  • Page 45: Refrigeration Maintenance

    Refrigeration Maintenance Maintenance Inspection Schedule Semi- Procedures Weekly Monthly Annual Annually Check refrigerant level. • • Replace dehydrator. • Check compressor pressure regulator and suction • pressure regulator settings if applicable. NOTE: The following procedures involve 4. After completing the evacuation procedure, servicing the refrigeration system.
  • Page 46 Refrigeration Maintenance 11. Start the unit on engine operation and run the truck engine at approximately 1000 rpm. 12. Set the thermostat at 32 F (0 C), and run the unit in cool until the box temperature approaches 32 F (0 C). 13.

  • Page 47: Checking The Refrigerant Charge

    Refrigeration Maintenance Testing the Refrigerant Charge with 22. The above conditions MUST be established a Loaded Box each time the refrigerant level is checked, or if refrigerant needs to be added for any reason. 1. Install a gauge manifold. NOTE: To prevent oil migration from one 2.

  • Page 48: Refrigeration System Checks

    Refrigeration Maintenance Clean-up Procedure 3. Charge with 6.0 to 7.0 lb (2.7 to 3.2 kg) of refrigerant. 1. Make sure all hose routing is correct. 4. Operate at a low speed (600 to 800 rpm) for 2 2. Make sure that the oil trap is correctly hours, or until the compressor oil level reaches installed.
  • Page 49 Refrigeration Maintenance 8. Remove the internal parts from the expansion 9. Install correct amount of oil. valve. 10. If no leaks are found, evacuate the system. A leak-free and dry system will maintain a 1000 9. Remove the internal parts from the expansion valve.

  • Page 50: Refrigeration Service Operations

    Refrigeration Service Operations NOTE: It is generally good practice to replace WARNING: Disconnect the power supply the filter drier whenever the high side is opened before servicing the unit to prevent or when the low side is opened for an extended personal injury.

  • Page 51: Engine Driven Compressor

    Refrigeration Service Operations Engine Driven Compressor 5. Keep the compressor ports and the suction and discharge lines for the compressor covered to prevent contamination of system components. Removal 6. Remove the compressor mounting screws and 1. Recover the refrigerant charge from the remove the compressor.

  • Page 52: Drier

    Refrigeration Service Operations Defrost Solenoid Test 8. Recharge the unit. 1. Install a gauge manifold set on the engine Drier driven compressor. 2. Disconnect the 2-pin connector with the LIS Removal and CLU wires in main wire harness from 1. Recover the refrigerant charge. wires to the liquid injection switch at the engine driven compressor.

  • Page 53: Condenser Blocking Solenoid Test (Model 30 And 50 Only)

    Refrigeration Service Operations Condenser Blocking Solenoid Liquid Solenoid Test Test (Model 30 and 50 Only) (SPECTRUM Only) 1. Install a gauge manifold set on the engine 1. Install a gauge manifold set on the engine driven compressor. driven compressor. 2. Set the thermostat on the lowest setting. 2.

  • Page 54: Solenoid Valve Replacement

    Refrigeration Service Operations Oil Separator 5. The suction pressure should fall because the suction bypass solenoid closes when the frozen compartment shifts to Cool. Removal 6. Check the temperatures of the refrigeration 1. Recover the refrigerant charge. lines on both sides of the suction bypass 2.

  • Page 55: Liquid Line Check Valve (Model 30 And 50 Only)

    Refrigeration Service Operations Liquid Line Check Valve (Model 2. Place the liquid line check valve tube assembly in position and tighten the ORS nut. 30 and 50 Only) Hold the tubes with a backup wrench on the The liquid line check valve prevents refrigerant hex behind the ORS fitting.

  • Page 56: Discharge Check Valve Replacement

    Refrigeration Service Operations Installation increasing or has increased noticeably, the discharge check valve to the standby NOTE: A heat sink must be used on the in-line compressor is leaking internally and should be check valve when it is being soldered in place to replaced.

  • Page 57: Suction Pressure Regulator Valve Replacement

    Refrigeration Service Operations remove the protective cap and try to adjust the 2. Install the defrost termination switch. suction pressure regulator valve to the correct 3. Install the temperature sensor. setting before assuming it is faulty. 4. Install the evaporator fans. 6.

  • Page 58: Low Pressure Cutout Switch (Lpco)

    Refrigeration Service Operations below 5 to 11 in. Hg of vacuum (-17 to -37 kPa), the low pressure cutout switch should open. 6. Reconnect the wires that were disconnected and remove the gauge manifold set when finished with the test. Figure 29: Location of Expansion Valve Bulb Low Pressure Cutout Switch Replacement...

  • Page 59: Compressor Pressure Regulator Valve Test

    Refrigeration Service Operations 5. Remove the gauge manifold set and the additional compound gauge when finished with the test. Compressor Pressure Regulator Valve Replacement Removal 1. Recover the refrigerant charge. 2. Remove the mounting hardware from the compressor pressure regulator valve. 3.

  • Page 60: Advanced Control System Components And Operation

    Refrigeration Service Operations Advanced Control System 7. With the unit running, set the suction pressure Components and Operation to the recorded value from step 4 by adjusting the suction bypass CPR valve. Once the • The advanced control system module contains suction pressure has been set, turn the unit off.

  • Page 61: Replacing Refrigerant Hoses (Speedy Clip System)

    Refrigeration Service Operations Replacing Refrigerant Hoses 4. Manually insert the fitting into the hose. The hose should touch the projecting part of the (Speedy Clip System) fitting without rising over it. Clean off the excess oil. Disassembly 1. Recover the refrigerant charge. 2.

  • Page 62: Compressor Maintenance

    Compressor Maintenance Refrigerant Handling Refrigerant Recovery Instructions Some refrigeration system refrigerant compounds are chlorofluorocarbons, and therefore may be Refrigerant Handling Safety damaging to the earth’s ozone layer. Consequently, the release of refrigerant into the DANGER: Explosion Hazard! Never atmosphere must be avoided. Whenever throw or strike refrigerant bottles and refrigerant is to be removed from the refrigeration never handle the packing carton roughly.

  • Page 63: Compressor Rotation Test

    Compressor Maintenance 2. Voltage Test 5. Check to make sure the compressor clutch has a good ground. Paint on the mounting brackets Confirm that the clutch is receiving at a minimum can impede a good ground connection. 11.5 V or 23 V for 12 V and 24 V systems 6.

  • Page 64: Pulley Or Rotor Spin Check

    Compressor Maintenance 3. Pulley or Rotor Spin Check With clutch disengaged the pulley should spin freely with no wobbling or roughness. Figure 45: Coil Resistance Check 6. Pressure or Pumping Test Compressors circulate refrigerant through the Figure 43: Pulley or Rotor Spin Check system by creating a pressure differential, high and low pressures.

  • Page 65: Recommended Pressures And Temperatures

    Compressor Maintenance Recommended Pressures and Temperatures Discharge • Short term 430 psig max. • Long term continuous less than 300 psig • Max continuous temperature 280 F Suction • Short term 6 psig minimum • Long term 14 psig minimum Temperature •...

  • Page 66: Compressor Oil Balance

    Compressor Maintenance Compressor Oil Balance • Adding oil to the system is required when refrigerant loss occurs due to leakage at any Compressor lubrication occurs as the oil which system component. Since oil is held in circulates with the refrigerant passes through the suspension with the refrigerant, oil will be lost compressor crankcase during operation.
  • Page 67 Compressor Maintenance New units are built with a set amount of oil in the refrigeration system. When replacing a compressor the original factory oil amount should be maintained. During normal operation oil and refrigerant circulate through the system, at shutdown as much as 75% of the oil can stored in system components.

  • Page 68: Compressor Oil Type

    Compressor Maintenance Typical Oil Amount Typical Oil Amount Component Multi-Temp System Single Temperature System Compressor 3 oz (89 cc) Minimum 3 oz (89 cc) Minimum Suction Line to Front Evaporator 2 oz (59 cc) 4 oz (118 cc) Suction Line to Rear Evaporator 2 oz (59 cc) Receiver Drier 1 oz (30 cc)

  • Page 69: Mounting

    Compressor Maintenance Torque Requirements Fastener Ft-Lb N•m Kgf-cm Armature Retaining Nut 13.0 ± 2.0 17.7 ± 2.9 180 ± 30 Oil Fill Plug 14.5 ± 3.6 19.6 ± 4.4 200 ± 50 Hose Fitting 1”- 14 26.7 ± 2.9 36.3 ± 3.9 370 ±...

  • Page 70: Clutch Removal

    Compressor Maintenance Clutch Removal and Replacement Shaft Nut Shaft Key Bearing Dust Cover (Optional) Dust Cover Screws (Optional) Pulley 10. Snap Ring Dust Cover (Option) Field Coil Lead Wire Clamp Armature Plate Armature Shims Coil Snap Ring Figure 54: Clutch Components – Wobble Type Compressor Clutch Removal Armature Nut Removal –...
  • Page 71 Compressor Maintenance Armature Nut Removal – Swash Armature Removal – Swash Type Compressor Remove armature plate assembly by screwing a 1. Use a screw driver to support rubber dampers 10 mm bolt into the armature plate. Tightening the and prevent armature rotation. bolt will move the armature off of the shaft.

  • Page 72: Clutch Replacement

    Compressor Maintenance Clutch Pulley Removal 2. Remove field coil snap ring. 1. Remove pulley snap ring. 3. Remove the field coil assembly. 2. Insert the lip of the jaws into the snap ring groove. 3. Place rotor pulley shaft protector (Puller set) over the exposed shaft.
  • Page 73 Compressor Maintenance Armature Plate Installation 3. Place the installer against the pulley/bearing and drive over the compressor nose with a 1. Install clutch shims. hammer or arbor press until bearing is seated against front housing. 2. Shim selection determines clutch air gap. When installing a clutch on a used compressor, try the original shims first.
  • Page 74 Compressor Maintenance Spline Shaft – Swash Compressor Tighten Armature Retaining Nut 1. Insert armature nut into hub and hold in place 1. Replace TK 5H and TK 7H retaining nut and with fore finger. torque to specification. 1/2-20: 20-25 ft-lb (27-34 N•m, 270-350 kg-cm) M8: 11-15 ft-lb (15-21 N•m).

  • Page 75: Pressure Release Valve (Prv) Replacement

    Compressor Maintenance Air Gap Set 1. Check air gap with feeler gauge. Specification is 0.016 - 0.031 in. (0.4 - 0.8 mm). If gap is not even around the clutch, gently tap down at the high spots. 2. If the overall gap is out of spec., remove the armature assembly and change the shims as necessary.
  • Page 76 Compressor Maintenance Direct Drive Compressor Selection Guide Selecting the correct compressor is vital to providing your customer with the most capacity and highest quality product. Step 1 Identify what unit model has been Unit Model Standard Recommended Compressor selected for the vehicle. V-200 (MAX) TK 13 Consult the Thermo King Unit Selection...
  • Page 77 Compressor Maintenance Step 3 Identify the Clutch Pulley Assembly that will be used with the unit. Figure 75: Double A Groove Figure 76: Poly V Groove Figure 77: Variable Groove Clutch Pulley Diameter: Clutch Pulley Diameter: Clutch Pulley Diameter: 5.31 in. (135 mm) 4.69 in.
  • Page 78 Compressor Maintenance Step 5 Check compressor dimensions from the V-Series Compressor Chart below; verify the fit of the compressor in the vehicle. Figure 78: Tab Mount Assembly Figure 79: Direct Mount Assembly Step 6 Find the compressor product number by using the chart that corresponds with your selected Mount Kit and your compressor, as determined above.
  • Page 79 Compressor Maintenance POLY V GROOVE Manufacturing Aftermarket Model Dimensions Product Number Product Number TK 13 A: 3.28 in. (83.3 mm) 702828 102-1017 Tab Mount B: 4.41 in. (112 mm) Displacement: 8.0 cid (131 cc) C: 9.14 in. (232.2 mm) D: 4.72 in. (120 mm) TK 15 A: 3.28 in.

  • Page 80: Belt Tensions

    Compressor Maintenance Belt Tensions Engine Driven Compressor Belt and Pulleys Correct pulley alignment and proper belt tension are very important factors in compressor installation. The compressor clutch must be perfectly aligned with the engine pulley and any auxiliary idler or belt adjustment pulley components.

  • Page 81: Structural Maintenance

    Structural Maintenance Maintenance Inspection Schedule Semi- Procedures Weekly Monthly Annual Annually Visually inspect unit and refrigerant hoses for fluid leaks. • • • • Visually inspect unit for damaged, loose or broken parts. • • • • Clean defrost drains. •...

  • Page 82: Over-The-Road Mechanical Diagnosis

    Over-the-Road Mechanical Diagnosis Air is not condensable. Its presence Air In System: If desired box temperature cannot be obtained in the system increases head pressure. When the during engine driven compressor operation, any compressor is stopped, air will gather at the high of the following may be indicated: point of the high side.

  • Page 83: 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 by operating manually. Replace relay if defective Fuses blown Replace fuses Open circuit in motor winding...
  • Page 84 Electric Standby Mechanical Diagnosis Condition Possible Cause Remedy Unit operates long or Shortage of refrigerant Repair leak and recharge continuously Discharge valve leaking Replace leak ECM faulty Repair or replace Dirty condenser Clean condenser Air in system Evacuate and recharge system Compressor inefficient Replace compressor Plugged expansion valve...
  • Page 85 Electric Standby Mechanical Diagnosis Condition Possible Cause Remedy Head pressure too low Refrigerant shortage Repair leak and recharge Compressor suction or discharge Replace valve valve inefficient Noisy unit Insufficient compressor oil Add oil to proper level Mounting bolts loose Tighten Refrigerant flooding back Adjust oil level or refrigerant charge.

  • Page 86: Electric Standby Service Checks

    Electric Standby Mechanical Diagnosis Electric Standby Service Checks 1.Compressor does not run. a.Check for power at source. b.Check for power at plug. c.Check for power at compressor contactor. d.Check for power at overload terminals (contactor closed). e.Check for power at motor terminals. 2.Power at compressor terminals but motor does not a.Replace compressor.

  • Page 87: Refrigeration Diagnosis Chart

    Refrigeration Diagnosis Chart POSSIBLE CAUSES • • Overcharge of refrigerant • • • • • • • Shortage of refrigerant • • • • • • • • No refrigerant • Air through condenser too hot (ambient) • Air flow through condenser restricted (dirty) •...

  • Page 88: Index

    Index evaporator fan motors 41 removal and installation 41 about this manual 5 expansion valve assembly 55 after start inspection 37 alarm code descriptions 36 alarms 35 heat mode 28 high pressure transducer 50 belt tensions 78 initiating the manual defrost cycle 34 Checking the Software Revision 34 Cleanup Procedure for Small Truck Units 46 clearing alarm codes 36...
  • Page 89 Index refrigeration system checking charge 45 cleanup procedure for small truck units 46 evacuating and charging 43 refrigeration system checks 46 replacing refrigerant hoses 59 roadside, definition 6 roadside/curbside terminology, explained 6 Safety Precautions 11 safety precautions battery installation and cable routing 14 Safety, Auto Start/Stop 11 Safety, Electrical Hazards 12 Safety, High Voltage 13...

  • Page 90: Wiring, Schematic, And Refrigeration Diagrams Index

    Wiring, Schematic, and Refrigeration Diagrams Index Dwg No. Drawing Title Page 2E54899 V-520 10/30, V-520 MAX 10/30 Wiring Diagram 89-90 2E54898 V-520 10/30, V-520 MAX 10/30 Schematic Diagram 91-92 2E54901 V-520 20/50 1PH, V-520 MAX 20/50 1PH Wiring Diagram 93-95 2E54900 V-520 20/50 1PH, V-520 MAX 20/50 1PH Schematic Diagram 96-98...
  • Page 91 V-520 10/30, V-520 MAX 10/30 Wiring Diagram, page 1 of 2 RELEASED 26/Mar/2014 Thermo King...
  • Page 92 V-520 10/30, V-520 MAX 10/30 Wiring Diagram, page 2 of 2 RELEASED 26/Mar/2014...
  • Page 93 V-520 10/30, V-520 MAX 10/30 Schematic Diagram, page 1 of 2 RELEASED 26/Mar/2014 Thermo King...
  • Page 94 V-520 10/30, V-520 MAX 10/30 Schematic Diagram, page 2 of 2 RELEASED 26/Mar/2014 Thermo King...
  • Page 95 V-520 20/50 1PH, V-520 MAX 20/50 1PH Wiring Diagram, page 1 of 3 RELEASED 26/Mar/2014 Thermo King...
  • Page 96 V-520 20/50 1PH, V-520 MAX 20/50 1PH Wiring Diagram, page 2 of 3 RELEASED 26/Mar/2014...
  • Page 97 V-520 20/50 1PH, V-520 MAX 20/50 1PH Wiring Diagram, page 3 of 3 RELEASED 26/Mar/2014 Thermo King...
  • Page 98 V-520 20/50 1PH, V-520 MAX 20/50 1PH Schematic Diagram, page 1 of 3...
  • Page 99 V-520 20/50 1PH, V-520 MAX 20/50 1PH Schematic Diagram, page 2 of 3...
  • Page 100 V-520 20/50 1PH, V-520 MAX 20/50 1PH Schematic Diagram, page 3 of 3...
  • Page 101 V-520 20/50 3PH, V-520 MAX 20/50 3PH Wiring Diagram, page 1 of 3 RELEASED 26/Mar/2014 Thermo King...
  • Page 102 V-520 20/50 3PH, V-520 MAX 20/50 3PH Wiring Diagram, page 2 of 3 RELEASED 26/Mar/2014...
  • Page 103 V-520 20/50 3PH, V-520 MAX 20/50 3PH Wiring Diagram, page 3 of 3 RELEASED 26/Mar/2014 Thermo King...
  • Page 104 V-520 20/50 3PH, V-520 MAX 20/50 3PH Schematic Diagram, page 1 of 3...
  • Page 105 V-520 20/50 3PH, V-520 MAX 20/50 3PH Schematic Diagram, page 2 of 3...
  • Page 106 V-520 20/50 3PH, V-520 MAX 20/50 3PH Schematic Diagram, page 3 of 3...
  • Page 107 V-520 MAX 10 SPECTRUM Wiring Diagram...
  • Page 108 V-520 MAX 10 SPECTRUM Schematic Diagram, page 1 of 2...
  • Page 109 V-520 MAX 10 SPECTRUM Schematic Diagram, page 2 of 2...
  • Page 110 V-520 MAX 20 SPECTRUM 1PH Wiring Diagram, page 1 of 3...
  • Page 111 V-520 MAX 20 SPECTRUM 1PH Wiring Diagram, page 2 of 3...
  • Page 112 V-520 MAX 20 SPECTRUM 1PH Wiring Diagram, page 3 of 3...
  • Page 113 V-520 MAX 20 SPECTRUM 1PH Schematic Diagram, page 1 of 3...
  • Page 114 V-520 MAX 20 SPECTRUM 1PH Schematic Diagram, page 2 of 3...
  • Page 115 V-520 MAX 20 SPECTRUM 1PH Schematic Diagram, page 3 of 3...
  • Page 116 V-520 MAX 20 SPECTRUM 3PH Wiring Diagram, page 1 of 3...
  • Page 117 V-520 MAX 20 SPECTRUM 3PH Wiring Diagram, page 2 of 3...
  • Page 118 V-520 MAX 20 SPECTRUM 3PH Wiring Diagram, page 3 of 3...
  • Page 119 V-520 MAX 20 SPECTRUM 3PH Schematic Diagram, page 1 of 3...
  • Page 120 V-520 MAX 20 SPECTRUM 3PH Schematic Diagram, page 2 of 3...
  • Page 121 V-520 MAX 20 SPECTRUM 3PH Schematic Diagram, page 3 of 3...
  • Page 122 V-520 MAX 20 SPECTRUM 3PH, 50/60 Hz Wiring Diagram, page 1 of 2...
  • Page 123 V-520 MAX 20 SPECTRUM 3PH, 50/60 Hz Wiring Diagram, page 2 of 2...
  • Page 124 V-520 MAX 50 SPECTRUM 1PH Wiring Diagram, page 1 of 2 RELEASED 26/Mar/2014 Thermo King...
  • Page 125 V-520 MAX 50 SPECTRUM 1PH Wiring Diagram, page 2 of 2 RELEASED 26/Mar/2014 Thermo King...
  • Page 126 V-520 MAX 50 SPECTRUM 1PH Schematic Diagram, page 1 of 3...
  • Page 127 V-520 MAX 50 SPECTRUM 1PH Schematic Diagram, page 2 of 3...
  • Page 128 V-520 MAX 50 SPECTRUM 1PH Schematic Diagram, page 3 of 3...
  • Page 129 V-520 MAX 50 SPECTRUM 3PH Wiring Diagram, page 1 of 2 RELEASED 26/Mar/2014 Thermo King...
  • Page 130 V-520 MAX 50 SPECTRUM 3PH Wiring Diagram, page 2 of 2 RELEASED 26/Mar/2014 Thermo King...
  • Page 131 V-520 MAX 50 SPECTRUM 3PH Schematic Diagram, page 1 of 3...
  • Page 132 V-520 MAX 50 SPECTRUM 3PH Schematic Diagram, page 2 of 3...
  • Page 133 V-520 MAX 50 SPECTRUM 3PH Schematic Diagram, page 3 of 3...
  • Page 134 V-520 10 Refrigeration Diagram...
  • Page 135 V-520 20 Refrigeration Diagram...
  • Page 136 V-520 30 Refrigeration Diagram...
  • Page 137 V-520 50 Refrigeration Diagram...
  • Page 138 V-520 10 SPECTRUM Refrigeration Diagram...
  • Page 139 V-520 20 SPECTRUM Refrigeration Diagram...
  • Page 140 V-520 50 SPECTRUM Refrigeration Diagram RELEASED 19/Jul/2012 Thermo King...
  • Page 142 Ingersoll Rand’s Climate Solutions sector delivers energy-effi cient HVACR solutions for customers globally. Its world class brands include Thermo King, the leader in transport temperature control and Trane, a provider of energy effi cient heating, ventilating and air conditioning systems, building and contracting services, parts support and advanced controls for commercial buildings and homes.

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