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Thermo King V-500 Series User Manual

Thermo King V-500 Series
108 pages
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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.

Table of Contents

Questions and Answers:

Thermo King V-500 Series Specifications

General IconGeneral
BrandThermo King
ModelV-500 Series
CategoryControl Unit
LanguageEnglish

Summary

About This Manual

Purpose of the Manual

Explains the manual's goal to provide maintenance information for climate control units.

Manual Contents Overview

Lists the manual's chapters and their respective topics.

Before You Call Thermo King Service

Lists information needed before contacting technical support for service.

Blank Pages Notification

Notes that blank pages at chapter ends are normal and do not indicate missing information.

Roadside/Curbside Terminology

Defines terms used to describe unit sides relative to the vehicle's direction.

Using Model Tables for Unit Identification

Explains how to use model tables to identify unit information for service.

Safety Precautions

General Safety Practices

Outlines essential safety guidelines for handling equipment, tools, and hazardous substances.

Auto Start/Stop Safety Procedures

Warns about automatic unit startup and necessary precautions before inspection or work.

Refrigerant Handling Safety

Explains hazards associated with refrigerant exposure and necessary first aid measures.

Refrigeration Oil Safety and First Aid

Details precautions for handling refrigeration oil and first aid for exposure.

Electrical Hazards and Microprocessor Safety

Covers risks of electrical shock, microprocessor sensitivity, and safe servicing procedures.

Welding Safety Precautions

Advises on procedures to prevent damage when welding on units or truck chassis.

High Voltage Safety and First Aid

Emphasizes extreme caution with high voltage circuits and provides electrical shock first aid.

Low Voltage Safety Precautions

Highlights risks associated with low voltage but high current circuits and jewelry precautions.

Model Systems (System Designations)

Specifications

Electrical System Specifications

Lists fuse ratings, condenser fan motor specs, evaporator fan motor specs, and coil specifications.

Fuses and Electrical Components

Details specific fuses and their protected circuits within the electrical system.

Refrigerant System Specifications

Details refrigerant charge, switch cutouts, and system pressures for R-134a and R-404A.

Compressor Specifications

Provides details on main compressor types, oil capacity, oil type, refrigerant, and defrost methods.

Belt Tension and Motor Specifications

Covers engine driven compressor belt tension, AC electric motor details, and electric standby power requirements.

Solder Applications for Tubing

Specifies solder types and joint clearances for refrigeration and hot water tubing connections.

General Description

Introduction to Unit Models

Describes the Thermo King V-500 and V-500 MAX truck refrigeration systems.

System Components Overview

Explains the functions and mounting of the condenser, evaporator, and compressor assemblies.

Control Circuits and System Operation

Details control circuits, in-cab control box, oil separator, refrigerant, and liquid injection system.

Unit Features and Protection Mechanisms

Lists standard unit features and explains protection features like pressure cutout switches.

Control Box Components and Functions

Details the P.C. Board, connectors, and fuses within the control box.

Relays and Unit Operation Modes

Explains common relays, electric standby relays, overload relay, and unit operation modes.

Thermostat and Defrost Operation

Describes how the thermostat controls cooling/null modes and the defrost cycle initiation/termination.

Serial Number Locations and Unit Components

Identifies locations for serial numbers and components of the refrigeration unit.

Operating Instructions

In-Cab Control Box Description

Explains the functions of keys, LEDs, and indicators on the M13 in-cab control box.

In-Cab Control Box Operations

Guides on displaying temperatures, setting temperatures, and operating defrost mode.

Unit Operation Procedures

Covers weekly inspections, starting the unit, after-start checks, loading, and post-load procedures.

Weekly Post Trip Checks

Lists essential checks to be performed after unit operation to ensure proper function.

Maintenance Inspection Schedule

Electrical Maintenance Schedule

Details weekly, monthly, semi-annual, and annual checks for the electrical system.

Refrigeration/Heating Maintenance Schedule

Outlines weekly, monthly, semi-annual, and annual checks for the refrigeration and heating systems.

Structural Maintenance Schedule

Lists weekly, monthly, semi-annual, and annual checks for structural components and coils.

Electrical Maintenance

Selecting the Temperature Scale

Instructions on how to change the display between Celsius and Fahrenheit.

Electrical Maintenance Inspection Schedule

Lists procedures for electrical system checks with frequency intervals.

Troubleshooting In-Cab Control Box

Provides symptoms and remedies for common issues with the M-13 and M-16 control boxes.

Defrost System Operation and Settings

Explains how the defrost cycle works, its initiation, termination, and timer settings.

Defrost System Testing Procedures

Details procedures for testing the defrost system, including the timer and termination switch.

Condenser Fan Pressure Switch (CFPS) Testing

Explains the function and testing of the CFPS switch for R-134a units.

Liquid Injection System (R-404A Units)

Describes the function and testing of the liquid injection system for R-404A units.

Testing Liquid Injection Solenoid Valve

Steps to test the liquid injection solenoid valve and metering orifice.

Electric Standby Circuits Troubleshooting

Guides on troubleshooting issues with the unit's electric standby operation.

Refrigeration Maintenance

Refrigeration System Maintenance Schedule

Lists procedures for checking refrigerant level and replacing the dehydrator.

Charging the Refrigeration System

Step-by-step guide for charging the refrigeration system with refrigerant.

Checking Refrigerant Charge

Methods for determining if the unit has an insufficient or correct refrigerant charge.

Checking Compressor Oil Charge

Procedures for ensuring adequate oil supply in the compressor, especially after refrigerant loss.

High Pressure Cutout Switch (HPCO) Function

Explains the function, location, and testing of the HPCO switch.

Low Pressure Cutout Switch (LPCO) Function

Details the function, location, and testing procedure for the LPCO switch.

Cleanup Procedure for Small Truck Units

Step-by-step guide for cleaning the refrigeration system, especially after contamination.

Putting the Unit Back Into Operation

Steps to follow after cleaning and servicing to return the unit to operational status.

Structural Maintenance

Structural Maintenance Schedule

Lists checks for leaks, damaged parts, defrost drains, belts, and mounting bolts.

Evaporator and Condenser Coil Cleaning

Instructions for cleaning the evaporator and condenser coils to ensure proper airflow.

Unit Mounting Bolts Check

Guidance on periodically checking and torquing the unit mounting bolts for security.

Compressor Maintenance

Refrigerant Handling Safety and Recovery

Covers dangers of handling refrigerant bottles and safe recovery procedures.

Compressor Installation Guidelines

Provides instructions on compressor handling, storage, position, and precautions during installation.

Checking Compressor Oil Levels

Details oil check intervals, return procedures, and compressor removal steps.

Clutch Maintenance Procedures

Covers clutch testing, removal, inspection, and installation procedures.

Shaft Seal and Cover Maintenance

Instructions for removing, inspecting, and installing shaft seals and covers.

Compressor Leak Test Procedure

Steps for leak testing a compressor before installation to ensure system integrity.

Special Tools for Compressor Service

Lists specific tools required for compressor maintenance and installation.

Belt Tensions and Pulley Alignment

Emphasizes the importance of correct belt tension and pulley alignment for compressor installation.

Over-the-Road Mechanical Diagnosis

Electric Standby Mechanical Diagnosis

Compressor Not Running or Short Cycling

Troubleshooting steps for when the compressor does not run or cycles too frequently.

Unit Operation and Temperature Issues

Diagnosing problems like continuous operation, high box temperature, and head pressure.

Electric Standby Service Checks

Step-by-step checks for power at source, plug, terminals, and motor.

Refrigeration Diagnosis Chart

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