Thermo King V-520 Maintenance Manual
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Thermo King V-520 Maintenance Manual

Thermo King V-520 Maintenance Manual

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Maintenance Manual
Truck Edition
V-520, V-520 MAX, V-520 SPECTRUM
Revision C
T T K K 5 5 4 4 3 3 4 4 3 3 - - 1 1 8 8 - - M M M M - - E E N N
March 2023

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  • Page 1 Maintenance Manual Truck Edition V-520, V-520 MAX, V-520 SPECTRUM Revision C T T K K 5 5 4 4 3 3 4 4 3 3 - - 1 1 8 8 - - M M M M - - E E N N...
  • Page 2 This manual is published for informational purposes only. Thermo King® makes no representations warranties express or implied, with respect to the information recommendations and descriptions contained herein. Information provided should not be regarded as all-inclusive or covering all contingencies. If further information is required, Thermo King Service Department should be consulted.
  • Page 3 Regulations must be observed when working on refrigeration systems. At Thermo King®, we recognize the need to preserve the environment and limit the potential harm to the ozone layer that can result from allowing refrigerant to escape into the atmosphere.
  • Page 4 Wiring, Schematic and Refrigeration diagrams applicable to the unit. Before you Call Thermo King Service! Who to call: Your Thermo King Service Representative. Before you call Thermo King Service, have the following information on hand: • Bill of Material (usually located on the unit serial plate) •...
  • Page 5 Using the Model Systems Tables in “Model Systems (System Designations)” The Model Systems Tables in this section list important unit information that you will need to communicate with the Thermo King Service Department. Customer Satisfaction Survey Let your voice be heard! Your feedback will help improve our manuals.

  • Page 6: Table Of Contents

    Table of Contents S S a a f f e e t t y y P P r r e e c c a a u u t t i i o o n n s s ................................1 1 2 2 Danger, Warning, Caution, and Notice .
  • Page 7 T T a a b b l l e e o o f f C C o o n n t t e e n n t t s s Oil Separator ................. . 28 Refrigerant .
  • Page 8 T T a a b b l l e e o o f f C C o o n n t t e e n n t t s s Testing Liquid Injection Solenoid Valve and Metering Orifice ........62 Testing Liquid Injection Switch (LISW) .
  • Page 9 T T a a b b l l e e o o f f C C o o n n t t e e n n t t s s Evacuating and Charging the Refrigeration System ..........80 Checking the Refrigerant Charge .
  • Page 10 T T a a b b l l e e o o f f C C o o n n t t e e n n t t s s Installation ................95 Liquid Line Check Valve (Model 30 and 50 Single Temp Only) .
  • Page 11 T T a a b b l l e e o o f f C C o o n n t t e e n n t t s s Compressor Failures ................106 Compressor Test .

  • Page 12: Danger, Warning, Caution, And Notice

    Safety Precautions Danger, Warning, Caution, and Notice Thermo King® recommends that all service be performed by a Thermo King dealer and to be aware of several general safety practices. Safety advisories appear throughout this manual as required. Your personal safety and the proper operation of this unit depend upon the strict observance of these precautions.
  • Page 13 S S a a f f e e t t y y P P r r e e c c a a u u t t i i o o n n s s D D A A N N G G E E R R R R e e f f r r i i g g e e r r a a n n t t V V a a p p o o r r H H a a z z a a r r d d ! ! D D o o n n o o t t i i n n h h a a l l e e r r e e f f r r i i g g e e r r a a n n t t .

  • Page 14: Personal Protective Equipment (Ppe)

    S S a a f f e e t t y y P P r r e e c c a a u u t t i i o o n n s s Personal Protective Equipment (PPE) W W A A R R N N I I N N G G P P e e r r s s o o n n a a l l P P r r o o t t e e c c t t i i v v e e E E q q u u i i p p m m e e n n t t ( ( P P P P E E ) ) ! ! F F a a i i l l u u r r e e t t o o w w e e a a r r p p r r o o p p e e r r P P P P E E f f o o r r t t h h e e j j o o b b b b e e i i n n g g u u n n d d e e r r t t a a k k e e n n c c o o u u l l d d r r e e s s u u l l t t i i n n d d e e a a t t h h o o r r s s e e r r i i o o u u s s i i n n j j u u r r y y .

  • Page 15: Refrigerant Hazards

    S S a a f f e e t t y y P P r r e e c c a a u u t t i i o o n n s s W W A A R R N N I I N N G G P P e e r r s s o o n n a a l l P P r r o o t t e e c c t t i i v v e e E E q q u u i i p p m m e e n n t t ( ( P P P P E E ) ) R R e e q q u u i i r r e e d d ! ! A A b b a a t t t t e e r r y y c c a a n n b b e e d d a a n n g g e e r r o o u u s s .

  • Page 16: Refrigerant Oil Hazards

    S S a a f f e e t t y y P P r r e e c c a a u u t t i i o o n n s s N N O O T T I I C C E E E E q q u u i i p p m m e e n n t t D D a a m m a a g g e e ! ! W W h h e e n n b b e e i i n n g g t t r r a a n n s s f f e e r r r r e e d d , , r r e e f f r r i i g g e e r r a a n n t t m m u u s s t t b b e e i i n n l l i i q q u u i i d d s s t t a a t t e e t t o o a a v v o o i i d d p p o o s s s s i i b b l l e e e e q q u u i i p p m m e e n n t t d d a a m m a a g g e e .
  • Page 17 S S a a f f e e t t y y P P r r e e c c a a u u t t i i o o n n s s W W A A R R N N I I N N G G H H a a z z a a r r d d o o u u s s V V o o l l t t a a g g e e ! ! T T h h e e u u n n i i t t O O n n / / O O f f f f s s w w i i t t c c h h m m u u s s t t b b e e t t u u r r n n e e d d O O f f f f b b e e f f o o r r e e c c o o n n n n e e c c t t i i n n g g o o r r d d i i s s c c o o n n n n e e c c t t i i n n g g t t h h e e s s t t a a n n d d b b y y p p o o w w e e r r p p l l u u g g .

  • Page 18: Low Voltage

    S S a a f f e e t t y y P P r r e e c c a a u u t t i i o o n n s s Low Voltage W W A A R R N N I I N N G G L L i i v v e e E E l l e e c c t t r r i i c c a a l l C C o o m m p p o o n n e e n n t t s s ! ! C C o o n n t t r r o o l l c c i i r r c c u u i i t t s s u u s s e e d d i i n n r r e e f f r r i i g g e e r r a a t t i i o o n n u u n n i i t t s s a a r r e e l l o o w w v v o o l l t t a a g g e e ( ( 1 1 2 2 t t o o 4 4 8 8 V V d d c c ) ) .
  • Page 19 S S a a f f e e t t y y P P r r e e c c a a u u t t i i o o n n s s • S S k k i i n n : : Flush area with large amounts of warm water. Do not apply heat. Remove contaminated clothing and shoes. Wrap burns with dry, sterile, bulky dressing to protect from infection.
  • Page 20 MAX and SPECTRUM units built on and after December 12, 2022 are equipped with R-452A refrigerant. See Service Bulletin SB874 Transition to R–452A Refrigerant for Vehicle-Powered (VP) Truck Units in North America V-520 Truck Refrigeration Systems System System Number Install Kit...

  • Page 21: Electrical System

    Specifications Electrical System Fuses Fuse 1: Power Supply Circuit to PCB1 5 amps Fuse 2: Condenser Fan Motor 1 (M1 Model 10 and 30, M2 Model 20, 50, and 50 15 amps Spectrum, CFM1 Model 10 and 20 Spectrum) 15 amps Fuse 3: Evaporator Fan Motor 1 (M3 Model 10 and 30, M4 Model 20, 50, and 50 Spectrum, EFM1 Model 10 and 20 Spectrum) Fuse 4: Evaporator Fan Motor 2 (M4 Model 10 and 30, M5 Model 20, 50, and 50...
  • Page 22 S S p p e e c c i i f f i i c c a a t t i i o o n n s s Evaporator Fan Motors (Each) Full Load Current 5.7- 6.2 amps at 13 Vdc Resistance 2.0 ohms Coils for Hot Gas, Liquid Line, Condenser Inlet, and CPR Bypass Solenoids...

  • Page 23: Refrigeration System

    Refrigerant Charge: V-520 MAX - Model 10 (before December 12, 2022) 4.9 lb (2.22 kg) R-404A V-520 MAX - Model 10 (on or after December 12, 2022) 4.9 lb (2.22 kg) R-452A V-520 MAX - Model 20 (before December 12, 2022) 5.2 lb (2.37 kg) R-404A...

  • Page 24: Compressors

    S S p p e e c c i i f f i i c c a a t t i i o o n n s s Compressors Standard Engine Driven Compressor: TK-16, 10 cu. in. (147 cc), Swash Plate, 6 Cylinder Optional Engine Driven Compressor TK-312R, 11.4 cu.

  • Page 25: Contactors

    S S p p e e c c i i f f i i c c a a t t i i o o n n s s Contactors Compressor Motor Contactor (KP1) and Optional Electric Heat Contactor (HC) Contacts Normally Open Coil Voltage 12 Vdc...

  • Page 26: Solder Applications

    S S p p e e c c i i f f i i c c a a t t i i o o n n s s Solder Applications Refrigeration Components 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.

  • Page 27: Introduction

    Unit 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 the truck box or container. The system evaporator is mounted on the cargo compartment ceiling.

  • Page 28: Evaporator

    The DSR Control System is composed of an Electronic Control Module (ECM) located in the control box, and the In-Cab Control Box. This In-Cab Control Box, also called the HMI, allows the truck driver to operate the Thermo King refrigeration unit.

  • Page 29: Refrigerant

    V-520 10, V-520 20, V-520 30, and V-520 50 units use R-134a refrigerant. • V-520 MAX 10, V-520 MAX 20, V-520 MAX 30, V-520 MAX 50, V-520 SPECTRUM 10, V-520 SPECTRUM 20, and V-520 SPECTRUM 50 units use R-404A or R-452A refrigerant.

  • Page 30: Control Box

    U U n n i i t t D D e e s s c c r r i i p p t t i i o o n n Control Box P.C. Boards All Printed Circuit Boards within this unit, supplied by Thermo King can be easily identified by the Part Number stamped on them. Electronic Control Module (ECM) The ECM contains the system’s secondary microprocessors, I/O connectors, output relays, fuses, LEDs, cooling fan, and...

  • Page 31: Unit Operation

    U U n n i i t t D D e e s s c c r r i i p p t t i i o o n n Single Temp Units Component/ Schematic Refrigeration Wiring Diagram Diagram Diagram Liquid Injection S2 - Liq Inj Temp Switch (LISW)

  • Page 32: Operation

    U U n n i i t t D D e e s s c c r r i i p p t t i i o o n n Figure 2. Thermostat Algorithm For units with Electric Standby, there are protective delays for the electric compressor/compressor motor contactor. Options: •...
  • Page 33 U U n n i i t t D D e e s s c c r r i i p p t t i i o o n n C C o o o o l l M M o o d d e e M M o o d d e e l l 1 1 0 0 High pressure refrigerant vapor leaves the compressor and flows through the oil separator where oil is separated and returned to the suction tube.
  • Page 34 U U n n i i t t D D e e s s c c r r i i p p t t i i o o n n C C o o o o l l M M o o d d e e M M o o d d e e l l 2 2 0 0 E E n n g g i i n n e e O O p p e e r r a a t t i i o o n n High pressure refrigerant vapor leaves the engine driven compressor and flows through the discharge check valve and the oil separator where oil is separated and returned to the suction tube.
  • Page 35 U U n n i i t t D D e e s s c c r r i i p p t t i i o o n n C C o o o o l l M M o o d d e e M M o o d d e e l l 2 2 0 0 E E l l e e c c t t r r i i c c S S t t a a n n d d b b y y O O p p e e r r a a t t i i o o n n High pressure refrigerant vapor leaves the electric standby compressor and flows through the oil separator where oil is separated and returned to the suction tube.
  • Page 36 U U n n i i t t D D e e s s c c r r i i p p t t i i o o n n C C o o o o l l M M o o d d e e M M o o d d e e l l 3 3 0 0 High pressure refrigerant vapor leaves the compressor and flows through the oil separator where oil is separated and returned to the suction tube.
  • Page 37 U U n n i i t t D D e e s s c c r r i i p p t t i i o o n n C C o o o o l l M M o o d d e e M M o o d d e e l l 5 5 0 0 E E n n g g i i n n e e O O p p e e r r a a t t i i o o n n High pressure refrigerant vapor leaves the engine driven compressor and flows through the discharge check valve and the oil separator where oil is separated and returned to the suction tube.
  • Page 38 U U n n i i t t D D e e s s c c r r i i p p t t i i o o n n C C o o o o l l M M o o d d e e M M o o d d e e l l 5 5 0 0 E E l l e e c c t t r r i i c c S S t t a a n n d d b b y y O O p p e e r r a a t t i i o o n n High pressure refrigerant vapor leaves the electric standby compressor and flows through the oil separator where oil is separated and returned to the suction tube.
  • Page 39 U U n n i i t t D D e e s s c c r r i i p p t t i i o o n n S S P P E E C C T T R R U U M M M M o o d d e e l l 1 1 0 0 Z Z o o n n e e 1 1 C C o o o o l l , , Z Z o o n n e e 2 2 C C o o o o l l High pressure refrigerant vapor leaves the compressor and flows through the oil separator where oil is separated and returned to the suction tube.
  • Page 40 U U n n i i t t D D e e s s c c r r i i p p t t i i o o n n S S P P E E C C T T R R U U M M M M o o d d e e l l 2 2 0 0 E E n n g g i i n n e e O O p p e e r r a a t t i i o o n n Z Z o o n n e e 1 1 C C o o o o l l , , Z Z o o n n e e 2 2 C C o o o o l l High pressure refrigerant vapor leaves the engine driven compressor and flows through the discharge check valve and the oil separator where oil is separated and returned to the suction tube.
  • Page 41 U U n n i i t t D D e e s s c c r r i i p p t t i i o o n n S S P P E E C C T T R R U U M M M M o o d d e e l l 2 2 0 0 E E l l e e c c t t r r i i c c S S t t a a n n d d b b y y O O p p e e r r a a t t i i o o n n Z Z o o n n e e 1 1 C C o o o o l l , , Z Z o o n n e e 2 2 C C o o o o l l High pressure refrigerant vapor leaves the electric standby compressor and flows through the oil separator where oil is separated and returned to the suction tube.
  • Page 42 U U n n i i t t D D e e s s c c r r i i p p t t i i o o n n The Zone 1 liquid line solenoid is open so some of the refrigerant flows through the Zone 1 expansion valve into the evaporator.
  • Page 43 U U n n i i t t D D e e s s c c r r i i p p t t i i o o n n The Zone 1 liquid line solenoid is open so some of the refrigerant flows through the Zone 1 expansion valve into the evaporator.

  • Page 44: Null Mode - Single Temperature Units

    U U n n i i t t D D e e s s c c r r i i p p t t i i o o n n Null Mode – Single Temperature Units The unit operates in Null mode when the setpoint temperature is reached and cooling (or heating) is not required. All outputs are de-energized.
  • Page 45 U U n n i i t t D D e e s s c c r r i i p p t t i i o o n n H H e e a a t t M M o o d d e e M M o o d d e e l l 3 3 0 0 High pressure refrigerant vapor leaves the compressor and flows through the oil separator where oil is separated and returned to the suction tube.
  • Page 46 U U n n i i t t D D e e s s c c r r i i p p t t i i o o n n H H e e a a t t M M o o d d e e M M o o d d e e l l 5 5 0 0 E E n n g g i i n n e e O O p p e e r r a a t t i i o o n n High pressure refrigerant vapor leaves the engine driven compressor and flows through the discharge check valve and the oil separator where oil is separated and returned to the suction tube.
  • Page 47 U U n n i i t t D D e e s s c c r r i i p p t t i i o o n n H H e e a a t t M M o o d d e e M M o o d d e e l l 5 5 0 0 E E l l e e c c t t r r i i c c S S t t a a n n d d b b y y O O p p e e r r a a t t i i o o n n High pressure refrigerant vapor leaves the electric standby compressor and flows through the oil separator where oil is separated and returned to the suction tube.

  • Page 48: Heat Mode - Model 50 Spectrum Multi-Temp Units Only

    U U n n i i t t D D e e s s c c r r i i p p t t i i o o n n Heat Mode – Model 50 SPECTRUM Multi-Temp Units Only S S P P E E C C T T R R U U M M M M o o d d e e l l 5 5 0 0 E E n n g g i i n n e e O O p p e e r r a a t t i i o o n n Z Z o o n n e e 1 1 C C o o o o l l , , Z Z o o n n e e 2 2 H H e e a a t t High pressure refrigerant vapor leaves the engine driven compressor and flows through the discharge check valve and the oil separator where oil is separated and returned to the suction tube.
  • Page 49 U U n n i i t t D D e e s s c c r r i i p p t t i i o o n n S S P P E E C C T T R R U U M M M M o o d d e e l l 5 5 0 0 E E l l e e c c t t r r i i c c S S t t a a n n d d b b y y O O p p e e r r a a t t i i o o n n Z Z o o n n e e 1 1 N N u u l l l l , , Z Z o o n n e e 2 2 H H e e a a t t High pressure refrigerant vapor leaves the electric standby driven compressor and flows through the discharge check valve and the oil separator where oil is separated and returned to the suction tube.

  • Page 50: Defrost Mode - Single Temperature Units

    U U n n i i t t D D e e s s c c r r i i p p t t i i o o n n Defrost Mode – Single Temperature Units Defrost can be initiated any time the evaporator coil temperature is below 36 F (2.2 C), causing the defrost termination switch to close.
  • Page 51 U U n n i i t t D D e e s s c c r r i i p p t t i i o o n n D D e e f f r r o o s s t t M M o o d d e e M M o o d d e e l l 2 2 0 0 E E n n g g i i n n e e O O p p e e r r a a t t i i o o n n High pressure refrigerant vapor leaves the engine driven compressor and flows through the discharge check valve and the oil separator where oil is separated and returned to a suction line.
  • Page 52 U U n n i i t t D D e e s s c c r r i i p p t t i i o o n n D D e e f f r r o o s s t t M M o o d d e e M M o o d d e e l l 2 2 0 0 E E l l e e c c t t r r i i c c S S t t a a n n d d b b y y O O p p e e r r a a t t i i o o n n High pressure refrigerant vapor leaves the electric standby compressor and flows through the discharge check valve and the oil separator where oil is separated and returned to a suction line.

  • Page 53: Defrost Mode - Spectrum Multi-Temp Units

    U U n n i i t t D D e e s s c c r r i i p p t t i i o o n n Defrost Mode – SPECTRUM Multi-Temp Units Defrost can be initiated in a compartment any time its evaporator coil temperature is below 36 F (2.2 C), causing the defrost termination switch to close.
  • Page 54 U U n n i i t t D D e e s s c c r r i i p p t t i i o o n n S S P P E E C C T T R R U U M M M M o o d d e e l l 2 2 0 0 E E n n g g i i n n e e O O p p e e r r a a t t i i o o n n Z Z o o n n e e 1 1 D D e e l l a a y y e e d d C C o o o o l l , , Z Z o o n n e e 2 2 D D e e f f r r o o s s t t High pressure refrigerant vapor leaves the engine driven compressor and flows through the oil separator where oil is separated and returned to the suction tube.
  • Page 55 U U n n i i t t D D e e s s c c r r i i p p t t i i o o n n S S P P E E C C T T R R U U M M M M o o d d e e l l 2 2 0 0 E E l l e e c c t t r r i i c c S S t t a a n n d d b b y y O O p p e e r r a a t t i i o o n n Z Z o o n n e e 1 1 D D e e f f r r o o s s t t , , Z Z o o n n e e 2 2 D D e e l l a a y y e e d d C C o o o o l l High pressure refrigerant vapor leaves the electric standby compressor and flows through the oil separator where oil is separated and returned to the suction tube.

  • Page 56: Serial Number Locations

    U U n n i i t t D D e e s s c c r r i i p p t t i i o o n n Serial Number Locations 1. C C O O N N D D E E N N S S E E R R : : Nameplate located on the front inside edge of condenser frame (Cover needs to be removed). 2.
  • Page 57 U U n n i i t t D D e e s s c c r r i i p p t t i i o o n n Figure 26. Condenser Electric and Capacitor Boxes (Model 20 and 50) Electronic Control Module Motor Contactor Capacitor Box...
  • Page 58 U U n n i i t t D D e e s s c c r r i i p p t t i i o o n n Figure 28. Evaporator with Hot Water and Electric Heat Options Hot Water Heat Defrost Coil High Temperature Limit Switch Electric Heat Element...

  • Page 59: Electrical

    Maintenance Inspection Schedule N N o o t t e e : : Thermo King reserves the right to deny warranty coverage on claims due to lack of maintenance or neglect. Claims in question must be supported by maintenance records.

  • Page 60: Structural

    Inspect roadside (engine driven) compressor drive belt condition and tension. • Inspect evaporator and condenser mounting hardware. Maintenance Inspection Schedule Checklist Authentication Thermo King Dealership Name and Number Inspector / Technician’s Name Date Inspection Completed Thermo King Unit / Model Unit Serial Number...

  • Page 61: Electronic Control System

    Electrical Maintenance Electronic Control System Refer to the Direct Smart Reefer Microprocessor Control System Diagnostic Manual TK 52573 for complete service information about the Electronic Control System and the related components. Defrost System Defrost is initiated automatically by the programmable defrost timer, or manually by means of the In-Cab Control Box. If demand defrost is enabled, a demand defrost cycle occurs, based on the Defrost Initiation Timer (DIT) and the Defrost Termination Switch (S4/DTS1 or S6/DTS2) being closed.

  • Page 62: Liquid Injection System

    E E l l e e c c t t r r i i c c a a l l M M a a i i n n t t e e n n a a n n c c e e 2.

  • Page 63: Condenser Fan Motor

    E E l l e e c c t t r r i i c c a a l l M M a a i i n n t t e e n n a a n n c c e e 1.

  • Page 64: Evaporator Fan Motor Removal And Installation

    E E l l e e c c t t r r i i c c a a l l M M a a i i n n t t e e n n a a n n c c e e Evaporator Fan Motor Removal and Installation Removal 1.
  • Page 65 E E l l e e c c t t r r i i c c a a l l M M a a i i n n t t e e n n a a n n c c e e Figure 29.

  • Page 66: Fuses

    E E l l e e c c t t r r i i c c a a l l M M a a i i n n t t e e n n a a n n c c e e Fuses C C o o n n t t r r o o l l l l e e r r F F u u s s e e s s : : These fuses are located on the controller.

  • Page 67: Relays

    E E l l e e c c t t r r i i c c a a l l M M a a i i n n t t e e n n a a n n c c e e Figure 31.

  • Page 68: Relay Replacement

    E E l l e e c c t t r r i i c c a a l l M M a a i i n n t t e e n n a a n n c c e e 5.
  • Page 69 E E l l e e c c t t r r i i c c a a l l M M a a i i n n t t e e n n a a n n c c e e Figure 33.
  • Page 70 E E l l e e c c t t r r i i c c a a l l M M a a i i n n t t e e n n a a n n c c e e Figure 34.

  • Page 71: Electrical Contactors

    E E l l e e c c t t r r i i c c a a l l M M a a i i n n t t e e n n a a n n c c e e Figure 35.

  • Page 72: Electric Heat Contactor - Hc (Model 20 Option Only)

    E E l l e e c c t t r r i i c c a a l l M M a a i i n n t t e e n n a a n n c c e e 2.

  • Page 73: Transformer Testing

    E E l l e e c c t t r r i i c c a a l l M M a a i i n n t t e e n n a a n n c c e e Transformer Testing Test the transformer as follows: 1.

  • Page 74: Capacitor Testing

    E E l l e e c c t t r r i i c c a a l l M M a a i i n n t t e e n n a a n n c c e e W W A A R R N N I I N N G G H H a a z z a a r r d d o o u u s s V V o o l l t t a a g g e e w w / / C C a a p p a a c c i i t t o o r r s s ! ! B B e e c c a a r r e e f f u u l l w w h h e e n n w w o o r r k k i i n n g g w w i i t t h h e e l l e e c c t t r r i i c c a a l l c c i i r r c c u u i i t t s s t t h h a a t t c c o o n n t t a a i i n n c c a a p p a a c c i i t t o o r r s s .

  • Page 75: Start Relay Replacement

    E E l l e e c c t t r r i i c c a a l l M M a a i i n n t t e e n n a a n n c c e e 5.

  • Page 76: Electric Standby Circuits

    E E l l e e c c t t r r i i c c a a l l M M a a i i n n t t e e n n a a n n c c e e 7.

  • Page 77: Heat Option - Truck Engine Coolant

    E E l l e e c c t t r r i i c c a a l l M M a a i i n n t t e e n n a a n n c c e e 15.

  • Page 78: Heat Option - Truck Engine Coolant And Electric Standby Heater Strip

    E E l l e e c c t t r r i i c c a a l l M M a a i i n n t t e e n n a a n n c c e e Heat Option –...
  • Page 79 E E l l e e c c t t r r i i c c a a l l M M a a i i n n t t e e n n a a n n c c e e b.

  • Page 80: Evacuating And Charging The Refrigeration System

    Refrigeration Maintenance Evacuating and Charging the Refrigeration System Checking the Refrigerant Charge If the unit has an insufficient charge of refrigerant, the evaporator will be “starved” and the box temperature will rise even though the unit is operating. Also, an insufficient charge does not circulate enough oil to properly lubricate the compressor.

  • Page 81: Suction (Low Side) Bump Charging

    R R e e f f r r i i g g e e r r a a t t i i o o n n M M a a i i n n t t e e n n a a n n c c e e N N o o t t e e : : If no bubbles are present, there is sufficient refrigerant in the unit for that load at that particular box temperature.

  • Page 82: Refrigeration System Checks

    Cleanup Procedure for Small Truck Units N N o o t t e e : : If a Van Steenburgh reclaimer is available, do not use this procedure. Follow procedure described in Service Bulletin T&T 134 or contact your Thermo King Service Representative. Tools Required •...

  • Page 83: Putting The Unit Back Into Operation

    R R e e f f r r i i g g e e r r a a t t i i o o n n M M a a i i n n t t e e n n a a n n c c e e Remove Internal Parts From Expansion Valve Disconnect and Cap (If So Equipped) Replace Drier With Tube...
  • Page 84 R R e e f f r r i i g g e e r r a a t t i i o o n n M M a a i i n n t t e e n n a a n n c c e e 5.
  • Page 85 Refrigeration Service Operations N N o o t t e e : : 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. W W A A R R N N I I N N G G R R i i s s k k o o f f I I n n j j u u r r y y ! ! D D i i s s c c o o n n n n e e c c t t t t h h e e p p o o w w e e r r s s u u p p p p l l y y b b e e f f o o r r e e s s e e r r v v i i c c i i n n g g t t h h e e u u n n i i t t t t o o p p r r e e v v e e n n t t p p e e r r s s o o n n a a l l i i n n j j u u r r y y .

  • Page 86: R R E E F F R R I I G G E E R R A A T T I I O O N N S S E E R R V V I I C C E E O O P P E E R R A A T T I I O O N N S

    R R e e f f r r i i g g e e r r a a t t i i o o n n S S e e r r v v i i c c e e O O p p e e r r a a t t i i o o n n s s Figure 39.
  • Page 87 R R e e f f r r i i g g e e r r a a t t i i o o n n S S e e r r v v i i c c e e O O p p e e r r a a t t i i o o n n s s Figure 40.
  • Page 88 R R e e f f r r i i g g e e r r a a t t i i o o n n S S e e r r v v i i c c e e O O p p e e r r a a t t i i o o n n s s Figure 41.
  • Page 89 R R e e f f r r i i g g e e r r a a t t i i o o n n S S e e r r v v i i c c e e O O p p e e r r a a t t i i o o n n s s Figure 42.
  • Page 90 R R e e f f r r i i g g e e r r a a t t i i o o n n S S e e r r v v i i c c e e O O p p e e r r a a t t i i o o n n s s Figure 43.

  • Page 91: Engine Driven Compressor

    R R e e f f r r i i g g e e r r a a t t i i o o n n S S e e r r v v i i c c e e O O p p e e r r a a t t i i o o n n s s Engine Driven Compressor Removal 1.

  • Page 92: Installation

    R R e e f f r r i i g g e e r r a a t t i i o o n n S S e e r r v v i i c c e e O O p p e e r r a a t t i i o o n n s s 3.

  • Page 93: Liquid Injection Solenoid (Lis) Test

    R R e e f f r r i i g g e e r r a a t t i i o o n n S S e e r r v v i i c c e e O O p p e e r r a a t t i i o o n n s s 4.

  • Page 94: Cpr Bypass Solenoid Test (Spectrum Only)

    R R e e f f r r i i g g e e r r a a t t i i o o n n S S e e r r v v i i c c e e O O p p e e r r a a t t i i o o n n s s 7.

  • Page 95: Removal

    R R e e f f r r i i g g e e r r a a t t i i o o n n S S e e r r v v i i c c e e O O p p e e r r a a t t i i o o n n s s Removal 1.

  • Page 96: Liquid Line Check Valve Replacement

    R R e e f f r r i i g g e e r r a a t t i i o o n n S S e e r r v v i i c c e e O O p p e e r r a a t t i i o o n n s s Liquid Line Check Valve Replacement Removal 1.

  • Page 97: Discharge Check Valve Replacement

    R R e e f f r r i i g g e e r r a a t t i i o o n n S S e e r r v v i i c c e e O O p p e e r r a a t t i i o o n n s s Discharge Check Valve Replacement Removal 1.

  • Page 98: Evaporator Coil

    9. Install the evaporator cover (and fans on SPECTRUM units). 10. Evacuate and recharge the system. Expansion Valve Assembly Refer to Expansion Valve Check/Adjustment in Diagnosing Thermo King Truck and Trailer Refrigeration Systems TK 5984 for information checking and adjusting the expansion valve. Checking Superheat 1.

  • Page 99: Expansion Valve Replacement

    R R e e f f r r i i g g e e r r a a t t i i o o n n S S e e r r v v i i c c e e O O p p e e r r a a t t i i o o n n s s Figure 44.

  • Page 100: Low Pressure Cutout Switch (Lpco)

    R R e e f f r r i i g g e e r r a a t t i i o o n n S S e e r r v v i i c c e e O O p p e e r r a a t t i i o o n n s s 2.

  • Page 101: Low Pressure Cutout Switch Replacement

    R R e e f f r r i i g g e e r r a a t t i i o o n n S S e e r r v v i i c c e e O O p p e e r r a a t t i i o o n n s s 3.

  • Page 102: Compressor Pressure Regulator Valve Test

    R R e e f f r r i i g g e e r r a a t t i i o o n n S S e e r r v v i i c c e e O O p p e e r r a a t t i i o o n n s s Figure 47.

  • Page 103: Compressor Pressure Regulator Valve Replacement

    R R e e f f r r i i g g e e r r a a t t i i o o n n S S e e r r v v i i c c e e O O p p e e r r a a t t i i o o n n s s Compressor Pressure Regulator Valve Replacement Removal 1.

  • Page 104: Compressor Pressure Regulator Valve Setup Procedure

    R R e e f f r r i i g g e e r r a a t t i i o o n n S S e e r r v v i i c c e e O O p p e e r r a a t t i i o o n n s s Compressor Pressure Regulator Valve Setup Procedure The following procedure is used to set the compressor pressure regulator valve when the unit is installed.

  • Page 105: Replacing Refrigerant Hoses (Speedy Clip System)

    R R e e f f r r i i g g e e r r a a t t i i o o n n S S e e r r v v i i c c e e O O p p e e r r a a t t i i o o n n s s Replacing Refrigerant Hoses (Speedy Clip System) Refer to the Vehicle Powered Truck Installation Standards and Procedures Section 6 –...

  • Page 106: Compressor Failures

    Engine Driven Compressor Maintenance Compressor Failures Whenever a compressor fails check the compressor speed to verify it is within our guidelines. If the compressor speed exceeds guidelines, a larger pulley needs to be install on the compressor. See Service Bulletin SB644 and the Vehicle Powered Truck Installation Standards and Procedures Section 5 –...

  • Page 107: Engine Driven Compressor Belt And Pulleys

    E E n n g g i i n n e e D D r r i i v v e e n n C C o o m m p p r r e e s s s s o o r r M M a a i i n n t t e e n n a a n n c c e e I I m m p p o o r r t t a a n n t t : : This test should only be run for a short time.

  • Page 108: Condenser And Evaporator Coils

    Structural Maintenance Condenser and Evaporator Coils Clean the coils during scheduled maintenance inspections. Remove any debris (e.g., leaves or plastic wrap) that reduces the air flow. Clean dirty coils as described in Coil Cleaning Recommendations below. Be careful not to bend the fins when cleaning a coil.

  • Page 109: Unit Mounting Bolts

    S S t t r r u u c c t t u u r r a a l l M M a a i i n n t t e e n n a a n n c c e e In some instances, it may take a combination of two methods to result in a clean coil.
  • Page 110 Over-the-Road Mechanical Diagnosis CONDITION POSSIBLE CAUSE REMEDY Unit turned On—In-Cab Control Box Vehicle ignition switch is not on Turn the vehicle ignition switch on display does not come on Vehicle Ignition Switch Fuse F22 blown Check for short circuits and replace fuse Power Supply Circuit Fuse F1 blown Replace fuse Dead or disconnected vehicle battery...
  • Page 111 Electric Standby Mechanical Diagnosis CONDITION POSSIBLE CAUSE REMEDY Unit turned On—In-Cab Control Box Unit not connected to Standby power or Connect power cord. Verify that the Electric Standby display does not come on Standby power is turned off. power is turned on and is the correct voltage. Transformer Input Fuse F23 blown Check for short circuits and replace fuse Faulty transformer...
  • Page 112 Refrigeration Diagnosis CONDITION POSSIBLE CAUSE REMEDY Unit short cycles Shortage of refrigerant (low pressure Repair leak and recharge cutout) Restricted expansion valve Clean expansion valve Refrigerant overcharge (high discharge Remove excess charge pressure) Cycling on high discharge pressure Check condenser air flow and fan Dirty condenser coil Clean coil Defrost timer set too low for application.
  • Page 113 R R e e f f r r i i g g e e r r a a t t i i o o n n D D i i a a g g n n o o s s i i s s CONDITION POSSIBLE CAUSE REMEDY...
  • Page 114 Refrigeration Diagnosis Chart POSSIBLE CAUSES Overcharge of refrigerant • • • • Shortage of refrigerant • • • • • • • No refrigerant • • • • • • • • Air through condenser too hot (ambient) • Air flow through condenser restricted •...
  • Page 115 R R e e f f r r i i g g e e r r a a t t i i o o n n D D i i a a g g n n o o s s i i s s C C h h a a r r t t POSSIBLE CAUSES Condenser fan motor not operating •...
  • Page 116 Diagram Index The following table lists the diagrams that are relevant to these units. The diagrams are available on TSA Info Central and in the V-520 Series Diagrams Manual TK 56674-18-DM. Drawing No. Drawing Title 2E54898 V-520 10/30, V-520 MAX 10/30 Schematic Diagram...
  • Page 117 N N o o t t e e s s TK 54343-18-MM-EN...
  • Page 118 N N o o t t e e s s TK 54343-18-MM-EN...
  • Page 119 N N o o t t e e s s TK 54343-18-MM-EN...
  • Page 120 1938. For more information, visit www.thermoking.com or www.tranetechnologies.com. Thermo King has a policy of continuous product and product data improvements and reserves the right to change design and specifications without notice. We are committed to using environmentally conscious print practices.

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