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V-300 MAX TC-10
Manual
Thermo King V-300 MAX TC-10 Manual
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Contents
Table of Contents
Troubleshooting
Bookmarks
Table of Contents
Table of Contents
List of Figures
Safety Precautions
General Practices
Refrigerant
Refrigeration Oil
Electrical Hazards
High Voltage
Low Voltage
Specifications
General
R-134A Refrigeration System
R-404A Refrigeration System
Electrical System
Maintenance Inspection Schedule
Unit Description
Introduction
Condenser
Evaporator
Compressor
Control Circuits
In-Cab Control Box
Oil Separator
Refrigerant
Liquid Injection System
Evaporator Drain Tube Heaters
Electric Standby Operation
Unit Features
Protection Features
Control Box
P.C. Board
Connectors
Fuses
Figure 1: Typical P.C. Board
Figure 2: P.C. Board Fuses
Common Relays
Standby Relays
Multi-Temp Relays
Figure 3: Fuse 4/1
Defrost Timer
Clutch Timer
EFR Selector
Unit Operation
Thermostat Operation
Figure 4: Thermostat Algorithm
Serial Number Locations
Figure 5: Condenser
Figure 6: Evaporator
Figure 7: Control Box Side of Model 20 Condenser
Figure 8: Refrigeration Component Side of Model 20 Condenser
Operating Instructions
Introduction
Description
Figure 9: M13 & 16 In-Cab Control Box
Figure 10: M-17 In-Cab Control Box
Figure 11: On/Off Key & LED
Figure 12: Celsius/Fahrenheit LED
Figure 13: Setpoint Key & Dial
Figure 14: Misc. Led's
Figure 15: Defrost Key & LED
In-Cab Control Box Operating Instructions (M-13, M-16, M-17)
Display Return Air (Box) Temperature
Display Setpoint Temperature
Enter Setpoint Temperature
Defrost Mode Operation (M-13, and M-16 Only)
Figure 16: On/Off Key and Defrost Key
Figure 17: Setpoint Key
Figure 18: Entering Setpoint
Unit Operation
Weekly Pretrip Inspection
Starting the Unit
After Start Inspection
Loading Procedure
Post Load Procedure
Tabl E of C Onten Ts
Electrical Maintenance
Trouble Shooting In-Cab Control Box M-13 and M-16
Figure 19: BLOCK DIAGRAM M-13, M-16
Trouble Shooting M-17 In-Cab Control Box (TC Units Only)
Figure 20: BLOCK DIAGRAM M-17
Defrost System
Defrost Components
Defrost Timer Settings
Figure 21: Defrost Timer
Manual Defrost Switch
Defrost Termination Switch
Defrost Relay
Defrost Solenoid Valve
Testing the Defrost System
Defrost Timer Test
Condenser Fan Pressure Switch (CFPS) R-134A Units Only
Testing CFPS
Liquid Injection System (R-404A Units Only)
Testing Liquid Injection Valve and Metering Orifice
Figure 22: Testing CFPS
Electric Standby Circuits
Refrigeration Maintenance
Refrigerant Charge
Charging the Refrigeration System
Figure 23: Charging Refrigeration System
Checking the Refrigerant Charge
Checking Compressor Oil Charge
High Pressure Cutout Switch (HPCO)
Low Pressure Cutout Switch (LPCO)
Figure 24: High Pressure Cutout Manifold
Cleanup Procedure for Small Truck Units
Figure 25: Connecting Flushing Compressor to Unit
Refrigeration Service Operations
Compressor
Figure 26: Refrigeration Systems in Model 20 Configurations
Condenser Coil
Drier
High Pressure Cutout and Condenser Fan Pressure Switches
Solenoid Valves
Oil Separator
Liquid Injection Metering Orifice
Figure 27: Engine Driven Compressor
Testing the Liquid Injection Solenoid Valve and Metering Orifice
Discharge Check Valve (Model 20 Only)
Testing the Discharge Check Valve
Figure 28: Check Valve Assembly
Check Valve Repair
Check Valve Replacement
Evaporator Coil
Expansion Valve Assembly
Low Pressure Cutout Switch
Figure 29: Location of Expansion Valve Bulb
Figure 30: Completely Wrap Bulb with Tape
Suction Receiver Tank (Heat Option Only)
Suction Pressure Regulator Valve (TC Units Only)
In-Line Check Valves (TC Units Only)
Installation
Replacing Refrigerant Hoses (Speedy Clip System)
Figure 31: Cutting the Hose
Figure 32: Fitting the Clips
Figure 33: Lubricating the Cylinder of the Fitting
Figure 34: Manually Inserting the Fitting
Figure 35: Positioning the Clamp
Figure 36: Fitting the Clips
Figure 37: Tightening both Clips
Structural Maintenance
Unit Inspection
Evaporator Coil
Condenser Coil
Unit Mounting Bolts
Figure 38: Condenser
Figure 39: Evaporator
Clutch Maintenance
Clutch Removal
Clutch Test
Figure 40: Remove Center Bolt
Figure 41: Remove Drive Plate
Figure 42: Remove Snap Ring and Cover
Figure 43: Remove Pulley
Figure 44: Remove Coil
Figure 45: Inspect Components
Clutch Installation
Figure 46: Install Coil
Figure 47: Install Pulley
Figure 48: Install Cover and Snap Ring
Figure 49: Install Shims and Drive Plate
Figure 50: Remove Shaft Seal Cover
Figure 51: Remove Shaft Seal
Shaft Seal Cover and Shaft Seal: Removal and Installation
Figure 52: Inspect Shaft Seal
Figure 53: Place Guide on Shaft
Figure 54: Place Shaft Seal on Guide
Figure 55: Press Seal into Cylinder Head
Figure 56: Install Shaft Seal Cover
Figure 57: Proper Shaft Seal Cover Position
Figure 58: Clutch Remover P/N 204-806
Figure 59: Compressor Holder P/N 204-807
Special Tools
Figure 60: Clutch Installation Kit P/N 204-890
Figure 61: Snap Ring Pliers P/N 204-808
Figure 62: Shaft Seal Kit P/N 204-805
List of Figures
System Compressor and Oil
Checking the Oil Level
Figure 63: Pulley Arbor P/N 204-804
Figure 64: Draining the Oil
Belt Tensions
Engine Driven Compressor Belt and Pulleys
Electric Standby Compressor Belt
Over-The-Road Mechanical Diagnosis
Electric Standby Mechanical Diagnosis
Electric Standby Service Checks
Refrigeration Diagnosis Chart
Index
Diagram Index
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V-200/V-300 Series
TK 50982-1-MM (Rev. 3, 02/03)
Copyright© 2003 Thermo King Corp., Minneapolis, MN, USA.
Printed in USA.
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Table of Contents
Troubleshooting
Electrical Maintenance
35
Trouble Shooting M-17 In-Cab Control Box (TC Units Only)
37
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