V-200/V-300 Series

TK 50982-1-MM (Rev. 3, 02/03)

Copyright© 2003 Thermo King Corp., Minneapolis, MN, USA.

Printed in USA.
The maintenance information in this manual covers unit models:
V-200-10 (918247) V-300-10 (918260)
V-200-20 (918248) V-300-20 (918261)
V-200 MAX-10 (918249) V-300 MAX-10 (918262)
V-200 MAX-20 (918250) V-300 MAX-20 (918263)
V-200 MAX TC-10 (918255) V-300 MAX TC-10 (918264)
V-200 MAX TC-20 (918256) V-300 MAX TC-20 (918265)
V-200 MAX TC-20 SAFEWAY (919966)
For further information, refer to:
V-200/V-300 Series Operating Manual TK 51877
V200 Series Parts manual TK 50781
V300 Series Parts Manual TK 51308
V200 MAX TC TK 51140
Diagnosing Thermo King Refrigeration Systems TK 5984
Evacuation Station Operation and Field Application TK 40612
Tool Catalog TK 5955
The information in this manual is provided to assist owners, operators and service people in the proper
upkeep and maintenance of Thermo King units.

This manual is published for informational purposes only and the information so provided should
not be considered as all-inclusive or covering all contingencies. If further information is required,
Thermo King Corporation should be consulted.

Sale of product shown in this manual is subject to Thermo King’s terms and conditions
including, but not limited to, the Thermo King Limited Express Warranty. Such terms and
conditions are available upon request. Thermo King’s warranty will not apply to any
equipment which has been “so repaired or altered outside the manufacturer’s plants as,
in the manufacturer’s judgment, to effect its stability.”

No warranties, express or implied, including warranties of fitness for a particular

purpose or merchantability, or warranties arising from course of dealing or usage of
trade, are made regarding the information, recommendations, and descriptions
contained herein. Manufacturer is not responsible and will not be held liable in contract
or in tort (including negligence) for any special, indirect or consequential damages,
including injury or damage caused to vehicles, contents or persons, by reason of the
installation of any Thermo King product or its mechanical failure.

2
 Recover Refrigerant
At Thermo King, we recognize the need to preserve the environment
and limit the potential harm to the ozone layer that can result from
allowing refrigerant to escape into the atmosphere.

We strictly adhere to a policy that promotes the recovery and limits

the loss of refrigerant into the atmosphere.

In addition, service personnel must be aware of Federal regulations

concerning the use of refrigerants and the certification of
technicians. For additional information on regulations and technician
certification programs, contact your local Thermo King dealer.

R-404A/R-134a
WARNING: Use ONLY Polyol Ester based refrigeration compressor oil (TK P/N 203-413) in
R-404A and R-134a units.

DO NOT use Polyol Ester based oil in standard Thermo King units.

DO NOT mix Polyol Ester and standard synthetic compressor oils.

Keep Polyol Ester compressor oil in tightly sealed containers. If Polyol Ester oil becomes
contaminated with moisture or standard oils, dispose of properly—DO NOT USE!

WARNING: When servicing Thermo King R-404A and R-134a units, use only those service
tools certified for and dedicated to R-404A or R-134a refrigerant and Polyol Ester
compressor oils. Residual non-HFC refrigerants or oils will contaminate R-404A and
R-134a systems.

3
4
Table of Contents
List of Figures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
General Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Refrigeration Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Electrical Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
High Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Low Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
R-134A REFRIGERATION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
R-404A REFRIGERATION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Maintenance Inspection Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Unit Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Condenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Evaporator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Control Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
In-Cab Control Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Oil Separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Liquid Injection System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Evaporator Drain Tube Heaters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Electric Standby Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Unit Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Protection Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Control Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
P.C. Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Common Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Standby Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Multi-Temp Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Defrost Timer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Clutch Timer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
EFR Selector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Unit Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Thermostat Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Serial Number Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
In-Cab Control Box Operating Instructions (M-13, M-16, M-17) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Display Return Air (Box) Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Display Setpoint Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Enter Setpoint Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Defrost Mode Operation (M-13, and M-16 only). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Unit Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Weekly Pretrip Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Starting the unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
After Start Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Loading Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Post Load Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

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Table of Contents

Electrical Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Trouble Shooting In-Cab Control Box M-13 and M-16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Trouble Shooting M-17 In-Cab Control Box (TC Units Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Defrost System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Defrost Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Defrost Timer Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Manual Defrost Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Defrost Termination Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Defrost Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Defrost Solenoid Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Testing The Defrost System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Defrost Timer Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Condenser Fan Pressure Switch (CFPS) R-134a Units Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Testing CFPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Liquid Injection System (R-404A Units Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Testing Liquid Injection Valve And Metering Orifice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Electric Standby Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Refrigeration Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Refrigerant Charge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Charging the Refrigeration System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Checking the Refrigerant Charge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Checking Compressor Oil Charge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
High Pressure Cutout Switch (HPCO) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Low Pressure Cutout Switch (LPCO) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Cleanup Procedure for Small Truck Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Refrigeration Service Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Condenser Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Drier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
High Pressure Cutout And Condenser Fan Pressure Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Solenoid Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Oil Separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Liquid Injection Metering Orifice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Testing the Liquid Injection Solenoid Valve and Metering Orifice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Discharge Check Valve (Model 20 Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Testing the Discharge Check Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Check Valve Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Check Valve Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Evaporator Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Expansion Valve Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Low Pressure Cutout Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Suction Receiver Tank (Heat Option Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Suction Pressure Regulator Valve (TC Units Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
In-line Check Valves (TC Units Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Replacing Refrigerant Hoses (Speedy Clip System) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Structural Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Unit Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Evaporator Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Condenser Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Unit Mounting Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

6
 Table of Contents

Clutch Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Clutch Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Clutch Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Clutch Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Shaft Seal Cover and Shaft Seal: Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
System Compressor and Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Checking the Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Belt Tensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Engine Driven Compressor Belt and Pulleys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Electric Standby Compressor Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Over-the-Road Mechanical Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Electric Standby Mechanical Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Electric Standby Service Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Refrigeration Diagnosis Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Diagram Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

7
Table of Contents

8
List of Figures
Figure 1: Typical P.C. Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Figure 2: P.C. Board Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Figure 3: Fuse 4/1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Figure 4: Thermostat Algorithm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Figure 5: Condenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Figure 6: Evaporator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Figure 7: Control Box Side Of Model 20 Condenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Figure 8: Refrigeration Component Side of Model 20 Condenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Figure 9: M13 & 16 In-Cab Control Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Figure 10: M-17 In-Cab Control Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Figure 11: On/Off Key & LED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Figure 12: Celsius/Fahrenheit LED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Figure 13: Setpoint Key & Dial . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Figure 14: Misc. LED’s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Figure 15: Defrost Key & LED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Figure 16: On/Off Key and Defrost Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Figure 17: Setpoint Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Figure 18: Entering Setpoint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Figure 19: BLOCK DIAGRAM M-13, M-16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Figure 20: BLOCK DIAGRAM M-17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Figure 21: Defrost Timer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Figure 22: Testing CFPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Figure 23: Charging Refrigeration System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Figure 24: High Pressure Cutout Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Figure 25: Connecting Flushing Compressor to Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Figure 26: Refrigeration Systems In Model 20 Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Figure 27: Engine Driven Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Figure 28: Check Valve Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Figure 29: Location of Expansion Valve Bulb . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Figure 30: Completely Wrap Bulb with Tape . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Figure 31: Cutting The Hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Figure 32: Fitting The Clips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Figure 33: Lubricating The Cylinder Of The Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Figure 34: Manually Inserting The Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Figure 35: Positioning The Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Figure 36: Fitting The Clips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Figure 37: Tightening Both Clips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Figure 38: Condenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Figure 39: Evaporator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Figure 40: Remove Center Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Figure 41: Remove Drive Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Figure 42: Remove Snap Ring and Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Figure 43: Remove Pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Figure 44: Remove Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Figure 45: Inspect Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Figure 46: Install Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Figure 47: Install Pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Figure 48: Install Cover and Snap Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Figure 49: Install Shims and Drive Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

9
List of Figures

Figure 50: Remove Shaft Seal Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

Figure 51: Remove Shaft Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Figure 52: Inspect Shaft Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Figure 53: Place Guide on Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Figure 54: Place Shaft Seal on Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Figure 55: Press Seal Into Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Figure 56: Install Shaft Seal Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Figure 57: Proper Shaft Seal Cover Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Figure 58: Clutch Remover P/N 204-806 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Figure 59: Compressor Holder P/N 204-807 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Figure 60: Clutch Installation Kit P/N 204-890 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Figure 61: Snap Ring Pliers P/N 204-808 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Figure 62: Shaft Seal Kit P/N 204-805 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Figure 63: Pulley Arbor P/N 204-804 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Figure 64: Draining the Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

10
Safety Precautions

General Practices Refrigerant

1. ALWAYS WEAR GOGGLES OR SAFETY Although fluorocarbon refrigerants are classified
GLASSES. Refrigerant liquid, refrigeration as safe refrigerants, certain precautions must be
oil, and battery acid can permanently damage observed when handling them or servicing a unit
the eyes (see First Aid under Refrigeration in which they are used. When exposed to the
Oil). atmosphere from the liquid state, fluorocarbon
refrigerants evaporator rapidly, freezing anything
2. Never operate the unit with the compressor
they contact.
discharge valve closed.
3. Keep your hands, clothing and tools clear of First Aid
the fans and belts when the unit is running.
In the event of frost bite, the objectives of First
This should also be considered when opening
Aid are to protect the frozen area from further
and closing the compressor service valves.
injury, to warm the affected area rapidly and to
4. Make sure gauge manifold hoses are in good maintain respiration.
condition. Never let them come in contact
• EYES: For contact with liquid, immediately
with a belt, fan motor pulley, or any hot
flush eyes with large amounts of water and get
surface.
prompt medical attention.
5. Never apply heat to a sealed refrigeration
• SKIN: Flush area with large amounts of
system or container.
lukewarm water. Do not apply heat. Remove
6. Fluorocarbon refrigerants, in the presence of contaminated clothing and shoes. Wrap burns
an open flame or electrical short, produce with dry, sterile, bulky dressing to protect
toxic gases that are severe respiratory irritants from infection/injury. Get medical attention.
capable of causing death. Wash contaminated clothing before reuse.
7. Make sure all mounting bolts are tight and are • INHALATION: Move victim to fresh air and
of correct length for their particular use CPR if necessary. Stay with victim until
application. arrival of emergency medical personnel.
8. Use extreme caution when drilling holes in the
unit. The holes may weaken structural Refrigeration Oil
components, and holes drilled into electrical Avoid refrigeration oil contact with the eyes.
wiring can cause fire or explosion. Avoid prolonged or repeated contact of
9. Use caution when working around exposed refrigeration oil with skin or clothing. Wash
coil fins. The fins can cause painful thoroughly after handling refrigeration oil to
lacerations. prevent irritation.
10. Use caution when working with a refrigerant First Aid
or refrigeration system in any closed or
confined area with a limited air supply (for In case of eye contact, immediately flush with
example, a truck box or garage). Refrigerant plenty of water for at least 15 minutes. Wash skin
tends to displace air and can cause oxygen with soap and water. CALL A PHYSICIAN.
depletion resulting in suffocation and possible
death. Electrical Hazards
11. EPA Section 608 Certification is needed to
work on refrigeration systems. High Voltage
When servicing or repairing a refrigeration unit,
the possibility of serious or even fatal injury from
electrical shock exists. Extreme care must be used

11
Safety Precautions

when working with an operating refrigeration First Aid

unit. Lethal voltage potentials can exist on
IMMEDIATE action must be initiated after a
connections in the high voltage tray of the control
person has received an electrical shock. Obtain
box.
immediate medical assistance if available.
Precautions The source of shock must be immediately
removed by either shutting down the power or
1. When working on high voltage circuits on the
removing the victim from the source. If it is not
refrigeration unit, do not make any rapid
possible to shut off the power, the wire should be
moves. If a tool drops, do not grab for it.
cut with either an insulated instrument (e.g., a
People do not contact high voltage wires on
wooden handled axe or cable cutters with heavy
purpose. It occurs from an unplanned
insulated handles) or by a rescuer wearing
movement.
electrically insulated gloves and safety glasses.
2. Use tools with insulated handles that are in Whichever method is used do not look at the wire
good condition. Never hold metal tools in while it is being cut. The ensuing flash can cause
your hand if exposed, energized conductors burns and blindness.
are within reach.
If the victim has to be removed from a live circuit,
3. Treat all wires and connections as high pull the victim off with a non-conductive material.
voltage until a meter and wiring diagram show Use the victim’s coat, a rope, wood, or loop your
otherwise. belt around the victim’s leg or arm and pull the
victim off. DO NOT TOUCH the victim. You can
4. Never work alone on high voltage circuits on
receive a shock from current flowing through the
the refrigeration unit, another person should
victim’s body. After separating the victim from
always be standing by in the event of an
power source, check immediately for the presence
accident to shut off the refrigeration unit and
of a pulse and respiration. If a pulse is not present,
to aid a victim.
start CPR (Cardio Pulmonary Resuscitation) and
5. Have electrically insulated gloves, cable call for emergency medical assistance. If a pulse
cutters and safety glasses available in the is present, respiration may be restored by using
immediate vicinity in the event of an accident. mouth-to-mouth resuscitation, but call for
emergency medical assistance.

Low Voltage
Control circuits used in the refrigeration unit are
low voltage (12/24 volts dc). This voltage
potential is not considered dangerous, but the
large amount of current available (over 30
amperes) can cause severe burns if shorted or
ground.
Do not wear jewelry, watch or rings. These items
can short out electrical circuits and cause severe
burns to the wearer.

12
Specifications

GENERAL
Compressor TK208R, or SELTEC TM-13XD
or SELTEC TM-15XD
Compressor Oil Charge 1 Compressor systems 12 oz. (354.8 ml)
2 Compressor systems 24 oz. (709.7 ml)
Compressor Oil Type Polyol Ester P/N 203-413
Defrost Method: Hot gas
Defrost Timer: Initiation Interval Adjustable, 1 hour to 10 hours
Termination Interval Termination is not timed.
Defrost is terminated by Klixon switch.
R-134A REFRIGERATION SYSTEM (V-200/V-300-10, V-200/V-300-20)
Refrigerant Charge V-200 3.0 lbs. (1.36 Kg)
V-300 3.85 lbs. (1.75 Kg)
Defrost Termination Switch: Opens 48.0 ± 5.4 F (8.9 ± 3.0 C)
Closes 36.0 ± 5.4 F (2.2 ± 3.0 C)
High Pressure Cutout Switch: Opens 300 ± 10 psi (2068 ± 69 kPa)
Closes 200 ± 20 psi (1378 ± 69 kPa)
Low Pressure Cutout: Opens 5 to 11 in. Hg vacuum (-17 to -34 kPa)
Closes 4 to 7 psi (28 to 48 kPa)
Condenser Fan Pressure Switch: Opens 130 ± 10 psi (896 ± 69 kPa)
Closes 180 ± 10 psi (1241 ± 69 kPa)

13
Specifications

R-404A REFRIGERATION SYSTEM (V-200/V-300 Max-10, V-200/V-300

Max-20, V-200/V-300 Max TC-10, V200/300-Max TC-20)
Refrigerant Charge V-200 2.75 lbs. (1.25 Kg)
V-200TC 4.00 lbs. (1.81 Kg)
V-300 4.00 lbs. (1.81 Kg)
Defrost Termination Switch: Opens 48.0 ± 5.4 F (8.9 ± 3.0 C)
Closes 36.0 ± 5.4 F (2.2 ± 3.0 C)
Liquid Injection Switch: Opens 200 ± 5 F (93 ± 3 C)
Closes 230 ± 5 F (110 ± 3 C)
High Pressure Cutout Switch: Opens 450 ± 10 psi (3100 ± 69 kPa)
Closes 375 ± 10 psi (2585 ± 69 kPa)
Low Pressure Cutout: Opens 5 to 11 in. Hg vacuum(-17 to -34 kPa)
Closes 4 to 7 psi (28 to 48 kPa)
Suction Pressure Regulator 26 psi (180 kPa)
Condenser Solenoid Pressure Switch: Opens 300 ± 10 psi (2068 ± 69 kPa)
Closes 200 ± 20 psi (1378 ± 69 kPa)

14
 Specifications

ELECTRICAL SYSTEM
Fuses
Fuse 1: Evaporator Fan Motor (EF1) 12V Units = 15 amps, 24V Units = 10 amps
Fuse 2: Evaporator Fan Motor (EF2) 12V Units = 15 amps, 24V Units = 10 amps
Fuse 3: 2A Circuits 12V Units = 25 amps, 24V Units = 20 amps
Fuse 4: 2R1 Circuit 12V & 24V Units = 3 amps
Fuse 4/1: Cab Control Box 12V & 24V Units = 3 amps
Fuse 5 on TC Units: Remote Evaporator Fan Motor (EF3) 12V Units = 5 amps, 24V Units = 3 amps

Fuse 6 on TC Units: Transformer Fuse 12V & 24V Units = 4 amps

Fuse 7: Defrost Circuit 12V & 24V Units = 1 amps

Condenser Fan Motors

Voltage Full Load rpm Full Load Current

12 Vdc 2800 8.0 to 9.5 amps @ 13Vdc
24 Vdc 2800 3.9 to 4.1 amps @ 26Vdc

Evaporator Fan Motors

Voltage Full Load rpm Full Load Current

12 Vdc 2800 6.1 to 6.2 amps @ 13Vdc
24 Vdc 2800 3.5 to 3.9 amps @ 26Vdc

Coils for Hot Gas Solenoids, Condenser Solenoids, and Liquid Line Solenoids

Voltage Current Resistance

12 Vdc 2.3 amps 5.2 ohms
24 Vdc 1.3 amps 20 ohms

Liquid Injection Solenoid Coils

Voltage Current Resistance

12 Vdc 0.7 amps 17 ohms
24 Vdc 0.2 amps 67 ohms

BELT TENSION (Using Tool P/N 204-427) Field Reset

Engine Driven Compressor Belt 58

Electric Standby Compressor Belt 58

15
Specifications

16
Maintenance Inspection Schedule

Weekly Monthly Semi- Annual Inspect/Service These Items

Annual
ELECTRICAL
• • Check defrost initiation and termination.
• • Check thermostat cycle sequence.
• • Check operation of protection shutdown circuits.
• Check thermostat and thermometer calibration in 0 C (32 F)
ice-water bath.
• Inspect wire harness for damaged wires or connections.
• Inspect/replace DC fan motor brushes.
REFRIGERATION
• • Check refrigerant level.
• Replace dehydrator.
STRUCTURAL
• • • • Visually inspect unit and refrigerant hoses for fluid leaks.
• • • • Visually inspect unit for damaged, loose or broken parts.
• • • • Clean defrost drains.
• • • Inspect belts for condition and proper tension (belt tension tool P/N
204-427).
• • • Clean entire unit including evaporator coil and condenser coil.
• • Check all unit mounting bolts, brackets, lines, hoses, etc.

17
Maintenance Inspection Schedule

18
Unit Description

Introduction Compressor
The Thermo King V-200/V-300 and V-200/V-300 The compressor is mounted on and driven by the
MAX truck refrigeration systems are designed for truck engine. Refrigeration hoses or lines are used
low and medium temperature applications on vans to connect the condenser, the evaporator, the
and small-sized trucks with one compartment. compressor and any other components. Model 20
The V-200/V-300 MAX TC systems control the units have another compressor and an electric
temperatures in two compartments. There are two motor mounted in the condenser section for
basic models: electric standby operation.
• Model 10: Cool and defrost on truck engine The engine compressor is driven by a belt from
driven compressor operation. the engine. The electric standby compressor is
connected in parallel with the engine-driven
• Model 20: Cool and defrost on both truck
compressor. The standby compressor is driven by
engine driven compressor operation and
a belt from the electric motor. Both compressors
electric standby compressor operation.
use the same refrigeration system circuit. Check
The system consists of at least three separate valves isolate one compressor from the other
assemblies: the condenser, the evaporator, and the during operation.
compressor. TC units have an additional
Compressor operation is controlled by the
evaporator for the second compartment and an
thermostat, which energizes the compressor
optional TC/heat kit.
clutch during engine operation or starts the
electric motor and energizes the compressor
Condenser clutch on electric standby operation. The
The condenser has a unique design that allows it refrigeration system is protected by a high
to be mounted horizontally on the roof, or on the pressure cutout switch and a low pressure cutout
front of the truck box. switch.
When plugged into standby power, engine
Evaporator operation is automatically locked out. If the truck
engine is turned on while the power cord is still
An evaporator is mounted on the ceiling inside the plugged into a power receptacle, the unit will
truck box. The additional evaporator for the TC remain working in electric mode; the engine
unit is also mounted on the ceiling inside the truck driven compressor cannot be started until the
box. power cord is unplugged from the unit as the
selection of engine operation or standby operation
is automatic.

19
Unit Description

Control Circuits compressor. As the refrigerant passes through the

metering orifice it expands and evaporates,
The control circuits operate on 12V or 24V DC cooling the suction gas entering the compressor.
supplied by the truck batteries for engine This cooling effect is transferred to the discharge
operation. On standby operation, the power is gas leaving the compressor from the adjacent
rectified from an AC transformer. cavity in the compressor head. When the
discharge gas is cooled to 200 ± 5 F (93 ± 3 C),
In-Cab Control Box the liquid injection switch opens, the liquid
injection solenoid closes and refrigerant no longer
Unit operation is controlled with an in-cab control
flows through the liquid injection system.
box, which is mounted in the truck cab. It includes
an On-Off switch, manual defrost switch,
thermometer, thermostat, thermostat adjustment, Evaporator Drain Tube Heaters
and indicator lights. Evaporator heaters are used in R-404A units to
The TC unit has an additional in-cab control box avoid drain tube blockage because of ice
to operate the second compartment. It is switched accumulation inside the evaporator. Two
on and off from the main in-cab control box and harnesses are located inside the drain tube. These
includes a thermometer, thermostat, thermostat resistive wires melt the ice while the unit is in
adjustment and indicator lights. DEFROST mode.

Oil Separator Electric Standby Operation

An oil separator is a standard feature on all these During electric standby operation, the thermostat
units. The oil separator separates compressor oil controls the operation of the unit by energizing
from refrigerant vapor and returns the oil to the and de-energizing the power relay, the electric
compressor through the suction line. The oil relays, and the heat contactor. The thermostat
separator helps provide positive oil return at high places the unit in cool by energizing the power
compressor speeds and low operating relay and the electric relays.
temperatures. This feature enhances compressor The thermostat places the unit in null by
lubrication and extends compressor life. de-energizing all the relays and contactors. The
thermostat places the unit in heat by energizing
Refrigerant the heat contactor.
The V-200-10/V-300 and V-200/V-300-20 units When the power relay and the electric relays are
use R-134a refrigerant. The V-200/V-300 energized, they close contacts that energize the
Max-10, V-200/V-300 Max-20, V-200/V-300 fan relay, the motor contactor, and the electric
Max TC-10, V-200/V-300 Max TC-20 units use standby compressor clutch.
R-404A refrigerant.
When the heat contactor is energized, it energizes
the electric evaporator heaters and the fan relay.
Liquid Injection System
V-200/V-300 MAX and V-200/V-300 MAX TC
units use R-404A and have a liquid injection
system to limit discharge temperature of the
engine driven compressor. If the discharge gas
leaving the compressor reaches a temperature of
230 ± 5 F (110 ± 3 C) the liquid injection switch
closes, providing voltage to the liquid injection
solenoid. The solenoid opens a valve, allowing
liquid refrigerant to flow from the liquid line near
the drier inlet to the metering orifice attached to
the suction line fitting on the engine driven

20
 Unit Description

Unit Features Protection Features

• Condenser • High Pressure Cutout Switch - The High
Pressure Cutout Switch is a pressure sensitive
• ES200 Max Evaporator (V-200)
switch. It is located in the discharge line near
• ES300 Max Evaporator (V-300) the oil separator on Model 10 units. It is
located in the discharge check valve on Model
• Slim ES100 Max Evaporator for TC Units
20 units.
(V-200)
If the discharge pressure rises above the
• Slim ES150 Max Evaporator for TC Units
switch’s opening pressure, the switch opens
(V-300)
the circuit to the PR Relay to stop the unit.
• In-Cab Control Box with Digital LED The opening pressure for R-134a units is
Thermometer (Standard) 300 psi (2068 kPa). The opening pressure for
R-404A units is 450 psi (3100 kPa).
• Electronic Thermostat (Standard)
When the discharge pressure falls below the
• Defrost Timer (Standard)
switch’s closing pressure, the switch closes to
• Automatic Hot Gas Defrost (Standard) restart the unit. The closing pressure for
R-134a units is 200 psi (1379 kPa). The
• Manual Defrost Switch (Standard)
closing pressure for R-404A units is 375 psi
• Oil Separator (Standard) (2585 kPa).
• Seltec TM-13XD Engine Driven Compressor • Condenser Fan Pressure Switch - V200-20
(V-200 Standard) units with R-134a are equipped with a
Condenser Fan Pressure Switch. This switch
• Seltec TM-13XD Electric Standby
is located on the discharge line near the oil
Compressor (V-200 Standard)
separator. It helps the unit to keep the
• Seltec TM-13XD Engine Driven Compressor condenser head pressure higher in cool
(V-200 Standard) ambients and on-road. This feature allows
better control of the head pressure and the
• Seltec TM-13XD Electric Standby
thermostatic expansion valve, and at the same
Compressor (V-200 Standard)
time increases the evaporator pressure.
• Seltec TM-15XD Engine Driven Compressor Moreover, in cool ambients and on-road, the
(V-300 Standard) defrost is carried out quicker.
• Seltec TM-15XD Electric Standby When the condenser head pressure rises above
Compressor (V-300 Standard) 180 psi (1241 kPa), the condenser fan pressure
switch closes, starting the condenser fan.
• Condenser Fan Pressure Switch (Standard
with R-134a units) When the condenser head pressure falls below
130 psi (896 kPa), the condenser fan pressure
• Liquid Injection (Standard with Max units)
switch opens, stopping the condenser fan.
• Suction Pressure Regulator (Standard with
• Low Pressure Cutout Switch - The Low
Max units)
Pressure Cutout Switch is a pressure sensitive
• Evaporator Drain Heaters (Standard with Max switch located in the suction line. If the
units) pressure falls below 5 to 11 in. Hg vacuum
(-17 to -34 kPa), the switch opens the circuit
• Jet Lube™ Compressor Lubrication
to the PR Relay to stop unit operation.
(Standard)
• Jet Cool™ Compressor injection cooling
(Max Models) (Standard)

21
Unit Description

Control Box Fuses

P.C. Board 4

All Printed Circuit Boards manufactured by

Thermo King can be easily identified by the Part
6
Number stamped on them.
Even though that all P.C. Boards have a similar
layout, there are some differences from one to 5
another depending on the unit model and which
functions they carry out.
1
2

6 1 2 3
AJA1774

1. Fuse 1 4. Fuse 4
2. Fuse 2 5. Fuse 5 (TC units only)
3 3. Fuse 3 6. Fuse 6(TC units only)
Figure 2: P.C. Board Fuses

Fuses 1, 2, 3, and 4 are located on the P.C. Board.

TC units also have Fuse 5 and 6 on the P.C. Board.
5 4
Fuse 1 protects Evaporator Fan Motor 1 (EF1).
12V Units = 15 Amps
AJA1774
24V Units = 10 Amps
1. Connector C-4 5. Connector C-1 Fuse 2 protects Evaporator Fan Motor 2 (EF2).
2. Defrost Timer 6. Connector C-4 12V Units = 15 Amps
3. Relays 7. EFR Selector 24V Units = 10 Amps
4. Connector C-2
Fuse 3 protects the 2A circuit.
Figure 1: Typical P.C. Board 12V Units = 30 Amps
24V Units = 25 Amps
Connectors
Fuse 4 (Model 20 only) protects the 2R1 circuit.
All connector codes (C-1, C-2, etc.) are stamped
12V and 24V Units = 3 Amps
on the P.C. Board. Pins on the connectors are
numbered counter-clockwise. Fuse 5 (TC units only) protects the Remote
Evaporator Fan Motor (EF3).
12V Units = 15 Amps
24V Units = 10 Amps
Fuse 4/1 & Fuse 4/2 are located inside the In-Cab
Control Box. They protect the In-Cab Control box
from overload.
12V and 24V Units = 1 Amp

22
 Unit Description

The Defrost Relay will remain energized until the

defrost cycle is terminated by the Defrost
Termination Switch or the In-Cab Control Box
ON/OFF Switch is pressed.

Standby Relays
The standby relays CR1, CR2 and ER are located
on the P.C. Board in Model 20.
AGA1234
Commutation Relays (CR1 and CR2)
1
When the Commutation Relays are energized the
electric power for the unit changes from Battery
1. Fuse 4/1 Supply to Power Cord Supply.
Figure 3: Fuse 4/1
Electric Standby Relay (ER)
Fuse 6 (TC units only) When the Electric Standby Relay is energized it
12V Units = 15 amps turns on the AC Motor of the electric standby
compressor and de-energized engine driven
24V Units = 10 Amps compressor clutch.
Fuse 7 is located on the heat harness (optional
equipment) in the control box. Overload Relay (OL)

12V and 24V Units = 1 Amps The Overload Relay is located in the Control Box
below the P. C. Board.
Common Relays The Overload Relay switches off the unit when
the current draw through the AC Motor is
The common relays are located on the P.C. Board. excessive.
Power Relay (PR)
Multi-Temp Relays
The Power Relay is energized when the In-Cab
Control Box ON/OFF Switch is pressed (Unit The multi-temp relays FR2, PS2R, and PS3R are
Start) and the box temperature is higher than the located on the P.C. Board 11 used in TC units.
setpoint temperature.
Remote Fan Relay (FR2)
Evaporator Fan Relay (EFR) When the Remote Fan Relay is energized, battery
When the Fan Relay is energized, battery voltage voltage energizes evaporator fan motor EF3 in the
energizes evaporator fan motors EF1 and EF2. remote evaporator. It is controlled by the second
compartment thermostat.
Defrost Relay (D)
Pilot Solenoid Relay 2 (PS2)
The Defrost Relay controls operation of the
defrost cycle. When the Remote Fan Relay 2 is energized,
battery voltage energizes the liquid line solenoid
The Defrost Relay is energized when the In-Cab for the front evaporator. It is controlled by the first
Control Box Defrost Switch or by the Defrost compartment thermostat.
Timer completes the circuit through the Defrost
Termination Switch to ground.

23
Unit Description

Pilot Solenoid Relay 3 (PS3) The condenser fan is also controlled by the
condenser fan pressure switch (CFPS) on R-134a
When the Remote Fan Relay 3 is energized,
units. This normally open switch monitors the
battery voltage energizes the liquid line solenoid
compressor discharge pressure. When the
for the remote evaporator. It is controlled by the
discharge pressure rises to 180 psi (1241 kPa) the
second compartment thermostat.
switch closes and energizes the condenser fan.
When the discharge pressure drops below 130 psi
Defrost Timer (896 kpa) the switch opens and de-energizes the
The Defrost Timer automatically initiates the condenser fan.
Defrost Cycle at the preset time intervals. The
time interval can be set with the Red Round Thermostat Operation
Selector and the A and B Switches.
Cool
The Defrost Timer is powered directly by truck
battery, this means that the Defrost Timer is The thermostat energizes the (PR) at box
always counting (while the Defrost Termination temperatures higher than 5.4 F (3.0 C) above
Switch is closed) even when the unit is turned off. setpoint. The thermostat keeps PR energized
while the box temperature is higher than setpoint.
Clutch Timer The fans and the compressor run and the unit
cools.
The clutch timer is located on the P.C. Board. It
delays stand-by compressor clutch activation for Null
12 to 15 seconds when the stand-by electric motor
is first started. The clutch timer LED indicator The thermostat de-energizes PR at box
(P.C. Board) will be lit during this period of time. temperatures lower than setpoint. The thermostat
keeps PR de-energized while the box temperature
is lower than 5.4 F (3.0 C) above the setpoint
EFR Selector temperature. When PR is de-energized and the
The EFR selector allows the user to choose if the unit does not operate. On TC units PR is
evaporator fan keeps running or not in Null mode. de-energized only when the condition is required
If the jumper is between 1 and 2 the evaporator from both thermostats.
fan will run in Null mode. If the jumper is Temperature Temperature
between 2 and 3 the fan will not run in the Null Drop
COOL
Rise
mode.
3.0 C (5.4 F)
Above Setpoint
Unit Operation
Setpoint
These units cycle between Cool and Null to
maintain the box temperature at the thermostat
setpoint. Heat is available as an option. The NULL
operating modes are: Cool, Null, Heat (optional)
and Defrost. Figure 4: Thermostat Algorithm

The thermostat controls the operation of the unit

by energizing and de-energizing the Power Relay
(PR). When PR is energized it energizes the
evaporator fans, the condenser fans, and the
compressor clutch (or the compressor motor
contactor during electric stand-by operation). On
TC units PR is energized by either thermostat and
is de-energized when neither thermostat is calling
for cool.

24
 Unit Description

Defrost Serial Number Locations

The defrost cycle can be initiated any time the CONDENSER: Nameplate located on the front
evaporator coil temperature is below 36 F (2.2 C). inside edge of condenser frame.
Defrost is initiated automatically by the defrost EVAPORATOR: Nameplate located on the outside
timer, or manually by pressing the manual defrost edge of the evaporator cover.
switch.
ENGINE DRIVEN COMPRESSOR: Nameplate
The defrost relay energizes the defrost solenoid located on compressor body. The engine driven
valve (and the condenser solenoid valve on units compressor is located in the truck engine
equipped with the heat option) to route hot compartment.
refrigerant gas to the evaporator when PR is
STANDBY COMPRESSOR: Nameplate located on
energized. The defrost relay also interrupts power
compressor body. The Standby compressor is
to the evaporator and condenser fans during
located inside the Condenser assembly.
defrost.
The defrost cycle will continue until the
evaporator coil temperature rises 48 F (8.9 C),
causing the defrost termination switch to open
ending the defrost cycle. Defrost cycle can be also
terminated stopping the unit pressing the ON/OFF
Switch twice.

25
Unit Description

ARA047

Figure 5: Condenser

ARA050

Figure 6: Evaporator

26
 Unit Description

AJA1800

4
1

2
3

1. Transformer 3. Motor Contactor

2. Overload Relay 4. P.C. Board
Figure 7: Control Box Side Of Model 20 Condenser

27
Unit Description

AJA1801

4
10 5
6
9 7
8

1. Compressor 6. Liquid Line Sight Glass

2. Electric Motor 7. Defrost Solenoid Valve
3. Condenser Coil 8. Discharge Check Valve
4. Liquid Injection Valve 9. Oil Separator
5. Drier 10. Suction Pressure Regulator Valve
Figure 8: Refrigeration Component Side of Model 20 Condenser

28
Operating Instructions
Description
1. ON-OFF KEY (M-13, and M-16 only)
It is used to start/stop the unit. The internal
return air temperature will be automatically
displayed.

AJA1772
2. ON LED Indicator (M-13, and M-16 only)
When on, it indicates that the unit has been
Figure 9: M13 & 16 In-Cab Control Box
started by pressing the on-off key.
Introduction
Unit operation is controlled with a in-cab control 1
box, which is mounted in the truck cab. It includes
an on-off switch, manual defrost switch,
thermometer, thermostat, thermostat adjustment,
and indicator lights. The in-cab controller comes
in several model numbers as follow:
• V-200/V-300 =Model M-13 Control Box 2
AJA1802

• V-200/V-300 Max=Model M-13 Control

Figure 11: On/Off Key & LED
Box
• V-200/V-300 MaxTC=Model M-16 3. Celsius LED Indicator (M-13, M-16, M-17)
Control Box When on, it indicates the temperature being
displayed is in degrees celsius.
The M-13 controller cools single temp units.
4. Minus Sign
The M-16 controller cools multi-temp units. It can Indicates the temperature being displayed is
function as a master on a TC unit. below zero.
5. Fahrenheit LED Indicator (M-13, M-16,
M-17) When on, it indicates the temperature
being displayed is in degrees fahrenheit.

4
AJA1771
3
Figure 10: M-17 In-Cab Control Box

The TC unit has an additional in-cab control box

to operate the second compartment (M-17 control
5
box). It is switched on and off from the main AJA1803
in-cab control box and includes a thermometer,
thermostat, thermostat adjustment and indicator
lights.
Figure 12: Celsius/Fahrenheit LED
The M-17 controller is a remote, and cools the
second compartment on TC units. It operates as a
slave of M-16 with only a thermostat adjustment
for the second compartment.

29
Operating Instructions

6. Setpoint Adjust Dial (M-13, M-16, M-17)

It is used to adjust the setpoint temperature.
7. Setpoint Key (M-13, M-16, M-17) 11
It is used to display the setpoint temperature.

12
6
AJA1806

Figure 15: Defrost Key & LED

7
AJA1804
8. Power Cord LED (M-13, and M-16 only)
When on, it indicates the unit is plugged to the
A.C. voltage power supply.
Figure 13: Setpoint Key & Dial 9. AC Overload LED (M-13, and M-16 only)
When on, it indicates the unit has been
8 11 stopped by the AC overload relay.
10. Unit Operation LED (M-13, M-16, M-17)
9 When on, it indicates the unit is cooling.
When the unit is Stopped by the Thermostat,
HPCO or LPCO, the Unit Operation LED
must be “OFF” and the ON LED Indicator
10 AJA1805 must remain “ON”.
11. Defrost LED Indicator (M-13, and M-16 only)
Figure 14: Misc. LED’s When on, it indicates the unit is working on
defrost mode.
12. Manual Defrost Key (M-13 and M-16 only)
It is used to initiate the defrost cycle manually.

30
 Operating Instructions

In-Cab Control Box Operating

Instructions (M-13, M-16, M-17)
2
Display Return Air (Box)
Temperature
During normal operation (unit is ON and cooling),
the ON LED Indicator, the Unit Operation LED
and Celsius/Fahrenheit LED Indicator should be
AJA1808
ON; the return air (box) temperature should be 1
displayed on the screen. (See Figure 16.)

Display Setpoint Temperature

During normal operation, press the Setpoint Key 1. On/Off Key
to display the Setpoint Temperature.
2. Manual Defrost Key

Enter Setpoint Temperature Figure 16: On/Off Key and Defrost Key

Press and hold the Setpoint Key. The Setpoint

Temperature will be displayed on the screen. (See
Figure 17.)
13. At the same time, turn the Setpoint Adjust
Dial until the display shows desired
temperature.(See Figure 18.)
AJA1809
14. Release the Setpoint Key. The box
1
temperature will be displayed on the screen.
(See Figure 17.) 1. Setpoint Key

Figure 17: Setpoint Key

Defrost Mode Operation (M-13, and
M-16 only).
Initiate a Manual Defrost : Pressing the Manual
Defrost Key will start the defrost cycle if the 1
evaporator coil temperature is below 36 F (2.2
C). The defrost LED will go ON. The unit will
return to the cool mode automatically when
the defrost cycle is finished. (See Figure 16.)
2
Initiate a Automatic Defrost: If the evaporator coil
temperature is below 36 F (2.2 C), the defrost AJA1807
timer will initiate a defrost cycle. The defrost
LED will go ON. The unit will return to the
cool mode automatically when the defrost is 1. Setpoint Adjustable Dial
finished.(See Figure 16.) 2. Setpoint Key
Stop the Defrost Cycle: Press andrelease the Figure 18: Entering Setpoint
On-Off Key twice to stop the defrost cycle.
NOTE: The M-17 In-Cab control boxes do not
have all components shown in the illustrations.

31
Operating Instructions

Unit Operation 2. Press the On-Off switch in the In-Cab Control

Box, the ON LED should go ON.
Weekly Pretrip Inspection 3. Adjust the thermostat setting. Adjust the
The following Weekly Pretrip Inspection should thermostat setting in the second In-Cab
be completed before loading the truck. While the Control Box on TC units.
weekly inspection in not a substitute for regularly NOTE: The unit will work on Electric Standby
scheduled maintenance inspections, it is important even though the truck engine is started if the
part of the preventive maintenance program power cord is plugged in.
designed to head off operating problems before
they happen.
After Start Inspection
1. LEAKS. Inspect for refrigerant leaks and 1. THERMOSTAT. Dial the thermostat setting
worn refrigerant lines. above and below the box temperature to check
2. BELTS. Inspect for cracks, wear and proper thermostat operation.
belt tension. 2. PRE-COOLING. With the thermostat set at
3. MOUNTING BOLTS. Inspect bolts are the desired temperature, allow the unit to run
properly tightened. for one-half to one hour (longer if possible)
before loading the truck. Pre-cooling will
4. ELECTRICAL. Electrical connections should remove residual body heat and moisture from
be securely fastened. Wires and terminals the box interior and provide a good test of the
should be free of corrosion, cracks or refrigeration system.
moisture.
3. DEFROST. When the unit has finished
5. DEFROST DRAINS. Check the defrost drain pre-cooling the truck interior (evaporator
hose and fittings to be sure that they are open temperature dropped below 36 F [2.2 C),
so condensate can run out during defrosting. initiate a defrost cycle with the manual defrost
Check the bottom end of drain hose to be sure switch. The defrost cycle should end
that is not plugged or crushed. automatically.
6. STRUCTURAL. Visually check for physical
damage. Loading Procedure
7. REFRIGERANT CHARGE. Check for proper 1. Be sure the unit is OFF before opening the
refrigerant charge level. doors to minimize frost accumulation on the
evaporator coil and heat gain inside the box.
Starting the unit (Unit may be running when loading the truck
from a warehouse with door seals.)
Engine Operation 2. Spot check and record load temperature while
1. Start the truck engine. loading. Especially note any off-temperature
product.
2. Press the On-Off switch on the In-Cab Control
Box, the ON/OFF LED must go ON. 3. Load product so that there is adequate space
for air circulation completely around the load.
3. Adjust the thermostat setting. Adjust the DO NOT block the evaporator inlet or outlet.
thermostat setting in the second In-Cab
Control Box on TC units. 4. Products should be pre-cooled before loading.
Thermo King units are designed to maintain
Electric Standby Operation loads at the temperature at which they were
loaded. Transport refrigeration units are not
1. Connect the external power supply to the designed to pull hot loads down to
power receptacle. Make sure that the power temperature.
supply voltage is correct for the unit. The
Power Cord LED should go ON.

32
 Operating Instructions

Post Load Procedure

1. Be sure all the doors are closed and locked.
2. Adjust the thermostat(s) to the desired
temperature setpoint(s).
3. Start the unit.
4. Half an hour after loading, defrost the unit by
momentarily pressing the Manual Defrost
switch. If the coil temperature has dropped
below 36 F (2.2 C), the unit will defrost. The
defrost cycle should stop automatically.

Weekly Post Trip Checks

1. Wash the unit.
2. Check for leaks.
3. Check for loose or missing hardware.
4. Check for physical damage to unit.

33
Operating Instructions

34
Electrical Maintenance

Trouble Shooting In-Cab

Control Box M-13 and M-16
Before starting this trouble shooting, verify that
the In-Cab Control Box 12/24V selector is placed
in the correct position and check the ground
circuit through Pin 9 Connector C-9.

AJA1775

Figure 19: BLOCK DIAGRAM M-13, M-16

IMPORTANT: This trouble shooting only covers

In-Cab Control Box functions and should not be
considered as all-inclusive or meant to cover all
other electric contingencies; on these cases you
should check wiring against diagram.
SYMPTOMS REMEDY
Blank display when the ON/OFF Switch is pressed. 1st. Check voltage on Pin 3 C-9 (Pin 2 when is working
in electric mode).
2nd. Check Fuse 4/1 located inside the Cab Control
Box.
3rd. Replace Cab Control Box.

Unit is not cooling when the Box Temperature is 1st. Check voltage on Pin 6 C-9.
higher than the Setpoint Temperature.
2nd. Replace Cab Control Box.

Unit Operation LED is OFF when the unit is cooling. 1st. Check voltage on Pin 7 C-9.
2nd. Replace Cab Control Box.

35
Electrical Maintenance

SYMPTOMS REMEDY
Defrost cycle is not initiated when the Manual 1st. Box temperature must be higher than Setpoint
Defrost Switch is pressed. temperature: unit must be in cool mode.
2nd. Evaporator coil temperature must be lower than
36.0 ± 5.4 F (2.2 ± 3.0 C) (defrost termination switch
closed).
3rd. Keeping pressed the Manual Defrost Switch check
voltage on Pin 8 C-9.
4th. Replace Cab Control Box.

Defroster LED is OFF when the unit is in Defrost 1st. Check for open circuit on Wire Y, between Pin 4
Mode. C-9 and Pin 2 C-3.
2nd. Check voltage on Pin 8 C-9.
3rd. Replace Cab Control Box.

Temperature displayed is out of range. 1st. Check that the Cab Control Box 12/24V selector is
in the correct position.
2nd. Check the thermostat sensor.

Unit is not working in Electric Mode. 1st. Check the AC Overload Relay (AC Overload Led
must be OFF).
2nd. Check the fuses on the P.C. Board.
3rd. Check voltage on Pin 2 C-9.
4th. Check voltage on Pin 1 C-9.
5th. Replace Cab Control Box.

Unit is stopped by the AC OL Relay, but the AC 1st. Check voltage on Pin 5 C-9.
Overload LED is OFF.
2nd. Replace Cab Control Box.

36
 Electrical Maintenance

Trouble Shooting M-17 In-Cab

Control Box (TC Units Only)
Before starting this trouble shooting, verify that
the In-Cab Control Box 12/24V selector is placed
in the correct position and check the ground
circuit through Pin 9 Connector C-11.

AJA1810

Figure 20: BLOCK DIAGRAM M-17

IMPORTANT: This trouble shooting only covers

In-Cab Control Box functions and should not be
considered as all-inclusive or meant to cover all
other electric contingencies; on these cases you
should check wiring against diagram.

SYMPTOMS REMEDY
Blank display when the display on the main control 1st. Check voltage on Pin 3 C-11 (Pin 2 when is
box is reading. working in electric mode).
2nd. Check Fuse 4/1 located inside the Cab Control
Box.
3rd. Replace Cab Control Box.

Unit is not cooling when the Box Temperature is 1st. Check voltage on Pin 6 C-11.
higher than the Setpoint Temperature.
2nd. Replace Cab Control Box.

Unit Operation LED is OFF when the unit is cooling. 1st. Check voltage on Pin 7 C-11.
2nd. Replace Cab Control Box.

Temperature displayed is out of range. 1st. Check that the Cab Control Box 12/24V selector is
in the correct position.
2nd. Check the thermostat Sensor.

37
Electrical Maintenance

Defrost System The factory setting for the defrost timer is four
hours. Use the following information to change
A defrost cycle can be started by pressing the the setting of the defrost timer.
manual defrost switch or automatically by the
defrost timer, when the defrost termination switch 1 2
is closed and the unit is in cool mode.
The defrost cycle operates by energizing the
defrost relay. The defrost relay energizes the
defrost solenoid valve (and the condenser
solenoid valve on units equipped with the heat
option). The defrost relay also interrupts power to
the evaporator and condenser fans, which stops
the evaporator and condenser fans.
Energizing the defrost solenoid valve diverts hot
gas into the evaporator coil, melting ice. A defrost
termination switch de-energizes the defrost relay
when evaporator temperature rises above 48 F AGA1225

(8.9 C).
Figure 21: Defrost Timer
To check the defrost cycle, run the unit on Cool to
drop the evaporator coil to a temperature below 36 1. Refer the following timing table. A similar
F (2.2 C). table is located on the printed circuit board.
TIMING TABLE Switch SCALE
Press the manual defrost switch. The unit should
A B
shift from Cool to Defrost Mode. If the unit
continues to Cool, double check the evaporator 0.25 - 2.5 Ø ¦ From 0.25 to 2.5
coil temperature, and refer to Testing the Defrost minutes
System. 1 - 10 ¦ Ø From 1 to 10 minutes

On TC units defrost is performed on both 8 - 80 ¦ ¦ From 8 to 80 minutes

evaporators at the same time. Defrost termination 64 - 640 Ø Ø From 1 to 10 hours
is controlled by the defrost termination switch on
the main evaporator. 2. Choose the range in the timing table in which
your timing needs are included and set
switches A and B to the desired position.
Defrost Components
Example: Setting selector switches A and B to
Defrost Timer Settings positions A:↓ and B:↓ chooses the time range
of approximately 1 to 10 hours6 (4 to 640
NOTE: The defrost timer is directly connected to
minutes).
the battery. This means that the defrost timer is
always timing, even if the unit is turned off. 3. Set the round red selector to the desired value.
The round red selector multiplies the
The defrost timer has two selector switches (A
minimum value of the chosen range by the
and B) and a round red selector that are used to set
value it is pointing at.
the timer interval.
Example: If the selector points to position 2,
approximately. 2 hours (2 x 64 = 128 minutes)
Example: If the selector points to position 4,
approximately. 4 hours (4 x 64 = 256 minutes)

38
 Electrical Maintenance

Manual Defrost Switch If the unit doesn’t shift to defrost cycle go to step
1.
A manual defrost switch is located in the In-Cab
control box. Pressing the manual defrost switch 1. Check the evaporator temperature.
initiates the defrost cycle if the defrost termination
Be sure the evaporator temperature is actually
switch is closed and the unit is in cool mode.
below 36.0 ± 5.4 F (2.2 ± 3.0 C), otherwise
the unit will not defrost. Use a test
Defrost Termination Switch thermometer to check the evaporator
The switch is mounted in the evaporator coil and temperature.
controls the defrost cycle in response to the
2. Check the defrost termination switch.
evaporator coil temperature. The switch is closed
when the evaporator coil temperature is below 36 If the unit fails to defrost, place a jumper wire
F (2.2 C). completing the defrost circuit to ground between the 12 and CH wires at the defrost
and preparing the electrical system for the defrost termination switch. Press the manual defrost
cycle. switch.
When the unit does shift into a defrost cycle, the If the unit shifts to defrost, the defrost
evaporator fan stops, and heat from the hot termination switch is defective.
refrigerant gas melts the frost from the evaporator
If the unit does not shift to defrost, check for
coil. The switch opens and terminates the defrost
an open circuit in the 12 wire back to Pin 2
cycle when the evaporator coil temperature rises
C-3. If the 12 wire is not open go to step 3.
above 48 F (8.9 C).
3. Check voltage on Pin 1 C-3.
Defrost Relay If voltage is present on Pin 1 C-3, replace the
The defrost relay controls operation of the defrost defrost relay.
cycle. When the defrost timer or the manual
If voltage is not present, go to step 4.
defrost switch completes the circuit through the
defrost termination switch to ground, the defrost 4. Check for open circuit on wire GR that goes to
relay is energized. This energizes the defrost the In-Cab control box (Pin 8 C-9).
solenoid valve (wire 26) and de-energizes the fan
If the wire GR is not open, go to step 5.
relay.
5. Press and hold manual defrost switch, check
The defrost relay stays energized until the defrost
the voltage on Pin 8 C-9.
cycle is terminated by the defrost termination
switch or the ON-OFF Key is pressed. If voltage is present on Pin 8 C-9 and the rest
of the above mentioned points are correct,
Defrost Solenoid Valve replace the printed circuit board.
The defrost solenoid valve is an electrical valve If voltage is not present on Pin 8 C-9, check
that controls the flow of refrigerant through the the In-Cab control box.
refrigeration system.
The defrost solenoid valve is energized by the 26 Defrost Timer Test
wire (Pin 1 C-1). When the defrost solenoid valve The defrost timer initiates the defrost cycle.
is energized it routes hot refrigerant gas to the
evaporator. 1. Verify that the evaporator coil temperature is
lower than 36.0 ± 5.4 F (2.2 ± 3.0 C). If not,
place a jumper wire between the 12 and CH
Testing The Defrost System wires at the defrost termination switch.
To test the defrost system, run the unit on cool
2. Set the defrost timer to approximately 1
until the evaporator coil temperature is below
minute (selector switches A:↓, B:↓ and round
36.0 ± 5.4 F (2.2 ± 3.0 C) and press the manual
red selector in position 4).
defrost switch.

39
Electrical Maintenance

3. After approximately one minute, defrost Liquid Injection System

should be initiated. The Defrost LED, defrost (R-404A Units Only)
relay, and defrost solenoid valve must be
activated. This liquid injection switch is a temperature
sensitive switch located on the discharge fitting of
the truck engine compressor. When the discharge
Condenser Fan Pressure temperature rises above 230 ± 5 F (110 ± 3 C), the
Switch (CFPS) R-134a Units switch closes to open the liquid injection solenoid.
Only When the discharge temperature falls below 200 ±
When the condenser head pressure rises above 5 F (93 ± 3 C), the switch opens to close the liquid
180 ± 10 psi (1241 ± 69 kPa) the condenser fan injection solenoid.
pressure switch closes, starting the condenser fan.
Testing Liquid Injection Valve And
When the condenser head pressure falls below Metering Orifice
130 ± 10 psi (896 ± 69 kPa), the condenser fan
pressure switch opens, stopping the condenser 1. Disconnect the LIS wire from the liquid
fan. injection solenoid.
2. Install the gauge manifold set on the
Testing CFPS engine-driven compressor.
The CFPS is located on the discharge line. 3. Set thermostat on the lowest setting.
Electrically it is located between wires CF and
CF1. 4. Start and run the unit on the engine-driven
compressor until the suction pressure
stabilizes.
5. Place a jumper between CH and LIS terminal
on the liquid injection solenoid. This
simulates that the discharge temperature is
higher than 230 F (110C).
AGA1226 6. With the jumper wire in place the suction
pressure should rise.
Figure 22: Testing CFPS
7. Remove the jumper. The suction pressure
Use the following procedure to test the CFPS: should return to the stabilized pressure in step
1. Install a manifold gauge set on the 4.
compressor. 8. If the suction pressure does not change, check
2. Connect a voltmeter between the CF and the the CLU wire for voltage, the liquid injection
CF1 wires by CFPS switch connector. solenoid valve, or the metering orifice.
3. Run the unit on Cool. When the condenser 9. Shut off the unit and the truck, remove the
head pressure is higher than 180 ± 10 psi gauge manifold set, and replace the LIS wire.
(1241 ± 69 kPa) the condenser fan motor must
be running and the voltmeter should indicate
approximately 0 volts.
4. Run the unit on Cool. When the condenser
head pressure is lower than 130 ± 10 psi (896
± 69 kPa) the condenser fan motor must be
stopped and the voltmeter should indicate
approximately truck battery voltage.

40
 Electrical Maintenance

Electric Standby Circuits 2. Measure the transformer output voltage (AC)

at the terminal board. Measure the voltage
If the unit does not run in the electric standby between wires X1 and X4. The voltage
mode use the following procedure. reading should be approximately 12/24V
Make sure the unit is connected to the proper (depending on the unit voltage). If not, the
power source. transformer is defective. If the transformer
output voltage is acceptable, go to step 3.
Check the power cable receptacle for power. If
power is there, check for power at the unit 3. Check the rectifier output voltage (DC) on the
terminal plug. 2R wire (Pin 3 C-2). If this voltage is less than
approximately 12/24V, the rectifier bridge is
If the contactor is pulled down and the overload defective. If the rectifier output voltage is
relay is closed, but the standby motor fails to start, acceptable, go to step 4.
the trouble is probably in the standby motor.
4. Check the voltage on 2R1 wire (Pin 4 C-4). If
If the contactor is not pulling down proceed as voltage is not present, check Fuse 4. If Fuse 4
follows: is intact, go to step 5.
1. Check the AC line voltage and the transformer 5. Check the voltage on Pin 2 C-9. If voltage is
fuse. If the AC line voltage is acceptable and not present, check for open circuits on wires
the transformer fuse is intact, go to step 2. 2R1 and R. If voltage is present on Pin 2 C-9,
check the cab control box.

41
Electrical Maintenance

42
Refrigeration Maintenance
NOTE: The following procedures involve 1
servicing the refrigeration system. Some of these
2
service procedures are regulated by Federal, and
in some cases, by State and Local laws.
All regulated refrigeration service procedures
must be performed by an EPA certified
technician, using approved equipment and
complying with all Federal, State and Local
laws.
3
4
Refrigerant Charge
Charging the Refrigeration System
ARA053
The liquid line sight glass helps the operator to
determine the amount of charge under established
operating conditions. These units can be damaged 1. Gauge Manifold Set
by an overcharge of refrigerant. The amount of 2. Engine Driven Compressor
refrigerant the system can hold depends on circuit 3. Evacuation Station
volume which is affected by hose length. 4. Refrigerant Drum
Figure 23: Charging Refrigeration System
The most satisfactory method of charging the
engine driven compressor circuit and the electric 6. After the additional hour of evacuation, close
standby driven compressor circuit is as follows: the valve at the evacuation pump, stop the
1. Connect a gauge manifold set to the suction vacuum pump, and observe the reading on the
and discharge service ports on the engine vacuum gauge for 5 minutes. The pressure
driven compressor. should not exceed 2000 microns.

2. Connect the center hose of the gauge manifold NOTE: If it does, repeat steps 5. and This
to the manifold of an evacuation station. The time if the pressure exceeds 2000 microns
use of Thermo King Evacuation Station P/N within 5 minutes, look for a leak in the
204-725 is recommended. system or in the evacuation and charging
equipment hoses. Find and repair the leak.
3. Connect the hose from a drum of refrigerant to
the manifold of the evacuation station. Make 7. Open the vacuum valve at the vacuum pump,
sure the valve on the refrigerant drum is start the vacuum pump, and evacuate the
closed. system to 500 microns.

4. Open the valves on the gauge manifold and 8. When the system reaches 500 microns, close
the valves on the evacuation station. the vacuum valve at the evacuation station
manifold. The system is now ready to charge.
5. Start the vacuum pump and evacuate the
system to 500 microns. After the system 9. Close the low side valve on the gauge
reaches 500 microns, evacuate the system for manifold, leave the high side valve on the
an additional hour. gauge manifold open, and open the valve on
the refrigerant drum to deliver liquid.
NOTE: If the system will not come down to
500 microns, there is probably a leak in the 10. Allow 2.60 lb (1.20 kg) of R-134a or 2.75 lb
system or in the evacuation and charging (1.25 kg of R- 404A refrigerant to enter the
equipment hoses. Find and repair the leak. system. Then close the valve on the refrigerant
drum and the high side valve on the gauge
manifold.

43
Refrigeration Maintenance

11. Start the unit on engine operation and run the 22. The above conditions MUST be established
truck engine at approximately 1000 rpm. each time the refrigerant level is checked or if
refrigerant needs to be added for any reason.
12. Set the thermostat at 32 F (0 C), and run the
unit in cool until the box temperature NOTE: To prevent oil migration from one
approaches 32 F (0 C). compressor to another, and for proper oil
return when a compressor is operating,
13. Make sure that the unit is running in cool, the
operate a compressor for a minimum of 15
compressor is running at approximately 1000
minutes. Do not operate the compressor for
rpm, the suction pressure is 2 to 8 psi (14 to 55
shorter intervals.
kPa), and the head pressure is at least 180 psi
(1241 kPa) for R-134a systems or 275 psi
(1896 kPa) for R-404A systems. If necessary, Checking the Refrigerant Charge
raise the head pressure by covering the If the unit has an insufficient charge of refrigerant,
condenser. the evaporator will be “starved” and the box
temperature will rise even though the unit is
14. With these conditions established, open the
operating. Also, an insufficient charge does not
valve on the refrigerant drum to deliver liquid.
circulate enough oil to properly lubricate the
15. Observe the suction pressure and slowly open compressor. The charge may be determined by
the low side gauge manifold valve to allow inspection of the refrigerant through the sight
liquid refrigerant to flow into the compressor glass with the following conditions established:
suction service valve.
Testing the Refrigerant Charge with an
16. Control the liquid flow so the suction pressure
Empty Box
increases approximately 138 kPa (20 psi).
1. Place a test box over the evaporator.
17. Observe the liquid line sight glass. Close the
valve on the refrigerant drum when the 2. Install gauge manifold set.
bubbles disappear from the sight glass.
3. Run the unit in cool on engine driven
18. Close the low side valve on the gauge compressor operation until the thermometer
manifold and operate the unit for 15 minutes. reads 32 F (0 C).
19. Model 20 only. 4. Establish head pressure of 180 psi (1241 kPa)
for R-134a systems or 275 psi (1896 kPa) for
a. Turn the unit OFF and shut off the truck
R-404A systems. It may be necessary to
engine.
partially cover the condenser grille on the
b. Connect the electric power receptacle to front of the unit to create the desired head
an appropriate electric power supply. Start pressure.
and run the unit in cool on electric
5. Look at the liquid line sight glass. Under these
operation for a minimum of 15 minutes.
conditions there should be no bubbles in the
c. Turn the unit OFF and disconnect the flow of refrigerant through the liquid line sight
electric power supply. Start the truck and glass. Bubbles in the refrigerant indicate the
run the unit in cool on engine operation for unit is low on refrigerant. Refer to add
a minimum of 15 minutes. refrigerant.
20. Check the liquid line sight glass for bubbles.
Repeat steps 13. through 20. if bubbles are
visible.
21. Stop the unit, shut OFF the truck engine and
remove the gauge manifold set.

44
 Refrigeration Maintenance

Testing the Refrigerant Charge with a 1. Install a compressor on the system having a
Loaded Box residual oil supply and self-lubricating system
such as a TK 214 model. Connect an oil
1. Install a gauge manifold.
separator on the discharge or suction line to
2. Run the unit in cool on engine driven collect and drain out circulated oil.
compressor operation.
NOTE: A suction line oil separator can be
3. Cover the condenser to drive any excess improvised by installing a suction filter
refrigerant from the condenser into the upside down in the suction line near the
receiver tank. compressor. Cap off both access ports, and
use the lower one to drain off the
4. As the head pressure rises, check the liquid
accumulated oil.
line sight glass. There should be no bubbles in
the flow of refrigerant through the liquid line 2. Place a normal amount of oil in the cleanup
sight glass. Bubbles in the refrigerant indicate compressor before operating.
the unit is low on refrigerant. Refer to add
3. Charge with 6.0 to 7.0 lb (2.7 to 3.2 kg) of
refrigerant.
refrigerant.
NOTE: If no bubbles are present, there is
4. Operate at a low speed (600 to 800 rpm) for 2
sufficient refrigerant in the unit for that load
hours, or until the compressor oil level reaches
at that particular box temperature. This test
a minimum allowable level, whichever occurs
does not determine if the unit contains a full
first. Drain the collected oil from the oil
charge of refrigerant.
separator as it fills, taking care to not allow
any collected oil to recirculate.
Checking Compressor Oil
5. Prepare the original compressor that was
Charge removed from the unit (or a replacement) by
The compressors are furnished with the amount of draining out any existing oil and replacing the
oil shown in. The oil level in the compressor will oil with the amount of oil shown in the
change after the compressor is initially run, Specifications chapter.
making any level measurements inaccurate.
6. Install the original compressor (or its
To ensure an adequate oil supply, the following replacement), and proceed with the manual
procedure must be followed whenever the evacuation and refrigerant charging
refrigerant charge is lost or removed from a unit: procedure.

45
Refrigeration Maintenance

High Pressure Cutout Switch 9. Raise the discharge pressure of the

(HPCO) compressor by blocking the condenser coil air
flow. When the discharge pressure reaches
The high pressure cutout switch is located on a 300 psi (2068 kPa) on R-134a units, or 450 psi
discharge line inside the condenser unit. If the (3102 kPa) on R-404A units, the High
discharge pressure rises above 300 psi (2068 kPa) Pressure Cutout will switch off the unit.
on R-134a units or 450 psi (3102 kPa) on R-404A
units, the switch opens the 7A circuit NOTE: The discharge pressure should never
de-energizing the power relay. be allowed to exceed a pressure of 450 psi
(3102 kPa).
To test the switch, rework a gauge manifold per
the High Pressure Cutout Manifold illustration. 10. Failure of the high pressure cutout system to
stop compressor operation should be
investigated first by checking the control
circuit operation and second by high pressure
cutout switch replacement.

Low Pressure Cutout Switch

(LPCO)
The low pressure cutout switch is located on the
suction line in the evaporator. If the suction
pressure drops below 5 to 11 in. Hg of vacuum
(-17 to -37 kPa), it opens the circuit to the power
relay to stop the unit. To check the low pressure
cutout:
1. Install a gauge manifold at the compressor.
2. Close the receiver tank outlet valve and run
the unit in cool.
3. When the suction pressure drops below 5 to
11 in. Hg of vacuum (-17 to -37 kPa), the
LPCO should open and the unit should stop.

1. Relief Valve (66-7392)

2. O-Ring (33-1015)
3. Adapter Tee Weather Head (No. 552X3)

Figure 24: High Pressure Cutout Manifold

7. Connect the gauge manifold to the compressor

discharge service port.
NOTE: Service manifold hoses must have
Schrader valve (tube valve) depressors.
8. Set the thermostat well below the box
temperature so that the unit will be in cool.

46
 Refrigeration Maintenance

Cleanup Procedure for Small Clean-up Procedure

Truck Units 1. Make sure all hose routing is correct.
2. Make sure that the oil trap is correctly
installed.
3. Recover contaminated refrigerant from
system.
4. Remove lines from compressors (engine
driven and standby).
5. Flush each compressor using the flushing
compressor and an HFC refrigerant. (Always
recover the refrigerant before disconnecting
flushing compressor.)
6. Remove check valve (or check valve seats)
from system to ensure flow in all directions.
7. Remove oil separator and install a connecting
pipe.
8. Remove internals from expansion valve.
9. Open suction pressure regulator (CPR) valve
1. Remove Internal Parts From Expansion to highest setting.
Valve
10. Install temporary suction line filter (P/N
2. Disconnect and Cap (If So Equipped) 204-498 and P/N 66-2988) in suction line.
3. Replace Drier With Tube
11. Install connecting pipe in place of standby
4. Discharge Line compressor.
5. Flushing Compressor
12. Connect flushing system to engine driven
6. Suction Line discharge and suction lines (see illustration).
7. Suction Oil
13. Evacuate the system and check for leaks.
8. Recovered Oil Continue to evacuate to remove moisture and
air.
Figure 25: Connecting Flushing Compressor to
Unit 14. Install HFC refrigerant and flush the system.
NOTE: If a Van Steenburgh reclaimer is (Energize defrost solenoid during 30% to 40%
available, do not use this procedure. Follow of the clean-up. Solid contaminants will
procedure described in Service Bulletin T&T collect in the suction line filter. Oil from the
134. system and from the flushing compressor will
drain out of the suction line filter. (Add
Tools Required: compressor oil as required.) Refrigerant oil in
the flushing compressor will absorb acids
• Motor-driven TK 214 “Flushing Compressor” from the system.
• Suction Line Filter (P/N 204-498 with Filter 15. Test compressor oil for acid contamination.
P/N 66-2988)
16. Continue flushing until compressor oil is
• Pipes (In Place of Oil Separator, Check Valve, clean.
Oil Separator and Standby Compressor)

47
Refrigeration Maintenance

Putting the Unit Back Into Operation

1. Replace check valve (or check valve seats).
2. Install new oil separator.
3. Install new liquid injection orifice.
4. Install new drier.
5. Install new expansion valve.
6. Install compressors and lines.
7. Use dry nitrogen to pressurize system to 150
psi (1034 kPa).
8. Use bubble solution to check for leaks.
9. Install correct amount of oil.
10. If no leaks, evacuate unit. A leak-free and dry
unit will maintain a 1000 micron vacuum for
five minutes or longer.
11. Charge unit with proper amount of the correct
refrigerant.
12. Operate and check for proper operation.
(Adjust suction pressure regulator.)
13. After two weeks of operation, change the
drier.

48
Refrigeration Service Operations
NOTE: It is generally good practice to replace 3. Disconnect the clutch wire and the discharge
the filter drier whenever the high side is opened and suction lines (and liquid injection hose if
or when the low side is opened for an extended necessary).
period of time.
4. Keep the compressor ports and the suction and
WARNING: Disconnect the power supply discharge lines for the compressor covered to
before servicing the unit to prevent prevent contamination of system components.
personal injury. 5. Remove the compressor mounting screws.
Remove the compressor.
Compressor
Installation
Removal
NOTE: Any compressor installed in this system
1. Recover the refrigerant charge from the must contain the proper amount of compressor
system. oil. Always check to make sure that the
compressor contains the proper amount of oil.
2. Loosen and remove the compressor drive belt.
Follow the system cleanup procedures to remove
old oil from the system.
2

AJA1801

3
4
5
11 6
7
10 8
9

1. Electric Standby Compressor 7. Liquid Line Sight Glass

2. Electric Motor 8. Defrost Solenoid Valve
3. Canalizer 9. Discharge Check Valve
4. Condenser Coil 10. Oil Separator
5. Liquid Injection Valve 11. Suction Pressure Regulator Valve
6. Drier
Figure 26: Refrigeration Systems In Model 20 Configurations

6. Place the compressor in position and install 9. Pressurize the system and test for leaks.
the mounting screws and the belt.
10. Evacuate the system and recharge.
7. Use belt tension tool P/N 204-427 to adjust
belt tension to a reading of 58 on the gauge.
8. Connect clutch wire and the refrigeration
hoses. Pour 2 oz. (59 ml) of compressor oil
into the suction hose before installation.

49
Refrigeration Service Operations

Condenser Coil 3. Install and tighten the ORS nuts. Hold the
drier with a back-up wrench on the hex behind
Removal the ORS fitting.
1. Recover the refrigerant charge. 4. Pressurize the system and test for leaks.
2. Remove the condenser cover. 5. Evacuate the system.
3. Remove the canalizer. 6. Reinstall the condenser cover.
4. Disconnect the inlet and liquid lines. 7. Recharge the unit.
5. Remove the mounting hardware.
High Pressure Cutout And
6. Remove the condenser coil. Condenser Fan Pressure
Installation
Switches
1. Clean the tubes for soldering. Removal
2. Place the coil in the unit and install the 1. Recover the refrigerant charge.
mounting hardware. 2. Remove the condenser cover.
3. Connect the inlet and liquid line connections.
3. Disconnect the wires and remove the switch.
4. Pressurize the system and test for leaks.
Installation
5. Evacuate the system.
1. Apply a refrigerant loctite to the threads of the
6. Reinstall the canalizer.
switch.
7. Reinstall the condenser cover.
2. Install and tighten the switch and reconnect
8. Recharge the unit. the wires.
3. Pressurize the system and test for leaks.
Drier
4. Evacuate the system.
Removal 5. Reinstall the condenser cover.
1. Recover the refrigerant charge. 6. Recharge the unit.
2. Remove the condenser cover.
3. Disconnect the ORS nuts at the ends of the
Solenoid Valves
drier. NOTE: Valves that have nylon seats must be
disassembled before soldering.
4. Loosen the mounting hardware and remove
the drier.
Removal
Installation 1. Recover the refrigerant charge.
1. Coat the new O-rings with refrigerant oil 2. Remove the condenser cover or the TC/Heat
(same type that is used in the system) and kit cover to access the solenoid valve.
place the new rings in the ORS fittings on the
3. Remove the coil and disassemble the valve if
ends of the drier.
unsoldering the valve.
2. Install the new drier and tighten the mounting
4. Unsolder or disconnect the refrigeration lines
screws and nuts.
from the valve, remove the and remove the
valve from the unit. Note the direction of the
flow arrow on the valve.

50
 Refrigeration Service Operations

5. Reinstall the condenser cover.

CAUTION: Use a heat sink to prevent
6. Recharge the unit.
damaging the valve when soldering.

Installation
Liquid Injection Metering
Orifice
1. Clean the tubes for soldering if necessary.
2. Remove the coil and disassemble the valve if Removal
soldering. 1. Recover the refrigerant charge.
3. Place the valve in position with the flow arrow 2. Disconnect the refrigeration hose from the
pointing in the direction noted when removed. metering orifice and remove the metering
4. Solder or connect the inlet and outlet orifice from the suction hose fitting.
connections. After the valve cools, assemble NOTE: This orifice may become plugged
the valve and install the coil. with dirt unless the refrigeration hose and
solenoid valve are kept clean.
CAUTION: Use a heat sink to prevent
damaging the valve when soldering.

5. Pressurize the refrigeration system and test for 1

leaks.
6. Evacuate the system.
7. Reinstall the cover.
8. Recharge the unit.

Oil Separator
Removal
1. Recover the refrigerant charge.
AJA243
2. Remove the condenser cover.
3. Disconnect the ORS nuts at the end of the oil
separator.
1. Liquid Injection Metering Orifice
4. Loosen the mounting hardware and remove
the oil separator. Figure 27: Engine Driven Compressor

Installation Installation
1. Coat the new O-rings with refrigerant oil 1. Install the metering orifice on the suction hose
(same type that is used in the system) and fitting.
place the new rings in the ORS fittings on the 2. Connect the refrigeration hose to the metering
ends of the oil separator. orifice fitting.
2. Install and tighten the inlet and outlet ORS 3. Pressurize the system and check for leaks.
nuts. Hold the oil separator with a backup
wrench on the hex behind the ORS fitting. 4. Evacuate the system.
3. Pressurize the system and check for leaks. 5. Recharge the unit.
4. Evacuate the system.

51
Refrigeration Service Operations

Testing the Liquid Injection Discharge Check Valve (Model

Solenoid Valve and Metering Orifice 20 Only)
1. Disconnect the CLU and LIS wires from the
liquid injection switch. Testing the Discharge Check Valve
2. Install a gauge manifold set on the engine The discharge check valve is a very important part
driven compressor. of the Model 20 system. The discharge check
valve isolates the engine driven compressor from
3. Set the thermostat on the lowest setting. the electric standby compressor, ensuring the
4. Start the truck and run the unit on the engine compressor oil and refrigerant do not migrate
driven compressor until the suction pressure between compressors. The check valve should be
stabilizes. tested when the system is initially charged and
operating and anytime the system has been
5. Place a jumper wire between CLU and the LIS opened for service or repair. Testing the check
wires that were disconnected from the liquid valve requires two gauge manifold sets.
injection switch.
1. Disconnect the liquid injection solenoid valve
6. With the jumper wire in place the suction wires.
pressure should rise.
2. With the unit off, install a gauge manifold set
7. With the jumper wire removed the suction on each compressor.
pressure should return to the stabilized
pressure in step 4. 3. Observe the gauge manifold readings of the
electric standby compressor. If the high side
8. If the suction pressure does not change, check and low side readings are not the same, open
the CLU wire for voltage, the liquid injection the gauge manifold valves and equalize the
solenoid valve, or the metering orifice. pressures. Close the gauge manifold valves.
9. Shut off the unit and the truck, remove the 4. Adjust the thermostat so the unit will run in
gauge manifold set and reconnect the CLU cool. Start the truck and run the unit with the
and LIS wire to the liquid injection switch. engine driven compressor.
5. Observe the gauge manifold readings of the
engine driven compressor. The head pressure
should increase and the suction pressure
should decrease.
6. Observe the gauge manifold readings of the
electric standby compressor. The high side
pressure should remain the same as the
pressure in step 3 after the high and low sides
were equalized. If the high side pressure is
increasing or has increased noticeably, the
discharge check valve is leaking internally.
7. Turn the unit off and shut off the truck engine.
Connect the remote control box to an
appropriate electric power source.

52
 Refrigeration Service Operations

ARA054

1. Cover Nut 5. Piston Spring

2. Sealing Washer 6. Sealing Washer
3. Piston Screw/Piston Seat 7. Cap Nut
4. Piston 8. Valve Body
Figure 28: Check Valve Assembly

8. Observe the gauge manifold reading of the 11. Observe the gauge manifold readings of the
engine driven compressor. If the high side and engine driven compressor. The high side
low side readings are not the same, open the pressure should remain the same as the
gauge manifold valves and equalize the pressure in step 8 after the high and low sides
pressures. Close the gauge manifold valves. were equalized. If the high side pressure is
increasing or has increased noticeably, the
9. Adjust the thermostat so the unit will run in
discharge check valve is leaking internally.
cool. Start the unit and run on electric standby.
Stop the unit.
10. Observe the gauge manifold readings of the
12. Remove the gauge manifold sets and the
electric standby compressor. The head
electric standby power source. Connect the
pressure should increase and the suction
wires to the liquid injection solenoid valve.
pressure should decrease.
If the check valve is leaking internally, refer to
the repair procedures.

53
Refrigeration Service Operations

Check Valve Repair 4. If no leaks are found, evacuate the system.

5. Recharge the unit with refrigerant and check
Disassembly
compressor oil.
1. Recover the refrigerant charge.
2. Loosen the cap nut and remove the cap nut, Evaporator Coil
sealing washer, spring, and piston assembly.
Removal
3. Check the spring. The free length should be
0.57 in. (14.4 mm). Replace the spring if the 1. Recover the refrigerant charge.
free length is less than 0.51 in. (13.0 mm). 2. Remove the evaporator cover. Disconnect the
4. Inspect the pistons and the piston seats. evaporator fan motor wires.
Replace the pistons or the piston seats if they 3. Disconnect the expansion valve from the
are worn or damaged. distributor.
5. Inspect the valve body. The piston bores and 4. Disconnect the hot gas line from the
the valve body seats should be clean and distributor.
undamaged. The pistons should move freely
in the piston bores. Clean or replace if 5. Remove the defrost termination switch wire.
necessary. 6. Unsolder the suction line from the evaporator
coil.
Assembly
7. Remove the mounting bolts and slide the coil
NOTE: Coat all parts with compressor oil before from the unit.
assembly.
1. Place the sealing washer on the cap nut. Installation
2. Place the spring on the piston assembly. 1. Place the coil in the housing.
3. Place the piston and spring in the cap nut. 2. Install the mounting bolts and tighten them.
4. Carefully place the piston and cap nut in the 3. Clean the tubes for soldering.
valve body. 4. Solder the suction line to the evaporator coil.
5. Tighten the cap nut. 5. Connect the hot gas line to the distributor.

Check Valve Replacement 6. Connect the expansion valve to the distributor.

7. Connect the defrost termination switch wire.
Removal
8. Pressurize the refrigeration system and test for
1. Recover the refrigerant charge. leaks.
2. Disconnect the refrigeration line connections. 9. If no leaks are found, evacuate the system.
3. Remove the mounting hardware and remove 10. Connect the evaporator fan motor wires.
the check valve. Install the evaporator cover.

Installation 11. Recharge the unit with refrigerant and check

compressor oil.
1. Place the check valve in position and install
the mounting hardware.
2. Connect the refrigeration lines.
3. Pressurize the refrigeration system and test for
leaks.

54
 Refrigeration Service Operations

Expansion Valve Assembly

Removal
1. Recover the refrigerant charge.
2. Remove the evaporator cover. Disconnect the
evaporator fan motor wires.
3. Remove the feeler bulb from the suction line
clamps. Note the position of the feeler bulb on
the suction line.
4. Disconnect the equalizer line from the
expansion valve.
5. Disconnect the liquid line and the distributor Figure 30: Completely Wrap Bulb with Tape
from the expansion valve. 1. Pressurize the refrigeration system and test for
6. Remove the expansion valve from the unit. leaks.
2. If no leaks are found, evacuate the system.
Installation
3. Connect the evaporator fan motor wires.
1. Install the expansion valve assembly in the Install the evaporator cover.
unit.
4. Recharge the unit with refrigerant and check
2. Connect the liquid line and the distributor to compressor oil.
the expansion valve.
3. Connect the equalizer line to the expansion Low Pressure Cutout Switch
valve.
4. Clean the suction line to a bright, polished Removal
condition. Install the feeler bulb clamps and 1. Recover the refrigerant charge.
the feeler bulb on the side of the suction line
in its former position. The feeler bulb must 2. Remove the evaporator cover. Disconnect the
make good contact with the suction line or evaporator fan motor wires.
operation will be faulty. Wrap the bulb with 3. Disconnect the wires and remove the switch.
insulating tape.
Installation
1. Apply refrigerant locktite to the threads of the
switch.
2. Install and tighten the switch and reconnect
the wires.
Figure 29: Location of Expansion Valve Bulb
3. Pressurize the refrigeration system and test for
leaks.
4. If no leaks are found, evacuate the system.
5. Connect the evaporator fan motor wires.
Install the evaporator cover.
6. Recharge the unit with refrigerant and check
compressor oil.

55
Refrigeration Service Operations

Suction Receiver Tank (Heat In-line Check Valves (TC Units

Option Only) Only)
TC units use in-line check valve in the hot gas
Removal
and/or liquid lines. These check valves are located
1. Recover the refrigerant charge. in the TC/heat kit. An in-line check valve is not
repairable and must be replaced if it fails. A heat
2. Remove the TC/heat kit cover.
sink must be used on the in-line check valve when
3. Unsolder the suction receiver tank from the it is being soldered in place to prevent damage to
suction tubes. the neoprene seal.

Installation Removal
1. Clean the tubes for soldering. 1. Recover the refrigerant charge.
2. Place the suction receiver tank in position and 2. Remove the TC/heat kit cover.
solder the connections.
3. Remove the mounting hardware from the
3. Pressurize the refrigeration system and test for check valve if used.
leaks.
4. Place a heat sink on the check valve.
4. If no leaks are found, evacuate the system.
5. Unsolder the lines and remove the check
5. Install the TC/heat kit cover. valve.
6. Recharge the unit with refrigerant and check
compressor oil. Installation
NOTE: A heat sink must be used on the in-line
Suction Pressure Regulator check valve when it is being soldered in place to
prevent damage to the neoprene seal.
Valve (TC Units Only)
1. Clean the tubes for soldering.
Removal
2. Place the check valve in position. The arrow
1. Recover the refrigerant charge. on the valve body indicates the direction of
refrigerant flow through the valve.
2. Remove the TC kit cover.
3. Place a heat sink on the check valve.
3. Unsolder the suction pressure regulator valve
from the suction tubes. 4. Solder the inlet and outlet connections.
5. Install the mounting hardware for the check
Installation
valve if used.
1. Clean the tubes for soldering.
6. Pressurize the refrigeration system and test for
2. Place the valve in position and solder the leaks.
connections.
7. If no leaks are found, evacuate the system.
3. Pressurize the refrigeration system and test for
8. Install the TC/heat kit cover.
leaks.
9. Recharge the unit with refrigerant and check
4. If no leaks are found, evacuate the system.
compressor oil.
5. Install the TC kit cover.
6. Recharge the unit with refrigerant and check
compressor oil.

56
 Refrigeration Service Operations

Replacing Refrigerant Hoses 4. Manually insert the fitting into the hose. The
(Speedy Clip System) hose should touch the projecting part of the
fitting without rising over it. Clean off excess
Disassembly oil.
1. Drain the refrigerant charge or drain the low
pressure side.
2. Loosen the hose fittings using two spanner
ASA129
wrenches.
Figure 34: Manually Inserting The Fitting
3. Remove the hose and the hose connectors.
5. Place the clamp for the clips into the fitting
Assembly slot. The clamp is properly positioned when it
1. Cut the hose to the desired length. Use the can rotate in the slot.
recommended hose-cutting tool. Do not use
saws, knives or similar tools.

Figure 35: Positioning The Clamp

6. Fit the clips in the clamp arm seat.

Figure 36: Fitting The Clips

Figure 31: Cutting The Hose
7. Tighten both clips using recommended pliers.
2. Fit two clips of appropriate diameter over the Check that the clips are properly positioned
hose. Use only one clip for hose #4. and tightened.

ASA127

Figure 32: Fitting The Clips

3. Lubricate the cylinder of the fitting to be

inserted in the hose using Thermo King
refrigerant oil.

Figure 37: Tightening Both Clips

ASA128

Figure 33: Lubricating The Cylinder Of The Fitting

57
Refrigeration Service Operations

58
Structural Maintenance

Unit Inspection
Inspect the unit during the pre-trip inspection and
during scheduled maintenance inspections for
loose or broken wires or hardware, compressor oil
leaks, or other physical damage which might
affect unit performance and require repair or
replacement of parts.

Evaporator Coil
Clean the coils during scheduled maintenance
inspections. Remove any debris (e.g., leaves or Figure 38: Condenser
plastic wrap) that reduces the air flow. Clean dirty
coils with compressed air or a pressure washer. Be
careful not to bend the fins when cleaning a coil.
If possible, blow the air or water through the coil
in the direction opposite the normal air flow.
Repair bent fins and any other noticeable damage.

CAUTION: Air pressure should not be

high enough to damage coil fins.

Condenser Coil
Figure 39: Evaporator
Clean the coils during scheduled maintenance
inspections. Remove any debris (e.g., leaves or
plastic wrap) that reduces the air flow. Clean dirty
coils with compressed air or a pressure washer. Be
careful not to bend the fins when cleaning a coil.
If possible, blow the air or water through the coil
in the direction opposite the normal air flow.
Repair bent fins and any other noticeable damage.

Unit Mounting Bolts

Periodically check and torque the unit mounting
bolts.

59
Structural Maintenance

60
Clutch Maintenance

Clutch Test
1. If the field coil lead wire is broken, replace the
field coil.
2. Check the amperage and voltage. The
amperage range should be 3.6 to 4.2 amps at
12 volts or 1.8 to 2.1 amps at 24 volts. Note
the following symptoms and conditions.
a. A very high amperage reading—a short
within the field coil.
b. No amperage reading—an open circuit in
the winding.
c. An intermittent or poor system ground
results in lower voltage at the clutch. 1. Holder
Check for tight fit of the coil retaining Figure 40: Remove Center Bolt
snap ring or coil retaining screws for good
ground. 2. Remove the drive plate using the shaft seal kit
(P/N 204-805). Then remove the shims from
d. Replace field coil if it has an open or short
either the drive shaft or the drive plate.
circuit.
3. Air Gap—An incorrect air gap could cause
erratic engagement or disengagement and/or
clutch rattle. Check the air gap with a feeler
gauge (0.01 to 0.02 in. [0.3 to 0.6 mm]).

Clutch Removal
NOTE: Make sure the proper tools are available
before performing maintenance procedures.
Refer to the tool listing at the end of this chapter
for tools required. Contact your local Thermo
King dealer for further information.
Figure 41: Remove Drive Plate

Removal 3. Remove the snap ring using external snap ring

1. Remove the center bolt using the puller arbor pliers (P/N 204-808).
(P/N 204-804) to prevent drive plate rotation. 4. Remove the cover

61
Clutch Maintenance

NOTE: DO NOT hold the coil by the lead

wire.

Figure 44: Remove Coil

1. Snap Ring
2. Cover Inspection
Figure 42: Remove Snap Ring and Cover 1. Drive Plate
5. Remove the pulley assembly using the clutch If the contact surface is scorched, the drive
remover (P/N 204-806) and the spacer plate and pulley should be replaced.
positioned on the cylinder head hub.
2. Pulley Assembly
NOTE: To avoid damaging the pulley
Inspect the appearance of the pulley assembly.
groove, the pulley claws should be hooked
If the pulley’s contact surface is excessively
into (NOT UNDER) the pulley groove.
grooved due to slippage, both the pulley and
drive plate must be replaced. There should
also be no foreign matter, such as oil or grit,
lodged between the clutch plate and pulley.
Thoroughly clean these contact surfaces and
the drive plate.
3. Coil
Inspect the coil for a loose connector or
cracked insulation. If the insulation is cracked,
replace the coil. If the field coil lead wire is
broken, replace the field coil.

Figure 43: Remove Pulley

6. Remove the coil’s lead wire from the holder

1. Drive Plate
on the top of the compressor.
2. Pulley Assembly
7. Remove the three screws that attach the coil to
3. Coil
the compressor and remove the coil.
Figure 45: Inspect Components

62
 Clutch Maintenance

Clutch Installation 5. Install the cover and the snap ring using
external ring pliers (P/N 204-808).
NOTE: Before installation refer to “Inspection”
above. NOTE: When installing the snap ring, the
chamferred inner edge of the snap ring
1. Confirm that the felt is installed on the front of should face upward.
the cylinder head.
2. Install the coil on the compressor (with the
lead wire on top). At this time, confirm that
the coil’s concave portion is aligned with the
felt and then tighten the mounting screws to
the specified torque.
NOTE: Specified torque: 2.9 to 4.3 ft-lbs (3.9
to 0.6 N•m).
3. Install the lead wire in the wire holder on the
compressor.

1. Snap Ring
2. Cover

Figure 48: Install Cover and Snap Ring

6. Install the driver plate on the drive shaft,

together with the original shim(s). Press the
drive plate down by hand.

1. Felt

Figure 46: Install Coil

4. Install the pulley assembly using the

compressor holder (P/N 204-807) and a hand
press.

1. Shims
Figure 49: Install Shims and Drive Plate

7. Tighten the bolt to the specified torque using

the puller arbor (P/N 204-804) to prevent
drive-plate rotation.
NOTE: Specified torque: 8.7 to 10.1 ft-lbs
(11.8 to 13.7 N•m).

Figure 47: Install Pulley After tightening the bolt, ensure that the
pulley rotates smoothly.

63
Clutch Maintenance

NOTE: The shaft seal cover SHOULD NOT

be reused. Always use a new shaft seal cover
when reassembling a compressor.

8. Ensure that the clutch clearance is as

specified. If necessary, adjust the clearance
using shims.
Adjusting shims are available in the following
thicknesses: 1. Shaft Seal Cover
Shim P/N Thickness 2. Felt Pad
11-8031 0.004 in. (0.1 mm) Figure 50: Remove Shaft Seal Cover
11-8032 0.012 in. (0.3 mm)
11-8033 0.020 in. (0.5 mm) 4. Use the seal remover (from the shaft seal kit
P/N 204-805) to remove the shaft seal. Turn
NOTE: Specified clearance: 0.01 to 0.02 in. the seal remover to engage the hook on the
(0.3 to 0.6 mm). seal remover with the hook on the shaft seal,
Check Clearance then slowly pull the shaft seal out of the
cylinder head.
Electrical Connection
1. Connect the lead wire to the electrical circuit.
NOTE: The stationary field is grounded at
the factory; therefore, it is necessary only to
connect the hot (lead) wire.
2. Engage and disengage the clutch several times
to check the clutch engagement. The disc
should snap firmly against the pulley.

Shaft Seal Cover and Shaft Seal:

Removal And Installation
Removal 1. Shaft Seal
1. Remove the magnetic clutch assembly. Figure 51: Remove Shaft Seal
2. Remove the felt pad.
Inspection
3. Use the seal remover (from the shaft seal kit
P/N 204-805) to remove the shaft seal cover. The shaft seal should not be reused. Always use a
Turn the seal remover to engage the hook on new shaft seal when reassembling a compressor.
the seal remover with the hook on the shaft Be extremely careful to make sure the lip of the
seal cover, then slowly pull the shaft seal shaft seal that is being installed is not scratched or
cover out of the cylinder head.

64
 Clutch Maintenance

damaged in any way. Make sure the shaft seal is 4. Place the shaft seal on the seal guide and slide
free from lint and dirt that could damage the shaft the seal into the cylinder head.
seal surface.

Figure 52: Inspect Shaft Seal

Shaft Seal Installation

Before installing a shaft seal inspect it carefully
(see “Inspection” above).
1. Seal Guide
1. Clean the section of the front cylinder head 2. Shaft Seal
that holds shaft seal.
Figure 54: Place Shaft Seal on Guide
2. Apply clean compressor oil to the new shaft
seal and to the front cylinder head. If the slip 5. Use the seal installer (from the shaft seal kit
surfaces are dirty, clean them with thinners, P/N 204-805) to press the shaft seal into the
dry the clean surfaces and apply clean cylinder head as far as possible.
compressor oil. 6. Remove the seal guide from the shaft.
3. Place the seal guide (from the shaft seal kit
P/N 204-805) on the end of the shaft.

Figure 55: Press Seal Into Cylinder Head

7. Place the seal guide (from the shaft seal kit

P/N 204-805) on the end of the shaft.
1. Seal Guide

Figure 53: Place Guide on Shaft

65
Clutch Maintenance

8. Place the shaft seal cover on the seal guide Special Tools
and slide the shaft seal cover into the cylinder
head.

8932a

Figure 56: Install Shaft Seal Cover

Figure 58: Clutch Remover P/N 204-806
9. Use the seal installer (from the shaft seal kit
P/N 204-805) to press the shaft seal cover into
the cylinder.
10. Remove the seal guide from the shaft.
NOTE: Position the shaft seal cover as shown in
the illustration. The felt pad should also be
replaced with a new one when the shaft seal is
replaced. 8932b

Figure 59: Compressor Holder P/N 204-807

Figure 57: Proper Shaft Seal Cover Position

66
 Clutch Maintenance

8932e
8932c

Figure 60: Clutch Installation Kit P/N 204-890 Figure 62: Shaft Seal Kit P/N 204-805

8932d

Figure 61: Snap Ring Pliers P/N 204-808

67
Clutch Maintenance

During normal operation there is always a

quantity of oil that travels around inside the
system. This oil lubricates all the components,
returns to the compressor for a while, and again
travels around the system.

Adding Extra Oil to the System

The initial oil charge into a new system is based
on the size of the system and the amount of oil,
which remains in the compressor during
operation.
The correct oil to use in a unit using R-134a or
R-404A is Polyol Ester (POE) oil (P/N 203-413).
Any extra or replacement oil should be placed into
the system at the receiver tank port.

CAUTION: keep all oil containers tightly

sealed from the air. oil tends to absorb
moisture fro the air and can become
contaminated if left open. If contaminated
oil is put into a system, it may damage the
components of the system.

Major Loss of Refrigerant

In case of a major loss of refrigerant, it must be
assumed that some system oil is lost also. The oil
8932f
level should be verified. Refer to the following,
“Checking the Oil Level” for details.
Figure 63: Pulley Arbor P/N 204-804
Checking the Oil Level
System Compressor and Oil
Drain the Oil
Installation of the Compressor
The compressor is mounted in the engine
compartment. The side to side mounting angle of
the compressor must remain ± 45° from the
horizontal. The forward to backward angle must
be within ± 10° of horizontal.
Each compressor comes with a standard charge of
Polyol Ester (POE) oil inside. This quantity of oil
is enough to supply the compressor lubrication
when it is installed into an already “oil wet”
system. New systems require an extra quantity of
oil be added to “wet” all the interior surfaces of
the system.
Figure 64: Draining the Oil

68
 Clutch Maintenance

Remove the compressor from the unit and drain

the oil from the compressor drain plug and all CAUTION: Any extra or replacement oil
other ports. Turn the clutch (rotating the internal should be placed into the system at the
compressor parts) by hand and drain oil again. receiver tank port.
Repeat until all oil is removed from the
compressor. Measure the oil removed from the Belt Tensions
compressor. Also, inspect the oil for signs of
contamination. Engine Driven Compressor Belt and
Pulleys
Correct pulley alignment and proper belt tension
are very important factors in compressor
installation. The compressor clutch must be
perfectly aligned with the engine pulley and any
auxiliary idler or belt adjustment pulley
components. When installing the clutch, be sure
the shaft drive key is in place and the shaft bolt is
properly tightened. Check the pulley alignment by
holding a 24 to 35 in. (60 to 90 cm) long rod, 0.5
in.(13 mm) in diameter firmly into the V-groove
of the clutch pulley and make sure the rod aligns
squarely with the engine drive pulley groove.
Double check by making sure the belt goes from
Oil contamination. pulley to pulley in perfect alignment with no
1. Dirt in the oil. indication of a sideward bend.
2. Color changed to a varnish color. Adjust the belt tension to 58 to 60 on TK Gauge
P/N 204-427. Check the belt tension again after
3. Presence of foreign substances, metal 36 to 48 hours of initial operation of the unit
shavings, etc. in the oil. because the belt may stretch slightly during the
NOTE: Always replace oil with new fresh oil first hours of use. Remember, good alignment and
taken from a sealed container only. proper belt tension ensure long belt life.
NOTE: Always replace the system filter drier
Electric Standby Compressor Belt
anytime the system has been opened for service.
Loosen the four mounting bolts on the end of the
When a System Becomes Contaminated electric motor. Move electric motor (rotate it on
the gyrator axis) to obtain a belt tension of 58 to
A severely contaminated system may be indicated 60 on TK Gauge P/N 204-427. Tighten the
by black oil in the compressor. If severe electric motor mounting bolts and recheck the belt
contamination occurs, it will be necessary to flush tension. Readjust the belt tension if necessary.
the complete system. If flushing is required, use Check the belt tension again after 36 to 48 hours
industry approved materials. of initial operation of the unit because the belt
In all cases when this occurs you must determine may stretch slightly during the first hours of use.
the extent of contamination. Do this by removing
the filter-drier and determine if the darker colored
oil is present at that point of the system too. If it
is, flushing the system is recommended.
If the oil appears clean at the filter drier, install a
new filter drier and replace the compressor with
clean new oil. Refer to checking and draining the
compressor oil section for details.

69
Clutch Maintenance

70
Over-the-Road Mechanical Diagnosis
If desired box temperature cannot be obtained refrigerant, evacuate the system to 500 microns
during engine driven compressor operation, any and recharge with the proper amount of
of the following may be indicated: refrigerant.
EXCESSIVE HEAT LOAD: An excessive heat load TEMPERATURE OF THE LIQUID LINE: During
on the system will be caused by too many, or normal operation, the liquid line will be slightly
excessively long, stops with the doors open. warmer than surrounding air. An extremely hot
Excessive heat loads will also be caused by loose line indicates either shortage of refrigerant or lack
doors, loose body panels, warm loads and poor of a liquid seal at the receiver outlet. A cold line
insulation. indicates a restriction, and some flashing takes
DIRT ON COILS: Dirt on the condenser or place in the liquid line sight glass.
evaporator coil acts as an insulator reducing the DIRTY OR WET FILTER DRIER: If the outlet line of
capacity of the unit. the filter drier is colder than the inlet line, the
INCORRECT BELT TENSION: If the drive belt is filter is either saturated with moisture or is dirty
not correctly tensioned, the compressor will not and must be replaced.
be driven at proper speed, and unit efficiency will DIRT IN THE EXPANSION VALVE SCREEN:
be reduced. By contrast, too much tension will
Reclaim the refrigerant charge, remove the screen
place an additional load on the bearings causing
and clean. Moisture is in the system will collect at
rapid wear.
the expansion valve and freeze. This is indicated
SHORTAGE OF REFRIGERANT: Shortage of by abnormally low suction pressure. Replace the
refrigerant reduces capacity of the unit. Find and drier, dry the system and recharge.
remedy the cause of the shortage and recharge the
ICE ON THE EVAPORATOR COIL: Note operation
system. DO NOT operate the unit if there is an
under DEFROST CYCLE.
indication of low charge.
AIR FLOW: Do not load product directly in front
FAULTY EXPANSION VALVE ADJUSTMENT: High
of the air return or discharge. Insure that the fan is
superheat settings will starve the evaporator
correctly positioned in the orifice to achieve
causing low suction pressure. Low superheat
maximum air flow.
settings will flood the coil causing high suction
pressure. The superheat setting should be adjusted COMPRESSOR LIFE: The following will shorten
ONLY by a trained refrigeration serviceman. the life of the compressor:
EXCESSIVE OIL: Too much compressor oil in the • Operating a contaminated system
system may result in lower than normal suction
• No oil trap
pressure as well as lowered capacity.
MOISTURE IN THE SYSTEM: Symptom:
• Clogged oil separator (JetLube™)
Expansion valve freeze-up—will not refrigerate. • Clogged liquid injection orifice
Usually this can be checked by warming the (JetCool™)
expansion valve with either the hand or hot towels
to see if the valve opens. Evacuate the system in • Defective liquid injection switch
the same manner used during installation. Install a (JetCool™)
new drier. • Insufficient oil charge
EXPANSION VALVE LOSES ITS CHARGE: If the • Wrong or mixed oil
expansion valve loses its charge, the valve will
close causing the system to go into vacuum. • Lack of compressor lubrication on
Replace the valve. installation and startup
AIR IN SYSTEM: Air is not condensable. Its • Excessive compressor speed (maximum
presence in the system increases head pressure. speed 3,000 rpm)
When the compressor is stopped, air will gather at
the high point of the high side. Reclaim the

71
Over-the-Road Mechanical Diagnosis

72
Electric Standby Mechanical Diagnosis
Condition Possible Cause Remedy

Compressor does not run Improperly wired Check wiring against diagram

Low line voltage Check line voltage, determine

location of voltage drop

Relay contacts not closing Check by operating manually.

Replace relay if defective

Fuses blown Replace fuses

Open circuit in motor winding Check stator leads

High pressure cutout open Eliminate cause of excessive

pressure

Thermostat faulty Repair or replace

Compressor faulty Replace compressor

Shortage of refrigerant Recharge

Low pressure cutout open Recharge leak test

Overload relay open Locate overload, reset

Unit short cycles Shortage of refrigerant Repair leak and recharge

(low pressure cutout)

Restricted expansion valve Clean expansion valve

Refrigerant overcharge Remove excess charge

(high pressure cutout)

Cycling on high pressure cutout Check air flow and fan

Dirty condenser coil Clean coil

73
Electric Standby Mechanical Diagnosis

Condition Possible Cause Remedy

Unit operates long or Shortage of refrigerant Repair leak and recharge

continuously
Discharge valve leaking Replace leak

Thermostat faulty Repair or replace

Dirty condenser Clean condenser

Air in system Evacuate and recharge system

Compressor inefficient Replace compressor

Plugged expansion valve Clean expansion valve

Iced or plugged coil Defrost or clean coil

Defective truck body insulation Correct or replace

Too many door openings Keep doors closed, install plastic

curtains

Load too warm Precool hot product

Excessive superheat at expansion Adjust superheat

valve

Door seals worn Repair/replace

Box temperature too high Refrigerant shortage Repair leak and recharge

Thermostat setpoint too high Reset thermostat

Expansion valve or strainer plugged Clean or replace

Restricted lines Clean restriction. Tubing pinched

shut

Hot load Precool hot product

Expansion valve superheat too high Adjust superheat

or too low

Head pressure too high Refrigerant overcharge Remove excess

Air in system Evacuate and recharge system

Dirty condenser Clean

Restricted condenser Clean condenser

Condenser fan not running Check fan motor

Condenser fan rotation Check fan motor polarity

74
 Electric Standby Mechanical Diagnosis

Condition Possible Cause Remedy

Head pressure too low Refrigerant shortage Repair leak and recharge

Compressor suction or discharge Replace valve

valve inefficient

Noisy unit Insufficient compressor oil Add oil to proper level

Mounting bolts loose Tighten

Refrigerant flooding back Adjust oil level or refrigerant charge.

Check expansion valve for proper
superheat

Compressor loses oil Shortage of refrigerant Repair leak and recharge

Plugged expansion valve or strainer Clean expansion valve

Wrong oil viscosity Use proper oil

Short cycling Refer to unit “short cycling”

Superheat too high Adjust expansion valve

Frosted or sweating suction line Expansion valve set too low, Adjust expansion valve
admitting excess refrigerant

Hot liquid line Shortage of refrigerant Repair leak and recharge

Condenser fan not running Check fan motor

Dirty condenser coil Clean condenser

Frosted liquid line Restricted dehydrator or strainer Replace restricted part

Condenser coil is cool when unit Refrigerant undercharge Repair leak and recharge
is in cool operation
Compressor inefficient Replace compressor

Unit in vacuum. Frost expansion Ice plugging expansion valve orifice Apply hot wet cloth to expansion
valve only valve. Moisture indicated by
increase in suction pressure.
Replace drier

Plugged expansion valve strainer Clean strainer

Sensor bulb lost charge Replace expansion valve

75
Electric Standby Mechanical Diagnosis

Electric Standby Service Checks

1.Compressor does not run. a.Check for power at source.
b.Check for power at plug.
c.Check for power at compressor contactor.
d.Check for power at overload terminals (contactor
closed).
e.Check for power at motor terminals.
2.Power at compressor terminals but motor does not a.Replace compressor.
run.
3.Compressor hums but does not run. a.Check for locked rotor.
b.Check for worn bearings. Replace if necessary.
c.Check for locked compressor and repair.
d.Check power source for single phasing (on three
phase units).
e.Check capacitors (on single phase units).
f.Check start relay.
4.Check transformer. a.Check for power output.
5.Check rectifier. a.Check for rectifier output.

76
Refrigeration Diagnosis Chart

Unit cools in defrost cycle

Suction line frosting back

Unit operating in vacuum
High suction pressure
Low suction pressure

Unit not refrigerating

No suction pressure

SYMPTOM
High head pressure
Low head pressure

Sight glass / empty

Unit not defrosting

Noisy compressor
No head pressure
Unit Not Heating
Rapid cycling

POSSIBLE CAUSES
• • Overcharge of refrigerant
• • • • • • • Shortage of refrigerant
• • • • • • • • No refrigerant
• Air through condenser too hot (ambient)
• Air flow through condenser restricted (dirty)
• • Air through condenser too cold (ambient)
• • • Air in refrigerant system
• Condenser fan blades bent or broken
• Air short cycling around evaporator coil
• • • • Air through evaporator restricted
• • • • • • Evaporator needs defrosting
• • Broken compressor belt
• Compressor discharge valves leaking
• • • Too much compressor oil in system
• Loose compressor pulley
• Compressor bearing loose or burned out
• • • • Broken valve plate in compressor
• • • • Expansion valve power element lost its charge
• • • Expansion valve feeler bulb improperly mounted
• • • Expansion valve feeler bulb making poor contact
• • • • Expansion valve open too much
• • Expansion valve closed too much
• • • Expansion valve needle eroded or leaking
• • • • Expansion valve partially closed by ice, dirt or wax
• Hot gas solenoid stuck open
• Water valves not open
• Water pump not working.
• Truck engine not running
• • • • Liquid refrigerant entering compressor
• • • Restricted line on the low side
• • Restricted line on the high side
• • • Restricted dehydrator
• • Reverse fan rotation
• • • • Faulty pilot solenoid
• • Loose or broken electrical connections
• • • • Gauge out of calibration
• Condenser fan motor not operating
• • • • • • Evaporator fan motor not operating

77
Refrigeration Diagnosis Chart

78
Index
A Expansion Valve Assembly 55
After Start Inspection 32
F
B Fuses 22
BELT 15
Belt Tensions 69 G
GENERAL 13
C General 11
Check Valve Repair 54
Check Valve Replacement 54 H
Checking Compressor Oil Charge 45 High 11
Checking the Oil Level 68 High Pressure Cutout And Condenser Fan Pressure
Checking the Refrigerant Charge 44 Switches 50
Cleanup Procedure for Small Truck Units 47 High Pressure Cutout Switch (HPCO) 46
Clutch Maintenance 61
Clutch Test 61 I
Clutch Timer 24 In 20
Common Relays 23 In-Cab Control Box 20
Compressor 19, 49 In-Cab Control Box Operating Instructions 31
Condenser 19 In-line Check Valves (TC Units Only) 56
Condenser Coil 50, 59 Installation 56
Condenser Fan Pressure Switch (CFPS) R-134a Units Introduction 19, 29
Only 40
Connectors 22 L
Control 20
Liquid Injection Metering Orifice 51
Control Box 22
Liquid Injection System 20
Control Circuits 20
Liquid Injection System (R-404A Units Only) 40
Loading Procedure 32
D Low 12
Defrost Components 38 Low Pressure Cutout Switch 55
Defrost Mode Operation (M-13, and M-16 only). 31 Low Pressure Cutout Switch (LPCO) 46
Defrost Relay 39
Defrost Solenoid Valve 39 M
Defrost System 38
Maintenance Inspection Schedule 17
Defrost Termination Switch 39
Manual Defrost Switch 39
Defrost Timer 24
Multi-Temp Relays 23
Defrost Timer Test 39
Description 29
Diagram Index 81
O
Oil 20
Discharge Check Valve (Model 20 Only) 52
Oil Separator 51
Display Return Air (Box) Temperature 31
Operating Instructions 29
Display Setpoint Temperature 31
Over-the-Road Mechanical Diagnosis 71
Drier 50

E P
P.C. Board 22
EFR Selector 24
Post Load Procedure 33
Electric Standby Circuits 41
Protection Features 21
Electric Standby Compressor Belt 69
Electric Standby Mechanical Diagnosis 73
Electric Standby Operation 20
Electric Standby Service Checks 76
ELECTRICAL 15
Electrical 11
Electrical Maintenance 35
Engine Driven Compressor Belt and Pulleys 69
Evaporator 19
Evaporator Coil 54, 59
Evaporator Drain Tube Heaters 20

79
Index

R
R 14
Refrigerant 11, 20
Refrigerant Charge 43
Refrigeration 11
Refrigeration Diagnosis Chart 77
Refrigeration Maintenance 43
Refrigeration Service Operations 49
Replacing Refrigerant Hoses (Speedy Clip System) 57

S
Safety 11
Safety Precautions 11
Serial Number Locations 25
Shaft Seal Cover and Shaft Seal
Removal And Installation 64
Solenoid Valves 50
Special Tools 66
Specifications 13
Standby Relays 23
Starting the unit 32
Structural Maintenance 59
Suction Pressure Regulator Valve (TC Units Only) 56
Suction Receiver Tank (Heat Option Only) 56
System Compressor and Oil 68

T
Testing CFPS 40
Testing Liquid Injection Valve And Metering Orifice 40
Testing The Defrost System 39
Testing the Discharge Check Valve 52
Testing the Liquid Injection Solenoid Valve and Meter-
ing Orifice 52
Trouble Shooting M-17 In-Cab Control Box (TC Units
Only) 37

U
Unit Description 19
Unit Features 21
Unit Inspection 59
Unit Mounting Bolts 59
Unit Operation 24, 32

W
Weekly Pretrip Inspection 32

80
Diagram Index
Dwg No. Drawing Title Pg

1B20489 “V200-10/R134a Refrigeration Diagram” - Page 1 of 1 83

1B19462 “V-200/V-300 Condenser Outline Drawing” - Page 1 and 2 of 2 84

1B19463 “ES200 & ES200 MAX Evaporators Outline Drawing” - Page 1 and 2 of 2 86

1B21121 “V200-20/R134a Refrigeration Diagram” - Page 1 of 1 88

1B20490 “V200 MAX-10/R404A Refrigeration Diagram” - Page 1 of 1 89

1B19464 “V200-20MAX Jet Cool Installation” - Page 1 of 1 90

1B21122 “V200 MAX-20/R404A Refrigeration Diagram” - Page 1 of 1 91

1B22363 “Draining Tubes & Heaters Installation Drawing” - Page 2 and 4 of 4* 92

1B20494 “V200 MAXTC-20 Refrigeration Diagram” - Page 1 of 1 94

3B15699 “MTCH Kit Outline Drawing” - Page 1 and 3 of 6* 95

3B17818 “V-300-10/R134a Refrigeration Diagram” - Page 1 of 1 97

3B17822 “V300-20/R134a Refrigeration Diagram” - Page 1 of 1 98

3B17823 “V300 MAX-10/R404A Refrigeration Diagram” - Page 1 of 1 99

3B17825 “V300 MAX-20/R404A Refrigeration Diagram” - Page 1 of 1 100

3B17752 “ES300 Evaporator Outline Drawing” - Page 1 and 2 of 2 101

3B18615 “ES150 Evaporator Outline Drawing” - Page 1 and 2 of 2 103

3B18440 “V-200-10/AC V-300-10AC 12V; 24V 134a Wiring Diagram” - Page 1 of 2* 105

3B18441 “V-200-10/AC V-300-10/AC 12V; 24V Schematic Diagram” - Page 1 of 2* 106

1E11769 “V-200/V-300-20/AC V200/300 MAX-20/50/AC 1 PH 60Hz 12V; 24V Wiring Diagram” - Pg 1 of 3* 107

1E11770 “V-200/V-300-20/AC 1PH 60 Hz 12V; 24V Schematic Diagram” - Page 1 of 3* 108

3B16068 “V-200 MAXTC-10/30 V-200 MAXTCI-10 12V/24V Wiring Diagram” - Page 1 of 3* 109

3B16069 “V-200 MAXTC-10/30 12V/24V Schematic Diagram” - Page 1 of 3* 110

3B18446 “V-200-20/AC V-300-20/AC 1 PH 60Hz 12V; 24V Wiring Diagram” - Page 1 of 2* 111

3B18447 “V-200-20/AC V-300-20/AC 1 PH 60Hz 12V; 24V Schematic Diagram” - Page 1 of 2* 112

3B18451 “V-200-20/AC V-300-20/AC 3PH 60Hz 12V; 24V Schematic Diagram” - Page 1 of 2* 113

3B18450 “V-200-20/AC V-300-20/AC 3PH 60Hz 12V; 24V Wiring Diagram” - Page 1 of 2* 114

3B16078 “V-200/V-300 MAXTC-20, 3PH 60Hz; 12V; 24V Wiring Diagram” - Page 1 of 3* 115

3B16079 “V-200/V-300 MAXTC-20, 3PH 60Hz; 12V/24V Schematic Diagram” - Page 1 of 3* 116

1E02178 “V-200 MAXTC-20 3PH 60Hz; 12V/24V (Safeway) Wiring Diagram” - Page 1 of 1 117

1E02179 “V-200 MAXTC-20 3PH 60Hz 12V/24V (Safeway) Schematic Diagram” - Page 1 of 1 118

*Drawings included in this section reflect NAD units only. Pages not included do not apply to these NAD units.

81
Diagram Index

82
V200-10/R134a Refrigeration Diagram

83
V-200/V-300 Condenser Outline Drawing

84
V-200/V-300 Condenser Outline Drawing

85
ES200 & ES200 MAX Evaporators Outline Drawing

86
ES200 & ES200 MAX Evaporators Outline Drawing

87
V200-20/R134a Refrigeration Diagram

88
V200 MAX-10/R404A Refrigeration Diagram

89
V200-20MAX Jet Cool Installation

90
V200 MAX-20/R404A Refrigeration Diagram

91
Draining Tubes & Heaters Installation Drawing

92
Draining Tubes & Heaters Installation Drawing

93
V200 MAXTC-20 Refrigeration Diagram

94
MTCH Kit Outline Drawing

95
MTCH Kit Outline Drawing

96
V-300-10/R134a Refrigeration Diagram

97
V300-20/R134a Refrigeration Diagram

98
V300 MAX-10/R404A Refrigeration Diagram

99
V300 MAX-20/R404A Refrigeration Diagram

100
ES300 Evaporator Outline Drawing

101
ES300 Evaporator Outline Drawing

102
ES150 Evaporator Outline Drawing

103
ES150 Evaporator Outline Drawing

104
V-200-10/AC V-300-10AC 12V; 24V 134a Wiring Diagram

105
V-200-10/AC V-300-10/AC 12V; 24V Schematic Diagram

106
V-200/V-300-20/AC V200/300 MAX-20/50/AC 1 PH 60Hz 12V; 24V Wiring Diagram

107
V-200/V-300-20/AC 1PH 60 Hz 12V; 24V Schematic Diagram

108
V-200 MAXTC-10/30 V-200 MAXTCI-10 12V/24V Wiring Diagram

109
V-200 MAXTC-10/30 12V/24V Schematic Diagram

110
V-200-20/AC V-300-20/AC 1 PH 60Hz 12V; 24V Wiring Diagram

111
V-200-20/AC V-300-20/AC 1 PH 60Hz 12V; 24V Schematic Diagram

112
V-200-20/AC V-300-20/AC 3PH 60Hz 12V; 24V Schematic Diagram

113
V-200-20/AC V-300-20/AC 3PH 60Hz 12V; 24V Wiring Diagram

114
V-200/V-300 MAXTC-20, 3PH 60Hz; 12V; 24V Wiring Diagram

115
V-200/V-300 MAXTC-20, 3PH 60Hz; 12V/24V Schematic Diagram

116
V-200 MAXTC-20 3PH 60Hz; 12V/24V (Safeway) Wiring Diagram

117
V-200 MAXTC-20 3PH 60Hz 12V/24V (Safeway) Schematic Diagram

118