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Thermo King VM-405 Max EL User Manual

Thermo King VM-405 Max EL
112 pages
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Revision B
June 2022
TTKK 5566443300--1188--IIPP--EENN
Installation Standards and Procedures Guide
V220 and V320 Series Units
User Guide

Table of Contents

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Thermo King VM-405 Max EL Specifications

General IconGeneral
BrandThermo King
ModelVM-405 Max EL
CategoryAutomobile Accessories
LanguageEnglish

Summary

How To Use This Guide

Section 2 - Safety Precautions

Covers general safety information and specific hazards.

Section 4 - Unit Installation Standards and Procedures

Details standards for installing unit components.

Section 5 - Compressor Selection and Installation Standards

Covers compressor selection and installation requirements.

Section 6 - Refrigerant Hose and Fittings Standards

Defines standards for hoses and fittings.

Section 7 - Electrical Standards

Outlines electrical connection standards.

Section 10 - System Evacuation Procedures

Outlines unit evacuation procedures.

Section 11 - System Leak Check Procedures

Details leak check procedures.

Section 12 - System Charging Procedures

Outlines refrigerant charging procedures.

Section 2 - Safety Precautions

Overview

Provides a general overview of safety precautions for unit installation.

Danger, Warning, Caution, and Notice

Defines the different types of safety advisories used throughout the manual.

Safety Precautions

General safety information and practices to follow during installation and service.

Safety Precautions - Specific Hazards

Risk of Injury!

Warns about hazards associated with moving parts and equipment.

Refrigerant Vapor Hazard!

Details risks associated with refrigerant vapor inhalation.

Personal Protective Equipment (PPE) Required!

Stresses the importance of wearing PPE when working with the unit.

Proper Equipment Condition!

Ensures service equipment is in good condition to prevent injury.

Equipment Damage!

Highlights risks of equipment damage due to improper installation or handling.

Safety Precautions - Auto Start and Refrigerant Hazards

Auto Start Hazards

Warns about potential hazards from automatic unit start-up.

Refrigerant Hazards

Details hazards related to refrigerant pressure and gases.

Refrigerant Oil Hazards

Highlights risks and precautions when handling refrigerant oil.

Safety Precautions - Electrical and Other Hazards

Electrical Hazards

Details dangers associated with hazardous voltages and live components.

Battery Removal Hazards

Warns about explosion risks during battery removal and reconnection.

Welding Precautions

Advises on precautions before performing electric welding on the unit.

Safety Precautions - Microprocessor Handling

Microprocessor Precautions

Provides procedures for working with microprocessor-based control systems.

Safety Precautions - First Aid and Decals

First Aid

Offers first aid instructions for exposure to refrigerant, oil, coolant, and electrical shock.

Safety Decals

Advises to observe all safety decals placed on the unit.

Section 4 - Unit Installation Standards and Procedures

Cargo Box Requirements

Specifies requirements for the cargo box for refrigeration applications.

Installation Manuals

Advises on accessing unit-specific installation manuals online.

Unit Installation - Templates and Inspection

Installation Templates

Describes the use of paper templates for accurate component mounting.

Unpacking and Inspecting Components

Provides guidance on unpacking and checking components for damage or missing parts.

Unit Installation - Drilling Holes

Drilling Holes

Details procedures and precautions for drilling holes in the vehicle or cargo box.

Unit Installation - Sealing Holes

Sealing Holes

Emphasizes sealing all holes to prevent air/water leakage.

Unit Installation - Sealing Methods

Sealing Methods

Lists acceptable methods for sealing holes and component mounts.

Unit Installation - Sealing Harnesses

Sealing Refrigerant Lines and Electrical Harnesses

Details steps for sealing access holes for hoses and harnesses.

Unit Installation - Mounting Hardware

Mounting Hardware

Covers proper selection and use of mounting hardware.

Threads, Grade and Finish

Specifies requirements for hardware threads, grade, and finish.

Hardware Length

Details correct hardware length requirements for applications.

Nuts and Washers

Specifies correct nut and washer requirements.

Tightening Mounting Hardware

Provides guidance on securely tightening mounting hardware.

Unit Installation - Vehicle Types

Vehicle Powered Truck Units

Describes available versions of vehicle powered truck units.

Nosemounted Units

Details the design and installation of nosemount units.

Rooftop Mounted Units

Details the design and installation of rooftop mounted units.

Unit Installation - System Similarities and Sequence

Nosemount and Rooftop Mount Similarities

Highlights common requirements for nosemount and rooftop split systems.

Installation Sequence

Provides the recommended installation sequence for vehicle powered units.

Unit Installation - Nosemount Condenser

Unit Installation - Rooftop Condenser

Unit Installation - Remote Evaporator

Unit Installation - Evaporator Support Plates

Unit Installation - Evaporator without Support Plates

Section 5 - Compressor Selection and Installation Standards

Compressor Speeds and Pulley Selection

Compressor Installation Procedures

Compressor Torque Specifications

Compressor Ground Strap Installation

Compressor Belt Alignment

Compressor Clutch - Changing and Removal

Compressor Clutch - Installation

Compressor Clutch - Setting Air Gap

Section 6 - Refrigerant Hose and Fittings Standards

Hose Layout - Allowing for Movement

Hose Design Examples

Hose Standards - Bend Radius and Securing

Hose Protection - Abrasion and Covers

Hose Protection - Heat Shields and Fittings

Fitting and Hose Size Determination

Hose Fittings - O-Rings and Tightening

Suction Line Splice Connector Installation

Hose Connectors - Oil Return and Jet Cool

TK 2000+ System Hose Fabrication

TK 2000+ Hose Fabrication - Clamps and Nipple

TK 2000+ Hose Fabrication - Closing Clips

Section 7 - Electrical Standards

Electrical Standards - Sealed Connectors

Electrical Standards - Unsealed Connectors

Electrical Standards - Sealed Splice Connectors

Electrical Standards - Heat Shrink Splice Connectors

Electrical Standards - Parallel Crimp Connectors

Electrical Standards - Ground Wire Connection

Electrical Standards - Main Power and Fuse Practices

Electrical Standards - Ignition and High Voltage

Electrical Harness Protection and Routing

Electrical Harness Routing - Metal Holes

Electrical Harness Protection - Heat Shields

Section 10 - System Evacuation Procedures

Section 11 - System Leak Check Procedures

Section 12 - System Charging Procedures

Overview

Outlines refrigerant charging procedures for optimal performance.

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