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Thermo King
Refrigerator
V-300 MAX TC-20
Thermo King V-300 MAX TC-20 User Manual
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V
-200/V
-300 Series
TK 50982
-1-MM (Re
v
. 3, 02/0
3)
Copyright©
2003 Thermo King C
orp., Minneapo
lis, MN, U
SA.
Printe
d in
USA.
2
Table of Contents
Default Chapter
5
Table of Contents
5
List of Figures
9
Safety Precautions
11
General Practices
11
Refrigerant
11
Refrigeration Oil
11
Electrical Hazards
11
High Voltage
11
Low Voltage
12
Specifications
13
General
13
R-134A Refrigeration System
13
R-404A Refrigeration System
14
Electrical System
15
Maintenance Inspection Schedule
17
Unit Description
19
Introduction
19
Condenser
19
Evaporator
19
Compressor
19
Control Circuits
20
In-Cab Control Box
20
Oil Separator
20
Refrigerant
20
Liquid Injection System
20
Evaporator Drain Tube Heaters
20
Electric Standby Operation
20
Unit Features
21
Protection Features
21
Control Box
22
P.C. Board
22
Connectors
22
Fuses
22
Figure 1: Typical P.C. Board
22
Figure 2: P.C. Board Fuses
22
Common Relays
23
Standby Relays
23
Multi-Temp Relays
23
Figure 3: Fuse 4/1
23
Defrost Timer
24
Clutch Timer
24
EFR Selector
24
Unit Operation
24
Thermostat Operation
24
Figure 4: Thermostat Algorithm
24
Serial Number Locations
25
Figure 5: Condenser
26
Figure 6: Evaporator
26
Figure 7: Control Box Side of Model 20 Condenser
27
Figure 8: Refrigeration Component Side of Model 20 Condenser
28
Operating Instructions
29
Introduction
29
Description
29
Figure 9: M13 & 16 In-Cab Control Box
29
Figure 10: M-17 In-Cab Control Box
29
Figure 11: On/Off Key & LED
29
Figure 12: Celsius/Fahrenheit LED
29
Figure 13: Setpoint Key & Dial
30
Figure 14: Misc. Led's
30
Figure 15: Defrost Key & LED
30
In-Cab Control Box Operating Instructions (M-13, M-16, M-17)
31
Display Return Air (Box) Temperature
31
Display Setpoint Temperature
31
Enter Setpoint Temperature
31
Defrost Mode Operation (M-13, and M-16 Only)
31
Figure 16: On/Off Key and Defrost Key
31
Figure 17: Setpoint Key
31
Figure 18: Entering Setpoint
31
Unit Operation
32
Weekly Pretrip Inspection
32
Starting the Unit
32
After Start Inspection
32
Loading Procedure
32
Post Load Procedure
33
Tabl E of C Onten Ts
35
Electrical Maintenance
35
Trouble Shooting In-Cab Control Box M-13 and M-16
35
Figure 19: BLOCK DIAGRAM M-13, M-16
35
Trouble Shooting M-17 In-Cab Control Box (TC Units Only)
37
Figure 20: BLOCK DIAGRAM M-17
37
Defrost System
38
Defrost Components
38
Defrost Timer Settings
38
Figure 21: Defrost Timer
38
Manual Defrost Switch
39
Defrost Termination Switch
39
Defrost Relay
39
Defrost Solenoid Valve
39
Testing the Defrost System
39
Defrost Timer Test
39
Condenser Fan Pressure Switch (CFPS) R-134A Units Only
40
Testing CFPS
40
Liquid Injection System (R-404A Units Only)
40
Testing Liquid Injection Valve and Metering Orifice
40
Figure 22: Testing CFPS
40
Electric Standby Circuits
41
Refrigeration Maintenance
43
Refrigerant Charge
43
Charging the Refrigeration System
43
Figure 23: Charging Refrigeration System
43
Checking the Refrigerant Charge
44
Checking Compressor Oil Charge
45
High Pressure Cutout Switch (HPCO)
46
Low Pressure Cutout Switch (LPCO)
46
Figure 24: High Pressure Cutout Manifold
46
Cleanup Procedure for Small Truck Units
47
Figure 25: Connecting Flushing Compressor to Unit
47
Refrigeration Service Operations
49
Compressor
49
Figure 26: Refrigeration Systems in Model 20 Configurations
49
Condenser Coil
50
Drier
50
High Pressure Cutout and Condenser Fan Pressure Switches
50
Solenoid Valves
50
Oil Separator
51
Liquid Injection Metering Orifice
51
Figure 27: Engine Driven Compressor
51
Testing the Liquid Injection Solenoid Valve and Metering Orifice
52
Discharge Check Valve (Model 20 Only)
52
Testing the Discharge Check Valve
52
Figure 28: Check Valve Assembly
53
Check Valve Repair
54
Check Valve Replacement
54
Evaporator Coil
54
Expansion Valve Assembly
55
Low Pressure Cutout Switch
55
Figure 29: Location of Expansion Valve Bulb
55
Figure 30: Completely Wrap Bulb with Tape
55
Suction Receiver Tank (Heat Option Only)
56
Suction Pressure Regulator Valve (TC Units Only)
56
In-Line Check Valves (TC Units Only)
56
Installation
56
Replacing Refrigerant Hoses (Speedy Clip System)
57
Figure 31: Cutting the Hose
57
Figure 32: Fitting the Clips
57
Figure 33: Lubricating the Cylinder of the Fitting
57
Figure 34: Manually Inserting the Fitting
57
Figure 35: Positioning the Clamp
57
Figure 36: Fitting the Clips
57
Figure 37: Tightening both Clips
57
Structural Maintenance
59
Unit Inspection
59
Evaporator Coil
59
Condenser Coil
59
Unit Mounting Bolts
59
Figure 38: Condenser
59
Figure 39: Evaporator
59
Clutch Maintenance
61
Clutch Removal
61
Clutch Test
61
Figure 40: Remove Center Bolt
61
Figure 41: Remove Drive Plate
61
Figure 42: Remove Snap Ring and Cover
62
Figure 43: Remove Pulley
62
Figure 44: Remove Coil
62
Figure 45: Inspect Components
62
Clutch Installation
63
Figure 46: Install Coil
63
Figure 47: Install Pulley
63
Figure 48: Install Cover and Snap Ring
63
Figure 49: Install Shims and Drive Plate
63
Figure 50: Remove Shaft Seal Cover
64
Figure 51: Remove Shaft Seal
64
Shaft Seal Cover and Shaft Seal: Removal and Installation
64
Figure 52: Inspect Shaft Seal
65
Figure 53: Place Guide on Shaft
65
Figure 54: Place Shaft Seal on Guide
65
Figure 55: Press Seal into Cylinder Head
65
Figure 56: Install Shaft Seal Cover
66
Figure 57: Proper Shaft Seal Cover Position
66
Figure 58: Clutch Remover P/N 204-806
66
Figure 59: Compressor Holder P/N 204-807
66
Special Tools
66
Figure 60: Clutch Installation Kit P/N 204-890
67
Figure 61: Snap Ring Pliers P/N 204-808
67
Figure 62: Shaft Seal Kit P/N 204-805
67
List of Figures
64
System Compressor and Oil
68
Checking the Oil Level
68
Figure 63: Pulley Arbor P/N 204-804
68
Figure 64: Draining the Oil
68
Belt Tensions
69
Engine Driven Compressor Belt and Pulleys
69
Electric Standby Compressor Belt
69
Over-The-Road Mechanical Diagnosis
71
Electric Standby Mechanical Diagnosis
73
Electric Standby Service Checks
76
Refrigeration Diagnosis Chart
77
Index
79
Diagram Index
81
4
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Thermo King V-300 MAX TC-20 Specifications
General
Model
V-300 MAX TC-20
Refrigerant
R-404A
Voltage
12/24 V DC
Power Supply
DC
Temperature Range
-20°C to +30°C
Fuel Type
Diesel
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