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V-500 MAX-20 3PH
Thermo King V-500 MAX-20 3PH User Manual
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V
-500 Series
TK 51859-1-MM (Rev
. 1, 05/05)
Copyright© 2004 Thermo King
Corp., Minneapolis, MN, USA.
Printed in USA
.
2
Table of Contents
About this Manual
5
Purpose
5
Contents
5
Before You Call Thermo King Service
6
Blank
6
Roadside/Curbside Terminology
6
Using the Model Tables in "About this Unit
6
Table of Contents
7
List of Figures
11
Safety Precautions
13
General Practices
13
Auto Start/Stop
13
Refrigerant
13
First Aid
13
Refrigeration Oil
14
First Aid
14
Electrical Hazards
14
Microprocessor Service
14
Welding of Units or Truck Bodies
15
High Voltage
15
Low Voltage
16
Model Systems (System Designations)
17
Specifications
19
Electrical System
19
Refrigerant System
20
Compressors
20
Belt Tension (Using Tool P/N 204-427)
21
AC Electric Motors
21
Electric Standby Power Requirements
21
Solder Applications
21
General Description
23
Introduction
23
Condenser
23
Evaporator
23
Compressor
23
Control Circuits
24
In-Cab Control Box
24
Oil Separator
24
Refrigerant
24
Liquid Injection System
24
Evaporator Drain Tube Heaters
24
Electric Standby Operation
24
Unit Features
25
Protection Features
25
Control Box
26
P.C. Board
26
Connectors
26
Fuses
26
Figure 1: P.C. Board Fuses
26
Figure 2: Fuse 4/1
26
Common Relays
27
Electric Standby Relays
27
Unit Operation
27
Thermostat Operation
28
Figure 3: Thermostat Algorithm
28
Serial Number Locations
29
Unit Components
29
Figure 4: Unit Components (Model 20)
29
Figure 5: Condenser Electric and Capacitor Boxes (Model 20)
30
Figure 6: Evaporator
31
Figure 7: Evaporator with Hot Water and Electric Heat Options
32
Table of Contents
33
Operating Instructions
33
Introduction
33
Description
33
Figure 8: M13 In-Cab Control Box
33
Figure 9: On/Off Key & LED
33
Figure 10: Celsius/Fahrenheit LED
33
Figure 11: Setpoint Key & Dial
33
Figure 12: Misc. Led's
33
In-Cab Control Box Operating Instructions
34
Display Return Air (Box) Temperature
34
Display Setpoint Temperature
34
Enter Setpoint Temperature
34
Defrost Mode Operation
34
Figure 13: Defrost Key & LED
34
Figure 14: On/Off Key and Defrost Key
35
Figure 15: Setpoint Key
35
Figure 16: Entering Setpoint
35
Unit Operation
36
Weekly Pretrip Inspection
36
Starting the Unit
36
After Start Inspection
36
Loading Procedure
36
Post Load Procedure
36
Maintenance Inspection Schedule
39
Electrical
39
Refrigeration/Heating
39
Structural
39
Electrical Maintenance
41
Maintenance Inspection Schedule
41
Figure 17: Back of Cab Control Box with Cover Removed
41
Trouble Shooting In-Cab Control Box M-13 and M-16
42
Figure 18: Block Diagram M-13, M-16
42
Defrost System
43
Defrost Timer Settings
43
Defrost Termination Switch
44
Defrost Relay
44
Defrost Solenoid Valve
44
Testing the Defrost System
44
Figure 19: Defrost Timer
44
Defrost Timer Test
45
Condenser Fan Pressure Switch (CFPS) R-134A Units Only
45
Testing CFPS
45
Liquid Injection System (R-404A Units Only)
45
Figure 20: Testing CFPS
45
Testing Liquid Injection Solenoid Valve and Metering Orifice
46
Electric Standby Circuits
46
Refrigeration Maintenance
47
Maintenance Inspection Schedule
47
Rcharging the Refrigeration System
47
Figure 21: Charging Refrigeration System
47
Checking the Refrigerant Charge
48
Checking Compressor Oil Charge
49
High Pressure Cutout Switch (HPCO)
50
Low Pressure Cutout Switch (LPCO)
50
Figure 22: High Pressure Cutout Manifold
50
Cleanup Procedure for Small Truck Units
51
Figure 23: Connecting Flushing Compressor to Unit
51
Structural Maintenance
53
Maintenance Inspection Schedule
53
Evaporator Coil
53
Condenser Coil
53
Unit Mounting Bolts
53
Figure 24: Evaporator
53
Figure 25: Condenser
53
Compressor Maintenance
55
Refrigerant Handling Instructions
55
Refrigerant Handling Safety
55
Refrigerant Recovery
55
Figure 26: Typical Recovery Unit
55
Compressor Installation Guidelines
56
Compressor Handling
56
Compressor Storage
56
Compressor Installation Position
56
Compressor Installation Precautions
56
Figure 27: Rotate Compressor Clutch
56
Figure 28: Compressor Installation Range
56
Compressor Installation
57
Figure 29: Loosen Cap Slowly
57
Figure 30: Rotate Compressor Clutch
57
Mounting Compressors
58
Adding Extra Oil to System
58
Figure 31: Shim Installation
58
Major Loss of Refrigerant
58
Checking Compressor Oil
59
Oil Check Interval
59
Oil Return Procedure (System Operational)
59
Compressor Removal
59
Figure 32: Oil Inspection Procedure
59
Draining and Replacing Oil
60
Figure 33: Draining the Oil
60
Figure 34: Typical Compressor Oil Fill Procedure
60
Clutch Removal, Inspection, and Installation
61
Removal
61
Figure 35: Remove Center Bolt
61
Figure 36: Remove Armature Plate
61
Figure 37: Remove Snap Ring and Cover
61
Inspection
62
Installation
62
Figure 38: Remove Pulley
62
Figure 39: Remove Coil
62
Figure 40: Inspect Clutch Components
62
Figure 41: Install Coil
62
Figure 42: Install Pulley
63
Figure 43: Install Cover and Snap Ring
63
Figure 44: Install Cover and Snap Ring
63
Figure 45: Install Shims and Drive Plate
63
Clutch Run in
64
Clutch Test
61
Shaft Seal Cover and Shaft Seal Removal, Inspection, and Installation
64
Removal
64
Figure 46: Check Air Gap
64
Figure 47: Shaft Seal Cover Removal
64
Figure 48: Remove Shaft Seal
64
Inspection
65
Installation
65
Figure 49: Inspect Shaft Seal
65
Figure 50: Place Guide on Shaft
65
Figure 51: Place Shaft Seal on Guide
65
Figure 52: Press Seal into Cylinder Head
65
Seal Cover Installation (When Equipped)
66
List of Figures
65
Front and Rear Cylinder Head Disassembly, Inspection, and Reassembly
66
Disassembly
66
Figure 53: Install Snap Ring
66
Figure 54: Install Shaft Seal Cover (When Equipped)
66
Figure 55: Proper Shaft Seal Cover Position
66
Figure 56: Remove Body Bolts
67
Figure 57: Tap Front Cylinder Head Projections
67
Figure 58: Front Cylinder Head Assembly
67
Figure 59: Front Valve Plate and Suction Valve
67
Inspection
68
Figure 60: Tap Rear Cylinder Head Projections
68
Figure 61: Rear O-Ring and Gasket
68
Figure 62: Rear Valve Plate and Suction Valve
68
Figure 63: Front Cylinder and Valve Plate
68
Reassembly
69
Figure 64: Rear View
69
Figure 65: Rear Suction Valve
69
Figure 66: Rear Cylinder Head Assembly
69
Figure 67: Front Suction Valve
70
Figure 68: Front Cylinder Head Assembly
70
Figure 69: Tightening Sequence
70
Compressor Leak Test Procedure
71
Figure 70: Compressor Drain Plug Location
71
Figure 71: Discharge and Suctions Caps
71
Figure 72: Pulley Arbor P/N 204-804
72
Figure 73: Shaft Seal Kit P/N 204-805
72
Figure 74: Clutch Remover P/N 204-806
72
Special Tools
72
Belt Tensions
73
Engine Driven Compressor Belt and Pulleys
73
Figure 75: Compressor Holder P/N 204-807
73
Figure 76: Snap Ring Pliers P/N 204-808
73
Figure 77: Clutch Installation Kit P/N 204-890
73
Over-The-Road Mechanical Diagnosis
75
Electric Standby Mechanical Diagnosis
77
Electric Standby Service Checks
79
Refrigeration Diagnosis Chart
81
Index
83
5
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Thermo King V-500 MAX-20 3PH Specifications
General
Brand
Thermo King
Model
V-500 MAX-20 3PH
Category
Control Unit
Language
English
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