Related Manuals for Ingersoll-Rand THERMO KING NAD Truck Edition V-200 Series
Summary of Contents for Ingersoll-Rand THERMO KING NAD Truck Edition V-200 Series
- Page 1 Installation Manual NAD Truck Edition V-200 and V-300 Series TK 51856-1-IM (Rev. 7, 02/12)
- Page 2 Installation Manual NAD Truck Edition V-200 and V-300 Series TK 51856-1-IM (Rev. 7, 02/12) © Copyright 2003 Thermo King Corp., Minneapolis, MN, U.S.A.
- Page 3 V-200 and V-300 Installation Manual Release History Released 04/03 Rev. 0 05/03 Rev. 1 06/03 Page 38: changed electrical hose to electrical harness. Rev. 2 10/03 Pages 76-83: replaced text and art, changed heater option information at rear of manual. Rev.
- Page 4 Introduction This installation manual was written to help assist with the installation of Thermo King V-200 and V-300 Series refrigeration units with remote evaporators onto either a truck or a van designed and built for refrigerated applications. Due to its complexity, do not attempt this installation unless you: •...
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Page 5: Table Of Contents
Table of Contents Safety Precautions ..........5 Installation of Hoses to the Condenser Unit . -
Page 6: Safety Precautions
Safety Precautions Caution Thermo King V-200 and V-300 Condensing units are shipped with a 35-69 kPa (5-10 psi) holding charge of nitrogen. This holding charge may be safely vented into the atmosphere. IMPORTANT: Do not release the holding charge until necessary to prevent moisture from entering the system. - Page 7 Safety Precautions WARNING: Always wear goggles or safety glasses. Refrigerant symbol appears next to a point that is particularly important: liquid, refrigeration oil, and battery acid can permanently damage the eyes (see First Aid under Refrigeration Oil). CAUTION: Addresses a circumstance that, if encountered, may cause damage to equipment or minor injury.
- Page 8 Safety Precautions Battery Cable Routing Refrigerant WARNING: Although fluorocarbon refrigerants are classified as WARNING: Improperly installed battery cables could result in safe refrigerants, certain precautions must be observed when fire or explosion! Battery cables must be installed, routed and handling them or servicing a unit in which they are used. When secured properly to prevent them from rubbing, chaffing or released to the atmosphere in the liquid state, fluorocarbon making contact with hot, sharp or rotating components.
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Page 9: Tips For A Successful Installation
Tips for a Successful Installation • Read the Installation Manual to understand how and where components • Verify the rear of the evaporator is installed a minimum distance of are to be located and installed. 101.1mm (4.00 in.) from the wall to allow for refrigerant hose connections. - Page 10 Tips for a Successful Installation • Always keep electrical harness and refrigeration hoses from rubbing or • Electrical power to the In-Cab controller must be connected to a fused chafing against sharp metal objects and near or rotating components. circuit of the vehicle to provide power only when the ignition switch is in the ON position.
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Page 11: Required Tools
Required Tools 1. Drill 20. Hose Cutting Tool (204-677) 2. Drill Bits (1/8 and 31/64) 21. Wire Strippers 3. Hole Saws (3.00 in.) 22. Wire Cutters 4. Protective Eye Wear 23. Hand Saw 5. Adhesive Tape 24. Electrical Terminal Crimpers 6. - Page 12 Required Tools...
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Page 13: Unpacking And Inspecting Components
Unpacking and Inspecting Components Unpacking the Components 2. Remove the cover from the Condenser and inspect for the following: • The condenser is charged with helium gas. 1. Carefully open the packaging and remove the components. • Defrost is set to 4 hours. 2. - Page 14 Unpacking and Inspecting Components...
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Page 15: Installation Sequence
Installation Sequence Single Compartment Units The operations indicated in this manual should be carried out by a mechanic in the exact sequence in which they are presented in the manual. In order to speed up the installation, two mechanics can work together. In this case, the installation can be completed in less than eight hours (one working day). - Page 16 Installation Sequence...
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Page 17: Installation Of The Engine Driven Compressor
Installation of the Engine Driven Compressor CAUTION: Always disconnect the vehicle’s negative (-) battery cable to prevent damage to equipment or personal injury during the installation of this product. IMPORTANT: DO NOT remove the caps on the Suction and Discharge fittings on the compressor. - Page 18 Installation of the Engine Driven Compressor...
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Page 19: Installation Of The Roof Mounted Condenser Unit
Installation of the Roof Mounted Condenser Unit IMPORTANT: Verify the roof of the vehicle can support the weight of the 5. Apply caulking around all mounting holes. condenser unit. Additional supports (installer supplied) may be required. 6. Position the large rubber mounts over each mounting hole and place the IMPORTANT: Before drilling any mounting holes, verify there is no condenser onto the roof. - Page 20 Installation of the Roof Mounted Condenser Unit...
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Page 21: Installation Of The Nose Mounted Condenser Unit
Installation of the Nose Mounted Condenser Unit IMPORTANT: Verify the front wall of the vehicle can support the weight 4. Position the condenser template (nose mount version) onto the front of the condenser. Additional supports (installer supplied) may be wall and mark the mounting holes and access holes. required. - Page 22 Installation of the Nose Mounted Condenser Unit...
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Page 23: Installation Of The Evaporator
Installation of the Evaporator ES-200 / ES-200 MAX and ES-300 / ES-300 MAX Applications IMPORTANT: Verify the ceiling of the vehicle can support the weight of 3. Position the template onto the ceiling (aligned with centerline and rear the remote evaporator. Additional supports (installer supplied) may be wall measurements) and mark the mounting locations. - Page 24 Installation of the Evaporator...
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Page 25: Fabricating Refrigeration Hoses
Fabricating Refrigeration Hoses TK 2000 Assembly System Assembly Materials Checklist • Hose Fitting Tool (204-1045 The TK 2000 System is designed for assembly with Multi-refrigeration hose only. • Hose Cutting Tool (204-677) The benefits are virtually endless: • TK 2000 Multi-Refrigerant Hose •... - Page 26 Fabricating Refrigeration Hoses Cut the Hose Slip on Two Clamps 1. Cut the hose to proper length with an appropriate cutting tool. 2. Install two proper- size clips onto the cut end of the hose. Orientation of Hand-held hose cutter (204-677) has been specially designed for the clips does not affect the performance of the connection.
- Page 27 Fabricating Refrigeration Hoses Oil the Nipple 4. Insert the nipple into the hose. To ensure that the nipple is fully inserted, check the gap between the cut end of the hose and the 3. Lubricate the nipple with a generous amount of the refrigeration or A/C shoulder on the nipple.
- Page 28 Fabricating Refrigeration Hoses Snap on the Cage. Slide the Clips 5. Snap the cage into the groove on the nipple. The arms should extend 6. Slide the clips over the cage arms and into the channels on each arm. over the hose length. When the cage has been carefully installed in the cage grove, the cage will be able to rotate in the grove.
- Page 29 Fabricating Refrigeration Hoses Correct Nose of the pliers should be firmly seated under the assembly bump and lock latch. Incorrect If the pliers are not kept square during closing the clip, the clasp may have an offset. Use the piers to correct the clasp alignment.
- Page 30 Fabricating Refrigeration Hoses CAUTION: TK 2000 Speedy Clip System components should not be reused. Failure to follow these instructions and/or the use of TK 2000 Speedy Clip System hose with fittings supplied by other manufactures could result in sudden or unintended escape of refrigerant gases.
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Page 31: Installation Of Hoses To The Vehicle's Compressor
Installation of Hoses to the Vehicle’s Compressor IMPORTANT: Refrigerant hoses should not be stretched tight. Always 1. Fabricate suction and discharge refrigeration hoses. allow excess hose at compressor for engine movement. 2. Lubricate the compressor refrigeration fittings with refrigerant oil. Pour IMPORTANT: Secure all refrigerant hoses adequately to the truck frame the remaining refrigerant oil into the suction hose. - Page 32 Installation of Hoses to the Vehicle’s Compressor...
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Page 33: Installation Of The Jet Cool System
Installation of the Jet Cool System MAX Units Only 1. Remove the Schrader valve from the suction service port. Mount the double nut, tee and orifice on the suction service port. 2. Route and mount the liquid injection hose from the injection solenoid valve down to the liquid orifice located on the compressor. - Page 34 Installation of the Jet Cool System...
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Page 35: Installation Of Hoses To The Condenser Unit
Installation of Hoses to the Condenser Unit NOTE: It is important to minimize the amount of time refrigeration systems and components are uncapped and open to ambient conditions. Always keep systems and components capped until ready to install. 1. Remove the filter-drier from the condenser. 2. - Page 36 Installation of Hoses to the Condenser Unit Without Electric Standby With Electric Standby...
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Page 37: Installation Of Hoses To The Evaporator
Installation of Hoses to the Evaporator ES-200 / ES-200 MAX Evaporators 1. Remove the rubber plugs or plastic caps from all the tubes. NOTE: Do not remove the metal plugs on a 10 Model unit. 2. Install the orifice screen into the expansion valve. 3. - Page 38 Installation of Hoses to the Evaporator...
- Page 39 Installation of Hoses to the Evaporator ES-300 / ES-300 MAX Evaporators 1. Remove the rubber plugs or plastic caps from all the tubes. NOTE: Do not remove the metal plugs on a 10 Model unit. 2. Install the orifice screen into the expansion valve. 3.
- Page 40 Installation of Hoses to the Evaporator...
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Page 41: System Leak Check And Evacuation
System Leak Check and Evacuation IMPORTANT: Thermo King Evacuation Station P/N 204-725 and 5. Start the vacuum pump and maintain suction until it reaches 500 Evacuation Station Operation and Field Application Instructions microns. (TK-40612) is required. 6. Once it reaches 500 microns, leave suction running for one hour. NOTE: The oil in the evacuation station vacuum pump should be 7. - Page 42 System Leak Check and Evacuation...
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Page 43: Electrical Connections To The Evaporator
Electrical Connections to the Evaporator ES-200 / ES-200 MAX / ES-300 / ES-300 MAX Evaporators 1. Pass the electrical hose and the return temperature sensor through as far as the evaporator. 2. Connect the low pressure cutout, the defrost temperature thermostat and the temperature sensor. - Page 44 Electrical Connections to the Evaporator...
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Page 45: Installation Of The Drain Hoses
Installation of the Drain Hoses ES-200 / ES-200 MAX / ES-300 / ES-300 MAX 1. Cut the drain hose into three sections of suitable length. 2. Join the three sections of hose using the Y connector. 3. ES-200 MAX / ES-300 MAX ONLY: Insert the defrost heater wire through each drainage hose, along its entire length. - Page 46 Installation of the Drain Hoses...
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Page 47: Installation Of The In-Cab Controller
Installation of the In-Cab Controller 1. Install the in-cab control mounting bracket. Find a location that is accessible and visible from the driver's position and that does not hinder the driver's mobility, visibility or access to the vehicle instruments and levers. 2. - Page 48 Installation of the In-Cab Controller...
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Page 49: Installation Of The Electric Standby Power Supply (Option)
Installation of the Electric Standby Power Supply (OPTION) Units with Electric Standby Option DANGER: Electrical cord must not be connected to an electrical power source during installation. The standby receptacle and power cable should be installed securely to the exterior of the vehicle. The location chosen should be easily accessible while not interfering with the driver’s visibility or operation of the vehicle. - Page 50 Installation of the Electric Standby Power Supply (OPTION)
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Page 51: Electrical Connections To The Battery
Electrical Connections to the Battery 1. Route the electrical wires (CH, 2 and 2) to the battery. 2. Cut the wires to the required length using the recommended tools. NOTE: Do not roll up the excess electrical wire. 3. Strip the wires and attach connectors using recommended tools. 4. - Page 52 Electrical Connections to the Battery...
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Page 53: System Charging
System Charging IMPORTANT: The V-200 condenser fan assembly and ES remote 9. Set the unit thermostat at 0C/32F (see operators manual). evaporator cover with fans must be installed prior to operating the system 10. Run the unit until it reaches a temperature lose to that indicated, and a during the charging procedures. -
Page 54: Checking The Installation
Checking the Installation • All mounting holes and access holes should be sealed with silicone or • Hoses should not be allowed to rub against moving parts, sharp parts, foam. or parts that can reach high temperatures. • Check with a sheet of paper that the fans blow in the right direction. •... -
Page 55: Installing The Heater (Option)
Installing the Heater (OPTION) Installing the Heater Assembly 4. Reinstall the temperature sensor to the OUTSIDE of the heater CAUTION: Before servicing the unit, disconnect the vehicle’s housing, over the oval hole, using the clamp and mounting hardware negative (-) battery cable and standby AC electrical power source removed in step #3. - Page 56 Installing the Heater (OPTION)
- Page 57 Installing the Heater (OPTION) Installing the Water Pump and Coolant Lines 3. Route the coolant hose from OUTLET of the water pump to the CAUTION: Before servicing the unit, disconnect the vehicle’s INLET of the heater assembly. negative (-) battery cable and standby AC electrical power source 4.
- Page 58 Installing the Heater (OPTION)
- Page 59 Installing the Heater (OPTION) Installing the Electrical Components for Hot Water Heat Only 7. Locate the 3-pin connector with jumper (Labeled S1) on the circuit CAUTION: Before servicing the unit, disconnect the vehicle’s board. Note: The S1 connector is easily located using the orange dial negative (-) battery cable and standby AC electrical power source on the circuit board as reference.
- Page 60 Installing the Heater (OPTION)
- Page 61 Installing the Heater (OPTION) Installing the Electrical Components for Hot Water Heat with Electric Heater Elements 1. Connect wire (L1-01) to the fuse connector. CAUTION: Before servicing the unit, disconnect the vehicle’s 2. Connect wire (H2-01) across from wire H2 on the transformers negative (-) battery cable and standby AC electrical power source terminal strip connector.
- Page 62 Installing the Heater (OPTION)
- Page 64 Our product brands include Thermo King®, a world leader in transport temperature control systems, and Hussmann®, a manufacturer of refrigeration and food merchandising equipment. www.thermoking.com www.hussmann.com www.ingersollrand.com ©2008 Ingersoll-Rand Company Printed in U.S.A. on Recycled Paper...
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