Thermo King VM-405 PBBD2 - Section 3 - Required Tools; Overview

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TK 56430-18-IP-EN

Section 3 - Required Tools

Overview

While basic mechanics tools and refrigeration service equipment are a necessity, there are also special tools that are

required when installing Thermo King Vehicle Powered Truck Units. Using these tools will assure the installation is

done correctly. Many of these are available from Thermo King.

*These are included with the Evacuation Station 204-725.

Main Page

S S E E C C T T I I O O N N 7 7 - - E E L L E E C C T T R R I I C C a a L L S S T T a a N N D D a a R R D D S1
S S E E C C T T I I O O N N 1 1 3 3 - - U U N N I I T T P P E E R R F F O O R R M M a a N N C C E E a a D D J J U U S S T T M M E E N N T T S2
S S E E C C T T I I O O N N 1 1 4 4 - - C C O O M M M M I I S S S S I I O O N N I I N N G G a a N N D D P P D D I I F F O O R R M M S3
Table of Contents4
S S E E C C T T I I O O N N 5 5 - - C C O O M M P P R R E E S S S S O O R R S S E E L L E E C C T T I I O O N N a a N N D D I I N N S S T T a a L L L L a a T T I I O O N N S S T T a a N N D D a a R R D D S4
S S E E C C T T I I O O N N 8 8 - - E E V V a a P P O O R R a a T T O O R R D D R R a a I I N N H H O O S S E E S S T T a a N N D D a a R R D D S5
S S E E C C T T I I O O N N 3 3 - - R R E E Q Q U U I I R R E E D D T T O O O O L L S6
S S E E C C T T I I O O N N 6 6 - - R R E E F F R R I I G G E E R R a a N N T T H H O O S S E E a a N N D D F F I I T T T T I I N N G G S S S S T T a a N N D D a a R R D D S7
S S E E C C T T I I O O N N 1 1 0 0 - - S S y y S S T T E E M M E E V V a a C C U U a a T T I I O O N N P P R R O O C C E E D D U U R R E E S7
S S E E C C T T I I O O N N 1 1 1 1 - - S S y y S S T T E E M M L L E E a a K K C C H H E E C C K K P P R R O O C C E E D D U U R R E E S7
Objective8
Defining Standards and Procedures8
Important Information about this Guide8
S S E E C C T T I I O O N N 4 4 - - U U N N I I T T I I N N S S T T a a L L L L a a T T I I O O N N S S T T a a N N D D a a R R D D S S a a N N D D P P R R O O C C E E D D U U R R E E S8
S S E E C C T T I I O O N N 2 2 - - S S a a F F E E T T y y P P R R E E C C a a U U T T I I O O N N S9
Overview9
Danger, Warning, Caution, and Notice9
Safety Precautions9
S S E E C C T T I I O O N N 9 9 - - C C O O N N F F I I G G U U R R I I N N G G S S O O F F T T W W a a R R E E a a N N D D C C O O N N T T R R O O L L L L E E R R P P R R O O C C E E D D U U R R E E S9
Auto Start Hazards11
Refrigerant Hazards11
Refrigerant Oil Hazards11
Electrical Hazards12
Battery Removal Hazards12
Welding Precautions12
Microprocessor Precautions13
First Aid14
Safety Decals14
Overview16
Overview18
Cargo Box Requirements18
Installation Manuals18
Installation Templates19
Unpacking and Inspecting Components19
Drilling Holes20
Sealing Holes22
Sealing Methods22
Sealing Refrigerant Lines and Electrical Harnesses23
Mounting Hardware24
Threads, Grade and Finish24
Hardware Length24
Nuts and Washers24
Tightening Mounting Hardware24
Vehicle Powered Truck Units25
Nosemounted Units25
Rooftop Mounted Units25
Nosemount and Rooftop Mount Similarities26
Installation Sequence26
Nosemount Condenser Installation27
Rooftop Mounted Condenser Installation30
Remote Evaporator Installation31
Evaporator Installation with Pre-Installed Support Plates32
Evaporator Installation Without Support Plates33
Overview34
Compressor Selection34
Understand Compressor Speeds35
Choose the Best Compressor Pulley35
Calculate the Compressor Speeds36
Compressor Installation36
Adding Oil36
Torque Specifications38
Ground Strap Installation39
Belt Alignment40
Changing Compressor Clutch41
Removal41
Installation43
Setting Air Gap44
Liquid Injection Temperature Sensor Installation Procedures(Max Units Only)45
Overview47
Hose Layout and Design47
Allowing for Movement48
Examples of Hose Designs49
Minimum Hose Bend Radius50
Securing Refrigeration Hoses50
Supporting Hoses50
Abrasion Protection51
Protective Covers and Guards51
Protective Heat Shields52
Refrigeration Fittings52
Determining Fitting Type53
Determining Fitting Size53
Refrigerant Hoses53
Determining Hose Size53
O-Rings54
Tightening Refrigeration Hose Fittings54
Suction Line Splice Connector55
Installation55
Splice Connector Service Ports55
Units with Oil Return Hose56
Units with Jet Cool (Liquid Injection System)56
Suction Line Routing and P-Trap Formation56
TK 2000+ System58
Assembly Materials Checklist58
Hose Fabrication Procedures58
Overview61
Dielectric Grease61
DC Low Voltage Harnesses61
Sealed Connectors62
Unsealed Connectors63
Sealed Splice Connectors64
Heat Shrink Sealed Butt Splice Connectors65
Parallel Crimp Connectors with Heat Shrink Tubing66
Unit Ground Wire to 12 VDC Negative Battery Connection67
Unit Main Power Connections to 12 VDC Positive Battery Connection68
12 VDC Positive Ignition Connection70
AC High Voltage Power Cable70
Receptacle Box Installation70
Standby Power Cable Wiring Connections71
Electrical Harness Protection72
Abrasion Protection72
Protective Covers and Guards72
Routing and Securing Electrical Harnesses72
Routing Harnesses through Metal Holes73
Protective Heat Shields74
Overview75
Drain Hose Standards75
Drain Heater Standards77
Heater Resistance Wires77
Controller Overview79
HMI Overview80
Controller Menu81
Main Menu81
Hour Meter81
Information Menu81
Installation Menu81
Configuration Files83
Flash Loading Configuration Files83
Overview87
Evacuation Procedures87
DSR Lll Equipped Units with 544.XX Firmware94
Overview97
Testing System for Leaks97
Using Pressurized Nitrogen98
Safety Precautions98
Procedures99
Overview100
Refrigerant Charging Procedures100
Discharge (High Side) Charging100
Suction (Low Side) Bump Charging101
Overview102
Commissioning Form Overview103
Pre-Delivery Inspection (PDI) Form Overview103

Thermo King VM-405 PBBD2 - Section 3 - Required Tools; Overview

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