User Manuals: Thermo King V-800 10 Refrigeration Unit

Manuals and User Guides for Thermo King V-800 10 Refrigeration Unit. We have 1 Thermo King V-800 10 Refrigeration Unit manual available for free PDF download: User Manual

Thermo King V-800 10 User Manual (112 pages)

Brand: Thermo King | Category: Automobile Accessories | Size: 28 MB

S S E E C C T T I I O O N N 7 7 - - E E L L E E C C T T R R I I C C a a L L S S T T a a N N D D a a R R D D S
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S S E E C C T T I I O O N N 1 1 3 3 - - U U N N I I T T P P E E R R F F O O R R M M a a N N C C E E a a D D J J U U S S T T M M E E N N T T S
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S S E E C C T T I I O O N N 1 1 4 4 - - C C O O M M M M I I S S S S I I O O N N I I N N G G a a N N D D P P D D I I F F O O R R M M S
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Table of Contents
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S S E E C C T T I I O O N N 5 5 - - C C O O M M P P R R E E S S S S O O R R S S E E L L E E C C T T I I O O N N a a N N D D I I N N S S T T a a L L L L a a T T I I O O N N S S T T a a N N D D a a R R D D S
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S S E E C C T T I I O O N N 8 8 - - E E V V a a P P O O R R a a T T O O R R D D R R a a I I N N H H O O S S E E S S T T a a N N D D a a R R D D S
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S S E E C C T T I I O O N N 3 3 - - R R E E Q Q U U I I R R E E D D T T O O O O L L S
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S S E E C C T T I I O O N N 6 6 - - R R E E F F R R I I G G E E R R a a N N T T H H O O S S E E a a N N D D F F I I T T T T I I N N G G S S S S T T a a N N D D a a R R D D S
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S S E E C C T T I I O O N N 1 1 0 0 - - S S y y S S T T E E M M E E V V a a C C U U a a T T I I O O N N P P R R O O C C E E D D U U R R E E S
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S S E E C C T T I I O O N N 1 1 1 1 - - S S y y S S T T E E M M L L E E a a K K C C H H E E C C K K P P R R O O C C E E D D U U R R E E S
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Objective
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Defining Standards and Procedures
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Important Information about this Guide
8
S S E E C C T T I I O O N N 4 4 - - U U N N I I T T I I N N S S T T a a L L L L a a T T I I O O N N S S T T a a N N D D a a R R D D S S a a N N D D P P R R O O C C E E D D U U R R E E S
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S S E E C C T T I I O O N N 2 2 - - 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
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Overview
9
Danger, Warning, Caution, and Notice
9
Safety Precautions
9
S S E E C C T T I I O O N N 9 9 - - C C O O N N F F I I G G U U R R I I N N G G S S O O F F T T W W a a R R E E a a N N D D C C O O N N T T R R O O L L L L E E R R P P R R O O C C E E D D U U R R E E S
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Auto Start Hazards
11
Refrigerant Hazards
11
Refrigerant Oil Hazards
11
Electrical Hazards
12
Battery Removal Hazards
12
Welding Precautions
12
Microprocessor Precautions
13
First Aid
14
Safety Decals
14
Overview
16
Overview
18
Cargo Box Requirements
18
Installation Manuals
18
Installation Templates
19
Unpacking and Inspecting Components
19
Drilling Holes
20
Sealing Holes
22
Sealing Methods
22
Sealing Refrigerant Lines and Electrical Harnesses
23
Mounting Hardware
24
Threads, Grade and Finish
24
Hardware Length
24
Nuts and Washers
24
Tightening Mounting Hardware
24
Vehicle Powered Truck Units
25
Nosemounted Units
25
Rooftop Mounted Units
25
Nosemount and Rooftop Mount Similarities
26
Installation Sequence
26
Nosemount Condenser Installation
27
Rooftop Mounted Condenser Installation
30
Remote Evaporator Installation
31
Evaporator Installation with Pre-Installed Support Plates
32
Evaporator Installation Without Support Plates
33
Overview
34
Compressor Selection
34
Understand Compressor Speeds
35
Choose the Best Compressor Pulley
35
Calculate the Compressor Speeds
36
Compressor Installation
36
Adding Oil
36
Torque Specifications
38
Ground Strap Installation
39
Belt Alignment
40
Changing Compressor Clutch
41
Removal
41
Installation
43
Setting Air Gap
44
Liquid Injection Temperature Sensor Installation Procedures(Max Units Only)
45
Overview
47
Hose Layout and Design
47
Allowing for Movement
48
Examples of Hose Designs
49
Minimum Hose Bend Radius
50
Securing Refrigeration Hoses
50
Supporting Hoses
50
Abrasion Protection
51
Protective Covers and Guards
51
Protective Heat Shields
52
Refrigeration Fittings
52
Determining Fitting Type
53
Determining Fitting Size
53
Refrigerant Hoses
53
Determining Hose Size
53
O-Rings
54
Tightening Refrigeration Hose Fittings
54
Suction Line Splice Connector
55
Installation
55
Splice Connector Service Ports
55
Units with Oil Return Hose
56
Units with Jet Cool (Liquid Injection System)
56
Suction Line Routing and P-Trap Formation
56
TK 2000+ System
58
Assembly Materials Checklist
58
Hose Fabrication Procedures
58
Overview
61
Dielectric Grease
61
DC Low Voltage Harnesses
61
Sealed Connectors
62
Unsealed Connectors
63
Sealed Splice Connectors
64
Heat Shrink Sealed Butt Splice Connectors
65
Parallel Crimp Connectors with Heat Shrink Tubing
66
Unit Ground Wire to 12 VDC Negative Battery Connection
67
Unit Main Power Connections to 12 VDC Positive Battery Connection
68
12 VDC Positive Ignition Connection
70
AC High Voltage Power Cable
70
Receptacle Box Installation
70
Standby Power Cable Wiring Connections
71
Electrical Harness Protection
72
Abrasion Protection
72
Protective Covers and Guards
72
Routing and Securing Electrical Harnesses
72
Routing Harnesses through Metal Holes
73
Protective Heat Shields
74
Overview
75
Drain Hose Standards
75
Drain Heater Standards
77
Heater Resistance Wires
77
Controller Overview
79
HMI Overview
80
Controller Menu
81
Main Menu
81
Hour Meter
81
Information Menu
81
Installation Menu
81
Configuration Files
83
Flash Loading Configuration Files
83
Overview
87
Evacuation Procedures
87
DSR Lll Equipped Units with 544.XX Firmware
94
Overview
97
Testing System for Leaks
97
Using Pressurized Nitrogen
98
Safety Precautions
98
Procedures
99
Overview
100
Refrigerant Charging Procedures
100
Discharge (High Side) Charging
100
Suction (Low Side) Bump Charging
101
Overview
102
Commissioning Form Overview
103
Pre-Delivery Inspection (PDI) Form Overview
103

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