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Thermo King V-520 User Manual

Thermo King V-520
120 pages
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Revision C
March 2023
TTKK 5544334433--1188--MMMM--EENN
Truck Edition
V-520, V-520 MAX, V-520 SPECTRUM
Maintenance Manual

Table of Contents

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Thermo King V-520 Specifications

General IconGeneral
BrandThermo King
ModelV-520
CategoryAir Conditioner
LanguageEnglish

Summary

Introduction

Revision History

Summary of manual updates and changes, including format and content revisions.

General Information

Overview of unit models covered and references for further information.

Safety Precautions

Danger, Warning, Caution, and Notice

Defines hazard advisory types for safe operation and potential risks.

Personal Protective Equipment (PPE)

Guidelines for required protective gear and safety practices during servicing.

Refrigerant Hazards

Describes risks associated with refrigerant handling, storage, and safety precautions.

Electrical Hazards

Outlines dangers and precautions for working with high and low voltage electrical systems.

Model Systems (System Designations)

V-520 Truck Refrigeration Systems

Lists V-520 models, system numbers, install kits, refrigerants, and diagrams.

Specifications

Electrical System

Details fuse specifications, component currents, and resistances.

Refrigeration System

Lists refrigerant charge amounts and system pressure settings for various models.

Compressors

Provides specifications for compressor types, oil capacity, and clutch data.

Unit Description

Introduction

Overview of V-520 and V-520 MAX truck refrigeration systems and their design.

Standard Features

Lists key features included as standard on the refrigeration units.

Compressor

Describes the main engine-driven and electric standby compressor functions.

Refrigerant

Details refrigerants used (R-134a, R-404A, R-452A) and their applications.

Unit Operation

Explains how the unit operates in different modes like Cool, Heat, and Null.

Cool Mode

Describes the cooling cycle, system operation, and fan control logic.

Heat Mode

Explains the heating cycle, system operation, and solenoid functions.

Defrost Mode

Details the defrost cycle initiation, termination, and system actions.

Maintenance Inspection Schedule

Electrical

Outlines daily, weekly, and periodic electrical system inspection tasks.

Refrigeration/Heating

Lists maintenance tasks for refrigeration and heating systems.

Structural

Covers inspection of structural components, coils, and mounting hardware.

Electrical Maintenance

Defrost System

Explains the defrost system operation, initiation, and termination settings.

Fuses

Identifies controller and harness fuse locations and ratings.

Relays

Details relay testing procedures, types, and replacement instructions.

Capacitors

Covers capacitor testing, replacement, and safety precautions.

Compressor Motor

Details testing procedures for 230/1/60 and 230/3/60 compressor motors.

Refrigeration Maintenance

Checking the Refrigerant Charge

Procedure to verify system refrigerant levels using sight glass and pressures.

Checking Compressor Oil Charge

Method for ensuring adequate compressor oil supply after refrigerant loss.

Cleanup Procedure for Small Truck Units

Steps for flushing the system and cleaning components after failure.

Refrigeration Service Operations

Drier

Removal and installation procedures for the system drier.

Hot Gas Solenoid (HGS) Test

Procedure to test the hot gas solenoid valve operation.

Liquid Line Solenoid Test (SPECTRUM Only)

Testing the liquid line solenoid for SPECTRUM unit operation.

Solenoid Valve Replacement

Steps for removing and installing solenoid valves, including soldering precautions.

Discharge Check Valve (Model 20 and 50 Only)

Testing and replacement procedures for the discharge check valve.

Evaporator Coil

Procedures for removing and installing the evaporator coil.

Engine Driven Compressor Maintenance

Compressor Test

Methods for testing engine-driven compressor performance and clutch.

Engine Driven Compressor Belt and Pulleys

Importance of correct pulley alignment and belt tension for compressor longevity.

Structural Maintenance

Condenser and Evaporator Coils

Recommendations and methods for cleaning condenser and evaporator coils.

Over-the-Road Mechanical Diagnosis

Unit turned On—In-Cab Control Box display does not come on

Troubleshooting steps for when the control box display does not activate.

Unit turned On—In-Cab Control Box display comes on but unit does not operate

Troubleshooting steps for when the unit fails to operate after display activation.

Electric Standby Mechanical Diagnosis

Unit turned On—In-Cab Control Box display does not come on

Troubleshooting for no display in electric standby mode.

Unit turned On—In-Cab Control Box display comes on but compressor motor does not run

Troubleshooting for compressor motor non-operation in standby mode.

Refrigeration Diagnosis

Unit short cycles

Identifies possible causes and remedies for unit short cycling.

Box temperature too high

Diagnosis and solutions for elevated box temperatures.

Head pressure too high

Troubleshooting steps for issues causing high head pressure.

Diagram Index

Wiring and Schematic Diagrams

Lists relevant diagrams available for unit systems and their drawing numbers.

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