Thermo King V-200 10 User Manual Download Page 16 | Manualshive

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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.

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Summary of Contents for V-200 10

Page 1: ...Revision B June 2022 T TK K 5 56 64 43 30 0 1 18 8 I IP P E EN N Installation Standards and Procedures Guide V220 and V320 Series Units User Guide...

Page 2: ...e ec ct t i in nd di ir re ec ct t s sp pe ec ci ia al l o or r c co on ns se eq qu ue en nt ti ia al l d da am ma ag ge es s w wh ha at ts so oe ev ve er r a ar ri is si in ng g o ou ut t o of f t th...

Page 3: ...s how to properly connect the harnesses to the unit s individual components and the vehicle s electrical system It also covers main fuse installation harness routing harness securing and ground connec...

Page 4: ...d 14 Safety Decals 14 S Se ec ct ti io on n 3 3 R Re eq qu ui ir re ed d T To oo ol ls s 1 16 6 Overview 16 S Se ec ct ti io on n 4 4 U Un ni it t I In ns st ta al ll la at ti io on n S St ta an nd da...

Page 5: ...allation 36 Adding Oil 36 Torque Specifications 38 Ground Strap Installation 39 Belt Alignment 40 Changing Compressor Clutch 41 Removal 41 Installation 43 Setting Air Gap 44 Liquid Injection Temperatu...

Page 6: ...nnection 67 Unit Main Power Connections to 12 Vdc Positive Battery Connection 68 12 Vdc Positive Ignition Connection 70 AC High Voltage Power Cable 70 Receptacle Box Installation 70 Standby Power Cabl...

Page 7: ...Leaks 97 Using Pressurized Nitrogen 98 Safety Precautions 98 Procedures 99 S Se ec ct ti io on n 1 12 2 S Sy ys st te em m C Ch ha ar rg gi in ng g P Pr ro oc ce ed du ur re es s 1 10 00 0 Overview 1...

Page 8: ...completed in a timely manner It is also recommended that installers of Thermo King equipment not only become familiar with this manual but also any other referenced publications listed herein before b...

Page 9: ...t t i in n e eq qu ui ip pm me en nt t o or r p pr ro op pe er rt ty y d da am ma ag ge e o on nl ly y a ac cc ci id de en nt ts s Safety Precautions D DA AN NG GE ER R H Ha az za ar rd d o of f E Ex...

Page 10: ...ze ed d S Sy ys st te em m o of f C Cl la as ss si if fi ic ca at ti io on n a an nd d L La ab be el ll li in ng g o of f C Ch he em mi ic ca al ls s g gu ui id de el li in ne es s f fo or r i in nf f...

Page 11: ...ce ed d T Th he es se e g ga as se es s c ca an n c ca au us se e s su uf ff fo oc ca at ti io on n e ev ve en n d de ea at th h W WA AR RN NI IN NG G P Pe er rs so on na al l P Pr ro ot te ec ct ti...

Page 12: ...ol lt ta ag ge e U Un ni it ts s e eq qu ui ip pp pe ed d w wi it th h E El le ec ct tr ri ic c S St ta an nd db by y o op pt ti io on n o op pe er ra at te e o on n 1 11 15 5 o or r 2 23 30 0 v vo ol...

Page 13: ...consisting of a battery and a light bulb to test circuits on any microprocessor based equipment Always turn the unit off by pressing the HMI Main Power On Off key before connecting or disconnecting t...

Page 14: ...rge amounts of water for at least 15 minutes Get prompt medical attention Wash skin with soap and water S Sk ki in n Immediately remove contaminated clothing Wash skin with large volumes of water for...

Page 15: ...TK 56430 18 IP EN 15 Figure 1 Typical Safety Decals S Se ec ct ti io on n 2 2 S Sa af fe et ty y P Pr re ec ca au ut ti io on ns s...

Page 16: ...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 correctl...

Page 17: ...TK 56430 18 IP EN 17 RCS481 1 tra n i c W S e o r f a tw WinTrac Software latest version must always be used S Se ec ct ti io on n 3 3 R Re eq qu ui ir re ed d T To oo ol ls s...

Page 18: ...rgo box must be designed and built for refrigeration applications with insulated walls ceilings and floors All cargo box doors must close and seal tightly Cargo boxes that fail to meet these requireme...

Page 19: ...stalling multiple units paper templates should be transferred to a more durable material such as aluminum This will allow you to reuse the templates as needed Unpacking and Inspecting Components Compo...

Page 20: ...vehicle Consult your vehicle s manufacturer box builder before drilling any holes in the chassis cargo box or structural supports Use the unit specific installation manual to determine how many refrig...

Page 21: ...rant hoses Protective edging material must be installed All mounting holes must be completely sealed to prevent water air leakage Refer to Sealing Holes p 22 S Se ec ct ti io on n 4 4 U Un ni it t I I...

Page 22: ...box Sealing Methods Any of the following sealing methods are acceptable Silicone Sealant neutral alcohol cure exterior grade flexible non hardening Strips of foam rubber material applied between surf...

Page 23: ...hole with expandable foam installer supplied Spray the foam in between the hoses and harnesses so the hole is completely filled with foam 5 Once the foam has cured trim excess foam around hoses and h...

Page 24: ...re length and nut requirements shown Nuts and Washers Figure 6 Correct nut and washer requirements shown Tightening Mounting Hardware Care must be taken when tightening mounting hardware to verify the...

Page 25: ...t of a cargo box while the remote evaporator s are installed inside the cargo box An engine driven compressor operates the unit on the road while the Electric Standby SmartPower option allows the unit...

Page 26: ...ration setup software programming and refrigeration system adjustments Adjustments to the Suction Pressure Regulator SPR or Compressor Pressure Regulator CPR valve if equipped for maximum performance...

Page 27: ...rt the weight of the condenser Additional supports installer supplied may be required Unit weights can be found in the product brochures Nosemount unit must not interfere with tilt cab function Tilt c...

Page 28: ...unit must not interfere with tilt cab function Figure 11 Nosemount installation template shown S Se ec ct ti io on n 4 4 U Un ni it t I In ns st ta al ll la at ti io on n S St ta an nd da ar rd ds s...

Page 29: ...0 18 IP EN 29 Figure 12 Lifting device and work platform shown S Se ec ct ti io on n 4 4 U Un ni it t I In ns st ta al ll la at ti io on n S St ta an nd da ar rd ds s a an nd d P Pr ro oc ce ed du ur...

Page 30: ...mounting holes and refrigeration fittings Refer to the unit specific installation manual for details The following points must be addressed when installing the rooftop mounted condenser The condenser...

Page 31: ...khead to the rear of the evaporator This distance is required to allow for refrigerant and drain hose connections Some evaporators include an accumulator assembly They evaporators must be installed a...

Page 32: ...he weight of the evaporator s The plate should be installed prior to insulating and finishing the cargo area The plate should also position the evaporator the required distance from the front bulkhead...

Page 33: ...ure 18 Example of backer plate shown Apply a bead of silicone sealant around the hole on both sides of each backer plate and install mounting hardware Remove the evaporator cover and install the evapo...

Page 34: ...t the correct compressor for the unit being installed Table 1 Compressor Selection Unit Model Required Compressor V 200 V 220 MAX TK 13 V 300 V 320 MAX TK 15 V 520 MAX TK 16 V 520 RT MAX TK 16 V 800 T...

Page 35: ...ime How to Calculate This is the compressor RPM at highway speed about 70 MPH when vehicle is in its highest gear Refer to Calculate the Compressor Speeds p 36 Note Vehicles with manual transmissions...

Page 36: ...or procedures Compressor Installation Adding Oil 1 Remove compressor from box and inspect the serial tag 2 Verify that the compressor model number is correct see the previous Compressor Selection 3 Ve...

Page 37: ...ution around the bolt Figure 23 Add blue thread locker to retainer bolts 10 Place the bolt through the manifold retainer and torque to 36 9 ft lbs 50 N m I Im mp po or rt ta an nt t Do not use an impa...

Page 38: ...s easier to add the oil before attaching the suction line fitting Figure 25 Add oil into suction line Torque Specifications When connecting the tube O style fittings to the compressor manifold the fol...

Page 39: ...Use an ohmmeter to check the resistance of the ground circuit Hold one probe of the ohmmeter to an unpainted area on the frame or chassis and hold the other probe onto the loose end of the chassis gr...

Page 40: ...w wh he en n a ar ro ou un nd d o ot th he er rs s a an nd d u us se e p pe er rs so on na al l p pr ro ot te ec ct ti iv ve e e eq qu ui ip pm me en nt t t to o m mi in ni im mi iz ze e r ri is sk k...

Page 41: ...the armature retaining bolt Figure 31 Removing Armature Retaining Bolt 1 Armature Retaining Bolt Remove the armature assembly from the compressor shaft and the snap ring holding the pulley onto the c...

Page 42: ...grooves Figure 33 Removing Compressor Pulley 1 3 Jaw Puller 2 Armature Retaining Bolt Remove the bolt from the compressor shaft and the three screws securing the clutch coil onto the compressor body F...

Page 43: ...er on each of the retaining screws Align the new compressor pulley with the compressor shaft If the pulley does not slide on the compressor use a 60 mm bearing seal driver and rubber mallet to install...

Page 44: ...re e c cl lu ut tc ch h f fa ai il lu ur re e Calculate the average of the three air gap readings If the average air gap between the three readings is out of specification remove the armature assembly...

Page 45: ...e sensor onto the straight portion of the compressor discharge fitting as shown below Figure 39 Temperature sensor shown correctly installed 3 Verify the temperature sensing pad is touching the fittin...

Page 46: ...l spring clip over the plastic clip to verify the temperature sensor stays on the fitting Figure 41 Spring clip shown correctly installed S Se ec ct ti io on n 5 5 C Co om mp pr re es ss so or r S Se...

Page 47: ...owered truck units Following these standards will result in a system that operates as designed Hose Layout and Design Determining ahead of time which types of fittings to use best hose routing along w...

Page 48: ...ngs Additionally hoses spanning the gap between the vehicle s engine the unit s compressor and the vehicle s frame must be properly secured to both the frame and the engine block This limits normal en...

Page 49: ...nts in such a way as to allow for movement I Im mp po or rt ta an nt t Hoses should never be stretched tight Hoses must be installed onto components in such a way as to allow for movement h ho ow we e...

Page 50: ...nts Band wraps can be used to secure unit hoses to existing vehicle harnesses frame mounts or electrical harnesses Insulated clamps can be used to secure hose s to vehicle s chassis when no existing a...

Page 51: ...n Abrasion protection is required on all refrigeration hoses where rubbing and chafing may be an issue Hoses must also be secured in these areas as well to minimize movement Always keep refrigeration...

Page 52: ...re used on vehicle powered truck units Tube O ORS and Flare Tube O fittings are used only on the compressor while ORS O Ring Seal fittings are used for the majority of the other connections Tube O and...

Page 53: ...l for the proper size hoses required for your specific model Typical hose sizes for vehicle powered trucks are shown below Determining Hose Size Measure the inside diameter I D of the hose to determin...

Page 54: ...0 10 335682 12 335683 16 334997 Tightening Refrigeration Hose Fittings A common cause of refrigeration leaks is caused by over tightening the fittings Always use two wrenches while tightening refriger...

Page 55: ...l le e without being on a section of hose between the frame and the engine The splice connector can be mounted vertically or horizontally The refrigerant hose must be secured on both sides of the spli...

Page 56: ...ach the liquid injection hose with 4 Flare fitting securely V Ve er ri if fy y o on nl ly y t th he e l li iq qu ui id d i in nj je ec ct ti io on n h ho os se e i is s a at tt ta ac ch he ed d t to o...

Page 57: ...moving components 4 P Trap to be formed immediately before vertical run upwards to compressor while maintaining minimum bend radius with no kinks It should be a minimum of 2 below the lowest point of...

Page 58: ...nd 204 1128 Hose Cutting Tools 204 677 TK 2000 Multi Refrigerant Hose Nipple Assembly Appropriately Sized Clips and Cage POE Refrigerant Oil 203 505 N No ot te es s 1 The two black O rings on the nipp...

Page 59: ...Oi il l t th he e N Ni ip pp pl le e 3 Lubricate the nipple and both O Rings with a generous amount of POE or PVE oil depending on the application This MUST be done to lower the force of nipple insert...

Page 60: ...o the channels on each arm Figure 59 Clips shown installed correctly C Cl lo os se e t th he e C Cl li ip ps s 7 Use the fitting tool 204 1045 or 204 1128 to close the clips The tool should be positio...

Page 61: ...of the connectors DC Low Voltage Harnesses Vehicle powered truck units operate on low voltage 12 Vdc with harnesses routed to the systems individual components and to the vehicle s battery or ignition...

Page 62: ...I Im mp po or rt ta an nt t All connectors must be clean and locked together securely Always follow these procedures when connecting sealed connectors 1 Apply a light film of dielectric grease to the...

Page 63: ...mating connector on the back of the controller I Im mp po or rt ta an nt t Harnesses with factory installed connectors are not be cut shortened or otherwise modified by installer Figure 62 Typical uns...

Page 64: ...pes of sealed splice connectors are provided by Thermo King heat shrink butt splice and a parallel crimp connector with heat shrink tubing I Im mp po or rt ta an nt t No other types of splice connecti...

Page 65: ...res Always follow these procedures when making sealed butt splice connections 1 Strip both wire ends the same length 2 Insert both wires all the way into splice 3 Crimp splice securely using correct c...

Page 66: ...ways follow these procedures when making a parallel crimp connection 1 Strip both wires 50 in 12 mm 2 Slide shrink tubing onto wire away from joint 3 Position wires side by side inside crimp 4 Crimp s...

Page 67: ...ed in the installation kit The installer is responsible to install the correct size terminal lugs for the specific size battery terminals I Im mp po or rt ta an nt t 1 Terminal lug must be sized for c...

Page 68: ...the large in line fuse to the unit s power wire may need to be shortened to eliminate excess or coiled wire Large In line fuse should be positioned v ve er rt ti ic ca al ll ly y to help promote wate...

Page 69: ...e shrink tubing onto wire and move it away from the wire end 4 Install proper size terminal lug and crimp securely using correct crimper tool 5 Position heat shrink tubing over lug so it does not inte...

Page 70: ...i ic ci ia an n a an nd d c co om mp pl ly y w wi it th h a al ll l N NE EC C s st ta at te e a an nd d l lo oc ca al l c co od de es s Units equipped with the standby option Models 20 and 50 come pre...

Page 71: ...p Loop Standby Power Cable Wiring Connections Figure 64 115V 1PH 60HZ Wiring Connections Figure 65 230V 1PH 60HZ Wiring Connections Figure 66 230V 3PH 60HZ Wiring Connections S Se ec ct ti io on n 7 7...

Page 72: ...nts Protective cover split loom shields or high temperature wraps installer supplied should be used if necessary Protective Covers and Guards Protective covers and guards are recommended for any expos...

Page 73: ...rnesses through Metal Holes Electrical wires routed through metal holes must be protected from damage and to avoid electrical shorts Figure 67 All burrs and sharp edges must also be removed from all h...

Page 74: ...d cause damage to electrical harnesses if they are not properly shielded Electrical harnesses need a shield when located within 4 00 in 102 mm from engine exhaust manifolds catalytic converters and mu...

Page 75: ...ese valves must be installed securely onto the end of the drain hose with a band wrap Drain Hose Standards Evaporators and drain hoses must have sufficient slope to verify the water drains away from t...

Page 76: ...h neutral alcohol cure silicone sealant One way water valves kazoos must be installed securely onto the end of the drain hose with a band wrap Drains that run inside the walls should be installed in a...

Page 77: ...ing All MAX R404A R 452A system evaporators are equipped with drain heaters They are also available as an option on Non MAX R 134a systems Spectrum Models when heater wires are installed in fresh comp...

Page 78: ...nosemounted SPECTRUM units ONLY All three drain hoses must be connected together into a single hose and immediately exit the cargo box Heater wires must extend into the drain pan and inserted into eac...

Page 79: ...DSR III Controllers both use the same DSR In Cab Display The DSR II and DSR III controllers have different firmware software that programs the controllers The DSR II controllers have version 3 38 80...

Page 80: ...1 When the vehicle battery and the optional Electric Standby power source are connected simultaneously 2 When the load compartment doors are opened while the unit is operating The LCD display has many...

Page 81: ...e information menu press and hold the Up Arrow key and the Enter key simultaneously for three seconds The information menu contains a display test activates all pixels on the display displays the soft...

Page 82: ...t Reefer Microprocessor Controller Menus and Screens viewed at the in cab control box S Se ec ct ti io on n 9 9 C Co on nf fi ig gu ur ri in ng g S So of ft tw wa ar re e a an nd d C Co on nt tr ro ol...

Page 83: ...oaded by the installing dealer The configuration files can be found on TSA Info Central using the following path Home Software Downloads Truck and Trailer Microprocessors Truck Microprocessor Updates...

Page 84: ...installed A dialogue box should appear asking What do you want to do with the file 9 Click the save as option and save the file to your desktop 10 Launch WinTrac and connect to the DSR controller 11...

Page 85: ...Figure 75 Cover removed from box showing switch positions and three jumper orientations d Once WinTrac has established communication with the controller the settings box appears which shows the config...

Page 86: ...window and close down WinTrac Disconnect power to the unit by turning the truck ignition off and or unplugging the unit from shore power 16 Verify that the correct configuration was stored by re powe...

Page 87: ...s can also be used e g gauge manifold s vacuum pump micron gauge etc N No ot te e Depending on the unit it will require a 2 3 or 4 point evacuation The minimum number of evacuation points required for...

Page 88: ...88 TK 56430 18 IP EN Figure 76 2 Point Evacuation using Thermo King Evacuation Station S Se ec ct ti io on n 1 10 0 S Sy ys st te em m E Ev va ac cu ua at ti io on n P Pr ro oc ce ed du ur re es s...

Page 89: ...56430 18 IP EN 89 Figure 77 2 Point Evacuation using Separate Vacuum Pump and Micron Gauge S Se ec ct ti io on n 1 10 0 S Sy ys st te em m E Ev va ac cu ua at ti io on n P Pr ro oc ce ed du ur re es...

Page 90: ...90 TK 56430 18 IP EN Figure 78 3 Point Evacuation using Thermo King Evacuation Station S Se ec ct ti io on n 1 10 0 S Sy ys st te em m E Ev va ac cu ua at ti io on n P Pr ro oc ce ed du ur re es s...

Page 91: ...56430 18 IP EN 91 Figure 79 3 Point Evacuation using Separate Vacuum Pump and Micron Gauge S Se ec ct ti io on n 1 10 0 S Sy ys st te em m E Ev va ac cu ua at ti io on n P Pr ro oc ce ed du ur re es...

Page 92: ...92 TK 56430 18 IP EN Figure 80 4 Point Evacuation using Thermo King Evacuation Station S Se ec ct ti io on n 1 10 0 S Sy ys st te em m E Ev va ac cu ua at ti io on n P Pr ro oc ce ed du ur re es s...

Page 93: ...56430 18 IP EN 93 Figure 81 4 Point Evacuation using Separate Vacuum Pump and Micron Gauge S Se ec ct ti io on n 1 10 0 S Sy ys st te em m E Ev va ac cu ua at ti io on n P Pr ro oc ce ed du ur re es...

Page 94: ...Units with 544 xx Firmware Some units B 100 V 220 V 320 V 800 are equipped with Evacuation Mode which energizes all of the normally closed valves This eliminates the need to manually open the normall...

Page 95: ...ge reads 500 microns Continue to pump down the system for an additional one hour after the system reached 500 microns N No ot te e If the system will not pump down to 500 microns there is likely a lea...

Page 96: ...sconnect the vacuum pump and micron gauge 7 D Di is sa ab bl le e E Ev va ac cu ua at ti io on n M Mo od de e To return to the Standard Display Press and hold the Up Arrow key and Down Arrow key for s...

Page 97: ...1 16 69 9 k kP Pa a p pr re es ss su ur re e i in n a a f fu ul ll l c cy yl li in nd de er r a at t 7 70 0 F F 2 21 1 C C Use a regularly calibrated electronic leak detector capable of detecting fluo...

Page 98: ...ss s t th ha at t c ca an n l le ea ad d t to o f fa ai il lu ur re e o of f c co om mp po on ne en nt ts s O Ob bs se er rv ve e t th he e p pr ro op pe er r h ha an nd dl li in ng g o of f c cy yl l...

Page 99: ...ply bottle Adjust the pressure regulator to the correct pressure for the required procedure Refer to Table 10 p 99 4 Purge the system from the high side to the low side Table 10 Testing Pressures Proc...

Page 100: ...gh Side valve on the gauge manifold set and add the recommended amount of refrigerant for your unit Refer to the unit specific installation manual to identify the recommended initial charging amount o...

Page 101: ...roadside compressor as possible Do NOT connect the Suction Low Side hose to the Suction service port at the roadside compressor Compressor damage may occur 3 Connect the gauge manifold set red hose Hi...

Page 102: ...R valve on units with hot gas heat will result in a reduction of heat capacity Secondly on multi temperature units the CPR valve is used for zone priority zone control When both fresh and frozen zones...

Page 103: ...e per Thermo King s Installation Standards and Procedures Guide and the unit operates as it should Commissioning Forms should be completed for all unit installations and retained by the i in ns st ta...

Page 104: ...104 TK 56430 18 IP EN Figure 83 Commissioning Form Page 1 of 3 S Se ec ct ti io on n 1 14 4 C Co om mm mi is ss si io on ni in ng g a an nd d P PD DI I F Fo or rm ms s...

Page 105: ...TK 56430 18 IP EN 105 Figure 84 Commissioning Form Page 2 of 3 S Se ec ct ti io on n 1 14 4 C Co om mm mi is ss si io on ni in ng g a an nd d P PD DI I F Fo or rm ms s...

Page 106: ...106 TK 56430 18 IP EN Figure 85 Commissioning Form Page 3 of 3 S Se ec ct ti io on n 1 14 4 C Co om mm mi is ss si io on ni in ng g a an nd d P PD DI I F Fo or rm ms s...

Page 107: ...TK 56430 18 IP EN 107 Figure 86 Pre Delivery Inspection PDI Form Page 1 of 2 S Se ec ct ti io on n 1 14 4 C Co om mm mi is ss si io on ni in ng g a an nd d P PD DI I F Fo or rm ms s...

Page 108: ...108 TK 56430 18 IP EN Figure 87 Pre Delivery Inspection PDI Form Page 2 of 2 S Se ec ct ti io on n 1 14 4 C Co om mm mi is ss si io on ni in ng g a an nd d P PD DI I F Fo or rm ms s...

Page 109: ...TK 56430 18 IP EN 109 N No ot te es s...

Page 110: ...110 TK 56430 18 IP EN N No ot te es s...

Page 111: ...TK 56430 18 IP EN 111 N No ot te es s...

Page 112: ...rs truck bodies buses air shipboard containers and railway cars since 1938 For more information visit www thermoking com or www tranetechnologies com Thermo King has a policy of continuous product and...

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